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Lochinvar 000 - 500 User's Manual

1. OUTLET FIG 33 F1 Gas Valve 90 000 270 000 Btu hr Models 6 Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Follow the steps in the What To Do If You Smell Gas section in the safety information on page 24 If you do not smell gas go on to the next step Remove the lower panel door to gain access to the pilot Find the pilot Follow the metal tube from the gas valve to the pilot The pilot is located on the right side of the burner approximately centered in the burner tray TOP OF FLAME SPREADER TO BE FLUSH WITH TOP OF BURNER MAIN uM PILOT FIG 34 Pilot Location 9 Turn the control knob on the gas valve counterclockwise to the PILOT position 25 PILOT COVER USE LIGHTING WAND TO LIGHT STANDING PILOT FIG 35 Lighting Wand The information package shipped with the appliance contains a wire lighting wand The loop end of the wand will hold a match The wand extends your reach to the pilot and makes lighting the pilot easier 10 11 12 13 14 15 Use the loop end of the wire lighting wand shipped with the instruction package to hold the match and reach the pilot An access slot is provided in the lower front jacket panel beside the burner to insert the lighting wand and match to the pilot Lift the pilot cover FIG 35 to access the
2. FIG 6 Combustion Air Through Ducts 2 If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed 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 1 FIG 7 Combustion Air from Interior Space 3 If air 1s taken from another interior space that 1 adequately ventilated 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 but not less than 100 square inches 645cm E FIG 8 Combustion Air from Outside Single Opening If a 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 30cm of the ceiling 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 of the two openings must have twice 2 times the free area required for Outside Air 2 Openings Table A lists the requirements for the appliance only additional gas fired appliances located in the same room will require an increase in the net free area to supply adequate combustion air for all appliances Combus
3. 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 homepage 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 HEAT EXCHANGER BURNER ACCESS a Turn OFF main power to the appliance b Turn OFF external manual gas shutoff valve to appliance c Remove the control panel door d Remove the outer air deflector FIG 38A Disconnect gas valve wiring and remove gas manifold assembly f Remove ignition wire leading to the pilot assembly from the ignition module g Disconnect the wiring from the flame roll out interlock switch see Figure 32 page 23 h Remove the lower front jacket panel 1 Remove the control panel mounting screws When removing the control panel lay the control panel to the side with the wiring intact being careful not to damage any of the wiring Remove the combustion chamber door Use caution to prevent damage to burners refractory pilot or wiring INSPECTION AND CLEANING
4. 000 Btu hr Models Wiring Diagram F1 Uni 000 270 90 Schematic Diagram F1 Uni 90 000 270 000 Btu hr Models 122197 MOTI3A A 1 3LIHM M ANY 9 31 2 NYL L 3ONVHO HO UYAHOIH HO 1 40 r 71 Q3 H AVHO AS ISN 9NIOV Td3H N3HM Aldddns SWALI IVNOlLdO 5191 M bl I1 AD S QS As fp x 26965 THOLIMS d gt Nou vinosiio AD Jasad 4122 44o1no d QN 9 MaLVM MOT 7771 L TA ERINBA M8 O sation ag o O HOLIMS LNOTION 5 H LIMS SS 11146 YOSNIS 9 4 i i E HOIH 14534 ONIDIAMAS 3304338 H3MOd LO3NNOOSIQ Ww 4 O GY q BOX DEPICTS OPTIONAL ITEMS L PUMP MANUAL RESET HIGH LIMIT A RA PR ENT DAMPER L H CIRCULATION THERMOSTAT W GAS VALVE INLET SENSOR TANK SENSOR L YELLOW 4 VENTER PROVING 24VDC RELAY 72 J ROLLOUT SWITCH OPERATOR on B BK PR R RED T TAN W WHITE LOW AWER CUTOFF PR 1 iP L LI Bk 2 ENT DAMPER W switcH AUTO RESET PK CN1 1 OPERATOR 1 2 BL 24VDC RELAY Ro d E I HIGH LIMIT GY OPERATOR GY GRAY OR ORANGE PR PURPLE CUTOFF
5. 30 o Check V baffles on top of the heat exchanger Remove and clean if necessary p Remove soot from the heat exchanger with a stiff bristle brush Soot may also be removed from the heat exchanger by washing thoroughly with detergent and water Remove the heat exchanger before using water for cleaning Rinse thoroughly and dry before re installing Use a vacuum to remove loose soot from surfaces and inner chamber q Remove the heat exchanger HEX filler bracket FIG 38A r The heat exchanger can be removed by sliding towards the front of the appliance Once the heat exchanger is removed from the appliance a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces s Ensure that all burner ports are cleaned to remove any soot See Inspection and Cleaning Procedure page 30 t Carefully re install the heat exchanger V baffles jacket panels and wires u Reassemble all gas and water piping Test for gas leaks v Cycle the appliance and check for proper operation UPPER FRONT JACKET PANEL OUTER AIR DEFLECTOR Acta jo in 5 7 SSS E 7 FLAME ROLL OUT SWITCH LOWER FRONT INTERLOCK SWITCH JACKET PANEL FIG 38A Outer Air Deflector and HEX Filler Bracket 5 Water Circulating Pump Inspect pump every 6 months and oil if required Use SAE 30 non detergent oil or lubricant specified
6. If the outdoor design and boiler design temperatures are known the Ratio setting can be calculated using the following formula Ratio boiler design temperature operator set point Max setting outdoor design temperature Note that the reset set point cannot exceed the maximum set point of the boiler thermostat These settings are illustrated graphically in Figure 30 RESET SET POINT MAX SET POINT RATIO 1 5 1 0 RATIO 0 5 OPERATOR SET POINT TEMP FIG 30 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 unit 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 supplied with a fixed setting auto reset high water temperature limit control The setting of this control limits maximum discharge water temperature If water temperature exceeds the setting the limit will break the control circuit and shut down the appliance The limit control will only be reset after the water tem perature has cooled well below the setting of the limit The auto reset high water temperature limit control is mounted in the outlet side of the front header Manual
7. 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 higher temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature A remote low tem perature range operator is recommended to control the boiler operation based on the lower system temperature This remote operator should be wired across the R and W terminals see Room Thermostat Connection and Terminal Strip Instructions THREE WAY VALVES SECONDARY BOILER PUMP EXPANSION TANK THREE WAY VALVE SLOW OPENING SLOW CLOSING TO SYSTEM 5 gt AIR SEPARATOR SYSTEM PUMP FIG 45 Boiler Piping with a 3 Way Valve Th
8. j Check the heat exchanger surface for sooting The external surfaces of the copper tubes should be free of any soot deposits A slight black smudge 1s normal with some types of gases If abnormal soot deposits are present the heat exchanger must be cleaned and the cause of the soot problem corrected Proceed as follows k Remove soot from burners and bottom of the finned tubes with a stiff bristle brush Dirt may also be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installing Damaged burners must be replaced 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 will probably require a thorough cleaning before the appliance is placed in service l Remove gas manifold as described in steps a thru e in Heat Exchanger Burner Access m Loosen mounting screws and remove front control panel n Loosen screws on the upper front jacket panel and remove toward front of the appliance Use caution to prevent damage to refractory on the doors inner surface
9. 3 BL WATER 1 120 GROUND LINE o 2728 REV SWALI TVNOILdO S1oIld3a LII 1018 Muvds 31ndONW QNO QNS Ave Ad Ad AW AW Wiring Diagram F9 Uni 90 000 399 999 Btu hr Models 120V NEUTRAL CIRCULATION PUMP 24VDC RELAY Bk 120 GROUND Schematic Diagram F9 Uni 90 000 399 999 Btu hr Models i TRANSFORMER SLIHM M NVI L 3dHnd ud MNId Md 3ONVHO HO 3339 9 NMOSS ZNS anma ig HOIH la3sdsroinv YOSNAS YOSNAS I3TNI SPILL SWITCH Te J m c THERMOSTAT MANUAL RESET HIGH LIMIT PR PR cn1 4 OPERATOR on1 3 CUTOFF SUR Low ROLLOUT SWITCH CN1 1 OPERATOR eN1 2 iP BL Le VENT DAMPER BL ae CUTOFF 3 BL 5 Fow WATER 1 jd OUVERRELAY WENTERRELAY c m Ng 315 amp 360 ONLY VENTER NT DAMPER 1 PR AONVS ANY a3univuadWal 30 JAIM FSN ONIHIM SNIOV Idas N3HM S 1 AY MPE Ape gt 78 gt 4401N9 W3IVM NO 1O9VINOO 1NIOdlas wwuwsudda 92 8 5 022 a L e 002 6 el 0 tol S 145440 HOLIMS o HOLIMS Hd
10. BK R VENT VALVE LOUVER RAL ONTACTS LOUVER MOTOR 60Hz NEUT LOUVERS B Ni CN1 2 v 12 CUTOFF J BL Y 7 VENTDAMPER 13 _ Rt THERMOSTAT W1 B 5 Ll uw BOILERS PR ONLY water pg ROLLOUT V waNUALRESET CUTOFF SWITCH HIGH LIMIT SWITCH E 0 O 4 agi PRI L 4 Ln PR oR Flow 1 4 a a d x o INLET MOUNTED ON OPERATOR OPTIONAL SYSTEM TANK escccccocccced BOILER ONLY SEE MANUAL 24VAC RELAY ALARM CONTACTS FIELD NSTALLED SENSORWRING LOH vZ 9 o r MANUAL RESET LOW MANUAL RESET HIGH GAS PRESSURE SW GAS PRESSURE SW o R GREEN GY GRAY RED R ROLL OUT SWITCH TLOUVER RELAY 1 Ponie oS VENTER FR VENT DAMPER PROVING L4 9 S Bk ort CX 16 BLUE PINK ORANGE BL P ont TAN Y YELLOW T AUTO RESET LIMIT Gasvalve LOW FIRE RELAY GAS VALVE W WHITE BK BLACK PR PURPLE BR BROWN OPTIONAL MANUAL PR RESET HIGH LIMI OPTIONAL ADJUSTABLE HIGH LIMIT PR PR I DISCONNECT POWER BEFORE SERVICING MV MV IGNITION 24V MODULE SPILL SWITC SPLICE BOILERS STANDARD ON WATER HEATERS SYSTEM PUMP STANDARD ON PUMP DELAY RELAY HIGH FIRE GAS VALVE OPERATOR OPTIONAL POWER VENTER SYS
11. Ensure that there are no air bubbles visible in the water Minimum flow is based on a 40 F temperature rise stream before closing the drain valve across the boiler Minimum flow may not prove a flow switch installed in the boiler piping Use care B Repeat this procedure for each circuit when operating a boiler at or near the minimum recommended flow because conditions unique to the 5 Open all valves after all circuits have been purged installation system pressure operation of multiple Make sure there are no system leaks zone valves glycol variations in flow etc may result in overheating of the boiler water causing noise or nuisance operation of safety limit controls Typical heating boiler applications will operate with a 20 F to 30 F temperature rise across the boiler Do not use petroleum based stop leak products AII system leaks must be repaired The constant addition of make up water can cause damage to the boiler heat exchanger due to scale accumulation Scale reduces flow and heat transfer causing overheating of the heat exchanger TYPICAL HEATING BOILER INSTALLATIONS 6 Run the system circulating pump for a minimum of General Roles 30 minutes with the boiler turned off 1 Check all local codes 7 Open all strainers in the system and check for 2 serviceability of the boiler always install debris unions 8 Recheck all air vents as described in step 4 3 Always pipe pressure
12. OFF position Wait five 5 minutes to clear out any gas then smell for gas including near the floor If you smell gas STOP Follow the steps in the What To Do If You Smell section in the safety information on page 26 If you do not smell gas go on to the next step 45 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve counterclockwise to the position 180 000 360 000 Btu hr models rotate the gas control knob on the gas valve counter clockwise to the line on the collar around the knob Allow the knob to up and continue rotation to the position Turn on all electric power to the appliance Set the thermostat to the desired setting Re install the control panel door If the appliance will not operate follow the instructions 7o Turn Off Gas To Appliance and call your service technician or gas supplier 27 1 2 3a 3b Set the thermostat to the OFF position Turn off all electric power to the appliance if service 1 to be performed 45 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position Do not force 180 000 360 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the OFF position Do not force WARNING Should ove
13. Pressure 1 the power OFF at the main disconnect switch 2 Turn gas valve control knob s to the OFF position 3 500 000 Btu hr model will have two gas valves Turn the gas valve control knob on each valve to the OFF position 4 Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P gas shut off gas supply at the tank 5 Remove the 1 8 hex plug located on the inlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge On two gas valve models remove the hex plug from the gas valve closest to the gas supply connection Range of scale should be 14 w c or greater to check inlet pressure See Figures 18 and 19 for location 16 Turn on gas supply at the manual valve turn on L P gas at tank if required Turn the power ON at the main disconnect switch Turn gas valve control knob to PILOT position on standing pilot models Follow the Lighting Instructions for standing pilot models to light the pilot Turn gas valve control knob to the ON position when the pilot is established Turn gas valve control knob s to the ON position on spark ignition models Set the thermostat s to call for heat Observe the gas supply pressure with all burners firing Ensure inlet pressure is within specified range Check gas supply pressure with all other gas fired appliances i
14. Reset High Water Temperature Limit Control Standard Fixed Settings on Water Heaters and Optional Adjustable Settings on Boilers and Water Heaters Water heaters are supplied with a fixed setting manual reset high water temperature limit control This manual reset temperature limit control has a fixed limit setting of 230 F 110 C If water temperature exceeds this setting the limit will break the control circuit and shut down the unit The limit control can only be reset after the water temperature has cooled well below the setting of the limit Reset of the limit control is accomplished by pushing the Red Reset Button Manual Reset High Limit see Figures 25 27 on pages 19 and 20 located on the front side of the control panel A label on the control panel indicates the exact location of the manual reset high water temperature limit control FLAME ROLL OUT SWITCH INTERLOCK SWITCH BLOCKED VENT AND FLAME ROLL OUT F LAME INTE RLOCK SWITCH FIG 32 Flame Roll Out Flame Interlock Switch Location All units are equipped with manual reset blocked vent and flame roll out flame interlock switches These temperature switches are located in the controls compartment and in the relief opening of the boiler s built in draft hood Each switch has a red reset button In the event the system has actuated to shut off the main burner gas supply wait for the boiler to cool then press the red reset to return the boiler t
15. approved for use on combustible surfaces Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the appliance FIG 3 Clearances Models 45 000 180 000 Btu hr FIG 4 Clearances Models 199 999 500 000 Btu hr 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 of the National Fuel Gas Code ANSI 7223 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 5 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 30cm of the floor 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 30cm of the ceiling
16. building codes Adequate combustion and ventilation air must be supplied to the room where the appliance is installed in accordance with the latest edition 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 distance of the vent terminal from adjacent buildings windows that open and building openings MUST comply with the latest edition 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 Vent connection is made directly to the top of the appliance This appliance is designed with a built in draft diverter No additional external draft hood is re quired The connection from the appliance vent to the common vent or chimney must be made as direct as possible FIG 9 Conventional Negative Draft Vertical Venting A CONVENTIONAL NEGATIVE DRAFT VENTING SYSTEM The negative draft in a conventional vent installation must be within the range of a negative 0 02 to 0 05 inches water column to ensure proper operation draft readings are made while the appliance is in stable operation approximately 2 to 5 minutes Multiple appliance installations with combined venting or common venting with other negative draft applianc es require that each appliance must have draf
17. diameter for a single unit installation 5 Common manifold piping for multiple unit instal lations will require larger minimum pipe sizes to tank tappings to ensure proper flow See Table Q on page 40 6 Multiple unit installations may also require a larger circulating pump to achieve the specified flow against the increased head loss of a multiple unit common manifold piping If the temperature rise 1 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 is steady at the required temperature rise as noted in Table P 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 REQUIRED TEMPERATURE RISE Temperature rise is based on the hardness of the potable water to be heated A different temperature rise is specified for soft water with a hardness of 0 to 7 grains per gallon or for unsoftened water with a hardness of 8 to 25 grains per gallon The total dissolved solids shall not exceed 350 ppm If there is any doubt about the hardness or total dissolved solids content of the water to be heated follow the temperature guidelines for water with 8 to 25 grains of hardness in Table P below The majority of all potable water supplies will f
18. 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 A 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 unit never violate the following safety rules 1 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 2 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 3 UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the 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 installation regulations in force in the local area where
19. knob to position Set the thermostat s to call for heat Observe gas regulator pressure when all burners are firing See Table D Manifold Pressure for proper regulator pressure settings If adjustment is necessary turn regulator adjustment screw clockwise to raise regulator gas pressure counterclockwise to lower gas pressure to proper setting Note Adjustment fitting is plastic and may require slightly greater turning force than a metal fitting Turn the power OFF at the main disconnect switch Do not increase regulator pressure beyond specified pressure setting 15 12 13 Turn gas valve control knob to PILOT position on standing pilot models Turn gas valve control knob to OFF position on spark ignition models Remove fitting from the gas valve and replace the 1 8 hex plug that was previously removed and tighten 14 Repeat the adjustment procedure for the second gas valve on the 500 000 Btu hr model 15 Turn the gas valve control knob s to position 16 Tum the power at the main disconnect switch The appliance is now ready to operate If manifold pressure can not be properly adjusted use the following procedure to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control CHECKING GAS SUPPLY PRESSURE Gas Supply Pressure Manometer Gas Valve FIG 19 Gas Supply
20. 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 excessive 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 If improper flame is observed examine the venting system ensure proper gas supply and adequate supply of combustion and ventilation air 3 Combustion Air Adjustment This appliance uses an atmospheric combustion process Combustion air is provided to the burners by the gas injection pressure into the venturi of the burners burners do not have an adjustable air shutter Adequate combustion air must be supplied to the room where the appliance is installed to ensure proper burner operation Check frequently to be sure the flow of combustion and ventilation air to the unit is not obstructed When the main burners light observe the burner flame Flames should be light blue in color with slight yellow tips flames should be settled on burner head with no lifting when supplied with correct volume of combustion air 4 Flue Gas Passageways Cleaning Procedures Any sign of soot around the outer jacket at the burners or in the areas between the fins on the copper
21. on the flue outlet located on the top of the draft hood see Figure 15 Do not alter the wire harness supplied with the vent damper Follow the instructions supplied with the vent damper A CAUTION An appliance which is shut down or will not operate may experience freezing due to convective air flow down the flue pipe connected to the unit Proper freeze protection must be provided see Freeze Protection GAS SUPPLY GAS PRESSURE TEST Verify that the appliance is supplied with the type gas specified on the 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 eleva tion Consult the factory for installations above 2000 feet elevation Field conversions for operation at high altitude must be performed by certified personnel only The appliance will be marked to indicate suitability for high altitude operation GAS SUPPLY PRESSURE Measured at the inlet pressure tap located upstream of the combination gas valve s see Figures 20 22 page 17 TABLE C GAS SUPPLY PRESSURE Nat Gas Gas Max Inches Water Column 10 5 Min Inches Water Column 4 5 Min Inches Water Column 5 0 Models 45 000 360 000 Btu hr Only Models 399 999 500 000 Btu hr Only 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 press
22. pilot which must be ignited by hand When lighting the pilot follow these instructions exactly B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor 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 neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to push in or turn the gas control knob Never use tools If the knob will not turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in a fire or explosion D Do not use this appliance if any part has been under water Immediately call a qualified service technician to inspect the appliance 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 LIGHTING INSTRUCTIONS 1 2 24 STOP Read the safety information Remove the control panel door Set the thermostat to the lowest setting OFF Turn off all electrical power to the appliance Turn the gas control knob on the gas valve clockwise to the OFF position
23. relief valves to an open General Plumbing Rules drain Inspect the liquid level in the expansion tank The system must be full and under normal operating pressure to ensure proper water level in the expansion tank Ensure that diaphragm type expansion tanks are properly charged and not water logged 4 Locate system air vents at the highest point of the system 5 Expansion tank must be installed near the boiler and on the suction side of the pump 6 Support all water piping 36 10 Start the boiler according to the Start Up Instructions in this manual Operate the system INSTALLATION WITH A CHILLED including the pump boiler and radiation units for WATER SYSTEM one hour 11 Recheck the water level in the expansion tank If TANK HEATINGAND it exceeds half the tank volume open the tank to E COOLING COIL reduce the water level Recheck pressure charge on diaphragm type tanks LOWWATER FLOW SWITCH 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 Np ke or debris the water makeup valve 14 Verify system pressure with the boiler pressure FIG 47 Installation with a Chilled Water System fi inni l tion panied Polore operon Pipe refrigeration systems in parallel I
24. require a back flow preventer or actual disconnect from city water supply when glycol 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 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 operation 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 the first year to determine inspection interval Check all joints and pipe connections for tightness corrosion or deterioration Clean louvers and or screens in the combustion air intake system as required Have the entire system including the venting system periodically inspected by a qualified service agency 2 Visually check main burner flames at each start up after long shutdown periods or at least every six months WARNING The area around the burners is hot and direct contact could result in burns YELLOW TIP YVAN VU AVE NORMAL Ll FLAME LIFT YELLOW FLAME FIG 37 Burner Flames 29 a Normal Flame A
25. 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 Drain the unit completely Remove 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 FREEZE PROTECTION FOR A HEATING BOILER SYSTEM If Required 1 Use only properly diluted inhibited glycol anti freeze designed for hydronic systems Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible CAUTION DO NOT use undiluted or automotive type antifreeze 2 solution of 50 propylene glycol will provide maximum protection of approximately 30 F 3 Follow the instructions from the glycol antifreeze manufacturer The quantity of glycol antifreeze required is based on total system volume including expansion tank volume 4 Glycol is more dense than water and changes the viscosity of the system The addition of glycol will decrease heat transfer and increase frictional loss in the heating 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
26. water temperature of 125 F which will satisfy hot water demands and prevent risk of scald injury Households with small children or invalids may require 120 F 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 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 remember 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 unit for correct piping Higher water temperatures reduce condensate formation A CAUTION Settin
27. wire gauge EXTERNAL SENSOR FOR TANK SYSTEM OR PUMP DELAY REMOTE SENSOR CONNECTOR IS LOCATED ON SIDE OF UNIT NOTE COLOR OF WIRES AND LEAD STYLES MAY VARY WITH SENSOR PROVIDED CONNECTIONS ARE POLARITY INSENSITIVE FIG 50 External Sensor for Tank System or Pump Delay 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 straight line two pass design of the tubes sends water into the headers at a properly rated velocity 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 nonferrous material providing clear clean rust free hot water Straight copper tubes finned on the outside for maximum heat transfer glass lined cast iron one piece cored headers make up an entirely rustproof unit 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 unit THERMOSTAT SETTINGS 1 The thermostat is adjusted to a low test setting when shipped from the factory 2 Set the thermostat to a maximum
28. 1 13S3M TWANVW 05125 13 WOlVH3dO 24V PROVING IGNITION MODULE TIMER Y Y T TANK SENSOR BL 24VDC RELAY ARMING RELAY 4 TENT DAMPE OPERATOR OFF RELAY el aC AUTO RESET HIGH LIMIT GY 6 FAILURE CONTACTS OFF RELAY 3158360 ONLY ARMING RELAY PR CONTACTS ON ANY FAILURE dnd NOILVINDYID SNIOIAH3S 5303538 H3MOd LOANNOOSIG LBL2727 REV AlddNS H3MOd GY GRAY BLACK BLUE BK BOX DEPICTS OPTIONAL ITEMS WHITE TELLOW T W Y ORANGE PINK PURPLE PR OR BROWN GREEN BL BN G iagram M9 Un ing Di Ir 45 000 399 999 Btu hr Models M9 Un 45 000 399 999 Btu hr Models ic Diagram Schemat 9220181 4 n 3onvo JYNLYYIANIL MOTHA A gdHnd td N33H9 9 USHOIH YO 1VhO3 JO SW3LI TWNOILdO SL1IHM M NMOMS NS8 4 SLOIldad 1 1 gONVHO HO WJWHOJSNVHL 2 AVHO AO Mov18 8 4 L gt 350119 Muvds 3umivd ANY WH31VM MOT NO LOVLNOO r NOILYINDYIO JINAON NOILINOI 1 104155 Ud Od ore HOLIMS QNO WANN iz 10118 AlddNS H3MOd anv Ave 0959615 0L ov SSVdA8 AdIAW gt 5 of ts HOLIMS 7195 HOSN3S 197 8 SN
29. 180 Seconds Maximum F9 M9 Intermittent Spark Ignition Pilot Models Pilot Trial for Ignition Period 90 Seconds 45 000 thru 399 999 Btu hr models Pilot Trial for Ignition Period 15 Seconds 500 000 Btu hr model Pilot Failure Response Time 0 8 Seconds at less than 1 0 flame current Pump Delay Timing Standard on Water Heaters and Optional on Boilers 30 Seconds after burner shut down 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 28 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 manufacturers instructions DO NOT use undiluted or automotive type antifreeze 5 A snow screen should be installed to prevent snow and ice accumulation around
30. 2 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 is recommended on rigid hangers installed with a copper system The boiler pressure relief valve must be piped to a suitable floor drain See the relief valve section in the Installation and Service Manual 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 Heating Boilers with inputs of 45 000 260 000 Btu hr have 1 1 2 NPT inlet and outlet connections Heating boilers with inputs of 315 000 500 000 Btu hr have 2 NPT All water heaters have 2 NPT Caution Field installed reducing bushings may decrease flow resulting in boiler noise or flashing to steam CIRCULATOR PUMP REQUIREMENTS This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation The boiler circulating pump must be purchased locally The boiler circulator pump must operate continuously while the boiler is firing Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system desi
31. 22 t Heating Boiler sese Installation Requirements sess Pump Requirements seen Press re Drop Chart reete terere Boiler Pump Operation sss Typical Piping Bypass Requirements 2 2 Low Temperature Systems Boiler Flow Rates eee Placing Boiler in Operation 36 Temperature Rise Chart sss 37 Boiler Temperature Control 38 Remote Thermostat Control Connection 38 Power Venter Connection cecinit niiit 38 Domestic Water sese 38 Water Velocity Control sss 39 Temperature Rise sse 39 Water Chemistry erre 40 Pump Operation sese 40 Risk of Scald Warnings sss 42 Troubleshooting essere enne 44 Witing Dia grains anten ten ortae 46 Revision Notes 64 080 Back Cover The information contained in this manual is intended for use by 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
32. 6 The combination gas valve has an integral vent limiting device and does not require venting to atmosphere outside the building MANIFOLD PRESSURE Btu hr Input Gas 45 000 Full or High Fire Settings Natural Gas L P Gas 3 5 10 Low Fire Settings Natural Gas L P Gas 0 9 2 97 3 5 500 000 10 two valves N A N A TABLE SUGGESTED GAS PIPE SIZE SINGLE APPLIANCE INSTALLATIONS Btu hr DISTANCE FROM METER In Feet INPUT 0 50 51 100 101 200 201 300 301 500 45 000 1 2 1 2 3 4 1 1 4 75 000 1 2 3 4 1 1 4 1 1 4 90 000 1 2 3 4 1 1 4 1 1 4 135 000 3 4 1 1 1 4 1 4 1 1 2 180 000 1 1 1 1 4 12 1 1 2 199 999 I 1 1 4 1 2 2 215 000 1 1 1 4 1 1 4 1 2 2 260 000 1 1 4 1 4 12 2 315 000 1 1 4 1 1 2 1 1 2 1 2 2 360 000 1 4 1 2 2 2 2 1 2 399 999 11 4 1 1 2 a 27 2 1 2 500 000 11 4 1 1 2 2 27 21 2 For each elbow or tee add equivalent straight pipe from Table F to total length TABLE F TABLE G FITTINGS EQUIVALENT GAS CONNECTIONS STRAIGHT PIPE 45 000 135 000 Diameter Pipe inches 180 000 315 000 3 4 11 4111 2 2 3 4 5 360 000 500 000 Equivalent length of Straight Pipe feet 7 Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes 13 TABLE H MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING S
33. ARNING Improper Installation Adjustment Alteration Service or Maintenance can cause injury or property damage Refer to this manual For assistance or additional information consult a qualified installer service agency or the gas supplier 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 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 unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors 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 instructions If you cannot reach your gas supplier call
34. IOIAH3S 380438 H3MOd LO3NNOOSIG 2 o SPILL NEUTRAL W vor V TRANSFORMER SWITCH B 5K O AY VENTER PROVING 24VAC RELAY eR 4 4 NO VENTER REL IGNITION 24V MODULE GND FAILURE CONTACTS 6 OPTIONAL ITEMS P 3158360 ONLY occ orc BOX DEPICTS LOW SWITCH pu CIRCULATION PUMP BK BYPASS PUMP PK Y v1 SYSTEM SENSOR Y E WHITE YELLOW ARMING RELAY RED ARMING RELAY y CN1 2 By J a ar a T TAN R THERMOSTAT W ROLLOUT V MANUAL W Y SWITCH HIGH LIMIT PR 5 m oxv L X lLOUVER RELA GAS VALVE m PR PR PERAT CN1 4 9 ATOR CN1 3 T 315 amp 360 ONLY Pe vent DAMPER AUTO RESET HIGH LIMIT OPERATOR 1 LOW WATER L CUTOFF R GRAY ORANGE PINK PURPLE 24VDC RELAY CN1 1 OFF RELAY OFF RELAY BL Y Ar BK BL OPERATOR 9 4 GY OR 120 GROUND LINE 5 VENT DAMPER 13 low WATER CUTOFF IGNITION MODULE CONTACTS ON ANY FAILURE BK BLACK G GREEN BL w LBL2723 REV Schematic Diagram 9 9 Unit Wiring Diagram F9 M9 Unit 500 000 Btu hr Models 500 000 Btu hr Models 120 STANDARD ON WATER HEATERS GROUND LINE ON BOILERS CIRCULATION r PUMP BK 24VDC RELAY LBL2726 inm 24VAC RELAY BOILERS ONLY SHUTOFF VALVE OPTIONAL LOUVER CONTACTS PROVING Ze
35. IZE CHART Length of Pipe in Straight Feet 30 40 50 60 70 80 90 100 125 150 69 256 205 174 155 141 128 121 113 106 95 86 79 74 697 477 384 328 292 267 1400 974 789 677 595 543 11 2 2 150 1 500 1 210 1 020 923 830 246 502 769 226 210 200 179 164 149 138 472 441 410 369 333 308 287 707 666 636 564 513 472 441 4 100 2 820 2 260 1 950 1 720 1 560 1 440 1 330 1 250 1 180 1 100 974 871 820 6 460 4 460 3 610 3 100 2 720 2 460 2 310 2 100 2 000 1 200 1 700 1 540 1 400 1 300 11 200 7 900 6 400 5 400 4 870 4 410 4 000 3 800 3 540 3 300 3 000 2 720 2 500 2 340 23 500 16 100 13 100 11 100 10 000 9 000 8 300 7 690 17 380 6 870 6 150 5 640 5 130 4 720 Maximum Capacity of Pipe Thousands of BTU s per hour for gas pressures of 13 5 Inches Water Column 0 5 PSIG or less and a pressure drop of 0 5 Inch Water Column Based on the calorific value of Natural Gas 1025 Btu ft 0 60 Specific Gravity FIG 16 Gas Line Connection All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes Tubing installations must comply with approved standards and practices Reference Figure 16 for a typical installation Install Piping to Control 1 gas line should be a separate line direct from the meter unless the existing gas line is of 14 sufficient capacity Verify pipe size with your gas supplier Use
36. MPORTANT 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 GAS TRAIN AND CONTROLS GAS FLOW FIG 39 Gas Train 45 000 399 999 Btu hr Models FIG 40 Gas Train 500 000 Btu hr Model PIPING OF THE BOILER SYSTEM The drawings in this section show typical heating boiler piping installations Before beginning the instal lation 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 The boiler circulating pump air separator expansion tank and other components required for proper installation must be purchased locally 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 expansion tank 1s 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 1
37. RCULATION PUMP TO BYPASS PUMP OPT FIG 41 Boiler Wiring Circulation Pump to Junction Box PUMP INSTALLATION AND MAINTENANCE The boiler circulating pump must be purchased locally For installation and maintenance information on the circulator pump refer to the pump manufacturers instruction package included with the pump BYPASS PUMP 45 000 260 000 Btu hr Heating Boilers Only These units are equipped with an integral bypass pump which is designed to provide efficiency optimization by maintaining a constant flow through the unit s heat exchanger loop when building system flow is reduced The bypass pump assembly is standard equipment and is NOT to be used as a system pump The bypass pump is dedicated to the unit and does not affect the building s system or primary secondary flow characteristics and will not circulate the building EXPANSION TANK MAKE UP WATER AIR SEPARATOR HEATING RETURN LOOP HEATING SUPPLY LOOP FIG 42 Single Boiler Full System Flow PRIMARY SECONDARY BOILER PIPING MAKE UP WATER EXPANSION TANK LWCO OPTIONAL p SYSTEM PUMP SECONDARY BOILER PUMP AIR SEPARATOR FROM SYSTEM FIG 43 Primary Secondary Piping of a Single Boiler Heating boilers with inputs of 315 000 500 000 Btu hr or larger installed on multiple zone systems are recom mended to be installed with a primary secondary piping system as shown in Figure 43 A primary secondary piping s
38. RSB i amp s 05 INSTALLATION AND SERVICE MANUAL 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 Excessive water hardness causing a lime buildup 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 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 HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 45 000 500 000 Btu hr MODELS CERTIFIED A W
39. TEM TANK SENSOR STANDARD ons ON WATER HEATERS OPTIONAL ON BOILERS STANDARD ON WATER HEATERS OPTIONAL ON BOILERS OPTIONAL JUNCTION PUMP BOX SWITCHES REMOTE 5 OPTIONAL JUMPER PROVING SWITCH HIGH LIMIT THERMOSTAT OPTIONAL OVAOZL LN3A WAZ TWNOILdO AUTO RESET HIGH LIMIT OFF RELAY ARMING RELAY OFF RELAY RR Hy Weep al T TAN BOX DEPICTS PK PINK W WHITE OPTIONAL ITEMS PR PURPLE Y YELLOW dE SS AdH 9616181 NOTES NOTES 51 52 Revision 4 RSB i amp s 04 reflects the removal of the inlet pipe and installing the inlet sensor inside the header Revision 5 RSB i amp s 05 reflects changes made to the O A section RSB i amp s 05 CP 5M 4 08
40. a closed system such as one with a backflow 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 be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow There should be no smoking or open flames near the faucet at the time it is open 43 TROUBLESHOOTING GUIDE 45 000 500 000 Btu hr Models Boilers amp Water Heaters F9 M9 Is the spark STEP 1 igniter sparking the ignition module Check the pilot STEP 2 Is the pilot tube for gas 2 Saing UN Check for draft Is there 24 VAC purple wire on the 4 pin connector plug on the temperature controller Check 24VAC at R and W on the EMS terminal strip Check all safety limit devices Check 4 pin low water cutoff connector 44 Check continuity of the spark Check for an ope
41. all within the range of 8 to 25 grains of hardness See Water Chemistry page 40 TABLE P REQUIRED TEMPERATURE RISE Btu hr 0 to 7 Grains Hardness Temp Rise F 8 to 25 Grains Hardness INPUT Temp Rise F Lower flows with soft water mean a higher temperature rise higher temperature rise may cause nuisance tripping of a high limit or opening of a relief valve when providing very hot water If this presents a problem increase the flow to the temperature rise specified for 8 to 25 grains hardness water WATER CHEMISTRY The required temperature rise and the standard pump sizing are based on the heating of potable water with chemistry within the specified limits Caution should be used when heating water softened to less than 5 grains per gallon Many commercial water softeners reduce hardness to 0 grains which may result in long term problems in the system Softened water will usually have a lower pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions Follow the temperature rise recommendations when heating soft water Unsoftened water with a hardness of 8 to 25 grains per gallon and or total dissolved solids not exceeding 350 ppm requires a higher velocity and lower temperature rise As water is hea
42. ances 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 Part 11 in the latest edition 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 VENTING TERMINATION 10 OR LESS 2 MIN VWV CHIMNEY FIG 10 Vent Termination from Peaked Roof 10 or Less from Ridge MORE THAN 10 10 RIDGE CHIMNEY FIG 11 Vent Termination from Peaked Roof More Than 10 from Ridge The vent terminal should be vertical and exhaust outside the building at least 2 feet 0 61m above the highest point of the roof within a 10 foot 3 05m radius of the termination The vertical termination must be a minimum of 3 feet 0 91m above the point of exit A vertical terminal less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall 10 OR EN CHIMNEY WALL OR CHIMNEY PARAPET FIG 12 Vent Termination from Flat Roof 10 or Less from Parapet Wall 10 OR MORE FROM WALLS OR 5 15 MORE CHIMNEY FIG 13 Vent Termination from Flat Roof More Than 10 from Parapet Wall The vent cap should have a minimum clearance of 4 feet 1 22m horizontally from and in no case abo
43. ature 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 control to shut the boiler off when a desired outdoor air temperature level 15 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 outdoors 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 wiring the sensor see Wiring of Remote Sensors this page Installation of Remote Sensors 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 Install the sensor in the system supply to the building Tank Sensor The tank sensor is used in water heating applications Install the sensor in a water storage tank to measure water temperature For more information on wiring the sensor see Wiring of Remote Sensors below Wi
44. ature 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 PLACING THE BOILER IN OPERATION MINIMUM REQUIRED FLOW FOR HEATING BOILER Filling the System All air must be purged from the system for proper operation An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water 45 000 feed and the system purge valve 75 000 1 Close all drain cocks and air vents 1 9 3 1 90 000 3 7 135 000 56 2 Open the makeup water valve and slowly fill the system 7 4 8 9 Input Btu hr GPM Flow 3 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 4 Close all valves Purge one circuit at a time as follows 500 000 20 7 A Open one circuit drain valve and let the water drain for at least five minutes
45. by pump manufacturer 31 Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Check frequently to be sure the flow of combus tion and ventilation air to the boiler is not obstructed Inspection of Heat Exchanger Waterways Appliances operated in hard water areas should have periodic inspections of the tubes to be sure that no sediment or scale accumulates on the heat transfer surfaces Inspection plugs are located at both ends of the heat exchanger Inspection plugs should be removed and tubes inspected at the end of the first 45 days of operation and again at the end of 90 days of operation If no scale accumulation is observed inspections can be made at the end of each six months of operation Pilot Flame Adjustment Procedure The pilot flame should envelop 3 8 to 1 2 10 to 13mm of the tip of the thermocouple see Figure 38B FIG 38B Pilot Flame on Thermocouple a Remove pilot adjustment cover screw on gas valve See Gas Valve Illustrations in the Lighting Instructions section for location of cover screw b Turn inner adjustment screw clockwise to decrease or counterclockwise to increase pilot flame c If difficulty is experienced in adjusting the pilot flame a tee may be installed in the pilot line from the gas valve to the pilot burner d Replace pilot adjustment cover screw on valve Tighten firmly after adjustment to prevent gas leakage I
46. ccur or the gas fail to shut INPUT FOR YOUR SAFETY READ off turn off the external manual gas valve to the BEFORE OPERATING SAFETY SHUTOFF TEST FOR A WARNING STANDING PILOT IGNITION SYSTEM If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance is equipped with an ignition device which automatically lights the pilot Do not try to light the pilot by hand B BEFORE OPERATING smell around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor WHAT TO DO IF YOU SMELL GAS E Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Pilot with Thermocouple Pilot with Spark Ignition Immediately call your gas supplier from a FIG 36 Pilot with Thermocouple and Spark Ignition neighbor s phone Follow the gas supplier s 1 With the main burners on and firing unscrew the instructions thermocouple connection from the gas valve If you cannot reach your gas supplier call the FIG 36 and remove from the fitting See Figure fire department 25 to locate the thermocouple outlet connection on C Use only your hand to turn the gas control the gas valve knob Never use tools If the knob will not turn by hand don t try to repair it cal
47. e rise across the heat exchanger you may be assured of 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 The pump must run continuously when the burners are firing 2 With the pump running and the water heater off the inlet and outlet thermometers should read the same temperatures If they do not an adjustment must be made to your final calculation 3 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 4 Compare the temperature rise on the heater with the required temperature rise in Table P 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 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 15 running in the proper direction 4 sure the circulation pipes between the water heater and storage tank are not less than 1 1 2
48. e 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 unit which requires a constant water flow rate for proper operation 35 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 If a three way valve must be installed please pipe in a primary secondary system as shown in Figure 45 Based on boiler sizing and system flow requirements this piping may still result in boiler short cycling BOILER FLOW RATES CAUTION The maximum flow rate through the boiler with a copper heat exchanger must not exceed 30 GPM MAKE UP WATER EXPANSION TANK BYPASS VALVE FROM SYSTEM FIG 46 Boiler Bypass Piping 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 30 GPM 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 temper
49. e valve has a gas control knob that must remain in the open position at all times when the appliance is in service Each gas valve has pressure taps located on the inlet and outlet sides 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 page 15 for proper adjustment Venting of Combination Gas Valves The combination gas valve regulator used on all models is equipped with an integral vent limiting orifice The vent limiter ensures that the volume of gas emitted from the valve does not exceed the maximum safe leakage rate allowed by agency requirements Combination gas valve regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors A dust cap is provided at the vent termination point on the valve to prevent blockage of the vent limiter by foreign material The combination gas valve regulator with an integral vent limiter complies with the safety code requirements of CSD 1 CF 190 a as shipped from the manufacturer without the installation of additional vent lines 17 RELIEF VALVE FIG 23A Relief Valve Water Heater RELIEF VALVE FIG 23B Relief Valve Boiler This appliance is supplied with a relief valve s sized in accordance with ASME Boiler and Pressu
50. em Consult the manufacturer of the glycol for additional recommendations when using a glycol and water fill for your boiler system The installer must ensure that the boiler has adequate flow without excessive temperature rise 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 installation of a larger circulator pump or installation of the boiler with a primary secondary piping system System noise may also indicate an oversized boiler A CAUTION At no time should the system pressure be less than 12 PSIG MAKE UP EXPANSION TANK TO SYSTEM a SYSTEM SECONDARY BOILER PUMP AIR SEPARATOR FROM SYSTEM FIG 44 Boiler with Low Temperature Bypass Piping Models 315 000 500 000 Btu hr 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 44 must be piped into the system at the time of installation 34 LOW TEMPERATURE BYPASS REQUIREMENTS 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
51. ems Type 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 SIDEWALL VENTING FIG 14 Sidewall Venting with an Induced Draft Fan This appliance is NOT approved for sidewall venting with the negative draft venting system as shipped from the factory An induced draft fan MUST be used if the installation requires that the flue gases be vented out a sidewall A properly sized and installed induced draft fan may also be used to vent the flue gases vertically if required by jobsite restrictions The induced draft fan must be listed by a nationally recognized test agency be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements Use care to ensure that the mechanical ly supplied draft does not exceed the range of a negative 0 02 to 0 05 inches water column to ensure proper operation If draft exceeds the specified range the fan must be adjusted or the installation of a baro metric damper in the flue may be required to properly control draft An induced draft fan MUST be interlocked into the appliance s control circuit to start when the appliance calls for heat The induced draft fan MUST also be equipped with a proving switch properly interlocked into the appliance s control circuit to pro
52. ere 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 55 50 60 a 40 70 SHUTDOWN 55 S 45 O A SENSOR ENABLE DISABLE O A SHUTDOWN 50 60 FIG 29 Optional Outdoor Air Reset Control Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the unit 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 15 determined by the ratio and outdoor air temperature below the O A Max setting OUTDOOR AIR RESET OPTION 22 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 for every 1 0 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 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature
53. es 1 cold water tee Plus the following length of straight pipe based on the heater size 90 000 thru 360 000 Btu hr Models Not more than 45 feet of straight pipe 399 999 thru 500 000 Btu hr Models Not more than 25 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 MINIMUM PUMP PERFORMANCE Based on heating potable water with a hardness of 8 to 25 grains per gallon and total dissolved solids not exceeding 350 ppm See Water Chemistry page 40 BTU hr INPUT 90 000 500 000 GPM Ft Hd 30 8 REMOTE SENSOR INSTALLATION INSTRUCTIONS Water heaters are provided with an extra temperature sensor that MUST BE field installed The sensor is shipped loose in the I amp O packet This remote mounted sensor will be the primary temperature sensor which will inform the appliance s built in thermostat control For domestic water heating the sensor MUST BE installed into a bulbwell on the storage tank This is required to maintain the desired temperature in the tank and reduce cycling of the heater 41 The sensor must also be connected to two blue wires provided in the upper left hand corner of the control panel It will be necessary to add additional wire to reach from the appliance to the remote water source Use twisted pair wire minimum 18 gauge or larger See Table O page 38 regarding distance versus
54. g the temperature selector to higher settings provides hotter water which increases the risk of scald injury The manufacturer recommends the use of a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 140 F Storing the water at a higher temperature and thermostatically mixing the water will increase the available quantity of mixed hot water greatly reduce the possibility of condensate formation on the heat exchanger and help prevent the growth of water born bacteria Adequate care MUST be taken to prevent potential scald injury when storing water at 140 F and hotter ___ ADANGER Water temperature over 125 F 52 C can cause 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 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 APPLIANCE AUTOMATIC VENT DAMPERS Automatic vent dampers are not required or furn
55. gn water temperature rise A heat exchanger pressure drop chart Table L is provided to assist in proper pump selection Also provided is a System Temperature Rise Chart Table N 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 while the boiler is firing Example The boiler inlet temperature is 160 F and the boiler outlet temperature is 180 F this means that there is a 20 F temperature rise across the boiler 32 FOOT HEAD LOSS 90 CIRCULATOR PUMP SPECIFICATIONS 1 Maximum operating pressure for the pump must exceed system operating pressure 2 Maximum water temperature should not exceed nameplate rating 3 Cast iron circulators may be used for closed loop systems 4 properly sized expansion tank must be installed near the boiler and located on the suction side of the pump CIRCULATOR PUMP OPERATION Heating Boilers Only Boilers are equipped with a relay for controlling the circulation pump for the hot water loop The relay turns ON and OFF in response to the W input from the wall thermostat or zone control The field installed boiler pump MUST NOT exceed 1 h p For continuous pump operation wire the system pump to the 120V supply The pump should be connected at the junction box as shown in Figure 41 33 d CI
56. he installation of a gas fired appliance Venting of an 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 gases from an appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft This will result in condensing of flue gases damage the masonry flue tile insufficient draft and possible spillage of flue gases 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 gases 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 gases from this appliance An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner syst
57. he CSA 22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 All wiring between the appliance and field installed devices shall be made with type T wire 63 F 35 C rise IS Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable 3 pump must run continuously when the appliance is being fired 19 4 avoid serious damage DO NOT energize the appliance until the system is full of water Serious damage may result 5 Provide the unit with proper overload protection 6 Install a wall thermostat on the inside wall DO NOT install the thermostat in an area affected by drafts sunlight light fixtures hot or cold water pipes or near a fireplace See Terminal Strip Con nection of a Room Thermostat page 38 for proper wiring connection TABLE J AMP DRAW DATA 45 000 thru 500 000 Btu hr Models MAXIMUM TOTAL AMPS 120 VAC FIRING CONTROLS F1 Standing Pilot Single Stage 90 000 260 000 Btu hr F9 Intermittent Pilot Single Stage 90 000 399 999 Btu hr F9 Intermittent Pilot Single Stage 2 valves 500 000 Btu hr 9 with Internal Pump 45 000 260 000 Btu hr MO Intermittent Pilot Two Stage Valve 315 000 399 999 Btu hr MO Intermittent Pilot Two Stage 2 valves 500 000 Btu hr Pump Wiring for a Heating Boiler The heating boiler circulating pump must be purchased locally The maximum load for the pum
58. heat exchanger indicates a need for cleaning The following cleaning procedure must only be performed by 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 INSPECTION CLEANING PROCEDURE 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 I A R C has concluded Crystalline silica inhaled in the form of quartz 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 LA R C Monograph 68 June 1997 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
59. hree setting knobs the temperature control unless your unit is specified as a boiler only with an outdoor air reset option If your unit 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 22 The three setting knobs on the temperature control are for Set point Differential and High Fire Offset see Figure 28 20 HIGH FIRE OFFSET DIFFERENTIAL TST2314 7 77 240 OFF O SETPOINT FIG 28 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 K TABLE K Maximum Set point Determination Max Set Point 240 F 190 F 200 F 160 F 042 Connected Connected Cut Connected Cut Connected Cut Cut Anytime that 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 a new overlay is required
60. ile 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 COMBINATION GAS VALVES Pressure Regulator Adjustment under cap screw Outlet Pressure Tap Inlet Pressure Tap Pilot Outlet Gas Control Knob Red Reset Button FIG 20 F1 Gas Valve 90 000 270 000 Btu hr Models Pressure Regulator Wiring Terminals Adjustment under cap screw Outlet Pressure Tap Pilot Outlet Inlet Pressure Tap Gas Control Knob FIG 21 F9 Gas Valve 90 000 500 000 Btu hr Models Wiring Terminals Pressure Regulator Adjustment under cap screw Outlet Pressure Inlet Pressure Tap Pilot Outlet Gas Control Knob FIG 22 M9 Gas Valve 45 000 399 999 Btu hr Models Each unit has a combination gas valve s to control the gas supply to the burners The 500 000 Btu hr model has two combination gas valves to supply gas to the burners The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves Th
61. ional sensor can be purchased and installed for use as a remote system sensor Boilers with the outdoor air reset option also have an outside air temperature sensor Water Heater Application Water heater units 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 1s a two stage temperature control that controls the burner ignition and pump functions This temperature controller can measure up to three different sensor inputs depending upon how the unit is set up They are as follows 1 Inlet Water Temperature Sensor 2 Multi Purpose Temperature Sensor 3 Outside Air Temperature Sensor Inlet Water Temperature Sensor This sensor measures the inlet water temperature coming into the unit The inlet water temperature sensor is placed into the inlet bulbwell on the boiler This sensor is installed by the factory in new units Multi Purpose Temperature Sensor Depending upon how your unit is set up this sensor can be used as a system sensor in a boiler system or a tank sensor 21 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 outside air sensor is optional This sensor allows you to tie boiler operation to the outdoor air temper
62. irements Set the boiler operating temperature control as described in this section FIG 48 Terminal Strip Connections POWER VENTER CONNECTION TO TERMINAL STRIP A terminal connection strip is provided for ease of connection for Power Venting Systems see Figure 48 inset A TABLE O TERMINAL STRIP WIRING Wire Gauge Maximum Allowable Length DOMESTIC WATER HEATERS 90 000 500 000 Btu hr MODELS This section applies only to those units used to supply direct fired domestic hot water and installed with a storage tank s The use of a properly sized pump and the control of water velocity as explained in the Water Velocity Control section are important for correct operation of your hot water heater 38 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 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 temperatur
63. ished on potable water heaters All water heaters will have a plug installed in the damper terminal on the side of the control panel to allow operation without a vent damper The damper plug MUST be in place if an optional vent damper 1s not used a water heater Water heaters with inputs of 360 000 Btu hr and less may be ordered with the vent damper as an option Remove the damper plug from the terminal to connect an optional vent damper wire harness The optional damper must be properly installed and the wire harness plugged into the terminal on the side of the control panel to allow the unit to function See the Automatic Vent Damper section in the basic portion of the manual THE A CAUTION Do not install an optional vent damper within 6 152mm of combustible materials OPTIONAL RELIEF VALVE This water heater hot water supply boiler is normally supplied with a temperature and pressure relief valve s sized in accordance with applicable codes Units may be supplied with an optional pressure only relief valve s When a water heater hot water supply boiler 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 42 THERMAL EXPANSION A relief valve which discharges periodically may be due to thermal expansion in a closed system A hot water supply boiler installed in
64. k the heat exchanger finned tubes headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure TABLE A MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY Combustion Air Source Outside Air 2 Openings Input Btu hr 45 000 Outside Air 1 Opening Inside 2 Openings 75 000 90 000 135 000 180 000 199 999 215 000 225 000 260 000 270 000 315 000 360 000 399 999 500 000 EXHAUST FANS Any fan or equipment which ex hausts air from the room where the appliance is installed may deplete the combustion air supply and or cause a down draft in the venting system spilling flue products into the room Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected im mediately If a fan is used to supply combustion air to the room where the appliance is installed the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance VENTING 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 CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local
65. ks found in the gas train or related components Not operate an appliance with a leak in the gas train valves or related piping GAS MANIFOLD PRESSURE ADJUSTMENT PROCEDURE Pressure Regulator Adjustment under cap screw Outlet Pressure Tap Inlet Pressure Tap Pilot Outlet Red Reset Button Gas Control Manometer Knob Gas Valve FIG 18 Manifold Pressure Adjustment 10 11 Turn the power OFF at the main disconnect switch Turn gas valve control knob to PILOT position on standing pilot models Ensure that the standing pilot remains on If the pilot goes out follow the Lighting Instructions for standing pilot models to light the pilot Turn gas valve control knob to OFF position on spark ignition models Remove the 1 8 hex plug located on the outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge See Figure 18 Minimum range of scale should be up to 5 w c for Natural gas models and 10 w c for L P gas models The 500 000 Btu hr model will have two gas valves with a pressure regulator on each valve Repeat the following adjustment procedure to set the manifold pressure on each gas valve Remove pressure regulator adjustment cap screw on the gas valve See Figure 18 for location Turn the power at the main disconnect switch Turn gas valve control
66. l a qualified service technician Force or attempted repair may result in a fire or explosion 2 The main gas valve should extinguish the burners immediately after removal of the thermocouple 3 If burners do not extinguish immediately follow D Do not use this appliance if any part has been steps in 7o Turn Off Gas To Appliance under water Immediately call qualified service technician to inspect the appliance The possible damage to a flooded boiler can be extensive and present numerous safety hazards Any appliance that has been under water must be replaced 4 Immediately call a qualified serviceman or installer to repair an ignition system that fails to operate properly and shut down the burners 26 OPERATING INSTRUCTIONS TO TURN OFF GAS APPLIANCE L 2 6b 8a 8b 10 11 12 STOP Read the safety information first Remove the control panel door Set the thermostat to the lowest setting OFF Turn off all electrical power to the appliance This appliance is equipped with an ignition device which automatically lights the pilot DO NOT try to light the pilot by hand 45 000 135 000 and 399 999 500 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the OFF position 180 000 360 000 Btu hr models rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob Depress the knob and continue rotation to the
67. n cable Check for 24VAC on sensor If not open the TH terminal gray wire replace temperature controller Is there 24 tan wire on the 4 pin connector plug on the temperature controller Check X and B on the terminal strip if the flow switch is installed Check for an open auto reset high limit Check vent damper 3 pin louver relay connectors and venter proving Check the vent damper or the vent damper plug and the voltage to and from the transformer TROUBLESHOOTING GUIDE 90 000 270 000 Btu hr Models Water Heaters F1 Check for gas Check the pilot Check for an open STEP 1 1 the pilot lit assembly and thermocouple sensor not open Check the gas valve for proper replace temperature operation Clean and replace controller Is there 24 VAC Is there 24VAC STEP 2 Is Mi dics purple wire on the 4 tan wire on the geuing pin connector plug on 4 pin connector the temperature plug on the 2 controller temperature controller STEP 3 Check X and B on the terminal strip if the flow Switch is installed Check for an open auto reset high limit Check vent damper 3 pin louver relay connectors and venter proving Check 24VAC at R and W on Check the vent damper or the EMS terminal strip the vent damper plug and the voltage to and from the transformer Check all safety limit devices Check 4 pin low water cutoff connector 45
68. n operation to ensure proper gas volume during periods of peak gas usage If 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 If the gas supply pressure is within the specified range proceed with the following steps to return the appliance to service Turn the power OFF at the main disconnect switch Turn gas valve control knob to PILOT position on standing pilot models Turn gas valve control knob s to OFF position on spark ignition models Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P Gas shut off gas supply at the tank Remove the manometer and related fittings from the inlet side of the gas valve replace 1 8 hex plug in gas valve Turn on gas supply at the manual valve turn on L P Gas at tank if required Turn the power ON at the main disconnect switch Turn the gas valve control knob s to the ON position If the pilot is not burning follow the Lighting Instructions for standing pilot models to light the pilot Spark ignition models will automat ically light the pilot on a call for heat 20 Set the thermostat to call for heat The appliance is now ready to operate IMPORTANT Upon completion of any testing on the gas system leak test all gas connections with a soap solution wh
69. new properly threaded black iron pipe free from chips If tubing is used make sure the ends are cut squared deburred and clean All tubing bends must be smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide proper volume of gas Run pipe or tubing to the gas valve or manifold inlet If tubing is used obtain a tube to pipe coupling to connect the tubing to the gas valve or manifold inlet Thread pipe the proper amount for insertion into gas valve or manifold inlet as shown in Table H DO NOT OVER TIGHTEN Over tightening may result in damage to the gas valves Valve distortion or malfunction may result if the pipe is inserted too deeply into the gas valve Apply a moderate amount of good quality pipe compound DO NOT use Teflon tape to pipe only leaving two end threads bare Remove seal over gas valve or manifold inlet Connect pipe to gas valve or manifold inlet Use wrench to square ends of the gas valve FIG 17 WHEN FLANGE IS NOT USED WHEN FLANGE APPLY WRENCH FROM TOP OR BOTTOM OF GAS CONTROL TO EITHER SHADED AREA APPLY WRENCH f TO FLANGE ONLY p gt m FIG 17 Wrench 8 For L P gas consult your L P gas supplier for expert installation IMPORTANT Upon completion of any piping connections to the gas system leak test all gas connections with a soap solution while system is under pressure Immediately repair any lea
70. nstall duct coil downstream at the 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 circulation 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 15 satisfied This provides greater economy over maintaining standby heat 15 Within three days of start up recheck and bleed all air vents and the expansion tank using these instructions TABLE N SYSTEM TEMPERATURE RISE CHART Based Boiler Output in Btu hr Btu hr 10 F AT 20 F AT 30 F AT 40 F AT 50 F AT Input Output Ft hd GPM Ft hd GPM Ft hd GPM Ft hd GPM Ft hd 45 000 36 900 7 4 1 9 0 2 135 000 110 700 1 2 2 4 E 3 4 4 2i 7 5 0 2 215 000 176 300 2 5 3 6 2 6 6 260 000 213 200 572 e NE 73 as 8 3 0 2 0 2 0 3 0 4 0 4 0 5 1 3 1 5 0 3 5 BOILER OPERATING TEMPERATURE CONTROL The operating temperature control is located in the control panel behind the control panel fron
71. nt 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 m from the appliance to the vent terminal Follow manufacturer s instructions Do not use an existing chimney as a raceway for a flue pipe if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the appliance Adequate support of the venting system must be provided in compliance with local codes and other applicable codes All connections should be secured with rustproof sheet metal screws 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 chimney may cause flue products to be discharged into the living space causing serious health injury 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 remaining connected to the common venting system placed in operation while other appliances remaining connected to the common venting system are not in operation a Seal any unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine the
72. o operation Operation EUN of a blocked vent and or flame roll out interlock switch usually indicates a problem with the venting system obstruction of the heat exchanger flue gas Inverted to show reset passageway and or a combustion air supply problem underneath 4 The cause for operation of the blocked vent and or flame roll out interlock switch must be determined and J corrected If the boiler cannot be restored to normal Draft Hood operation contact a qualified service installer service agency or the gas supplier INITIAL START UP Follow the Lighting Instructions on the label applied to the appliance FIG 31 Blocked Vent Switch Location A On water heaters and boilers with the system pump delay option the operating temperature control will energize the pump relay which energizes the pump on a call for heat The operating temperature control will de energize the pump relay approximately 30 seconds after the call for heat ends 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 23 On boilers the pump will operate whenever the W terminal is energized B Location The appliance should be located within a room having a temperature safely above freezing 32 F 0 C C Shutdown and Draining If for any reason the appliance is shut off the following precauti
73. onary measures must be taken 1 Shut off gas supply 2 Shut off water supply 3 Shut off electrical supply 4 Drain the heat exchanger completely Re move one 3 8 NPT plug or bulb well from the inlet side and one from the outlet side of the front header of the heat exchanger 5 Drain the pump Remove the 3 4 plug in the bypass loop PRE START CHECKLIST Inspect the burners to be sure they are properly aligned Inspect the pilot gas line thermocouple leads ignition leads and wire connections to the gas valve to be sure none were damaged during shipment Check to ensure that gas connections have been made properly and the gas line is purged of air Check to ensure that water connections are tight and the appliance and piping system have been properly filled Ensure that discharge from the relief valve has been piped to a floor drain Verify that properly sized combustion and ventilation air openings are provided and not obstructed in any way Check carefully for gas leaks Read the appliance s safety warnings lighting instructions and check out procedure carefully before firing the system LIGHTING INSTRUCTIONS FOR STANDING PILOT MODELS F1 MODELS 90 000 THRU 270 000 Btu hr INPUT FOR YOUR SAFETY READ BEFORE OPERATING A WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance has a
74. or water heater will supply adequate flow to make the flow switch contacts and operate the boiler A water flow switch meets most code requirements for a low water cut off device on boilers requiring forced circulation for operation TABLE I MINIMUM FLOW RATE REQUIRED ACTUATE FLOW SWITCH GPM Flow Rate Pipe Size 1 1 2 3 2 LOW WATER CUTOFF IF EQUIPPED A hot water boiler installed above radiation level must be provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed An electronic low water cutoff is available as a kit on all units Low water cutoffs should be inspected every six months including flushing of float types TWO STAGE BURNER CONTROL SYSTEM The 45 000 thru 500 000 Btu hr boilers M9 are equipped with a two stage burner control system The 45 000 thru 399 999 Btu hr models will be equipped with a two stage gas valve to control high low burner operation The 500 000 Btu hr model achieves two stage burner firing by staging the operation of the two combination gas valves 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 unit is installed in Canada it must conform to t
75. p 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 Pump Relay Temperature Control Manual Reset High Limit if equipped FIG 25 Standing Pilot System F1 Control Panel Temperature Control Ignition Module Pump Relay Manual Reset High Limit if equipped Transformer FIG 26 Intermittent Pilot System F9 M9 Control Panel Ignition Module Manual Reset High Limit if equipped Transformer Pump Relay FIG 27 Control Panel Assembly 500 000 Btu hr TEMPERATURE ADJUSTMENT Operating Temperature Control The temperature controller is pre set at the factory with test settings You may need to adjust the settings to meet your specific needs A WARNING Return water temperatures must not be less than 140 If lower return water temperatures are follow the instructions for Low required Temperature Bypass Requirements or Three Way Valves see page 35 Locating Temperature Control Remove the control panel door on the front of the unit in order to locate and access the temperature control Temperature Control Settings There are t
76. pilot Push down and hold in the red button on the gas valve This should start gas flow to the pilot Continue to hold the red button in for about one 1 minute after the pilot is lit Release the button and it will pop back up The pilot should remain lit If the pilot goes out repeat steps 5 through 10 If the red button does not pop up when released stop and immediately call your gas supplier If the pilot will not stay hit after several tries turn the gas control to OFF and call your service technician or gas supplier Turn the gas control knob on the gas valve counterclockwise to the ON position Turn on all electric power to the appliance Re install the lower panel door Set the thermostat to the desired setting Re install the control panel door TO TURN OFF GAS TO APPLIANCE 5 After successful completion of test turn the control knob on the gas valve clockwise to the position Do not force 1 Set the thermostat to the OFF position 6 Carefully reconnect the thermocouple to the gas 2 Turn off all electric power to the appliance if valve service is to be performed 7 Follow the Lighting Instructions to relight the pilot 3 Turn the gas control knob on the gas valve and establish normal operation clockwise to the position Do not force LIGHTING INSTRUCTIONS FOR SPARK IGNITION PILOT MODELS F9 M9 MODELS 45 000 THRU 500 000 Btu hr A WARNING Should overheating o
77. proper operation of the unit as long as the water quality stays consistent COLD WATER SUPPLY HOT WATER SUPPLY FIG 49 Typical Water Heater Piping with Storage Tank COMMON WATER MANIFOLD SIZE FOR MULTIPLE HOT WATER SUPPLY BOILER INSTALLATIONS Pipe sizing chart provides minimum pipe size for common manifold piping and tank tappings to in sure adequate flow Number of Units Common Manifold Size Min PUMP OPERATION 1 water heater hot water supply boiler must be connected to a properly sized pump that circulates water between the heater and storage tank 2 Pump is sized to heater input and water hardness Care should be taken to size the pump correctly See Water Chemistry this page 40 The pump must run continuously when the burners are firing 4 Lubricate the pump to the manufacturers recommen dations Pump damage due to inadequate lubrica tion is non warrantable 5 A standard water heater hot water supply boiler is furnished with 1 6 HP 120 VAC 3 6 AMP circulating pump to be mounted on the units inlet water connection This pump 18 sized based on installation of a single storage tank and heater in close proximity If the number of fittings and straight pipe exceeds the quantities shown in this section a larger pump will be required The standard pump selection 15 based on the following pipe and fittings from the unit to the storage tank 6 90 elbows 2 unions 2 ball valv
78. re Vessel Code Section IV Heating Boilers The relief valve s is mounted directly into the heat exchanger inside the header To prevent water damage the dis charge 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 A CAUTION Avoid contact with hot discharge water WATER FLOW SWITCH IF EQUIPPED FLOW SWITCH X FIG 24A Water Flow Switch Water Heater Side Connections FLOW SWITCH FIG 24B Water Flow Switch Boiler Top Connections A water flow switch 1 available as a factory supplied option on all heating boilers and water heaters The flow switch should be wired between terminals X and B Remove the jumper between the X and B terminals on the terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition A flow switch installed with the factory supplied minimum adjustment setting requires a specific minimum flow to make the switch and start burner operation The minimum flow requirement to actuate the switch is specified in Table I The flow rate required 1s a function of the diameter of pipe and tee used for installation Ensure that the pump installed on the boiler
79. re is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c 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 ex haust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e 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 f After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use g Any improper 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 CGA Standard B149 Installation Code for Gas Burning Appli
80. rheating occur or the gas fail to shut off turn off the external manual gas valve to the appliance SAFETY SHUTOFF TEST FOR SPARK IGNITION PILOT SYSTEM 1 2 Turn OFF gas supply to the appliance Turn thermostat to highest setting Turn electric power Pump relay pulls in to start pump The ignition will begin sparking at the pilot The ignition module will lock out after the 90 second trial for ignition period on the 45 000 thru 399 999 Btu hr models and after the 15 second trial for ignition period on the 500 000 Btu hr model Immediately call a qualified serviceman or installer to repair an ignition system that fails to lock out and properly shut down burner operation After successful completion of the test readjust the thermostat to normal setting Turn ON gas supply Turn power OFF then ON to reset ignition module 11 If ignition system fails to operate properly repair work must be performed by qualified serviceman or installer INTERMITTENT PILOT SPARK IGNITION SYSTEM F9 M9 The 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 module IGNITION and CONTROL TIMINGS F1 Standing Pilot Models thermocouple supervised Pilot Flame Failure Response Time
81. ring of Remote Sensors To wire remote sensors follow the guidelines below Take care to correctly wire sensors to the unit Erratic temperature readings can be caused by poor wiring practices Twist the wires between the unit 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 Make sure good mechanical connections are made to the sensor any interconnecting wiring and the controller Do not mount sensor with leadwire end pointing up in an area where condensation can occur 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 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 For boilers ordered with the Outdoor Air Reset option there is an additional control FIG 29 Th
82. t access door The sensing element for the operator is placed in a bulb well installed in the heat exchanger Carefully observe the discharge water temperature on the initial boiler on cycles The exact temperature set point is based on your system s 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 STRIP 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 Figure 48 Remove the jumper between the R and W 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 R and W terminals on the terminal strip Connection to the terminal strip will allow the room thermostat to make and break the 24VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requ
83. t within the proper range the draft measured above the appliance s built in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances a barometric damper must be installed to control draft TABLE VENT PIPE SIZES Input Btu hr Flue Size 45 000 75 000 90 000 135 000 180 000 199 999 215 000 260 000 315 000 360 000 399 999 500 000 On conventionally vented negative draft appliance the connection from the vent to the chimney or vent termination on the outside of 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 Any vent materials used must be listed by a nationally recognized test agency for use as vent material Locate appliance as close as possible to a chimney or gas vent Avoid long horizontal runs of the ve
84. ted it becomes less soluble The dissolved minerals and solids will precipitate and collect as scale if water velocity is not properly controlled Follow the temperature rise requirements for unsoftened water Consult the manufacturer when heating potable water with hardness or total dissolved solids exceeding these specifications Heating of high hardness and or high total dissolved solids water may 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 SOFTENED WATER SYSTEMS Decreasing the flow rate will reduce the erosion process however the heat exchanger should be monitored to ensure the scale liming process is not made worse The unit should be placed on a comprehensive inspection schedule until optimum flow rates can be established Problematic water areas may require heat exchanger inspection every two weeks The total scale accumulation should never exceed the thickness of a piece of paper Should scale accumulation exceed this thickness the flow rate will need to be increased The tubes should not have a bright shiny copper look This would indicate that the erosion process has begun and the flow rate will need to be decreased Once the proper flow rates have been established the inspection intervals can be increased to every 30 days once a quarter or to a bi annual inspection This procedure should ensure
85. the fire department Installation and service MUST BE performed by a qualified installer service agency or the gas supplier CONTENTS USER WARNING lE lar iris PUR 1 Safety Warnings arret Reges 1 Codes uisa eee bittet mdi tern 3 Location daio 3 SIL rra COS ERR E d Combustion Ventilation Air Requirements 2 4 Conventional essere 7 Masonry Chimney Installations 10 Sidewall Venting essent 10 Automatic Vent Damper sess Gas SUDDply mL n dde 12 Gas Pressures amp 000 2 12 Manifold Pressure Adjustment 15 Supply Pressure Measurement 16 Gas Valves doc 17 Relief Valve acie tti t cit he i eet 18 18 Electrical Connections 19 Temperature Adjustment sse 20 Temperature Limit Control sss 22 Blocked Vent and Flame Roll Out System 23 Lighting Instructions Ignition amp Control Timings Freeze Protection i tee retten 1 Flame Patterns ce tet eiae Inspection Cleaning Procedure sss 30 Heat Exchanger Burner Access 30 Inspection and Cleaning
86. 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 instal lation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 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 Auto matically Fired Boilers ASME CSD 1 boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Where required by the authority having jurisdiction the installation must comply with the Canadian Association Code CAN CGA B149 1 and or B149 2 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 Z21 13 and ANSI Z21 10 3 INSTALLATION PROCEDURE FIG 1 Typical Front View Cabinet Construction FIG 2 Typical Boiler Rear View Cabinet Construction LOCATION OF UNIT 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 circ
87. tion air requirements are based on the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada refer to National Standard CAN B149 1 or B149 2 Check all local code requirements for combustion air dimensions are based on net free area in square inches 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 room where the appliance is installed Each opening must have a net free area as specified in Table A Single openings shall be located within 12 30 cm of the ceiling A CAUTION Under no circumstances should the room where the appliance is installed 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 appliance The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds most commonly present as refrigerants or solvents such as freon tricholorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attac
88. tu hr must have the vent damper properly installed and the vent damper wire harness plugged into the terminal block on the side of the control panel to allow the boiler to function Larger input heating boilers and water heaters will have a jumper plug installed in the terminal block to allow operation without a damper Remove the jumper plug from the terminal block to connect an optional vent damper wire harness The jumper plug MUST be in place if an optional vent damper is not used on water heaters and larger input heating boilers A CAUTION Do not install the vent damper within 6 152 mm of combustible materials Install the vent damper to service only the single appliance for which it is intended If improperly installed a hazardous condition such as an explosion or carbon monoxide poisoning could result The damper position indicator must be in a visible location with access for service following installation The damper must be in an open position when appliance main burners are operating 11 The part number for the automatic vent damper required on this heating boiler is printed on the rating plate Vent damper regulations are design certified per the latest edition of ANSI Z21 66 FIG 15 Vent Damper and Vent Damper Terminal Block A WARNING The vent damper must be installed directly
89. umstances is the manufacturer to be held responsible for water damage in connection with this appliance or any of its components 2 The appliance must be installed indoors where it is protected from exposure to wind rain and weather 3 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 4 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 unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18 46cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle 5 DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present CLEARANCE FROM COMBUSTIBLE CONSTRUCTION Clearances from Combustible Construction Right Side 6 Rear 6 Left Side 18 24 suggested for service Front 18 24 suggested for service Top measured from the top of the unit 45 000 180 000 Btu hr Models 14 199 999 500 000 Btu hr Models 29 All units have been approved for alcove installation an ALCOVE is a closet enclosure without a front door The boiler must not be installed on carpeting All units have been
90. under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200 F Set Point The Set Point knob specifies the target outlet 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 unit 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 at full rate while Low Fire operates the burners at approximately one half rate The High Fire Offset knob specifies the number of degrees below set point that the High Fire stage shuts down At that point the unit will continue to operate at the Low Fire stage until the set point 1s reached The High Fire Offset knob has settings between 0 F and 20 F If set at O F the High Fire Offset is disabled and the unit will operate the High Fire stage until the set point 1s reached and the temperature control shuts the unit off No matter what the High Fire Offset knob is set to the unit will light at Low Fire and operate for approximately 10 to 120 seconds before the High Fire stage actuates Boiler Application Standard boiler units are shipped with one sensor the inlet water temperature sensor An opt
91. ure tap on the downstream side of the combination gas valve s see Figures 20 22 on page 17 The gas regulator settings for single stage and two stage operation are factory set to supply proper manifold pressure for normal operation check manifold pressure see Manifold Adjustment Procedure Do not increase manifold pressure beyond specified pressure settings shown below in Table D TABLE D 1 The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5kPa 2 The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 PSIG 3 5kPa 3 The appliance and its gas connection must be leak tested before placing it in operation GAS CONNECTION 1 Safe operation of the appliance requires properly sized gas supply piping See data in Table E 2 Gas pipe size may be larger than appliance gas connection 3 Installation of a union is suggested for ease of service see Figure 16 on page 14 4 Install a manual main gas shutoff valve outside of the appliance gas connection and before the gas valve or manifold connection when local codes require 5 A trap drip leg MUST be provided by the installer in the inlet of the gas connection to the appliance see Figure 16 on page 14
92. ve fan operation before the main burners are allowed to fire A vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommendations of the fan manufacturer and provide proper clearances from any combustion ventilation openings windows doors or other openings into the building All induced draft fan installations must comply with local code requirements 10 AUTOMATIC VENT DAMPER This heating boiler is design certified for use with the automatic vent damper FIG 15 part number printed on the boiler s rating plate vent damper must be installed on all residential heating boilers with inputs of less than 300 000 Btu hr to comply with minimum efficiency requirements vent damper is factory supplied with residential heating boilers with inputs of 45 000 thru 260 000 Btu hr A vent damper is optional on all heating boilers above 260 000 Btu hr A vent damper is available as an option on all water heaters The vent damper 1 a useful tool for saving energy when installed inside the living space where air can circulate freely around the appliance The vent damper will not save as much if any energy if it is installed in locations such as Unheated garage Attic Crawlspace Mechanical room that is vented outdoors For installation and maintenance on the vent damper refer to the instructions supplied with the vent damper Residential heating boilers with inputs of less than 300 000 B
93. ve or below unless a 4 foot 1 22m horizontal distance is maintained from electric meters gas meters regulators and relief equipment The venting system shall terminate at least 3 feet 0 9m above any forced air inlet within 10 feet 3 05m The venting system shall terminate at least 4 feet 1 2m below 4 feet 1 2m horizontally from or 1 foot 30cm above any door window or gravity air inlet into any building Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent can not terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30cm above grade To avoid blocked vent 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 vent condition Flue gas condensate can cause discoloration of exterior building surfaces Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate IMPORTANT Examine the venting system at least once a year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration Immediately correct any problems observed in the venting system MASONRY CHIMNEY INSTALLATION A masonry chimney must be properly sized for t
94. ystem may also be installed on smaller input boilers to ensure proper boiler flow rates Primary sec ondary piping is also ideal for systems using a mixture of propylene glycol and water A primary secondary piping 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 only The secondary pump installed in the boiler piping ensures a constant water flow rate to the boiler for proper operation Boiler installation with a primary secondary piping system can prevent noise problems caused by low system water flows primary secondary piping system is recommended on any boiler where low water flow conditions may present an operational problem A primary secondary piping system is ideal for systems filled with a propylene glycol and water mixture A glycol and water mixture is more dense than water only and may result in a lower boiler flow rate A lower boiler flow may cause noise on operation or short cycling of the burners A larger secondary pump may be used on a primary secondary system to provide an increased boiler flow rate A glycol and water system may require from 10 to 20 more flow to compensate for the increased density of the glycol and its effect on the heat transfer process in the boiler exact increase in flow that may be required is based on the type and percentage of glycol added to the boiler syst

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