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INSTALLATION AND SERVICE MANUAL

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3. E iwco MRHL 141 9 Z FLOW 1 L TIAM GRIN 1 1 s s 4H P 3 7 P3410 Jermy OP 3 2 P380 Exe P33 MODULE J 3 6 201121 m RELAY ALARM 0 A G r HNO not fl e N EU dh ee CONTACTSL L4 o TE ALARM BELL 50 WIRING DIAGRAM WATER HEATER 150 000 300 000 BTU HR V A3H 11002181 W3IV3H H31VM 3 258 NOLLO3NNOO TvOl319313 ASN
4. The unit has a lighted ON OFF power switch on the outer cabinet left side and five 5 LED indicators on the electronic ignition control module to monitor the units operation TABLE P IGNITION MODULE INDICATING LIGHTS Function Indicating Light Power on Switch Power LED On 120 VAC supplied to unit On Module is powered from 24 VAC system and operating properly Blinks continuously if voltage is too high on transformer secondary Off Module is not powered Off Combustion air fan is not powered OR air flow is not proven On When unit is in prepurge or interpurge Blinks continuously when there is a pressure switch fault Off Igniter is off On When hot surface ignitor is on Off Gas valve is closed On Control signaling gas valve is on Blinks continuously when control is in LOCKOUT because it failed ignition Purge LED Ignitor LED Valve LED Flame LED IGNITION AND CONTROL TIMINGS Prepurge Combustion Air Fan Only 15 Seconds Off Flame is not present On Control signaling flame is present Blinks continuously when L1 and neutral are reversed Time to Prove Pressure Switch Airflow 5 Minutes Maximum NOTE Pressure switch must open within 45 seconds of call for heat or control will lockout Igniter Warm up Time 20 Seconds Trial For Ignition 6 Seconds 35 Postpurge Combustion Air Fan Only 30 Seconds Pump Del
5. 35 Freez Protection 4444 4104 eT eR Pu S 36 Maintenance eens 36 Flame Patterns 0 0 cece cee haja 37 Combustion Air Adjustments 37 Burtier Cleaning 38 Heat Exchanger Inspection 39 L bricatton etit aca tre ced bee 39 Gas r 40 Heating Boiler leerlo oem n Re Rede 40 Typical Piping 23i RR bead beeen bd 40 Pump Requirements 40 Pressure Drop Curve sx cies RR RR bees es 41 Boiler Pump Operation 41 Bypass Requirements 41 Low Temperature Systems 42 Boiler Plow Rates sso ceed RR kaa aa Seo pasa 43 Temperature Rise Chart 43 Placing Boiler in Operation 44 Boiler Temperature Control 45 Remote Thermostat Connection 45 Domestic Water Heater 46 Water Velocity Control 46 Water Chemistry 0 46 Piping Requirements 47 Pump Operation eee met Re PS pud 47 Thermostat Adjustment 48 Relief Valve eae eae aid 49 Wiring Diagrams 50 Troubleshooting Charts 54 Revision Notes Back Cover The information contained in this manual is intended for use b
6. STVNINYAL MIYOS OL 531035 NI 8 9 X as 8 21 STOH1NOO S3HOLIAS MOT SSHOLIMS TV SHIM Z MOH 3 SLOWSY N 193NNOO OL bY NIIMLIG 3AOWSH L NOO S31ON ONTEIM OL1O3NNOO 3913 LH OL SONS 193NNOO OOMTHLIM Bosas NI THY 140 LON 31 x 719 4 Ap ea Q 3 072 135 3015 LINN ONIOIANSS 448 LOANNOOSIC SIYINDTY THY TVNOILdO 51 LNAWdINDA TWNOILdO 3l 337108 V Aa 81002181 LADDER DIAGRAM BOILER 150 000 300 000 BTU HR TO 120 VAC POWER SUPPLY t 4 L2 POWER SWITCH eM I P E IGN MOD P5 IGN MOD P6 IENITERS 120 VAC COMBUSTION AIR BLOWER TRANSFORMER ENYN THERMOSTAT LIMIT SWITCH IGNITION 3 3 MODULE 225 r CONTACTS TDR 1 LOUVER CONTACTS 05 aame 77 52 WIRING DIAGRAM BOILER 150 000 300 000 BTU HR VAY 91002181 Manos
7. Drain the appliance completely Remove one threaded plug or bulb well from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger Blow all water out of the heat exchanger e Drain pump and piping 36 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM If Required 1 Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible A CAUTION DO NOT use undiluted or automotive type antifreeze 2 A solution of 50 antifreeze will provide maximum protection of approximately 30 F 3 Follow the instructions from the antifreeze manufacturer Quantity of antifreeze required based on total system volume including expansion tank volume 4 Glycol is denser than water and changes the viscosity of the system The addition of glycol will decrease heat transfer and increase frictional loss in the boiler and related piping A larger pump with more capacity may be required to maintain desired flow rates in a glycol system 5 Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system WATER TREATMENT In hard water areas water treatment should be used to reduce the introduction of minerals to the system Minerals in the water can collect in the heat exchanger tubes and cause
8. Loosen two combustion air blower mounting nuts and slide the air shutter to the specified A dimension See chart b Tighten the combustion air fan mounting nuts c Proceed to step N to check appliance for proper operation G If the appliance does not function properly after manually setting the air shutter use a magnahelic or slope gauge to set the air shutter based on differential air pressure H Install a tee in each of the hoses connecting the chamber pressure and burner venturi pressure to the pressure switch Install a connecting hose from the branch of each tee to a manometer magnahelic or slope gauge legible in 0 1 increments up to 3 w c Connect chamber pressure to the positive pressure side of the gauge and burner venturi pressure to the negative side of the gauge I Turn the power switch to ON position Combustion air fan should start Leave the gas valve OFF J With the combustion air fan running the gauge will read a system differential pressure The proper differential pressure should be in the following range depending upon length of pipe used TABLE R DIFFERENTIAL AIR PRESSURE Btu hr Input Differential Pressure 150 000 1 4 1 8 w c 199 999 1 4 1 8 w c 250 000 1 5 1 9 w c 300 000 1 5 1 9 w c K Ifadjustment is necessary follow these steps If no adjustment 1s necessary go to step L a Loosen two combustion air blower mounting nuts to allow the ai
9. esce HOLIMS B pg gm Ava anna SSS FU aka a uiv MO1 OWA 2 o B 5 2 te J uiv yo SONS YOOGLNO y ard I yo 18 SOY DE ow wa L j 5 gt V M 9 i 1 5185 AVE N JVISOWH3HL Xy SLOVLNOO quvog MAANOT N Z LA 9 9 OF o s lx ZM X 411 3 j oan B 4 C o 5 T ae HU exe 24128 024 7 1 18 N 1 880 SI AYIA 8 9 X N33ML38 SAOWSY 3LON f ya THANG 140 STVNINUSL MIYOS OL 641436 NI 8 9 X TER 181081 SSHOLIMS S3HOLIMS TIV3HIM Z l J LO3NNOO OL 1 LM N33MISS N 5 OS OINA Y 5 SALON SO OLIO3NNOO Ee m 3874 M OL TOaNNOS OOM HM NOSNJS MP p OHAV1dO 1 1 x q3addInO3 LON 4 WALSAS L 48 3 LINN 9NIOIAH3S 3310338 YAMOd LOANNOOSIG 53 TROUBLESHOOTING CHART STEP WITH 120 VAC POWER TO 1 APPLIANCE TURN ON POWER 120 VAC POWER TO UNIT CHECK 120 VAC POWER SUPP
10. metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe Ensure that the air inlet pipes are properly supported The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used The PVC CPVC or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection Dryer vent should use a screw type clamp to seal the vent to the appliance and air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume When a sidewall or vertical roof top E Vent combustion air supply system is disconnected for any reason the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume A WARNING Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation spillage of flue products and carbon monoxide emissions causing severe personal injury or death FIG 16 Sidewall Air Inlet Vent Kits The sidewall E Vent Kit must be ordered from the manufacturer for single appliance installations with sidewall air inlet The part number for each kit is listed by appliance size Each kit includes a sidewall combu
11. requirements for a low water cut off device on boilers requiring forced circulation for operation FLOW SWITCH FIG 34 Water Flow Switch LOW WATER CUTOFF IF EQUIPPED A hot water supply boiler installed above radiation level must be provided with a low water cutoff device either as part of the appliance or at the time of installation An electronic or float type low water cut off is available as a factory supplied option on all appliances Low water cutoffs should be inspected every six months including flushing of float types COMBINATION GAS VALVE Each appliance has a combination gas valve to cycle the gas supply on and off to the burners The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves The valve has a gas control knob that must remain in the open position at all times when the appliance is in service The gas control valve has pressure taps located on the inlet and discharge sides of the valve Manifold pressure is adjusted using the regulator located on the valve The manifold pressure is preset at the factory and adjustment is not usually required If the manifold pressure is to be adjusted follow the Gas Manifold Pressure Adjustment Procedure for proper adjustment ALARM BELL IF EQUIPPED An alarm bell is available as a factory supplied option on 150 000 300 000 Btu hr heating boilers and water heaters The alarm bell is shipped sepa
12. Check V baffles on top of heat exchanger Remove and clean if necessary e Remove soot from heat exchanger with a stiff bristle brush Use a vacuum to remove loose soot from surfaces and inner chamber f Carefully reinstall combustion chamber door jacket panels dividers burners manifolds wires and hoses Use new gasket material for proper air seal g Reassemble and test for gas leaks h Cycle appliance and check for proper operation An appliance installed in a dust or dirt contaminated atmosphere will require cleaning of the burners on a 3 to 6 month schedule or more often based on severity of contamination Contaminants can be drawn in with the combustion air Non combustible particulate matter such as dust dirt concrete dust or dry wall dust can block burner ports and cause non warrantable failure Use extreme care when operating an appliance for temporary heat during new construction The burners and fan will probably require a thorough cleaning before the appliance is placed in service 6 Combustion Air Fan The combustion air fan should be checked every 6 months Clean as required when installed in a dust or dirt contaminated location 7 Water Circulating Pump Inspect pump every 6 months and oil as necessary Use SAE 30 non detergent oil or lubricant specified by pump manufacturer 8 Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids 9 Check frequ
13. Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Refer to this manual for assistance or additional information consult a qualified installer service agency or the gas supplier This appliance contains material that has been identified as carcinogenic or possibly carcinogenic to humans CHECKING EQUIPMENT Upon receiving equipment check for signs of shipping damage Pay particular attention to parts accompanying the appliance which may show signs of being hit or otherwise being mishandled Verify total number of pieces shown on packing slip with those actually received In case there is damage or a shortage immediately notify carrier DO NOT Use this appliance if any part has been under water The possible damage to a flooded appliance can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced A WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbors phone Follow the gas supplier s instruc
14. Maintain required clearances from combustible surfaces 6 The appliance must not be installed on carpet or other combustible material other than wood flooring 7 Outdoor models require the installation of an optional outdoor kit Instructions for mounting the parts in the kit are included in the venting section of this manual Outdoor models MUST NOT be installed directly on the ground The outdoor appliance must be installed on a concrete brick block or wood flooring Outdoor models have additional special location and clearance requirements These are specifically addressed in the venting section under Outdoor Installation windproof rainproof cabinet protects the appliance from the weather CLEARANCES FROM COMBUSTIBLE CONSTRUCTION FIG 3 Installation Clearances Drawing Clearances from Combustible Construction Right Side 1 25 4 mm Rear 1 25 4 mm Left Side 6 15 cm 24 61 cm suggested for service Front 3 76 2 mm 24 61 cm suggested for service Top 3 76 2 mm Flue 1 25 4mm All appliances have been approved for closet installation Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the appliance COMBUSTION AND VENTILATION AIR REQUIREMENTS FOR CONVENTIONALLY VENTED APPLIANCES Provisions for combustion and ventilation air must be in accordance with Section 5 3 Air for Combustion and Ventilation of the latest edition
15. air inlet cap must be installed at least 1 foot 30 cm above ground level and above normal snow levels Multiple Sidewall Direct Vent Installations Multiple Sidewall Direct Vent Caps AIRINLETS 21 Installation of Multiple Direct Vent Caps The combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot 91 cm radius clearance below or horizontally from the closest flue outlet Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the 3 foot 91 cm radius minimum clearance between air inlet and flue outlet must be maintained All clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple appliance installations A CAUTION Appliances which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit Proper freeze protection must be provided see Freeze Protection 18 Vertical Direct Vent FIG 22 Vertical Direct Vent Installation The E 7 Vertical Direct Vent System A DIRECT VENT SYSTEM WITH VERTICAL THROUGH ROOF TERMINATIONS Follow all requirements in the General Venting section for venting flue products to the outdoors and general installation instructions All direct vent appliances must have combustion air supplied directly to the applia
16. direct vent vertical through roof vent system DOES NOT require the purchase of a special vent kit from the manufacturer The specified flue pipe vertical through roof flue outlet cap air inlet pipe and components to assemble the through roof combustion air inlet cap are purchased locally TABLE E DIRECT VENT FLUE AND AIR PIPE SIZES Direct Vent Flue Size Air Inlet Pipe Input Btu hr 150 000 199 999 250 000 300 000 Minimum diameter installer may increase diameter one pipe size for ease of installation if needed Air Inlet Cap for Vertical Direct Vent EXHAUST TERMINAL NOTE IF FLUE PASSES THRU FLAT ROOF WITH PARAPET WALLS SEE TERMINATIONS FLAT ROOF FIG 8 AND FIG 9 IF FLUE PASSES THRU A SLOPED OR PEAKED ROOF SEE VENT TERMINATIONS FIG 6 AND FIG 7 TYPICAL SOIL PIPE FLASHING ACCEPTABLE 23 Air Inlet Cap for Vertical Direct Vent System Roof Top Air Inlet Cap for Vertical Direct Vent The air inlet cap for the vertical through roof direct vent system is assembled from components purchased locally The air inlet cap consist of two 90 ells installed at the point of termination for the air inlet pipe The first 90 ell is installed on the roof top at the highest vertical point of the air inlet pipe and turned horizontal the second 90 ell is 19 installed on the horizontal outlet of the first ell and turned down A 90 ell and a 90 street ell may be used to make this asse
17. directly to the bell increaser on top of the appliance No additional draft diverter or barometric damper is required on single appliance installations with a dedicated stack and a negative draft maintained between 0 02 to 0 05 inches water The flue may be combined with the vent from any other negative draft Category I appliances Multiple appliance installations common vented with other negative draft appliances require that each appliance must have a barometric damper installed to regulate draft within the proper range The common vent and connectors from multiple appliances must be sized per the requirements of the venting tables for type B double wall vents in the latest edition of the National Fuel Gas Code ANSI Z223 1 The sidewall or vertical roof top E Vent combustion air supply system has specific vent material and installation requirements The air inlet pipe connects directly to the appliance to supply combustion air In most installations the combustion air inlet pipe will be a dedicated system with one air inlet pipe per appliance Multiple air inlets may be combined if the guidelines in Combined Air Inlet Points are followed The air inlet pipe will be connected to a combustion air inlet cap as specified in this section Combustion air supplied from outdoors must be free of contaminants see Combustion and Ventilation Air Section E Vent with Sidewall Air FIG 13 E Vent with Sidewall Air Sidewall Air Inlet T
18. drop in outdoor air temperature up to the maximum set point temperature See Figure 39 for an outdoor air reset chart example 33 RESET SET POINT RATIO 1 5 1 0 RATIO 0 5 OPERATOR SET POINT O A TEMP FIG 39 Outdoor Air Control Example Chart Outdoor Air Shutdown Enable Disable Switch The Outdoor Air Shutdown Enable Disable switch turns the outdoor air shutdown feature On and Off Disabling the Outdoor Air Shutdown feature allows the appliance to operate regardless of the outdoor air temperature This is needed for indirect domestic hot water systems for example ADDITIONAL TEMPERATURE CONTROLS High Water Temperature Limit Control The appliance is equipped with a fixed setting auto reset high water temperature limit control The heating boiler temperature limit control has a fixed limit setting of 240 F 115 C the water heater temperature limit control has a fixed limit setting of 200 F 93 C If water temperature exceeds the set point the limit will break the control circuit and shut down the appliance The limit control will only be reset after the water temperature has cooled below the set point of the limit The high water temperature limit control is mounted in the outlet side of the front header Manual Reset High Water Temperature Limit Control Standard on Water Heaters and Optional on Boilers The appliance may be optionally equipped with a fixed setting manual reset high water
19. gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate The vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Combustion Air Inlet Combustion air supply pipes can NOT be combined into a single pipe for multiple appliance installations Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation Air To prevent recirculation of flue products into the combustion air inlet follow all instructions in this section To help prevent recirculation of flue products The combustion air inlet cap MUST NOT be installed above the flue outlet cap The combustion air inlet cap must be installed horizontally or below the flue outlet and MUST maintain a minimum 3 foot 91 cm radius clearance from the flue outlet cap The combustion air inlet cap and vent cap for flue outlet MUST be located on the same sidewall and in the same pressure zone The combustion air inlet cap must not be installed closer than 10 feet 3 05 m from an inside corner of a L shaped structure The combustion
20. is recommended on rigid hangers installed with a copper system The boiler pressure relief valve must be piped to suitable floor drain See the relief valve section in the Installation and Service Manual 40 A CAUTION A leak in a boiler system will cause the system to intake fresh water constantly which will cause the tubes to accumulate a lime scale build up This will cause a NON WARRANTABLE FAILURE WATER CONNECTIONS HEATING BOILERS ONLY This boiler 1s shipped from the factory with 2 NPT inlet and outlet connections on the 150 000 through 300 000 Btu hr models If required field installed reducing bushings may be used to decrease the inlet and outlet water connections to 1 1 2 NPT on the 150 000 and 199 999 Btu hr models only Low boiler flow can result in noise on burner operation CIRCULATOR PUMP REQUIREMENTS This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system design water temperature rise A heat exchanger head loss chart Table Q is provided to assist in proper pump selection Also provided is a System Temperature Rise Chart Table S This table provides GPM and boiler head loss at various temperature rises for each boiler based on Btu hr input Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature wh
21. level in the expansion tank Ensure that diaphragm type expansion tanks are properly charged and not water logged 10 Start the boiler according to the Start Up Instructions in the Installation and Service Manual Operate the system including the pump boiler and radiation units for one hour 11 Recheck the water level in the expansion tank If it exceeds half the tank volume open the tank to reduce the water level Recheck pressure charge on diaphragm type tanks 12 Shut down the entire system and vent all radiation units and high points in the system 13 Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris Reopen the water makeup valve 14 Verify system pressure with the boiler pressure gauge before beginning regular operation 15 Within three days of startup recheck and bleed all air vents and the expansion tank using these instructions INSTALLATION WITH A CHILLED WATER SYSTEM EXPANSION N TAK t LOW WATER FLOW SWITCH c FIG 49 Installation with a Chilled Water System Pipe refrigeration systems in parallel Install duct coil downstream at cooling coil Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity circulatio
22. of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting FIG 4 Combustion Air Direct from Outside 1 If air is taken directly from outside the building with no duct provide two permanent openings a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5cm per kW This opening must be located within 12 30 cm of the top of the enclosure b Ventilation air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5cm per kW This opening must be located within 12 30 cm of the bottom of the enclosure FIG 5 Combustion Air through Ducts 2 If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu hr 11cm per kW FIG 6 Air from an Interior Space 3 If air is taken from another interior space each of the two openings specified above should have a net free area of one square inch for each 1000 Btu hr 22cm per kW of input b
23. plate The vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Locate units as close as possible to chimney or gas vent Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure Connection to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury The Vent terminal should be vertical and exhaust outside the building at least 2 feet 61 cm above the highest point of the roof within a 10 foot 3 05 m radius of the termination The vertical termination must be a minimum of 3 feet 91 cm above the point of exit in the rooftop A vertical termination less than 10 feet 3 05 m from a parapet wall must be a minimum of 2 feet 61 cm higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment 14 A CAUTION An appliance which is shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit Proper freeze protection m
24. requirements Turn the control set point dial to the desired operating water temperature Observe the boiler discharge temperature after each set point adjustment to ensure proper operation ROOM THERMOSTAT OR REMOTE THERMOSTAT CONNECTION TO TERMINAL BOARD A room thermostat or remote temperature control may be connected to the boiler The room thermostat should be installed on an inside wall away from the influences of drafts hot or cold water pipes lighting fixtures televisions sun rays or fireplaces Follow the manufacturers instructions supplied with the thermostat for proper installation and adjustment The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection Terminal Strip R1 W1 R2 W2 A X B C FIG 50 Terminal Strip Remove the jumper between the R1 and W1 terminals on the terminal strip Refer to the chart in this section to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the and W1 terminals on the terminal strip Connection to the terminal strip will allow the room thermostat to make and break the 24 VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requirements Set the boiler operating temperature control as described above TABLE V WIRE GAUGE REQUIREMENTS FOR TERMINAL STRIP CONNECTION Maximum Allowable Wire Gaug
25. system flow requirements this piping may still result in boiler short cycling BOILER FLOW RATES A CAUTION The maximum flow rate through the 150 000 through 300 000 Btu hr boilers must not exceed 60 GPM The heat exchanger is generally capable of operating within the flow rates of a residential heating system Should the flow rate exceed the maximum allowable flow rate through the boiler an external bypass must be installed The bypass should be fully sized with a balancing valve to allow for proper adjustment of flow Flow rate can be determined by measuring the temperature rise through the boiler The basic guide for minimum flow in this boiler is based on a 40 F 22 C temperature rise in most installations Lower flow and a higher temperature rise is acceptable if the boiler system is specifically designed for the characteristics of a higher temperature rise A system not specifically designed for a higher temperature rise may experience overheating of the boiler water This can cause short burner on cycles system noise and in extreme cases a knocking flash to steam These conditions can lead to operational problems and non warrantable failures of the boiler High temperature rise systems must be designed by a qualified engineer TABLE U MINIMUM REQUIRED FLOW 150 000 Btu hr 199 999 Btu hr 250 000 Btu hr 300 000 Btu hr TABLE T SYSTEM TEMPERATURE RISE CHART Based on Boiler Output in Btu hr Ft
26. temperature limit control This manual reset temperature limit control has a fixed limit setting of 230 F 110 C If water temperature exceeds this set point the limit will break the control circuit and shut down the appliance The limit control can only be reset after the water temperature has cooled below the set point of the limit Reset of the limit control is accomplished by pushing the Red Reset Button located on the control 3 Remove the upper front access panel The limit control will not reset until the water 4 Turn the power switch on the inside of the cabinet to temperature has dropped below the set point of OFF position the high limit 5 Set the thermostat to the lowest setting LIGHTING INSTRUCTIONS FOR YOUR SAFETY 6 This appliance is equipped with an ignition device which READ BEFORE OPERATING automatically lights the burners DO NOT try to light the burners by hand A WARNING 7 Turn the gas control knob on the gas valve clockwise to If you do not follow these instructions exactly a the OFF position fire or explosion may result causing property damage personal injury or loss of life WHAT TO DO IF YOU SMELL GAS WIRING TERMINALS 0 OUTLET PRESSURE TAP Do not try to light any appliance Do not touch any electric switch do not use any 4 7 poner phone in your building Immediately call your gas supplier from a neighbors phone Follow th liers instructions FI
27. the proper velocity in the tubes This will yield long life and economical operation from your water heater Excessive lime build up in the tube is a result of too little velocity in the tubes Excessive pitting or erosion in the tube is caused by too much velocity through the tubes Care should be taken to measure temperature rise and maintain a velocity as follows 1 With the pump running and the hot water supply boiler off the inlet and outlet thermometers should read the same temperatures If they do not an adjustment must be made to your final calculation 2 Tum the water heater on and allow time for the temperature to stabilize Record the difference between the inlet and outlet temperatures This difference will be the temperature rise 3 Compare the temperature rise on the heater with the required temperature rise in Table W Should adjustment be needed proceed as follows If the temperature rise is too high the water velocity is too low Check the following 1 Check for restrictions in the outlet of the water heater 2 Be sure all valves are open between the water heater and the tank 3 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction 4 Be sure the circulation pipes between the water heater and storage tank are not less than 2 diameter for a single appliance 150 000 through 300 000 Btu hr installation 5 Common manifold piping for multiple
28. vicinity of this appliance vent air intake system or any location from which fumes could reach the appliance or vent air intake system CODES The equipment shall be installed in accordance with those installation regulations in force in the local 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 In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD 1 All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Where required by the authority having jurisdiction in Canada the installation must comply with the CSA International CAN CGA B149 1 and or B149 2 Installation Code and or local codes This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas fired appliances ANSI 721 13 and ANSI Z21 10 3 INSTALLATION PROCEDURE AIR INTAKE W DUST COVER GAUGE RELIEF VALVE AIR SLOTS JUNCTION BOX FIG 1 Typical Fr
29. Air To prevent recirculation of flue products into the combustion air inlet follow all instructions in this section The combustion air inlet cap MUST be at least 2 feet 61 cm below the vertical through roof flue outlet cap if within 10 feet 3 05 m The combustion air inlet cap and vent cap for the flue outlet MUST be located on the same roof top surface and in the same pressure zone The combustion air inlet cap must not be installed closer than 10 feet 3 05 m from an inside corner of a L shaped structure The combustion air inlet cap must be installed at least one foot 30 cm above the roof top and above normal snow levels Multiple Vertical Direct Vent Installations 25 Multiple Vertical Direct Vent Installations Multiple Vertical Direct Vent Installations The combustion air inlet caps for multiple appliance installations must maintain the minimum 2 foot 61 cm clearance below the closest vertical flue outlet if within 10 feet 3 05 m Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the air inlet must always be at least 2 feet 61 cm below the closest flue outlet if the outlet is within 10 feet 3 05 clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple appliance installations CAUTION Boilers which are shut down or will not operat
30. BLE G INLET GAS PRESSURE Nat Gas 10 5 w c 4 0 w c Max Inches Water Column Min Inches Water Column Maximum inlet gas pressure must not exceed the value specified Minimum value listed is for the purposes of input adjustment MANIFOLD PRESSURE Measured at the pressure tap on the downstream side of the combination gas valve The gas regulator on the appliance s combination gas valve s is adjustable to supply proper manifold pressure for normal operation If adjustment of regulator pressure is required see Manifold Adjustment Procedure Do not increase regulator pressure beyond specified pressure setting TABLE H NET MANIFOLD PRESSURE Nat Gas Regulator Btu hr Input Setting 150 000 300 000 1 8 w c LP Gas Regulator Setting 4 6 w c Btu hr Input 150 000 300 000 TABLE MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING SIZE CHART Nominal Iron Pipe Size i e gt foe fie Length of Pipe in Straight Feet Maximum Capacity of Pipe in Thousands of Btu hr per hour for gas pressures of 14 Inches Water Column 0 5 PSIG or less and a pressure drop of 0 5 Inch Water Column Based on NAT GAS 1025 Btu hr per Cubic Foot of Gas and 0 60 Specific Gravity outside the building The appliance will not operate GAS PRESSURE TEST properly if the reference hose is removed or a vent to atmosphere is installed The appliance must be disconnected from t
31. E N AMP DRAW DATA 150 000 through 300 000 Btu hr Models Maximum Total Amps 120 VAC Valve Firing Control Controls 5 12 5 30 3 97 4 15 F 9 Single Stage M 9 Two Stage Pump Wiring for a Heating Boiler The heating boiler circulating pump must be purchased locally The maximum load for the pump switched by the internal pump relay must not exceed 1 HP The current draw for a field installed 120 VAC pump MUST be added to the boiler s current draw to determine the minimum wire size for 120 volt service TRANSFORMER THERMOSTAT POWER SWITCH TERMINAL STRIP IGNITION MODULE MANUAL RESET HIGH LIMIT SWITC THERMOSTAT POWER SWITCH TERMINAL STRIP IGNITION MODULE FIG 36 Water Heater Control Panel TEMPERATURE ADJUSTMENT Operating Temperature Control NOTE The temperature controller is pre set at the factory with test settings You may need to adjust the settings to meet your specific needs WARNING Return water temperatures must not be less than 140 F If lower return water temperatures are required follow the instructions for Low Temperature Bypass Requirements or Three Way Valves see pages 42 and 43 Locating Temperature Control Remove the control panel door on the front of the appliance in order to locate and access the temperature control Temperature Control Settings There are three setting knobs on the temperature cont
32. EB EW I S 09 INSTALLATION AND SERVICE MANUAL Z HOT WATER HEATING BOILERS D Domestic Water Heaters IMPORTANT This is a gas appliance and should be installed by a licensed electrician and or certified gas supplier Service must be performed by a qualified service installer service agency or the gas supplier WARRANTY Installation and service must be performed by a qualified service installer service agency or the gas supplier Factory warranty shipped with appliance does not apply to appliances improperly installed or improperly operated Experience has shown that improper installation or system design rather than faulty equipment is the cause of most operating problems 1 Excessive water hardness causing a lime build up in the copper tube is not the fault of the equipment and is not covered under the manufacturer s warranty see Water Treatment and Water Chemistry N Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer s warranty see Boiler Flow Rates and Temperature Rise for flow requirements SPECIAL INSTRUCTIONS TO OWNER This manual supplies information for the installation operation and servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation 150 000 300 000 Btu hr MODELS A WARNING
33. G 40 Combination Gas Valve If you cannot reach your gas supplier call the fire 8 Wait five 5 minutes to clear out any gas If you smell department gas STOP Follow the instructions in the safety information What To Do If You Smell Gas If you 1 This appliance does not have a pilot It is equipped with don t smell gas go on to the next step an ignition device which automatically lights the burner Do not try to light the burner by hand 9 Turn the gas control knob on the gas valve counterclockwise to the ON position 2 BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because 10 Set the thermostat to the desired setting some gas is heavier than air and will settle to the floor 11 Turn the power switch on the inside of the cabinet to the 3 Use only your hand to turn the gas control lever Never ON position use tools If the lever will not turn by hand don t try to repair it call a qualified service technician Force or 12 Replace control access panel attempted repair may result in a fire or explosion 13 Turn on all electrical power to the appliance 4 Do not use this appliance if any part has been under water Immediately call a qualified service technician to 14 If the appliance will not operate follow the instructions inspect the appliance and to replace any part ofthe control To Turn Off Gas To Appliance and call your service system and any gas control which has be
34. LED LIGHTS UP FUNCTIONS REPLACE ATA CONVENIENT TIME 24 VAC TO GAS VALVE CHECK WIRING CONNECTIONS STEP IGNITER LED TURNS OFF YES 11 amp VALVE LED STAYS ON GAS VALVE OPEN No REPLACE GAS VALVE CHASSIS GROUND amp WIRING CONNECTIONS TO IGNITER CHECK WIRING CONNECTIONS IGNITER SENSOR MOUNT PROPERLY CHECK MOUNTING SET GAS SUPPLY PRESSURE SEE INSTRUCTIONS 12 MAIN BURNER RUNS UNTIL CALL FOR HEAT ENDS AND VALVE LED TURNS OFF SET MANIFOLD PRESSURE SEE INSTRUCTIONS STEP 18 No TIGHTEN OR REPLACE GROUND STEP 14 No CORRECT MOUNTING STEP 15 REPLACE THERMOSTAT GAS VALVE CLOSES WHEN ONE LEAD IS REMOVED REPLACE GAS VALVE Er CAB STOPS AFTER 30 SEC POST PURGE n SYSTEM OK REPEAT PROCEDURE UNTIL SYSTEM OPERATES NORMALLY 55 Revision 6 EB EW i amp s 06 reflects changes made to the O A section Revision 7 EB EW I amp s 07 reflects changes made to LBLs on Pages 50 53 Revision 8 ECO C02870 reflects changes made to the scald section pages 47 49 and the addition of a mixing valve to the piping diagram FIG 51 pg 47 Revision 9 ECO C03126 reflects changes made to Table Q Air Shutter Adjustment Opening on page 37 EB EW I S 09 CP 5M 2 09
35. LOUVERS FRONT amp REAR GAS VALVE COVER FIG 27 Outdoor Kit Installed on Appliance The Outdoor Kit The required outdoor kit part numbers are listed by appliance size The venting kit must be furnished by the manufacturer in accordance with CSA International and ANSI requirements Each kit includes the outdoor vent cap top assembly gas valve cover assembly deflectors and weatherproof junction box assembly TABLE F Outdoor Kits Outdoor Kit with Pump Cover ODK3062 ODK3063 ODK3067 ODK3068 Outdoor Kit without Pump Cover ODK3069 ODK3070 ODK3071 ODK3072 150 000 199 999 250 000 300 000 CAUTION Appliances which are shut down or will not operate may experience freezing due to convective air flow down the vent cap installed on the Proper freeze protection must be appliance provided See Freeze Protection GAS SUPPLY Verify appliance is supplied with type gas specified on rating plate This appliance is orificed for operation up to 2000 feet altitude The appliance will be derated 4 per 1000 feet above 2000 feet elevation Consult the factory for installations above 2000 feet elevation Field conversions for operation at high altitude must be performed by factory authorized personnel only The appliance will be marked to indicate suitability for high altitude operation INLET GAS PRESSURE Measured at the inlet pressure tap located upstream of the combination gas valve TA
36. LY SWITCH SWITCH LIGHTS UP CHECK WIRING TO SWITCH CHECK WIRING CONNECTIONS REPLACE SWITCH CHECK 120 VAC THRU SWITCH 1 IGNITION CONTROL MODULE 120 VAC MODULE CHECK WIRING CONNECTIONS STEP 3 REPLACE MODULE STEP NOTE THIS CHART IS FOR NOTE MUST OPEN WITHIN 4 CONTINUOUS PUMPS ONLY 45 SEC AFTER CALL FOR SEE INSTALLATION INSTRUCTIONS HEAT AND CLOSE WITHIN FOR INTERMITTENT PUMP AND 5 MIN AFTER CAB STARTS PUMP DELAY OPTIONS FOR OR MODULE LOCKS OUT PUMP OPERATION STEP COMBUSTION AIR BLOWER 5 CAB STARTS AIR PROVING SWITCH OPEN REPLACE SWITCH YES CHECK FOR 120 VAC AT CAB No CHECK WIRING CONNECTIONS REPLACE CAB STEP AIR PROVING SWITCH AIR SHUTTER ADJUSTMENT ADJUST AIR SHUTTER TO 6 CLOSES CORRECT SEE INSTRUCTIONS PROPER SET POINTS CHECK FOR AIR LEAKS FROM BURNER COMPARTMENT PRESSURE HOSE REPLACE SWITCH STEP IGNITION MODULE PURGE LED BURNED OUT BUT CONTROL 7 LED LIGHTS UP FUNCTIONS REPLACE ATA CONVENIENT TIME STEP LED BURNED OUT BUT CONTROL IGNITION MODULE IGNITER LED LIGHTS UP amp PURGE LED TURNS OFF FUNC TIONS REPLACEATA CONVENIENT TIME 54 TROUBLESHOOTING CHART CONTINUED STEP IGNITER SENSOR WARMS UP 9 AND GLOWS RED 120 VAC AT IGNITER SENSOR CHECK WIRING CONNECTIONS REPLACE IGNITER SENSOR STEP IGNITION MODULE VALVE LED BURNED OUT BUT CONTROL 10
37. NAL A PRIMARY gt SUPPLY PUMP a BOILER BYPASS pUMP PRIMARY SECONDARY BOILER PIPING WITH BY PASS FOR LOW TEMPERATURE OPERATION FIG 47 LOW TEMPERATURE BYPASS REQUIREMENTS A boiler operated with an inlet temperature of less than 140 F 60 C must have a bypass to prevent problems with condensation A bypass as shown in Figure 47 must be piped into the system at the time of installation This piping is like a primary secondary boiler installation with a bypass in the secondary boiler piping Inlet water temperatures below 140 F 60 C can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue Condensation can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the vent system and related components The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140 F 60 C This should prevent the products of combustion from condensing in most installations The bypass should be fully sized with a balancing valve to allow for proper adjustment A valve must also be provided on the boiler discharge after the bypass Closing this discharge valve forces water through the bypass Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open A small amount of the high
38. Point The Set Point knob specifies the target water temperature in degrees Fahrenheit After the water temperature reaches the set point the temperature control shuts off the burners Differential The Differential specifies the number of degrees below the set point that the control will allow the water temperature to drop before it brings the appliance back on again High Fire Offset The temperature control operates a two stage firing system The two stages are High Fire and Low Fire High Fire operates all burners while Low Fire operates approximately one half of the burners The High Fire knob specifies the number of degrees below set point that the High Fire stage shuts down At that point the appliance will continue to operate at the Low Fire stage until the set point is reached The High Fire offset knob has settings between 0 F and 20 F If set at 0 F the High Fire offset is disabled and the appliance will operate at the High Fire stage until the set point is reached and the temperature control shuts the appliance off No matter what the High Fire offset knob is set to the appliance will light at Low Fire and operate for approximately 10 to 120 seconds before the High Fire stage actuates Boiler Application Standard boiler appliances are shipped with one sensor the inlet water temperature sensor An optional sensor can be purchased and installed for use as a remote system sensor Boilers with the outdoor air reset opti
39. RLESS CHIMNEY ae OR PARAPET FIG 10 Vent Termination from a Flat Roof 10 or less from Parapet Wall 10 OR MORE NO HEIGHT ABOVE PARAPET REQUIRED 4 WHEN DISTANCE FROM WALLS OR PARAPETS IS MORE THAN 10 WALL OR PARAPET CHIMNEY FIG 11 Vent Termination from a Flat Roof more than 10 from Parapet Wall A vertical termination less than 10 feet 3 05 m from a parapet wall must be a minimum of 2 feet 61 cm higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney To avoid a blocked flue condition keep the vent cap clear of snow ice leaves debris etc Flue gases will form a white plume in winter Plume could obstruct window view Flue gas condensate can freeze on exterior surfaces or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Flue gas condensate can cause discoloration of exterior building surfaces Adjacent brick or masonry surfaces should be protected with a rust resistant sh
40. VENTIONAL NEGATIVE DRAFT VENTING SYSTEM Follow all requirements in the General Venting section for venting flue products to the outdoors obtaining adequate combustion and ventilation air and general installation instructions All conventionally vented appliances must have combustion and ventilation air supplied to the mechanical room in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Conventional Venting Installation A bell increaser is installed directly on the appliance vent outlet The bell increases the vent size by 1 inch 25 4 mm in diameter The bell increaser MUST be installed on the appliance vent outlet for all conventional negative draft vent systems Vent connection is made directly to the bell increaser on top of the appliance No additional draft diverter or barometric damper is required on single appliance installations with a dedicated stack and a negative draft within the specified range of a negative 0 02 to 0 05 inches water Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have a barometric damper installed to regulate draft within the proper range If the draft in a dedicated stack for a single appliance installation exceeds the specified
41. a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted appliances seldom need flue cleaning All gaskets on disassembled components must be replaced with new gaskets on reassembly Gasket kits are available from your distributor a Turn off main power to appliance b Turn off main manual gas shutoff to appliance c Remove the front outer jacket panels d Remove gas valve from the manifold e Remove screws from manifold mounting brackets Pull manifold s orifice assembly away from burners Remove hose from burner tap id Remove mounting screws from each burner and slide burner out toward front of appliance Use caution to prevent damage to burner gaskets refractory hot surface igniter or wiring g Remove soot from burners with a stiff bristle brush Damaged burners or burner gaskets must be replaced 39 HEAT EXCHANGER CLEANING 5 Check the heat exchanger surface for sooting If present heat exchanger must be cleaned and problem corrected Proceed as follows a Remove manifold orifice assembly as described in steps a through e in Burner Removal b Disconnect wiring from hot surface igniter and hose from burner tap c Remove inner combustion chamber door mounting screws tilt slightly and slide door assembly out toward front of appliance Use caution to prevent damage to refractory hot surface igniter hose and wiring d
42. a sealed combustion air inlet pipe See E Vertical Direct Vent System or E Sidewall Direct Vent System installation requirements in this manual The connection from the vent to the vent termination outside the building MUST be made with type B double wall vent materials and must be direct as possible with no reduction in diameter The vent accessories such as firestop spacers thimbles caps etc MUST be from the same vent material and installed in accordance with the manufacturers listing The vent connection through the roof must provide correct spacing to combustible surfaces Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm per meter from the appliance to the vent terminal Follow manufacturers instructions The vent cap shall terminate at least 3 feet 91 cm above any forced air inlet within 10 feet 3 05 m The vent shall terminate at least 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 30 cm above any door window or gravity air inlet to the building Do not terminate the vent in a window well stairwell alcove courtyard other recessed area The vent can not terminate below grade Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal
43. able below TABLE K 90 FITTINGS TO EQUIVALENT STRAIGHT PIPE Diameter Pipe inches Equivalent length of Straight Pipe feet GAS PIPING MANUAL GAS BHUT OFF VALVE UNION SEDIMENT TRAP USE WRENCH TO HOLD PIPING GAS VALVE FIG 28 Gas Piping to Heater All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gases All piping must comply with local codes and ordinances Tubing installations must comply with approved standards and practices Install Piping to Control 1 The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity Verify pipe size with your gas supplier Use new properly threaded black iron pipe free from chips If tubing is used make sure the ends are square deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Run pipe or tubing to the control If tubing is used obtain a tube to pipe coupling to connect the tubing to the control 25 4 Install a sediment trap in the supply line to the gas control Thread pipe the proper amount for insertion into gas valve Effective length of standard 3 4 NPT thread is 9 16 overall length of thread is 3 4 DO NOT THREAD PIPE TOO FAR Valve distortion or malfunction may result if the pipe is inserted too d
44. ap and or air inlet cap other than the manufacturers recommended caps may result in operational problems with the appliance or potentially hazardous spillage of flue products which can cause personal injury death or property damage Flue Pipe Materials Select venting material from the following specified vent materials Heat Fab Saf T CI Vent with AL29 4C stainless steel Call 800 772 0739 for nearest distributor Z Flex Z Vent with AL29 4C stainless steel Call 1 800 654 5600 for nearest distributor Protech Systems Inc Fas N Seal Vent with AL29 4C stainless steel Call 1 800 766 3473 for nearest distributor Flex L International Inc Star 34 Vent with AL29 4C stainless steel Call 1 800 561 1980 for nearest distributor Metal Fab Corr Guard Vent with AL29 4C stainless steel Call 1 800 835 2830 for nearest distributor or other listed AL29 4C vent systems suitable for positive pressure Air Inlet Pipe Materials Select air inlet pipe material from the following specified materials PVC CPVC 4 5 or 6 LD Dryer Vent Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified below Plastic pipe requires an adapter not provided to transition between the air inlet and cap The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moi
45. appliance installations will require larger minimum pipe sizes to ensure proper flow See Table X If the temperature rise is too low the water velocity is too high Adjust as follows 1 Slowly throttle the valve on the outlet side of the water heater until the temperature rise 18 steady at the required temperature rise as noted in Table W 2 Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchanger This is a non warrantable failure Temperature rise must be properly adjusted to achieve the specified flow rate TABLE W WATER HEATER TEMPERATURE RISE Btu hr Input Temperature Rise F 150 000 199 999 250 000 300 000 WATER CHEMISTRY The required temperature rise and the standard pump sizing are based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 PPM Consult the manufacturer when heating potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water will require a larger circulating pump an optional cupro nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosi
46. as at full fire The difference in the gross manifold pressure and the front chamber pressure is the net manifold pressure setting of the gas valve s regulator Compare the net setting to the setting specified for the type of gas used Adjust regulator as required Set the thermostat to a setting lower than the appliance s water temperature to turn the burners off Allow appliance to run through the post purge sequence Turn the power switch to the OFF position TABLE L NET MANIFOLD PRESSURE Regulator Pressure Less Front Chamber Pressure Type of Gas Net Manifold Pressure Setting DIENEN NOTE The front chamber pressure must be subtracted from the gross regulator pressure to obtain actual net manifold pressure for normal operation The front chamber pressure may vary based on elevation For stages of operation vent length and model information on chamber pressure see Combustion Air Adjustment Do not increase net manifold pressure beyond the specified pressure setting 17 If adjustment is necessary remove the regulator cover screw on the gas valve 18 Turn regulator adjustment screw clockwise to raise regulator gas pressure counterclockwise to lower the regulator gas pressure Turn regulator adjustment 27 screw 1 4 turn in the desired rotation and cycle the burners on in the sequence listed below and record the observed chamber and regulator settings Subtract to determine the net manifold pressu
47. ay Timing 30 Seconds after burner shutdown on units equipped with an optional factory supplied pump delay or intermittent pump control system FREEZE PROTECTION 1 For water heaters and boilers with the pump delay option if either the inlet sensor or the optional multi purpose temperature sensor reads below 40 F the pump relay will turn ON When the temperature rises above 50 F the pump relay will turn OFF 2 Location Heating boilers and water heaters must be located in a room having a temperature safely above freezing 32 F 0 C 3 Caution A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing The cold outside air pulled down the flue may freeze a heat exchanger This condition must be corrected to provide adequate freeze protection 4 Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze Follow the manufacturer s instructions DO NOT use undiluted or automotive type antifreeze 5 snow screen should be installed to prevent snow and ice accumulation around the appliance venting system in cold climates 6 Shut down and Draining If for any reason the appliance is to be shut off the following precautionary measures must be taken a Shut off gas supply b Shut off water supply c Shut off electrical supply d
48. cumulation Air Inlet Cap for Roof Top Termination EXHAUST TERMINAL NOTE IF FLUE PASSES THRUA FLAT ROOF WITH PARAPET WALLS SEE TERMINATIONS FLAT ROOF FIG 8 AND FIG 9 IF FLUE PASSES THRU SLOPED OR PEAKED ROOF SEE VENT TERMINATIONS FIG 6 AND FIG 7 TYPICAL SOIL PIPE FLASHING ACCEPTABLE 15 Air Inlet Cap for Roof Top Termination The point of termination for the combustion air inlet cap MUST be at least 2 feet 61 cm below the point of flue gas termination vent cap if it is located within 10 3 05 m of the flue outlet Use care to ensure that the 90 ell assembly is properly installed on the air inlet pipe The combustion air inlet cap must not be installed closer than 10 feet 3 05 m from an inside corner of an L shaped structure The combustion air inlet cap must be installed at least one foot 30 cm above the roof top and above normal snow levels Incorrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury death or property damage Combined Air Inlet Points The air inlet pipes from multiple appliances can be combined to a single common connection if the common a
49. draft a barometric damper must be installed to control draft The vent pipe sizes are TABLE B CONVENTIONAL VENT FLUE SIZE Flue Size Input Btu hr 150 000 199 999 250 000 300 000 Vent size with 1 bell increaser installed for conventional negative draft venting On a conventionally vented negative draft appliance the connection from the vent to the stack or vent termination outside the building MUST be made with listed Type B double wall or equivalent vent connectors and must be direct as possible with no reduction in diameter Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks The Type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturer s listing The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes Locate appliances as close as possible to chimney or gas vent Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm per meter from the appliance to the vent terminal Follow manufacturers instructions Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure Connection to a positiv
50. e may experience freezing due to convective air flow in the air inlet pipe connected to the unit Proper freeze protection must be provided see Freeze Protection The Outdoor Vent System FIG 26 Outdoor Installation Illustration OUTDOOR INSTALLATION Appliances can be installed outdoors when equipped with the optional outdoor kit The outdoor kit includes the outdoor vent cap top assembly gas valve cover deflectors and a weatherproof junction box The bell increaser installed on the appliance vent outlet must be removed The bell increaser is NOT USED with the outdoor vent cap The outdoor vent cap top assembly mounts directly to the top of the appliance and covers the flue outlet The combustion air is provided through the slotted openings in the jacket The deflectors cover the slotted openings The appliance is self venting and requires no additional vent piping The gas valve cover mounts directly to the left side panel of the appliance and covers the gas valve and gas valve wiring connector The standard junction box that is installed on the left side panel of the appliance must be removed The weatherproof junction box mounts directly to the left side panel of the appliance and provides a weatherproof enclosure for the 120 VAC service and pump connections NOTE If the appliance is equipped with an optional indoor flow switch the flow switch must be changed to the outdoor version listed in the parts li
51. e Length DOMESTIC WATER HEATER This section applies only to those units used to supply domestic hot water usually in conjunction with a storage tank The use of a properly sized pump and the control of water velocity as explained below are important for correct operation of your water heater This section contains specific instructions for those units used to supply domestic hot water All warnings cautions notes and instructions in the general installation and service sections apply to these instructions Water heaters are designed for installation with a storage tank The use of a properly sized pump and the control of water velocity as explained below is important for correct operation of your water heater NOTE These water heaters are provided from the manufacturer with a single power supply to the unit for operation of both the standard circulating pump and controls All circulating pumps shipped with these units equipped with the Pump Delay Systems are all bronze pumps to ensure that no water discoloration can occur in an extended off cycle of the pump 46 WATER VELOCITY CONTROL ___ IMPORTANT To ensure proper velocity through the heat exchanger it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet This must be done on initial installation and periodically rechecked With the correct temperature rise across the heat exchanger you may be assured of
52. e open for several A WARNING minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If Should overheating occur or the gas supply fail hydrogen is present there will be an unusual sound such as to shut off do not turn off or disconnect the air escaping through the pipe as the hot water begins to electrical supply to the pump Instead shut off flow There should be no smoking or open flames near the faucet at the time it is open THERMAL EXPANSION More than 5 minutes the gas supply at a location external to the appliance OPTIONAL RELIEF VALVE The water heater is normally supplied with a temperature and pressure relief valve s sized in accordance with applicable codes Appliances may be supplied with an optional pressure only relief valve s When a water heater equipped with this optional relief valve is piped to a separate storage vessel the storage vessel must have a properly installed temperature and pressure relief valve which complies with local codes 49 LNAWdINOA TWNOILdO 3i 1 W3lV3H V Aa 6 002181 LADDER DIAGRAM WATER HEATER 150 000 300 000 BTU HR TO 120 VAC POWER SUPPLY POWER SWITCH OFF IGN MOD P5 IGNITER IGN MOD P6 A L1 HOT L2 COMBUSTION AIR BLOWER 120 VAC TRANSFORMER 24 VAC Lo LWCO
53. e pressure stack may cause flue products to be discharged into the living space causing serious health injury Any vent materials not provided or specified must be listed by a nationally recognized test agency for use as vent material The vent terminal should be vertical and exhaust outside the building at least 2 feet 61 cm above the highest point of the roof within a 10 foot 3 05 m radius of the termination The vertical termination must be a minimum of 3 feet 91 cm above the point of exit A vertical termination less than 10 feet 3 05 m from a parapet wall must be a minimum of 2 feet 61 cm higher than the parapet wall The vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment MASONRY CHIMNEY INSTALLATIONS Conventional Venting Only A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems Exterior masonry chimneys with one or more sides exposed to cold outdoor temperatures are more likely to have venting problems The temperature of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to genera
54. e severe burns instantly or death from scalds Children disabled and elderly are at highest risk of being scalded See instruction manual before setting temperature at heating appliance Feel water before bathing or showering If this appliance is used to produce water that could scald if too hot such as domestic hot water use adjust the outlet control limit or use temperature limiting valves to obtain a maximum water temperature of 125 F 52 C The following chart Table Z details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications A relief valve which discharges periodically may be due to TABLE 2 thermal expansion in a closed system A water heater APPROXIMATE TIME TEMPERATURE installed in a closed system such as one with a backflow RELATIONSHIPS IN SCALDS preventer or check valve installed in the cold water supply shall be provided with means to control expansion Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug or cap the relief valve discharge CATHODIC PROTECTION Hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet b
55. eeply 6 Apply a moderate amount of good quality pipe compound DO NOT use Teflon tape to pipe only leaving two end threads bare APPLY WRENCH FROM TOP OR BOTTOM OF CONTROL TO EITHER SHADED AREA FIG 29 Wrench to Support Gas Valve for Piping Connection 7 Remove seal over control inlet 8 Connect pipe to control inlet ends of the control Use wrench to square 9 For LP gas consult your LP gas supplier for expert installation 10 Ensure that all air is properly bled from the gas line before starting the ignition sequence Start up without properly bleeding air from the gas line may require multiple reset functions of the ignition control module to achieve proper ignition MANOMETER FIG 30 Manometer Connection for Manifold Pressure Adjustment GAS MANIFOLD PRESSURE ADJUSTMENT PROCEDURE IMPORTANT The gas valve is referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the left side of the jacket Reference the drawings in this section for component location and connection points for pressure measurement The referenced chamber pressure must be subtracted from the manifold pressure to obtain actual net manifold pressure for normal operation A manometer or magnahelic gauge legible in 0 1 increments up to 10 water column is required to check and adjust the manifold pressure The reg
56. eet metal plate IMPORTANT Examine the venting system at least once a year Check all joints and vent pipe connections for Also check for corrosion or tightness deterioration Immediately correct any problems observed in the venting system VENT SYSTEM OPTIONS This appliance has five venting options They are 1 Conventional Negative Draft Venting Conventional negative draft venting with vertical termination 2 E with a Vertical Conventional Vent E Vent with a vertical conventional vent for flue products and a combustion air pipe from either the sidewall or roof top 3 Direct Venting with Sidewall Terminations Direct vent with sidewall terminations for flue products and combustion air 4 Direct Venting with Vertical Terminations Direct vent with vertical through roof terminations for flue products and combustion air 5 Outdoor Installation Outdoor installation consists of the installation of a special vent cap top assembly gas valve cover deflectors and a weatherproof junction box All appliances are shipped from the factory equipped for conventional negative draft venting All other optional vent systems require the installation of specific vent kits and venting materials The following is a detailed explanation of the installation requirements for each venting system components used and part numbers of vent kits for each model E Conventional Venting Conventional Venting FIG 12 A CON
57. elow Plastic pipe requires an adapter not provided to transition between the air inlet and cap A WARNING Using other vent or air intake materials failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance 12 The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air Length of Air Inlet Pipe The total equivalent length of the sidewall or vertical roof top E Vent combustion air inlet pipe must not exceed a maximum of 50 15 24 m equivalent feet in length Subtract 5 feet 1 52 m for each elbow 1n the air intake system Do not exceed limits for the combustion air inlet piping lengths Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet pipe on a sidewall or vertical roof top E Vent Combustion Air Supply System 1 Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric Do not install seams of vent pipe on the bottom of horizontal runs Secure all joints with a minimum of three sheet
58. emaining connected to the common venting system placed in operation while other appliances remaining connected to the common venting system are not in operation Seal any unused opening in the common venting system Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other unsafe condition Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any other appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fire place dampers Place operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as above return doors windows exhaust fans fireplace dampers and other gas burning appliances to there previous conditions of use Any impr
59. en under water technician or gas supplier LIGHTING INSTRUCTIONS TO TURN OFF GAS TO APPLIANCE 1 STOP Read the safety information above 1 Turn off all electric power to the appliance if service is to be performed 2 Turn off all electrical power to the appliance 2 Turn the gas control knob on the gas valve clockwise to the OFF position Do not force 34 A WARNING Should overheating occur or the gas fail to shut off turn off the manual gas control valve to the appliance IGNITION SYSTEM CHECKOUT Turn off gas supply to appliance N Turn thermostat to highest setting Turn electric power on the 4 The ignition module will lock out and LED will blink Readjust thermostat to normal setting ON Turn on gas supply 4 Turn power off then on again to reset ignition module oo If ignition system fails to operate properly repair work must be performed by a qualified serviceman or installer HOT SURFACE IGNITION SYSTEM The hot surface ignition module is not repairable Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage personal injury fire explosion and or toxic gases A faulty ignition module must be replaced with a new unit The hot surface igniter 1s also the flame sensor OPERATION AND DIAGNOSTIC LIGHTS
60. entirely rust proof appliance On all models header inspection plugs can be removed for field inspection and cleaning of copper tubes The entire heat exchanger may be easily removed from the appliance THERMOSTAT SETTINGS 1 The thermostat is adjusted to a low test setting when shipped from the factory 2 Set the thermostat to the lowest settings which will satisfy hot water demands and prevent risk of scald injury 48 THERMOSTAT ADJUSTMENT Domestic Hot Water Use This appliance has an adjustable thermostat to control water temperature See temperature adjustment procedure in general section of the manual The thermostat is factory pre set at approximately 125 F 52 C Households with small children or invalids may require 120 F 49 C or lower temperature setting to reduce risk of scald injury Some states may require a lower temperature setting Check with your gas supplier for local requirements governing the temperature setting Remember no water heating system will provide exact temperature at all times Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs NOTE 1 This water heater when set at the lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes 2 Higher stored water temperature increases the ability of the water heater to supply desired quantities of hot water however reme
61. ently to be sure the flow of combustion and ventilation air to the boiler is not obstructed GAS TRAIN AND CONTROLS _COMBINATION GAS VALVE SHUT VALVE REGULATOR VALVE OFF 2 tk she Ur COMBINATION GAS VALVE SHUT VALVE REGULATOR VALVE O J 4 FIG 44 Gas Train Drawings PIPING OF THE BOILER SYSTEM The drawings in this section show typical heating boiler piping installations Before beginning the installation consult local codes for specific plumbing requirements The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for service An air separation device must be supplied in the installation piping to eliminate trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type compression tank is used The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation Caution this boiler system should not be operated at less than 12 PSIG Hot water piping must be supported by suitable hangers or floor stands NOT by the boiler Copper pipe systems will be subject to considerable expansion and contraction Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system Padding
62. er temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature A remote low temperature range operator 1s recommended to control the boiler operation based on the lower system temperature This remote operator should be wired across the and W1 terminals see Room Thermostat Connection and Terminal Strip instructions Boiler with Low Temperature Bypass Piping HEATING RETURN Loop SECONDRAY _ BOILER PUMP 12 MIN TO FIRST FITTING U 227 PRESSURE Sy Jr REDUCING 5 M VALVE A L J te ut 1227 gt lt gt 4 l AIR primary Sa SEPARTOR THREE WAY VALVE SYSTEM SLOW OPENING CLOSING FIRST FITTING HEATING SUPPLY FIG 48 Boiler with 3 Way Valve Piping THREE WAY VALVES The installation of a three way valve on this boiler is not generally recommended because most piping methods allow the three way valve to vary flow to the boiler This boiler is a low mass high efficiency appliance which requires a constant water flow rate for proper operation Low flow rates can result in overheating of the boiler water which can cause short burner on cycles system noise and in extreme cases a knocking flash to steam These conditions can cause operational problems and non warrantable failures of the boiler Ifa three way valve must be installed please pipe in a primary secondary system as shown in Figure 48 Based on boiler sizing and
63. gas supply at the manual valve turn on LP gas at tank if required 17 Turn the power switch to ON position 18 Turn the gas valve knob to ON position 19 Set the thermostat to call for heat IMPORTANT Upon completion of any testing on the gas system leak test all gas connections with a soap solution while main burners are operating Immediately repair any leak found in the gas train or related components Do Not operate an appliance with a leak in the gas train valves or related piping Check burner performance by cycling the system while you observe burner response Burners should ignite promptly Flame pattern should be stable see Maintenance Normal Flame Pattern Turn system off and allow burners to cool then cycle burners again to ensure proper ignition and flame characteristics WATER CONNECTIONS AIR INLET W DUST COVER FLUE OUTLET ACCESS PANEL WATER OUTLET WATER INLET BURNER VIEWPORT FIG 33 Connections to the Appliance Inlet and Outlet Connections For ease of service install unions on inlet and outlet of the appliance The connection to the appliance marked Inlet on the header should be used for return from the system The connection on the header marked Outlet is to be connected to the supply side of the system RELIEF VALVE This appliance is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Bo
64. hd Ft hd Ft hd 0 4 0 9 0 5 Ft hd Ft hd 0 3 8 4 0 2 6 3 0 2 10 1 1 4 0 6 0 5 13 4 1 7 1 2 0 7 16 8 2 6 1 6 1 1 20 2 TEMPERATURE PRESSURE GAUGE This boiler is equipped with a dial type temperature pressure gauge This gauge is factory installed in the outlet side of the heat exchanger The gauge has one scale to read system pressure and a separate scale to read water temperature in F The temperature pressure gauge can be used to determine temperature rise by first recording the temperature of the boiler water with the boiler off Record the temperature of the boiler water as the boiler fires and the discharge temperature stabilizes Subtract the boiler water temperature with the boiler off from the stable outlet water temperature with the boiler firing This temperature difference is the temperature rise TYPICAL HEATING BOILER INSTALLATIONS General Plumbing Rules 1 Check all local codes 2 For serviceability of boiler always install unions Always pipe pressure relief valve to open drain gt Locate system air vents at highest point of system Expansion tank must be installed near the boiler and on the suction side of the pump Support all water piping PLACING THE BOILER IN OPERATION Filling the System air must be purged from the system for proper operation An air scoop and air vent must be located close to the bo
65. he National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment Vent connection is made directly to the top of the appliance No additional draft diverter is required The connection from the appliance vent to the stack must be made as direct as possible The negative draft in conventional vent installations must be within the range of a negative 0 02 to 0 05 inches water to ensure proper operation All draft readings are made while appliance is in stable operation approximately 2 to 5 minutes Locate units as close as possible to chimney or gas vent See the vent material requirements for each of the specific venting options Conventional venting systems use Type B double wall vent material Direct vent systems have specific vent kits and material requirements noted for each application Any vent materials not provided or specified must be listed by a nationally recognized test agency for use as vent material Avoid long horizontal runs of the vent pipe 90 elbows reductions and restrictions Horizontal portions of the venting system shall be supported to prevent sagging Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm per meter from the appliance to the vent terminal Follow manufacturers instructions The weight of the venting system must not rest on the appliance Adequate support of the venting system must be prov
66. he gas supply piping system during any pressure testing of that system 7 Optional gas controls may require routing of bleeds and at a test pressure in excess of 1 2 PSIG 3 5 kPa vents to the atmosphere outside the building when required by local codes N The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during g Inlet gas connections to the gas valve is 3 4 NPT for the any pressure testing of the gas supply piping system at 150 000 through 300 000 Btu hr models test pressures equal to or less than 1 2 PSIG 3 5 kPa The appliance and its gas connection must be leak tested before placing it in operation TABLE J SINGLE APPLIANCE INSTALLATIONS GAS CONNECTION SUGGESTED GAS PIPE SIZE 1 Safe operation of appliance requires properly sized gas supply piping See data below DISTANCE FROM METER 2 Gas pipe size may be larger than heater connection 3 Installation of a union is suggested for ease of service 4 Install a manual main gas shutoff valve outside of the appliance gas connection and before the gas valve when local codes require 150 000 199 999 250 000 300 000 5 A trap drip leg MUST be provided in the inlet of the gas connection to the appliance 6 The combination gas valve has an integral vent limiting device and does not require venting to atmosphere 24 For each elbow or tee add equivalent straight pipe to total length from t
67. he sidewall air inlet cap is supplied in the E Sidewall Vent Kit which should be ordered from the manufacturer This sidewall cap will supply combustion air for a single appliance only Locate appliances as close as possible to sidewall where the combustion air supply system will be installed To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet follow all applicable clearance requirements in the latest edition of the National Fuel Gas Code and instructions in this manual The combustion air inlet cap must be installed at least one foot 30 cm above ground level and above normal snow levels E Vent with Roof Top Air 14 E Vent with Roof Top Air Vertical Roof Top Air Inlet The air inlet cap for the vertical roof top air inlet is assembled from components purchased locally The air inlet cap consist of two 90 ells installed at the point of termination for the air inlet pipe The first 90 ell is installed on the roof top at the highest vertical point of the air inlet pipe and turned horizontal the second 90 ell is installed on the horizontal outlet of the first ell and turned down A 90 ell and a 90 street ell may be used to make this assembly Ifa straight piece of pipe is used between the two ells it should not exceed 6 51 mm in length The termination ell on the air inlet must be located a minimum of 12 30 cm above the roof or above normal levels of snow ac
68. hes Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25 Check with louver manufacturers for exact net free area of louvers Where two openings are provided one must be within 12 30 cm of the ceiling and one must be within 12 30 cm of the floor of the mechanical room Each opening must have net free area as specified in Table A Single openings shall commence within 12 30 cm of the ceiling A CAUTION Under no circumstances should the equipment room ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the unit The combustion air supply must be completely free of any chemical fumes which may be corrosive to the appliance Common chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as Freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes tube headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure EXHAUST FANS Any fan or equipment which exhausts air from the mechanical room may deplete the combustion air supply and or cause a down draft in the venting system Spillage of flue products from
69. ible to the vertical through roof vent for flue products Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm per meter from the appliance to the vent terminal Follow manufacturers instructions The vertical through roof vent cap shall terminate at least 3 feet 91 cm above any forced air inlet within 10 feet 3 05 m The vertical through roof vent shall terminate at least 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 30 cm above any door window or gravity air inlet to the building The vent terminal shall not be installed closer than 10 feet 3 05 m from an inside corner of an L shaped structure Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate 21 The vertical through roof vent cap should have a minimum clearance of 4 feet 1 22 m horizontally from and in no case above or below unless a 4 foot 1 22 m horizontal distance is maintained from electric meters gas meters regulators and relief equipment Combustion Air Inlet Combustion air supply pipes can NOT be combined into a single pipe for multiple appliance installations Combustion air supplied from outdoors must be free of contaminants See Combustion and Ventilation
70. ided in compliance with local codes and other applicable codes All connections should be secured with rustproof sheet metal screws Barometric Damper Location Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the appliance s flue outlet The barometric damper MUST NOT be installed in a bull head tee installed on the appliance s flue outlet The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to appliance s flue outlet This location ensures that any positive velocity pressure from the appliance s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products Adjust weights on damper to ensure that draft is maintained within the specified range 10 ORLESS FIG 8 Vent Termination from Peaked roof 10 or less from Ridge MORETHAN10 _ FIG 9 Vent Termination from Peaked roof more than 10 from Ridge The vertical vent terminal should exhaust outside the building at least 2 feet 61 cm above the highest point of the roof within a 10 foot 3 05 m radius of the termination The vertical termination must be a minimum of 3 feet 91 cm above the point of exit 10 O
71. idewall vent cap MUST have a gas tight seal to prevent the leakage of flue products VENT HOOD MUST BE MOUNTED 4 MIN AWAY HORIZONTALLY FROM VENT HOOD MUST DOORS AND WINDOWS BE MOUNTED 1 MIN ABOVE DOORS AND WINDOWS VENT HOOD MUST BE MOUNTED AT LEAST 10 FROM INSIDE CORNER VENT HOOD MUST BE MOUNTED 4 MIN BELOW WINDOWS 3 ABOVE ANY OUTSIDE AIR INTAKE WITHIN 10 DIRECT VENT AIR INLET FIG 20 Sidewall Vent Locations Venting of Flue Products Locate appliances as close as possible to the sidewall where the vent for flue products will be installed Horizontal runs must slope upwards not less than 1 4 inch per foot 21 mm per meter from the appliance to the vent terminal Follow manufacturers instructions The vent cap shall terminate at least 3 feet 91 cm above any forced air inlet within 10 feet 3 05 m The vent shall terminate at least 4 feet 1 22 m below 4 feet 1 22 m horizontally from or 1 foot 30 cm above any door window or gravity air inlet to the building The vent system shall terminate at least 1 foot 30 cm above grade and above normal snow levels 17 The vent for a direct vent system shall NOT terminate above public walkways The vent shall not be installed closer than 10 feet 3 05 m from an inside corner of an L shaped structure Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent can not terminate below grade Flue
72. ile the boiler is firing Example The boiler inlet temperature 1s 160 F 71 C and the boiler outlet temperature is 180 F 82 C this means that there is a 20 F 11 C temperature rise across the boiler TABLE 5 PRESSURE DROP CURVE FOR 150 000 THROUGH 300 000 BTU HR MODEL LL i a i 2 gt m Maximum operating pressure for pump must exceed system operating pressure N Maximum water temperature should not exceed nameplate rating Cast iron circulators may be used for closed loop systems 4 An expansion tank must be installed near the boiler and on the suction side of the pump CIRCULATOR PUMP OPERATION Heating Boilers Only A factory wired pump control relay is supplied in the control panel of each heating boiler External wire leads are provided to supply 120 VAC power to the pump allowing the control relay to cycle the pump Caution The external power leads for pump operation may be Hot when the main power switch on the boiler is ON The field installed boiler pump using these wire leads must not exceed 1 HP at 120 As shipped from the factory this control relay is set to cycle the boiler pump on each call for heat with an external room thermostat installed across terminals and W1 on the internal terminal strip For continuous pump operation connect the pump to the 120V supply PUMP INSTALLATION AND MAINTENANCE F
73. iler outlet and there should be a minimum distance between the cold water feed and the system purge valve 1 Close all drain cocks and air vents 2 Open the makeup water valve and slowly fill the system Ifa makeup water pump is employed adjust the pressure to provide a minimum of 12 psi at the highest point in the system If a pressure regulator is also installed in the line it should be adjusted to the same pressure Close all valves Purge one circuit at a time as follows a Open one circuit drain valve and let the water drain for at least five minutes Ensure that there are 44 no atr bubbles visible in the water stream before closing the drain valve b Repeat this procedure for each circuit 5 Open all valves after all circuits have been purged Make sure there are no system leaks NOTE Do not use petroleum based stop leak products All system leaks must be repaired The constant addition of make up water can cause damage to scale accumulation Scale reduces flow and heat transfer causing overheating of the heat exchanger the boiler heat exchanger due to Run the system circulating pump for a minimum of 30 minutes with the boiler turned off Open all strainers in the system and check for debris Recheck all air vents as described in step 4 above Inspect the liquid level in the expansion tank The system must be full and under normal operating pressure to ensure proper water
74. ilers The relief valve s is installed in the vertical position and mounted in the hot water outlet No valve is to be placed between the relief valve and the appliance To prevent water damage the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs No reducing couplings or other restrictions shall be installed in the discharge line The discharge line shall allow complete drainage of the valve and line Relief valves should be manually operated at least once a year CAUTION Avoid contact with hot discharge water WATER FLOW SWITCH IF EQUIPPED A water flow switch is available as a factory supplied option on 150 000 through 300 000 Btu hr heating boilers and water heaters The flow switch should be wired across the X and B terminals on the appliance s internal terminal strip Remove the jumper between the terminals before 29 connecting flow switch wires to the terminals This wiring connection installs the flow switch in the 24 VAC safety circuit for the ignition control A flow switch installed in 1 1 4 pipe requires a minimum flow of 10 GPM to make the flow switch and start burner operation A flow switch installed in 1 1 2 pipe requires a minimum flow of 13 GPM to make the flow switch and start burner operation A flow switch installed in 2 pipe requires a minimum flow of 19 GPM to make the flow switch and start burner operation A water flow switch meets most code
75. ing Primary Secondary Piping SUPPLYPUMP AIR wW I Ped ornon FIG 46 Boiler with Primary Secondary Piping Boilers used with multiple zone systems are recommended to be installed with a primary secondary piping system as shown in Figure 46 This type of system uses a dedicated pump to supply flow to the boiler only This pump is sized based on desired boiler flow rate boiler head loss and head loss in the secondary system piping A primary secondary piping system may be installed on smaller input boilers but generally a properly sized system pump with a bypass will provide adequate flow The installer must ensure that the boiler has adequate flow without excessive temperature rise The temperature rise on a multiple zone system should be made when only the zone with the longest length and or highest head loss is open Low system flow can result in overheating of the boiler water which can cause short burner on cycles system noise and in extreme cases a knocking flash to steam These conditions indicate the need to open the bypass adjustment valve and or installation of a larger circulator pump System noise may also indicate an oversized boiler 42 A CAUTION At no time should the system pressure be less than 12 PSIG Low Temperature Bypass Piping MAKE UP WATER EXPANSION TANK PRESSURE REDUCING VALVE tha h L 27 SECONDARY LWCO e T OPTIO
76. ir inlet pipe has a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe Example two 5 air inlet pipes 19 6 in area each have a total area of 39 2 in require a 8 50 3 in area common air inlet pipe The air inlet point for multiple appliance air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet This exterior opening for combustion air must connect directly to the outdoors The total length of the combined air inlet pipe must not exceed a maximum of 50 15 25 m equivalent feet You must deduct the restriction in area provided by any screens grills or louvers installed in the common air inlet point These are common on the sidewall air inlet openings Screens grills or louvers installed in the common air inlet can reduce the free area of the opening from 25 to 75 based on the materials used Air Inlet Pipe Materials The air inlet pipe s must be sealed Choose acceptable combustion air inlet pipe materials from those specified in this section Select air inlet pipe material from the following specified materials PVC or CPVC 4 5 or 6 LD Dryer Vent not recommended for roof top air inlet Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified b
77. l all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the boiler Length of Flue Pipe and Air Inlet Pipe The total equivalent length of the direct vent flue pipe or the air inlet pipe must not exceed a maximum of 50 15 24 m equivalent feet in length for each pipe Subtract 5 feet 1 52 m for each elbow in the vent pipe or air intake system Do not exceed limits for piping lengths Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet pipe on a Direct Vent System 1 Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric Do not install seams of vent pipe on the bottom of horizontal runs Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe Ensure that the vent pipe and air inlet pipes are properly supported 20 The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used The PVC CPVC or Dryer Vent air inlet pipe sho
78. manual valve in the gas piping to the appliance If fuel supply is LP gas shut off gas supply at the tank 4 Remove the 1 8 hex plug located on inlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge Range of scale should be 14 w c or greater to check inlet pressure Turn on gas supply at the manual valve turn on LP gas at tank if required Turn the power switch to ON position Turn the gas valve knob to ON position Set the thermostat to call for heat Observe the gas supply pressure as the burners are firing Ensure inlet pressure is within specified range 28 TABLE M MINIMUM AND MAXIMUM GAS SUPPLY PRESSURES Max Inches Water Column Min Inches Water Column 10 1 gas pressure is out of range contact gas utility gas supplier qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control 11 If gas supply pressure is within normal range proceed to remove gas manometer and replace pressure tap fittings in the gas control 12 Turn the power switch and thermostat to OFF position 13 Turn gas valve knob to OFF position 14 Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is LP gas shut off gas supply at the tank 15 Remove the manometer and related fittings from inlet side of the gas valve replace 1 8 hex plug in gas valve 16 Turn on
79. mber A CAUTION Hotter water increases the risk of scald injury Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the heat exchanger and operational problems The cold water supply piping must be installed in the discharge piping from the heater to the storage tank This allows the cold water to be tempered in the storage tank before entering the heater See typical installation drawings provided with the appliance for correct piping Higher water temperatures reduce condensate formation A CAUTION Setting the temperature selector to higher settings provides hotter water which increases the risk of scald injury This water heater can deliver scalding temperature water at any faucet in the system Be careful whenever using hot water to avoid scalding injury Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances you may create the potential for scald injury To protect against injury you should install an ASSE approved mixing valve in the water system This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines Such valves are available from the local plumbing supplier Water temperature over 125 F 52 C can caus
80. mbly Ifa straight piece of pipe is used between the two ells it should not exceed 6 51 mm in length The termination ell on the air inlet must be located a minimum of 12 30 cm above the roof or above normal levels of snow accumulation The point of termination for the air inlet must be 24 61 cm lower than the point of flue gas termination if it is located within 10 3 05 m of the flue outlet Use care to ensure that the 90 ell assembly is properly installed on the air inlet pipe Incorrect installation and or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury death or property damage A vertical vent cap as specified by the vent material manufacturer MUST be used to vent the flue products to the outdoors The vent cap for the flue products is purchased locally The point of discharge for the flue products in a vertical direct vent system must terminate a minimum of 24 61 cm above the point where the air inlet is located if the air inlet is within a 10 3 05 m radius of the flue discharge Incorrect installation and or location of the vent cap for flue products can allow the discharge of flue products to be drawn into the c
81. n of the boiler water during the cooling cycle The coil must be vented at the high point and hot water from the boiler must enter the coil at this point Due to the fast heating capacity of the boiler it is not necessary to provide a ductstat to delay circulator operation Also omit thermostat flow checks as the boiler is cold when heating thermostat is satisfied This provides greater economy over maintaining standby heat see Figure 49 BOILER OPERATING TEMPERATURE CONTROL The operating temperature control is located in the control panel behind the control panel front access door The sensing element for the operator is placed in a bulb well installed in the inlet side of the heat exchanger Carefully observe the discharge water temperature on the initial boiler on cycles The location of the temperature sensor will generally require a lower temperature set point on the operating control to achieve the desired discharge water temperature from the boiler This sensing element location allows a boiler operating with a low to moderate flow rate to sustain longer burner on cycles preventing short boiler ON cycles based on high discharge water temperatures For example a boiler operating with a 180 F discharge and a 20 F temperature rise would require approximately a 160 F to 165 F set point with the temperature sensor installed on the inlet side of the heat exchanger The exact 45 temperature set point is based on your system s
82. nce with a separate air pipe The bell increaser installed on the vent outlet must be removed The bell increaser is NOT USED with the direct vent system Vent connection is made directly to the top of the appliance No additional bell increaser draft diverter or barometric damper is required The direct vent system uses a two pipe system one pipe for the flue products and one pipe for the combustion air supply The vertical through roof vented flue MUST be a dedicated stack The flue can NOT be combined with any other appliance vent or common vent from multiple appliances The vent on a direct vent system may have a positive pressure in the flue which requires all vent joints and seams to be sealed gas tight The direct vent vertical through roof venting system has specific vent material and installation requirements The flue from a direct vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system Choose acceptable vent materials from those listed below The combustion air inlet pipe must also be a dedicated system with one air inlet pipe per appliance The air inlet pipes from multiple appliances can NOT be combined to a single common connection The air inlet pipe connects directly to the appliance to supply combustion air The air inlet pipe must be sealed Choose acceptable combustion air pipe materials from those specified in this section The
83. ndard commercial pipe cement for the material used The PVC CPVC or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection Dryer vent should use a screw type clamp to seal the vent to the appliance and air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume 16 Sealing of vent material for use with the Sidewall Direct Vent system The vent materials Heat Fab Saf T CI Vent Z Flex Z Vent Protech Systems Fas N Seal Vent Flex L Star 34 Vent Metal Fab Corr Guard Vent or listed AL29 4C vent system suitable for positive pressure must be installed and sealed per the vent manufacturers installation instructions Drain Tee Installation 3 DIA CIRCULAR TRAP TO SUITABLE DRAIN FIG 19 Drain Tee Installation Drain Tee Installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee must be installed as the first fitting after the horizontal ell on the top of the appliance See the typical vent installation drawings Plastic drain tubing sized per the vent manufacturers instructions shall be provided as a drain line from the tee The drain tubing must have a trap provided by a 3 76 mm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small
84. noise on operation Excessive build up of minerals in the heat exchanger can cause a non warrantable failure MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations Verify proper operation after servicing A CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation 1 Examine the venting system at least once a year Check more often in first year to determine inspection interval Check all joints and pipe connections for tightness corrosion or deterioration Clean screens in the venting air intake system as required Have the entire system including the venting system periodically inspected by a qualified service agency Using the view port located below the water connections visually check main burner flames at each start up after long shutdown periods or at least every six months A WARNING This area is hot and direct contact could result in burns YELLOW FLAME FLAME LIFT OFF FIG 42 Burner Flame Patterns If improper flame is observed examine the venting system a Normal Flame A normal flame is blue with slight yellow tips with a well defined inner cone and no flame lifting b Yellow Tip Yellow tip can be caused by blockage or partial obstruction of air flow to the burner s c Yellow Flames Yellow flames can be caused by blockage of primary air flow to the burner s or e
85. of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Locate appliance at least 3 feet 0 91m from any wall or vertical surface to prevent adverse wind conditions from affecting performance Multiple appliance outdoor installations require 48 1 22m clearance between each vent cap The outdoor cap must be located 4 feet 1 22m below and 4 feet 1 22m horizontally from any window door walkway or gravity air intake 22 The combustion air inlet of the outdoor cap must be located at least 1 foot 0 30m above grade and above normal snow levels Locate appliance at least 10 feet 3 05m away from any forced air inlet Locate appliance at least 3 feet 0 91m outside any overhang Clearances around outdoor installations can change with time Do not allow the growth of trees shrubs or other plants to obstruct the proper operation of the outdoor vent system Do not install in locations where rain from building runoff drains will spill onto the appliance Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building or appliance surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate ONE PIECE TOP OUTDOOR UNCTION BOX
86. ombustion process on the heater This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury death or property damage Flue Pipe Materials Select venting material from the following specified vent materials Heat Fab Saf T CI Vent with AL29 4C stainless steel Call 1 800 772 0739 for nearest distributor Z Flex Z Vent with AL29 4C stainless Call 1 800 654 5600 for nearest distributor steel Protech Systems Inc Fas N Seal Vent with AL29 4C stainless steel Call 1 800 766 3473 for nearest distributor Flex L International Inc Star 34 Vent with AL29 4C stainless steel Call 1 800 561 1980 for nearest distributor Metal Fab Corr Guard Vent with AL29 4C stainless steel Call 1 800 835 2830 for nearest distributor or other listed AL29 4C vent systems suitable for positive pressure Air Inlet Pipe Materials Select air inlet pipe material from the following specified materials PVC or CPVC 4 5 or 6 LD Dryer Vent Galvanized steel vent pipe with joints and seams sealed as specified below Type B double wall vent with joints and seams sealed as specified below Plastic pipe requires an adapter not provided to transition between the air inlet and cap A WARNING Using other vent or air intake materials failure to properly sea
87. on also have an outside air temperature sensor Water Heater Application Water heater appliances are shipped with two sensors the inlet water temperature sensor and the multi purpose temperature sensor to be used as a tank sensor Temperature Control Sensors This is a two stage temperature control that controls the burner ignition pump and alarm functions This temperature controller can measure up to three different sensor inputs depending upon how the appliance is set up They are as follows 1 2 Multi Purpose Temperature Sensor Inlet Water Temperature Sensor 3 Outside Air Temperature Sensor Inlet Water Temperature Sensor This sensor measures the inlet water temperature coming into the appliance Multi Purpose Temperature Sensor Depending upon how your appliance is set up this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications Connect this sensor to the two blue wires in the upper left hand corner of the control panel Outdoor Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems The outside air sensor is optional This sensor allows you to tie boiler operation to the outdoor air temperature As outside temperatures drop the control will increase the temperature setting of the boiler As outdoor temperatures rise the control will decrease the temperature to the selected set point of the boiler You can set the cont
88. on due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions COLD WATER SUPPLY E EXPANSION TANK IF REQUIRED DOMESTIC WATER HEATER SUPPLY BOILER MIXING THERMOMETER BUILDING HOT WATER SUPPLY VERTICAL TANK INSTALLATION LOCK TEMP STORAGE TANK BUILDING RETURN FIG 51 Typical Water Heater Piping with Storage Tank 47 TABLE X COMMON WATER MANIFOLD SIZE FOR MULTIPLE WATER HEATER INSTALLATIONS Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow PUMP OPERATION The water heater must be connected to a properly sized pump that circulates water between the heater and storage tank N Pump is sized to heater input and water hardness Care should be taken to size pump correctly See Water Chemistry The water heater is equipped with factory supplied pump delay system A Lubricate pump to manufacturers recommendations Pump damage due to inadequate lubrication is non warrantable Standard 150 000 through 300 000 Btu hr water heaters are furnished with a 1 4 HP 120 VAC 5 8 Amp circulating pump The circulating pump must be mounted on the units inlet water connection The pump is sized based on installation of the storage tank and heater in close proximity If the number of fittings and straight pipe e
89. ont View Cabinet Construction AIR INTAKE W DUST COVER AIR SLOTS FIG 2 Typical Construction LOCATION OF UNIT 1 Locate the appliance so that if water connections should leak water damage will not occur When such locations cannot be avoided it is recommended that a suitable drain pan adequately drained be installed under the appliance The pan must not restrict combustion air flow Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components Boiler Rear View Cabinet 2 The appliance must be installed so that the ignition system components are protected from water dripping spraying rain etc during appliance operation and service circulator replacement control replacement etc 3 Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling appliance must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46 cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle 4 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present 5 The appliance must be installed on a level floor A combustible wood floor may be used without additional bases or special floor buildup
90. oor Air Reset Option For boilers ordered with the Outdoor Air Reset option there is an additional control FIG 38 There are three setting knobs for Shutdown Outdoor Air Max and Ratio There is also a switch to turn the outdoor air shutdown feature On or Off An O A Sensor is also included O A SENSOR ENABLE swt DISABLE O A SHUTDOWN 40 70 SHUTDOWN FIG 38 Optional Outdoor Air Reset Control Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the appliance from operating Outdoor Air Max O A Max The O A Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting When the outdoor air temperature is above the specified setting the unit will not function in the O A Reset Mode but will continue to run at the selected set point temperature Note that the set point knob will now indicate the minimum boiler temperature Target temperature is determined by the ratio and outdoor air temperature below the O A Max setting Ratio The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset The allowable ratios are as low as 0 5 1 or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 F for every 1 0 F drop in outdoor air temperature up to the maximum set point temperature Selecting the 1 5 1 ratio will increase the set point 1 5 F for every 1 0 F
91. oper operation of the common venting system should be corrected so that the installation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment When resizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix G in the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment 10 A CONVENTIONAL VERTICAL NEGATIVE DRAFT VENTING SYSTEM WITH COMBUSTION AIR PROVIDED FROM A SIDEWALL OR ROOF TOP INLET CAP Follow all requirements in the General Venting section and Conventional Negative Draft Venting for venting flue products to the outdoors and general installation instructions This vent system uses two pipes one vertical pipe with a roof top termination for the flue products and one pipe for combustion air The combustion air pipe may terminate horizontally with a sidewall air inlet or vertically with a roof top air inlet A bell increaser is installed directly on the vent outlet This bell increases the vent size by 1 25 4 mm in diameter The bell increaser MUST be installed on the vent outlet for all conventional negative draft vent systems Vent connection is made
92. or installation and maintenance information on the circulator pump refer to pump manufacturers instructions included in the instruction package 41 FIG 45 Boiler with Bypass Installed The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise It is recommended that this boiler be installed with a bypass in the piping a properly sized circulator and piping system The bypass will help to ensure that the boiler can be supplied with adequate water flow A typical bypass with a valve is shown in Figure 45 If the boiler temperature rise exceeds 40 F 22 C it is an indication that the boiler may not be receiving adequate flow and adjustment of the bypass is required If a high temperature rise is experienced check the pump for proper operation and check the system piping for any obstruction A larger pump may be necessary The installation of the recommended system bypass as shown in Figure 45 allows an increased flow through the boiler If there is any doubt that the pump may not provide adequate flow bypass piping should be provided at the time the boiler is installed The bypass should be fully sized with a balancing valve to allow for proper adjustment The balancing valve allows the flow through the bypass to be adjusted based on the individual system requirements A bypass is recommended on all multiple zone systems in addition to a properly sized circulator and system pip
93. quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use caution not to collapse or restrict the condensate drain line with the nylon wire ties The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material See Freeze Protection for more information When a direct vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturers instructions The air inlet pipe must also be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume A DANGER Failure to properly seal all vent joints and seams may result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death The connection from the vent to the vent termination outside the building MUST be made with one of the specified vent materials and must be direct as possible with no reduction in diameter The vent accessories not otherwise provided such as firestop spacers thimbles caps etc MUST be from the same vent material manufacturer and installed in accordance with the manufacturers listing The vent connection through the sidewall must provide correct spacing to combustible surfaces The vent pipe connection to the s
94. r magnahelic gauge see Figure 31 Minimum range of scale should be up to 5 w c for natural gas and 10 w c for propane gas A reference pressure hose is factory installed from the barbed connection on the gas valve regulator to the fan pressurized front chamber All manifold pressure measurements made with the reference hose in place will be the sum of the net manifold pressure and the air pressure in the front chamber Turn the power switch to the ON position Turn all gas valve knobs to the ON position Set the thermostat to call for heat 15 Before the valve opens the manometer or magnahelic gauge will read a positive air pressure of 1 4 w c to 1 8 w c in the jacket as supplied by the combustion air fan in the prepurge cycle There is no gas flow at this point This air pressure reading is normal 16 The gas valve will open at the end of the trial for ignition stage and remain open as the burners fire Observe the gas manifold pressure when valves open If insufficient gas pressure is supplied to the burners the burners will not fire Record the gas pressure indicated on the manometer or magnahelic Subtract the air pressure in the front chamber as recorded in Step 6 from the gross manifold pressure observed at the end of trial for ignition and when the burners are firing The gross manifold pressure will typically be within the range of 3 4 w c to 3 9 w c for Natural Gas and 6 1 w c to 6 7 w c for L P G
95. r property damage Venting of Flue Products On a conventionally vented negative draft appliance the connection from the vent to the stack or vent termination outside the building MUST be made with listed Type B double wall or equivalent vent connectors and must be direct as possible with no reduction in diameter The bell increaser factory installed on the flue outlet MUST be used Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks The type B vent and accessories such as firestop spacers thimbles caps etc MUST be installed in accordance with the manufacturers listing The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes The vertical flue of an E Vent must maintain a negative draft within the specified range An appliance installed in an application such as a restaurant or industrial installation where exhaust fans air handlers or other mechanical equipment are creating an excessive negative pressure in the mechanical room may require that the appliance be installed with an optional direct vent system Local codes which require the installation of a certified direct vent system must use one of the ANSI tested direct vent systems The direct vent system uses a sealed AL29 4C stainless steel vent material and
96. r shutter to slide See Figure 43 b If differential pressure needs increasing pull the air shutter out with thumb and finger gradually and evenly Push in the air shutter to decrease differential pressure 38 c If the differential pressure cannot be obtained shut the appliance down and inspect the vent system both air and flue gas passageways for obstructions or leaks d Tighten combustion air blower mounting nuts L Turn the power switch to OFF position M Remove gauge and tee connections ensuring connections are made at the pressure switch correctly the chamber pressure to the connection and the burner venturi pressure to the connection N Turm the gas valve knob to ON position the power switch to ON position P Replace upper front access door Q When the main burner lights observe the burner flame through observation port Flames should be light blue in color with slight yellow tips flames should be settled on burner head with no lifting R The appliance is now ready to operate BURNER REMOVAL AND CLEANING A WARNING The combustion chamber lining in this appliance contains ceramic fiber materials Ceramic fibers can transform into cristobalite crystalline silica when exposed to temperatures above 2192 F 1200 C dependent upon the length of exposure time The International Agency for Research on Cancer has concluded Crystalline silica inhaled in the form of q
97. rately for remote mounting and is not weatherproof If ordered on an outdoor unit mount the alarm bell inside a building Refer to the wiring diagram on page 53 of this manual for wiring connections ELECTRICAL CONNECTIONS This appliance is wired for 120 VAC service The appliance when installed must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements with the latest edition of the National Electrical Code ANSI NFPA No 70 When the appliance is installed in Canada it must conform to the CAE C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes All wiring between the appliance and field installed devices shall be made with type T wire 63 F 35 C rise Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable The pump must run continuously when appliance is being fired hot water supply boilers must use the optional pump delay or intermittent pump controller if the pump is to be cycled To avoid serious damage DO NOT energize the appliance until the system is full of water Serious damage may result Provide the appliance with proper overload protection Os Install wall thermostat on inside wall DO NOT install thermostat in an area affected by drafts sunlight light fixtures hot or cold water pipes or near a fireplace TABL
98. re setting Repeat as necessary to achieve the specified net manifold pressure setting 19 Replace cover screw on the regulator and turn the power switch to the ON position Set the thermostat to call for heat Observe gas regulator pressure again at the burner ON stages Repeat this sequence until the proper regulator setting has been obtained NOTE If the regulator cover screw is not in place and tight the appliance will not function properly 20 Turn the power switch to the OFF position 21 Turn gas valves and manual gas cock knob to the OFF position 22 Remove the gas pressure fitting from the gas valve and replace with the 1 8 hex plug that was previously removed and tighten 23 Ensure that the chamber pressure reference hose is properly connected to the gas valve 24 Turn the gas valve knobs to the ON position 25 Turn the power switch to the position and replace the jacket panel The appliance is now ready to operate If manifold pressure cannot be properly maintained check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control amp s NS MANOMETER GAS VALVE FIG 32 Manometer Connection for Gas Supply Pressure Measurement CHECKING GAS SUPPLY PRESSURE 1 Turn the power switch and thermostat to OFF position Turn gas valve knob to OFF position Shut off gas supply at the
99. rol unless your appliance is specified as a boiler only with an outdoor air reset option If your appliance is a boiler only with an outdoor air reset option there are additional controls for this option They are explained under Outdoor Air Reset Option page 32 The three setting knobs on the temperature control are for Set point Differential and High Fire Offset see Figure DIFFERENTIAL 240 OFF O TST2314 HIGH FIRE SETPOINT OFFSET FIG 37 Temperature Control Maximum Set Point Determination The maximum set point for the control is factory set Boilers can be set to 240 F max water heaters are set to 190 F max and specialty state and local codes to 200 F These maximum set points are established by cutting the and OJ2 jumpers located on the right side of the temperature controller The maximum set point is determined as shown below in TABLE O TABLE O Maximum Set point Determination Max Set Point Connected Connected Cut Connected Cut Connected Cut Cut 31 Anytime that OJ1 is the only jumper cut a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190 Anytime the OJ2 jumper is cut with or without OJ1 a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200 Set
100. rol to shut the boiler off when a desired outdoor air temperature level is reached You must purchase the sensor from the appliance manufacturer The sensor comes with a housing that helps protect the sensor from the elements Mount the air sensor housing under the eve of the roof Make sure the housing is out of direct sunlight This will ensure that the sensor will accurately read the true outdoor temperature Connect the outdoor air temperature sensor to the terminal block on the outdoor air reset board For more information on mounting the sensor see Remote Mounting of Sensors this page Placement of Sensors Inlet Temperature Sensor The inlet water temperature sensor is placed into the inlet bulbwell on the boiler This sensor is installed by the factory in new appliances Make sure to insert the sensor all the way into the bulbwell leaving no air pocket between the front surface of the sensor and the back of the bulbwell Air pockets are thermally non conductive and will cause sensors to read inaccurately System Sensor The system sensor is used for boiler applications This sensor will control the boiler operation based upon the water temperature within the building loop Tank Sensor The tank sensor is used in water heating applications Place the sensor in a water storage tank to measure water temperature For more information on mounting the sensor see Remote Mounting of Sensors this page 32 Remote Mounting of Senso
101. rs You must mount the outside air temperature sensor outside the building To mount remote sensors follow the guidelines listed on this page Take care to correctly wire sensors to the appliance Erratic temperature readings can be caused by poor wiring practices Twist the wires between the appliance and the remote sensor Turn wires at least three or four turns per linear foot of wiring This provides protection against some types of electrical interferences 1 Do not route temperature sensor wiring with building power wiring 2 Do not locate temperature sensor wiring next to control contactors 3 Do not locate temperature sensor wiring near electric motors 4 Do not locate temperature sensor wiring near welding equipment 5 Make sure good mechanical connections are made to the sensor any interconnecting wiring and the controller 6 Do not mount sensor with leadwire end pointing up in an area where condensation can occur 7 Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists Shielded cable is recommended on all cable runs of more than 25 feet in length NOTE Ground the cable shield at the connection to the boiler temperature control only Do not ground the shielded cable at the sensor end To maintain temperature accuracy sensor wires should be 18 AWG two conductor 18 2 Use shielded wire if required OUTDOOR AIR RESET OPTION Outd
102. st RPL7030 Combustion air supply must be free of contaminants see Combustion and Ventilation Air page 4 To prevent recirculation of the flue products into the combustion air inlet follow all instructions in this section WARNING Outdoor models MUST be installed outdoors and MUST use the vent cap supplied by the manufacturer Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors All covers doors and jacket panels must be properly installed to ensure proper operation and prevent hazardous condition CAUTION Appliances which are shut down or will not operate may experience freezing due to convective air flow in the outdoor vent cap installed on the appliance In cold climates continuous pump operation or pump delay is recommended to help prevent freezing of water on outdoor systems Proper freeze protection must be provided See Freeze Protection Outdoor Vent Air Inlet Location Keep venting areas free of obstructions Keep area clean and free of combustible and flammable materials Maintain a minimum clearance of 3 76 mm from the rear of the outdoor vent cap to combustible surfaces and a minimum clearance of 1 25 mm from the back of the unit To avoid a blocked air inlet or blocked flue condition keep the air inlet flue outlet and drain slot clear of snow ice leaves debris etc Do not locate appliance so that high winds can deflect off
103. stion air inlet cap to supply air to a single appliance and instructions for proper installation The flue pipe roof top vent cap and air inlet pipes are purchased locally The air inlet cap for a vertical roof top termination 1s fabricated from materials purchased locally The air inlet cap for the combined air supply from multiple appliances must be purchased locally TABLE C SIDEWALL VENT KITS Conventional Vent Flue Size Sidewall E Vent Kit Air Inlet Pipe Input Btu hr SVK3020 SVK3020 SVK3021 SVK3021 150 000 199 999 250 000 300 000 29 s Vent size with 1 increaser installed for conventional negative draft venting 13 Minimum diameter installer may increase diameter one pipe size for ease of installation if needed A 6 diameter air inlet cap may be ordered as Sidewall E Vent Kit SVK3022 The sidewall air inlet cap supplied in the Sidewall E Vent Kit is used to supply combustion air to a single appliance The roof top vent cap for flue products should be a standard commercial cap purchased locally The use of a sidewall air inlet cap other than the manufacturers recommended cap for single appliance installations or use of a common air inlet cap for multiple appliances with insufficient free area and or protection from wind and weather may result in operational problems with the appliance or potentially hazardous spillage of flue products which can cause personal injury death o
104. sture in the incoming combustion air A WARNING Using other vent or air intake materials failure to properly seal all seams and joints or failure to follow vent pipe manufacturer s instructions can result in personal injury death or property damage Mixing of venting materials will void the warranty and certification of the appliance Length of Flue Pipe and Air Inlet Pipe The total equivalent length of the direct vent flue pipe or the air inlet pipe must not exceed a maximum of 50 15 24 m equivalent feet in length for each pipe Subtract 5 feet 1 52 m for each elbow in the vent pipe or air intake system Do not exceed limits for piping lengths Sealing of Type B double wall vent material or galvanized vent pipe material used for air inlet pipe on a Direct Vent System 1 Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicon sealant such as those manufactured by Dow Corning or General Electric Do not install seams of vent pipe on the bottom of horizontal runs Secure all joints with a minimum of three sheet metal screws or pop rivets Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe Ensure that the air inlet pipes are properly supported The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and sta
105. te proper draft This will result in condensing of flue products damage the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems before installation If there is any doubt about the sizing or condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system Inspection of a Masonry Chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products A clay tile lined chimney must be structurally sound straight and free of misaligned tile gaps between liner sections missing sections of liner or any signs of condensate drainage at the breaching or clean out If there is any doubt about the condition of a masonry chimney it must be relined An unlined masonry chimney must not be used to vent flue products from this high efficiency appliance An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall or flexible or rigid metallic liners are recommended Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney Common venting systems may be too large when an existing appliance is removed At the time of removal of an existing appliance the following steps shall be followed with each appliance r
106. the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected If a fan is used to supply combustion air to the boiler room the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance E Vent and Direct Vent venting systems have specific requirements for combustion air ducts from the outside which are directly connected to the appliance See the requirements for this combustion air duct in the venting section for each specialized vent system VENTING General Vent installations for connection to gas vents or chimneys must be in accordance with Part 7 Venting of Equipment of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Conventionally vented applications where outside air is used must have adequate combustion and ventilation air supplied to the mechanical room in accordance with the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes The distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition of t
107. those listed on page 15 Sidewall Air Inlet for Direct Vent The combustion air inlet pipe must also be a dedicated system with one air inlet pipe per appliance The air inlet pipes from multiple appliances can NOT be combined to a single common connection The air inlet pipe connects directly to the appliance to supply combustion air The air inlet pipe must be sealed Choose acceptable combustion air pipe materials from those specified in this section Sidewall Direct Vent Caps gt AIRINLET FIG 18 Sidewall Direct Vent Caps Sidewall Direct Vent Kits The sidewall direct vent kit must be ordered from the appliance manufacturer The part number for each kit is listed by appliance size Each kit includes a sidewall vent cap for flue products a firestop a combustion air inlet cap and instructions for proper installation The flue pipe and air inlet pipes are purchased locally TABLE D SIDEWALL DIRECT VENT KITS Sidewall E Vent Kit Direct Vent Flue Size Air Inlet Pipe Input Btu hr HDK3013 HDK3013 5 HDK3014 2 HDK3014 Minimum diameter installer may increase diameter one pipe size for ease of installation if needed 150 000 199 999 250 000 300 000 4 4 15 The sidewall vent cap and sidewall air inlet cap supplied in the Sidewall Direct Vent Kit MUST be used to vent the flue products to the outdoors and supply combustion air Use of a vent c
108. tions 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 CONTENTS USER WARNING EUER 1 Safety Warnes wss shesin eki neei a y wee PR oS 1 Codes eho hues oie PU TDi guns 3 Location ihc dng canard case p bee 3 Clearances Mc hie os ees 4 Combustion Ventilation Air Requirements 4 Venting General s as ike en teen 6 Conventional Venting 8 ET Ventil os tessuti teta 11 Direct Vent Sidewall u esse 14 Direct Vent Vertical i e be Remb s 18 Outdoor Installation 22 Gas Supply 23 Gas Pressur amp amp Piping cos ce 24 Manifold Pressure Adjustment 26 Supply Pressure Measurement 28 Water Connections 29 Valve bee ek ech ete ieee ERA 29 Flow Switch 29 Gas Valve be PR a 29 Electrical Requirements 30 Temperature Adjustment 30 Outdoor Air Reset Option 32 Lighting Instructions 34 Hot Surface Ignition Control 35 Operation amp Diagnostic Lights 35 Ignition amp Control Timings
109. uartz or cristobalite from occupational sources is carcinogenic to humans Testing has confirmed that the ceramic fibers in this application do not reach 2192 F 1200 C Reference Dyson D Butler M Hughes R Fisher R and Hicks G The Devitrification of Alumino silicate Ceramic Fiber Materials The Kinetics of the Formation of Different Crystalline Phases Ann Occup Hyg Vol 41 No 55 1997 Reference I A R C Monograph 68 June 1997 NOTE The ceramic fiber material used in this appliance is an irritant when handling or replacing the ceramic materials it is advisable that the installer follow these safety guides REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS Avoid breathing dust and contact with skin and eyes Use NIOSH certified dust respirator N95 http www cdc gov niosh hompage html Lightly mist with water only those areas being handled the combustion chamber lining or base insulation to prevent airborne fibers Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal Wash potentially contaminated clothes separately from other clothing Rinse clothes thoroughly NIOSH stated First Aid Eye Irrigate immediately Breathing Fresh air 4 Flue Gas Passageways Cleaning Procedures Any sign of soot at burners indicates a need for cleaning The following cleaning procedure must only be performed by
110. ulator cover screw on the gas valve must be in place and tight for the appliance to operate properly 1 Turn the power switch to the OFF position 2 Remove the top front jacket panel 3 Locate the air pressure switch located to the right of the combustion air fan Trace the hose from the air pressure switch to the barb located in the top of the upper chamber Remove the hose from this barb and connect the hose from the manometer or magnahelic to this barb to measure the air pressure in the front chamber 26 Turn the power switch to the ON position Set the thermostat to call for heat The fan will start While the combustion air fan is running for the prepurge cycle and the pressure in the front chamber stabilizes record the pressure in the front chamber This pressure will be used to calculate the net manifold pressure Turn the power switch to the OFF position Remove the manometer or magnahelic hose from the front chamber barb and reinstall the hose from the air pressure switch to the barb Turn all gas valve knobs and the manual gas cock to the OFF position MANOMETER PRESSURE L REGULATOR MANIFOLD PRESSURE n y ADJUSTMENT UNDER CAP SCREW MANIFOLD PRESSURE TAP FIG 31 Manifold Gas Pressure Measurement 10 Remove the 1 8 hex plug located on the outlet side 1 12 13 14 of the gas valve and install a fitting suitable to connect to a manometer o
111. uld use a silicone sealant to ensure a proper seal at the boiler connection Dryer vent should use a screw type clamp to seal the vent to the boiler and the assembly of 90 ells which make up the air inlet cap Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume Sealing of vent material for use with the Vertical Direct Vent System The vent materials Heat Fab Saf T CI Vent Z Flex Z Vent Protech Systems Fas N Seal Vent Flex L Star 34 Metal Fab Corr Guard Vent or listed AL29 4C vent system suitable for positive pressure must be installed and sealed per the vent manufacturers installation instructions Drain Tee Installation TO SUITABLE DRAIN 24 Drain Tee Installation Drain Tee Installation A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system The drain tee must be installed as the first fitting after the horizontal ell on the top of the appliance See the typical vent installation drawings Plastic drain tubing sized per the vent manufacturers instructions shall be provided as a drain line from the tee The drain tubing must have trap provided by 3 76 mm diameter circular trap loop in the drain tubing Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent Secure the trap loop in position with nylon wire ties Use ca
112. ust be provided see Freeze Protection Direct Vent with Sidewall Vent and Air Inlet FIG 17 E Vent Sidewall Direct Vent System The E Sidewall Direct Vent System A DIRECT VENT SYSTEM WITH SIDEWALL TERMINATIONS Follow all requirements in the General Venting section for venting flue products to the outdoors and general installation instructions All direct vent appliances must have combustion air supplied directly to the appliance with a separate air pipe The bell increaser installed on the appliance vent outlet must be removed The bell increaser is NOT USED with the direct vent system Vent connection is made directly to the top of the appliance No additional bell increaser draft diverter or barometric damper is required The direct vent system uses a two pipe system one pipe for the flue products and one pipe for the combustion air supply The sidewall vented flue MUST be a dedicated stack The flue can NOT be combined with any other appliance vent or common vent from multiple appliances The vent on a direct vent system may have a positive pressure in the flue which requires all vent joints and seams to be sealed gas tight The sidewall direct vent system has specific vent material and installation requirements The flue from a direct vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system Choose acceptable vent materials from
113. ut not less than 100 square inches 645 cm FIG 7 Combustion Air from Outside Single Opening 4 single combustion air opening is provided to bring combustion air in directly from the outdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7cm per kW This opening must be located within 12 30 cm of the top of the enclosure CA See venting section for combustion air requirements on E Venting and direct vent applications TABLE A MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO MECHANICAL ROOM Inside Air 2 Openings 150 000 38 in 50 in 150 in 199 999 50 2 67 in 200 in 250 000 63 i 83 i 250 i 300 000 75 in 100 in 300 in Outside air openings shall directly communicate with the outdoors When combustion air is drawn from the outside through a duct the net free area of each opening must have twice 2 times the free area required for each Outside Air Openings The above requirements are for the appliance only additional gas fired appliances in the mechanical room will require an increase in the net free area to supply adequate combustion air for all appliances Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada refer to CSA International CAN CGA B149 1 or B149 2 Installation Code Check all local code requirements for combustion air All dimensions based on net free area in square inc
114. ution not to collapse or restrict the condensate drain line with the nylon wire ties The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material See Freeze Protection for more information When a direct vent system is disconnected for any reason the flue must be reassembled and resealed according to the vent manufacturers instructions The air inlet pipe must also be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume A DANGER Failure to properly seal all vent joints and seams may result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death The connection from the vent to the vent termination outside the building MUST be made with one of the specified vent materials and must be direct as possible with no reduction in diameter The vent accessories such as firestop spacers thimbles caps etc MUST be from the same vent material manufacturer and installed in accordance with the manufacturers listing The vent connection through the roof top must provide correct spacing to combustible surfaces The vent pipe connection to the roof top vent cap MUST have a gas tight seal to prevent the leakage of flue products Venting of Flue Products Locate appliances as close as poss
115. xceeds the quantities shown in this section a larger pump will be required The standard pump selection is based on the following pipe and fittings from the appliance to the storage tank 2 ball valves 6 90 elbows i 1 cold water tee 2 unions Not more than 45 feet of straight pipe For every elbow and tee in excess of those shown above DEDUCT 5 FEET from maximum allowable straight pipe in heater to tank circulating loop TABLE MINIMUM PUMP PERFORMANCE Based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding 350 PPM See Water Chemistry HEAT EXCHANGER This is a highly sophisticated heat exchanger designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build up of impurities The straight line two pass design of the tubes sends water into the headers at a properly rated velocity The configuration of the headers in turn creates a high degree of turbulence which is sufficient to keep all contaminants in suspension This scouring action provides greater cost savings for owners Tubes are always able to transfer heat at peak efficiency Every surface within this water containing section is of a non ferrous material providing clear clean rust free hot water Straight copper tubes finned on the outside for maximum heat transfer coated cast iron one piece cored headers make up an
116. xcessive gas input This condition MUST be corrected immediately d Lifting Flames Lifting flames can be caused by over firing the burner s or excessive primary air ensure proper gas supply and adjust the combustion air 3 Combustion Air Shutter Adjustment uses a fan assisted combustion process shutter is factory pre set and should not need adjustment in most cases If adjustment is required the fan air shutter may be manually adjusted to a dimension specified for each model Follow the steps below to adjust the fan air shutter if the appliance does not function properly or a continuous low air condition is observed _ TO PRESSURE SWITCH WHITE HOSE AIR SHUTTER COMBUSTION CHAMBER TOP FIG 43 Combustion Air Shutter Adjustment A Check for proper installation and draft in venting system Correct as required B Remove upper front access door C Turn the power switch to the OFF position D Turn the gas valve knob to the OFF position E Use aruler to measure the distance from the base of the fan to the end of the air shutter Compare this distance to the specified A dimension for the appliance TABLE Q AIR SHUTTER ADJUSTMENT OPENING Btu hr Input A Dimension Opening 150 000 1 1 16 199 999 1 3 16 250 000 1 5 8 This appliance The fan air 300 000 1 5 8 If adjustment is necessary follow these steps If no adjustment is necessary go to step I a
117. y qualified professional installers service technicians or gas suppliers Consult your local expert for proper installation or service procedures IMPORTANT Consult and follow local Building and Fire Regulations and other Safety Codes that apply to this installation Consult your local gas utility company to authorize and inspect all gas and flue connections IMPORTANT Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting WARNING Should overheating occur or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the pump Instead shut off the gas supply at a location external to the appliance A WARNING To minimize the possibility of serious personal injury fire or damage to your appliance never violate the following safety rules Boilers and water heaters are heat producing appliances To avoid damage or injury do not store materials against the appliance or the vent air intake system Use proper care to avoid unnecessary contact especially children with the appliance and vent air intake components Never cover your appliance lean anything against it store trash or debris near it stand on it or in any way block the flow of fresh air to your appliance UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the

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