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INSTALLATION AND SERVICE MANUAL

1. Q EF YOLOANNOD YALINS YOLDANNOD LINN Aad 710021871 N33NO MOTIBA D A amana UHMM 321146 038079 1 1NIOd SHATWA 0 omn qai 39715 0 5 3313 9312 3991 TOHLNOO Q33dS MOVHOIH A 18 9 IN gni eit 39vis SLOANNOOD SNOILOSNNOD m Sand NT n AV 133 Q9 SALVOIGNI 29 T HOLIMS 3dO NO 1 A A9 Nd MSS d d gg OS gga OSE Oe ul 16 140 Taa Wwauviv INOS A1
2. Figure 8 Outside Combustion Air Through Ducts 3 Combustion Air from Interior Space You can direct combustion air to this unit using air from an adjoining interior space You must provide two openings from the boiler room to the adjoining room Each of the two openings must have a net free area of one square inch per 1000 Btu input 22cm kW but not less than 100 square inches 645cm Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued NT SN Figure 9 Combustion Air from Interior Space 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 mechanical room Each opening must have a minimum net free area as specified in TABLE C page 12 Single openings shall be installed within 12 30 cm of the ceiling 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
3. 12 1 Conventional Negative Draft Venting 13 2 Outdoor Installation Venting 14 Connecting to Gas Supply sss 16 Gas Pressure Test oreet iis 16 Gas Piping ND RII 16 Connecting Gas Piping to 17 Gas Tram and Controls a n 17 Combination Gas Valves sess 18 Venting of Combination Gas 18 Checking Gas Supply 18 Gas Manifold Pressure 19 Connecting to Water Supply sees 20 Inlet and Outlet Connections 20 Relief isti 21 Water Flow Switch sss 21 Low Water Cutoll rrt rre eire std 21 Connecting to Electrical Supply 21 Terminal Strip Connection Options 22 Boiler System Piping iae 23 Primary Secondary Boiler Piping 24 Low Temperature Return Water Systems 25 Radiant Floor and Snow Melt Heating Systems 25 Table of Contents Installation with a Chilled Water System 26 Boiler Flow Rate Boiler Bypass Requirements
4. 1 SLIHM M 15 3313 1113 AATVA 3414 H9IH HOSN3S NO NO ANIMS Ad WNOILdO AATVA 3314 es 102 Ave Av YALINOI A ro MOT A9 19 AD of aNnouo Yanana 340 ATIVIAHON MR 2 FLOW 9 1531 8 BETA OLIMS MOTH om GION310S ON iwWN3INIA SISSVH2 vov L 89 4 317 _ O LINN AHL 9NIOIANH3S 330438 H3MOd LOANNOOSIG ZHOSDUADZL eti pundio 47 WIRING DIAGRAMS MAIN UNIT CONNECTIONS MODELS 495 000 745 000 BTU HR OPTIONAL SYSTEM TANK SENSOR B OFF HIGH LOW FIRE FIRE REMOTE THERMOSTATS 1 555551133 INLET 261 SENSOR NOC NC HI LIMIT HI LIMIT OPTIONAL NEGET POWER JUMPERED IF SWITCH NOT PROVIDED wee 120VAC TRIAL 24 VAC HEATING 24VAC FLAME FAILURE BKW BK GY rn y BL HI LIMITS PWR SW Le c SHUTOFF SPLICE LOW GAS COM NO NC F
5. 495 000 745 000 985 000 2 065 000 Heat Exchanger This is a highly sophisticated heat exchanger designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build up of impurities The straight line two pass design of the tubes sends water into the headers at a properly rated velocity The configuration of the headers in turn creates a high degree of turbulence which is sufficient to keep all contaminants in suspension This scouring action provides greater cost savings for owners Tubes are always able to transfer heat at peak efficiency Every surface within this water containing section is of a non ferrous material providing clear clean rust free hot water Straight copper tubes finned on the outside for maximum heat transfer and coated cast iron one piece cored headers make up an entirely rust proof 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 This unit has an adjustable temperature control to maintain the desired water temperature set point See Setting Temperature Control page 29 for instructions to program the temperature control The temperature control is factory preset at approximately 125 F 52 C or less Households with small children or invalids may require 120 F 49 or lower temperature hot water to redu
6. GAS VALVE CONTROL KNOB REFERENCE HOSE CONNECTION 1 8 HEX MANIFOLD PRESSURE TAP TERMINALS OUTLET Figure 33 Combination Gas Valve SETTING TEMPERATURE CONTROL Note The temperature controller is preset 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 required follow the instructions for Low Temperature Return Water Systems on page 25 Locating Temperature Control The temperature control is located behind the combustion air inlet panel on the left front of the unit see Figure 34 Follow the steps below to access the temperature control 1 Loosen the knurled knob at the bottom of the control panel cover 2 Pull the bottom of the panel out and down to remove Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued TEMPERATURE CONTROL Figure 34 Locating Temperature Control Temperature Control Settings There are three setting knobs on 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 31 The three setting knobs on the temperature contro
7. 27 Temperature Pressure Gauge 27 Filling the System eese 27 Water Treatment Leere 28 OD rati n doo oret a RD 28 Lighting Instructions 28 Turn Off Gas To 29 Setting Temperature 29 Locating Temperature 29 Temperature Control Settings 30 Outdoor Air Reset Option 31 Boiler Operating Temperature Control 31 Temperature Control 5 5015 32 Placement of Sensors sese een 32 Remote Mounting of Sensor 33 Hot Surface Ignition 33 Operation and Diagnostic Lights sss 35 Domestic Water 36 Water Velocity Control sss 36 Water cto cin eere rere eve aoa 37 Pipe 8126 Requirements te n aer ette 37 Circulating Putnp iiia rh et ne vehe 37 Minimum Pump 38 Heat Exchanger sess 38 Potable Hot Water Temperature Control Settings 38
8. WAINA SNITIVISNI N3HM XNVL W31SAS 3404 TWNOILdO 1531 snom esee ONE 2 Ae ageage z z3dws 5 2 NMOHS SNOLLO3NNOO ANOLOV i vos AS HOLO3NNOO N 5 HOLIMS AYOLOVS YOLOANNOD wo103NNoo A BOSNIS 9NIHIM SNOILO3NNOO SNIHIM 9 1V2I312313 NI 1 201 SHOL23NNOO NIG 1VNOILdO 145450 1 Es 1304135 330 9 SI NOILdO J 1393Y ON A1VISOWM3H AVidSIG NO 1 201 037 9NINIM Q31V201 HOSN3S vo 1 lt IVNOILdO HOLIMS 1X3 SLINT Xn V Xn V SV9 MOTIHSIH 833430 a1
9. 6500 46 34 80 os5000 46 34 80 Ignition Module 745000 46 34 Two Stage Thermostat Harness Momentary Off Round Control Panel Pushbutton Switch Two Stage Thermostat Wiring Diagram Location Danger Label Figure 23A Models 495 000 745 000 Btu hr Control Panel Component Location Drawing Low Water Cutoff Control Bushing Snap Relay 24 VAC Optional Round Pushbutton Momentary OFF Industrial Control Transformer Circuit Breaker 7 AMP Figure 23B Models 985 000 2 065 000 Btu hr Control Panel Component Location Drawing IMPORTANT Do not block access to the electrical cover plate when installing electrical conduit External EMS Connection to Terminal Strip for Stage Firing Control of Burners This unit is equipped with a factory installed terminal strip for connection of an energy management system EMS to the burner stages The EMS terminal strip is located in the unit s junction box Ensure that all wiring used for connection to this terminal strip is properly sized per the recommendations in TABLE L When connecting an EMS to this terminal strip to sequence on each stage of burner operation the unit s internal thermostat or electronic sequencer should be set as an additional high limit control This will prevent problems between the set points of the EM
10. ojo HE c OASENSOR n a rw 1 7 1 o 1 1 SENSOR H E ENABLE LOUVER DAMPER H L DISABLE ERU ad TUS TO LOUVER OR On SHUTDOWN DAMPER i SETPOINT DIFFERENTIAL OFFSET OPERATOR TEST NORMALLY SILENCE ALARM BELL CLOSED gt HIGH FIRE 9 H SILENCE ALARM BELL RESET SPLICE 8 Ro ESQ D PR 5 g contacts OO 0 1 Leo ALAR 5 120VAC POWER A W TO LOUVER OR mm TO LOUVER OR BL DAMPER DAMPER SPLICE WIRING CONNECTIONS DIAGRAM LBL20007 REV A 49 AND WIRING DIAGRAM MODELS 985 000 2 065 000 BTU HR 022197 NVH9VIG NOLLO3NNOO L ISH ANNOYS yanyna LEMS a L 1 J9YLS ei 39vis 1 ON svo aunous SISSVHD
11. nous 318vNa 11 INVIA Wav1v 7 2 7 8NO LEE asosa o 10 ENS 18 9191010 TT SL Ya TIONLNOD HOLOANNOS SINONLI23 13 V rr Xog 9 ATNO rasa H YOLOANNOO TVNOILdO H se a 8 d 3E gt any n 1183 Lip rte 58 55 218 MOLO3NNOO mz SNOILO3NNOO 1OHINOOD 51 Revision 4 CB CW E i amp s 04 reflects changes made to the O A section Revision 5 CB CW E i amp s 05 reflects changes made to text on Page 21 and the LBLs on pages 47 51 Revision 6 02870 reflects the addition of a mixing valve to FIG 41 page 37 and edits made to the scald warnings Revision 7 ECO 13545 reflects edits made to page 24 to correct a table callout CB CW E I S 07 08 13
12. 4 1 2 i H3S YIMOd 33O NO Z de Oam SISSVH2 ZH09 M SdWVSL punog IVA 021 1 SIHL 3211436 OL 9NILdW3 LLV 340439 2 TV MOOHS 1VOlMLOdT3 1 OL 5 IYON O1 Q3123NNOO 38 H3LV3H SIHL ONINSHVM SALON 50 WIRING DIAGRAM CONTROL BOX CONNECTIONS MODELS 985 000 2 065 000 BTU HR V 61007191 HOLIMS 1631 OL NOILOANNOD 4 0 sissvuo E LINN NIVW 31naow yaaa NOILINSI EI LINDAI HOIO93NNOO irl 401 133208 v m 1 1 1 1 9 v zi 13534 SWILNNY i TWNOLLdO 24VAC XFMR nowwos cEL T 26 i B 1 m H 9 TVNOlldOpg 00
13. 2 1 2 2 1 2 4 3 1 2 4 Runpipe or tubing to the unit s gas inlet If you use tubing obtain a tube to pipe coupling to connect the tubing to the unit s gas inlet 5 Install a sediment trap in the supply line to the unit s gas 2 065 000 2 1 2 Exi 3 1 2 inlet see Figure 17 For each elbow or tee add equivalent straight pipe to total length from table below 6 Apply a moderate amount of good quality pipe compound do not use Teflon tape to pipe only leaving two end Gas Train and Controls threads bare Note The gas train and controls assembly provided on 7 Remove seal over gas inlet to unit this unit have been tested under the applicable American National Standard to meet minimum safety and performance criteria such as safe lighting combustion and safety shutdown operation Connect gas pipe to inlet of unit Use wrench to support gas manifold on the unit 9 For L P gas consult your L P gas supplier for expert installation Figure 19 shows a typical gas train 10 Ensure that all air is properly bled from the gas line before TABLE G starting the ignition sequence Start up without properly Fittings to Equivalent Straight Pipe bleeding air from the gas line may require multiple reset Diameter Pipe inches of the ignition control module to achieve proper 3 4 1 14 112 2 3 4 Equivalent Length of Straight Pipe feet 2 3 4 5 10 14 20 WARNING Do not have any open flame
14. a non warrantable failure General Plumbing Rules Check all local codes For serviceability of boiler always install unions Always pipe the pressure relief valve to an open drain Locate system air vents at the highest point of system Expansion tank must be installed near the boiler and on the suction side of the pump Support all water piping Water Connections Heating Boilers Only Inlet and outlet water connections on models 495 000 745 000 Btu hr have 2 NPT and on models 985 000 2 065 000 Btu hr the inlet and outlet connections are 2 1 2 NPT Note Field installed reducing bushings may decrease flow resulting in boiler noise or flashing to steam Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued Circulator Pump Requirements This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system design water temperature rise Two heat exchanger head loss charts Figure 25A amp 25B are provided to assist in proper pump selection Also provided is a System Temperature Rise Chart TABLE L 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
15. low water cutoff control is located on the control panel directly behind the control panel cover The reset and test buttons if equipped are located on the control panel CONNECTING TO ELECTRICAL SUPPLY This unit is wired for 120 VAC service The unit 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 the CAE C22 1 Canadian Electrical Code Part 1 and or local Electrical Codes 1 Use only Type T wire 63 F 35 C rise on all wiring between the unit and field installed devices Enclose line voltage wire exterior to the unit in approved conduit or approved metal clad cable The pump must run continuously when the unit is being fired hot water heating boilers must use the optional pump delay if the pump is to be cycled See Freeze Protection page 7 when cycling the pump Water heaters use the pump delay as standard in accordance with ASHRAE 90 1 requirements To avoid serious damage do not energize the unit until the system is filled with water Provide the unit with proper overload protection Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued TABLE J Nominal AMP Draw Data Btu Hr Input Approximate Controls Fan Total Amps 405000 46
16. multiple boilers are connected to the manifold in reverse return to assist in balancing flow to multiple boilers A CAUTION DO NOT allow the flow in the primary loop to drop lower than the flow in the econdary loop at any time during boiler operation Improper operation of the boiler s and possible ripping of the high limits and relief valves may The installer must ensure that the boiler has adequate flow without excessive temperature rise 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 increase boiler flow by installation of a larger circulator pump or the installation of a system bypass System noise may also indicate an oversized boiler CAUTION At no time should the system pressure be less than 12 PSIG MAKE UP WATER EXPANSION TANK TO SYSTEM SYSTEM PUMP 12 OR 4 PIPE DIAMETERS AIR SEPARATOR SS inc FROM SYSTEM Figure 26 Primary Secondary Piping of a Single Boiler p m EXPANSION TANK LWCO P OPTIONAL i TO SYSTEM MAKE UP WATER SYSTEM PUMP 12 OR 4 PIPE DIAMETERS E AIR SEPARATOR FROM SYSTEM E d SECONDARY _ d BOILER PUMP Figure 27 Primary Secondary Piping of Multiple Boilers Low Temperature Return Water Systems Any non condensing boiler and venting system will develop operational pro
17. An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it Metallic liner systems Type B double wall or flexible or rigid metallic liners are recommended Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney Vertical Vent Termination Clearances and Location Follow all vertical venting termination information for clearances and location under Vertical Vent Termination Clearances and Location page 10 2 Outdoor Installation Venting IMPORTANT Before installing a venting system follow all venting clearances and requirements found in the Venting General Information section page 10 Units are self venting and can be used outdoors when installed with the optional outdoor caps These caps mount directly to the unit and cover the flue outlet and combustion air inlet openings No additional vent piping is required WARNING Only install outdoor models outdoors and only use the vent caps supplied by the appliance manufacturer Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors Properly install all covers doors and jacket panels to ensure proper operation and prevent a hazardous condition Combustion air supply must be free of contaminants see Combustion and Ventilation Air page 8 To prevent recirculation of the flue products into
18. CONTROL MANOMETER KNOB 17 Remove hoses replace and tighten plugs and caps when complete 1 8 HEX 17 18 Replace front upper jacket access panels and control OUTLET PRESSURE panel door in reverse order TAP 19 If proper ignition and burner operation is not achieved after Figure 21 Measuring Manifold Gas Pressure checking gas supply pressure see Cleaning and Maintenance page 41 for Combustion Air Fan Adjustment Follow the 2 Turn the power switch located in the lower left corner procedure to adjust the combustion air fans as necessary behind the control panel access door to the O or position 3 Remove the top front jacket access panels to access the gas TABLE 1 valve s NET MANIFOLD PRESSURE 4 Locate the reference hose on the first gas valve which goes from the vent fitting on the gas valve to the barbed fitting Regulator Pressure Less on the deck of the unit see Figure 21 Front Chamber Pressure 5 Remove the flexible cap from the barbed fitting on the located in this line and hook one side oF the Nat Gas 495 000 745 000 Btu hr ien manometer or side of a magnahelic gauge to this Retain this cap for future use Nat Gas 985 000 2 065 000 Btu hr 1 2 w c 6 Remove the 1 8 hex plug from the manifold pressure tap LP Gas 495 000 2 065 000 Btwhr on the gas valve see Figure 21 Retain plug for future use 7 Install a fitting
19. Locate the ON OFF switch inside the control area The switch is located to the left of the control panel see Figure 32 Turn the power switch to the OFF position This unit is equipped with an ignition device which automatically lights the burners Do not try to light the burners by hand 28 KNURLED KNOB Figure 31 Control Panel Cover Figure 32 ON OFF Switch 8 9 10 11 12 13 Turn the manual gas cock clockwise to the OFF position Wait five 5 minutes to clear out any gas If you smell gas STOP Follow in the safety information If you do not smell gas go on to the next step Turn the manual gas cock counterclockwise to the ON position Turn the power switch to the position Reinstall the control panel cover Tighten the knurled knob at the bottom of the control panel cover If the unit will not operate follow the instructions Turn Off Gas To Appliance and call your service technician or gas supplier 29 Installation and Service Manual To Turn Off Gas To Appliance Remove the control panel cover to access control panel 2 Turn power switch to OFF position 3 Turn the manual gas cock clockwise to the OFF position WARNING Should overheating occur or the gas fail to shut off turn off the manual gas control valve to the unit 1 8 HEX INLET PRESSURE TAP PRESSURE REGULATOR ADJUSTMENT UNDER CAP SCREW
20. Low Voltage Supply Transformer 120VAC to 24VAC transformer located within the control panel provides 24VAC 60Hz to many of the components located on the unit One of its 24VAC outputs blue is connected to a circuit breaker and the other yellow is connected to chassis ground 24VAC Circuit Breaker A circuit breaker is provided on the 985 000 2 065 000 Btu hr models for protection of the low voltage supply transformer from overloads and short circuits The breaker 1 located inside the unit on the lower right corner of the control panel Power from this breaker goes to the electronic temperature controller ignition module and various other components and or options on the unit When tripped all factory installed 24VAC components will lose their 24VAC power Manual Reset High Limit Thermostat A manual reset high limit thermostat 15 provided as backup for the temperature controller This will either be an adjustable dial or fixed temperature bulb capillary style thermostat that will trip and require resetting should water temperature exceed its settings When tripped all controls remain powered but 24VAC 1 prevented from being delivered to the ignition module s thermostat input EMS Sequencer Remote Aquastat Terminals The EMS sequencer remote aquastat terminals are provided for connection of the unit to an external energy management system or sequencer and are located along the top edge of the terminal strip located within
21. TABLE 0 Status LED Diagnostic Codes Code Sequence Condition Constant ON Constant OFF Possible control fault check power LED may be effective do not replace control if all operational sequences function properly see Trouble Shooting Guide Low Air check air pressure switch and hoses to pressure sensing points fan venting and sealing of pressurized chamber Note Brief flashing normal o fan start up proving System OK no faults present One Flash Flame without call for heat check for a gas valve stuck in the open position air venting burners and the combustion process Fan will remain on Two Flashes Three Flashes Lockout due to flame failure push reset button on inner control panel after correcting ignition problem Initial heater start up without properly bleeding air from the gas line may require multiple reset functions to achieve proper ignition Igniter failure igniter will not maintain minimum 2 75 amp current draw caused by low voltage bad wiring continuity high resistance or igniter failure Four Flashes Power supply problem check for low supply voltage or transformer output less than 18VAC Six Flashes Five Flashes Replace ignition module internal fault Installation and Service Manual Prepurge Trial for Ignition Stage 1 On operating Stage 2 On Status Alarm TABLE P Status LED Diagnostic Codes Condition Lights Operation of combustion air f
22. The boiler inlet temperature is 160 F 71 C and the boiler outlet temperature is 180 F 82 C this means that there is a 20 F 11 C temperature rise across the boiler Heat Exchanger Pressure Drop Chart Pressure Drop Chart 495 000 745 000 Btu hr Models E a Q E a E e 9 8 8 8 Flow in Gallons Per Minute Figure 25A Pressure Drop Chart Models 495 000 745 000 Btu hr Pressure Drop Chart 985 000 2 065 000 Btu hr Models PRESSURE DROP IN FEET HEAD 25 35 45 55 65 75 85 95 105 FLOW IN GALLONS PER MINUTE Figure 25B Pressure Drop Chart Models 985 000 2 065 000 Btu hr Circulator Pump Specifications 1 Maximum operating pressure for 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 A properly sized expansion tank must be installed near the boiler and on the suction side of the pump Circulator Pump Operation Heating Boilers Only The boiler pump should run continuously unless the boiler is provided with the optional pump delay control system This optional pump control system is available as a factory installed option External wire leads are furnished with this option to allow the power supply for the pump to be switched across the normally open contacts of
23. control or the RESET button on the diagnostic panel on the left end of the unit Upon a flame failure the reset button 1s only active after the control module has completed its post purge cycle Turning main power OFF and then ON or cycling the thermostat will not reset a hard lockout condition Wait five seconds after turning on main power before pushing the reset button when the ignition module is in a hard lockout The ignition module will go into a soft lockout if conditions of low air low voltage or low hot surface igniter current are present A soft lockout condition will operate the combustion air fans for the post purge cycle and then the ignition module will pause for approximately five minutes At the end of this timed pause the ignition module will attempt a new trial for ignition sequence If the soft lockout fault condition has subsided or has been corrected at the end of the timed pause main burner ignition should be achieved with the resumption of the normal trial for ignition sequence If the control sensed fault 1s not corrected the ignition module will continue in the soft lockout condition If the electronic thermostat opens during the soft lockout period the ignition module will exit soft lockout and wait for a new call for heat from the thermostat A soft lockout condition may also be reset by manually cycling the thermostat or turning the main power switch OFF and then ON after the control sensed fault ha
24. either allow ignition to continue or shut down the gas valves should flame not be proven and proceed to a Flame Failure condition If flame was proven briefly during the ignition period the module may not proceed to Flame Failure but rather post purge and then go into another trial for ignition Heat Transfer Process Gas Valves Burner and Heat Exchanger Once flame has been proven the ignition module will hold the gas valves open as long as there is proof of flame and a call for heat 5 present If the low fire stage cannot provide enough heat to raise the system temperature the electronic temperature controller turns on the high fire stage The high fire stage will operate until the system water temperature shows a gain that can be handled by low fire operation The high fire stage shuts off at this point When the low fire stage alone produces more heat than is required the electronic temperature controller turns off the call for heat Post Purge Ignition Module Function When 24VAC is removed from the ignition module s thermostat input the module turns off the gas valves and maintains the blower for approximately 25 seconds in order to allow the combustion chamber to be purged of all combustion by products Pump Delay Electronic Thermostat Function When the electronic thermostat removes 24VAC from the ignition module it continues to hold the pump relay on for 30 seconds in order to get the remaining heat out of the combu
25. generally two weeks or more To prevent the possibility of injury under these conditions open the kitchen sink hot water faucet for several minutes before using any electrical appliance 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 Do not smoke or have open flames near the faucet at this time Hydronic Heating Boilers and Domestic Water Heaters CLEANING AND MAINTENANCE Listed below are items that must be checked to ensure safe reliable operations Verify proper operation after servicing CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Appliance Area Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Water Circulating Pump Inspect pump every six months and oil as necessary Use SAE 30 non detergent oil or lubricant specified by pump manufacturer Burner Flames Visually check main burner flames at each start up after Lifting Flames The usual causes for lifting flames are over firing the burner s excessive primary air or high draft If you observe improper flame patterns examine the venting system ensure proper gas supply and ensure adequate supply of combustion and ventilation air Flue Gas Passageways Cleaning Procedures Any sign of soot around
26. pad Outdoor models have additional special location and clearance requirements See Outdoor Installation Venting page 14 A wind proof cabinet protects the unit from weather Clearances from Combustible Construction Maintain minimum specified clearances for adequate operation Allow sufficient space for servicing pipe connections pump and other auxiliary equipment as well as the unit See rating plate for specific service clearance requirements Right Side 3 7 5 Rear 3 7 5 cm 3 min from any surface Left Side 6 15cm 24 0 61m suggested for service Front Alcove 30 0 76m suggested for service Top 3 7 5 Flue 17 25 4mm Hot Water Pipes 1 25 4mm An Alcove is a closet without a door Note No additional clearance is needed on the right side of the unit for the observation port An observation port is located on both the right and left side of the unit LEFT 3 FROM TOP AND SIDE MINIMUM Figure 2 Clearances from Combustible Construction Base for Combustible Floors There is no manufactured combustible floor base kit available for 985 000 2 065 000 Btu hr models You must construct base for combustible floor installation Install unit over base of hollow clay tiles or concrete blocks from 8 to 12 thick and extending at least 24 beyond the unit sides Place tiles or blocks so that the holes line up horizontally to provide a clear passage through the tiles
27. pressure 24 The burners light by carryover from the burners currently firing The heater is now firing at full rated input 20 21 22 23 25 M9 MODULE FIRING 26 The first stage gas valve s opens and supplies gas to the orifice and burner inlet to pre mix 27 The gas air mixture is forced into the burner and out of the burner ports under pressure 28 The hot surface igniter lights the gas air mixture and then serves as a flame sensor to prove main burner flame by rectification 29 Burners now firing for approximately 50 of the heater s input 30 24VAC is supplied from the second stage of the electronic temperature control across the 2C and 2NO terminals on the terminal strip on to a control to a relay 31 The control relay switches the fan on the 985 000 2 065 000 Btu hr models to high speed and energizes the gas valves for the remaining 50 of burner input 32 The remaining gas valves open and supply gas to the orifice inlet to pre mix 33 The gas air mixture is forced out of the burner ports and light by carryover from the burners currently firing 34 The heater is now firing at full rated input HEAT TRANSFER PROCESS 35 Heated products of combustion pass over the heat exchanger transferring heat to the water 36 The rate of flue product movement is controlled by baffles on the heat exchanger to maximize heat transfer 37 Flue products pass into the flue collector and are exhau
28. refrigerants or solvents such as Freon trichlorethylene perchlorethylene chlorine etc These chemicals when burned form acids which quickly attack the heat exchanger finned tubes headers flue collectors and the vent system The result is improper combustion and a non warrantable premature appliance failure Exhaust Fans Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and or cause a down draft in the venting system Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately If a fan is used to supply combustion air to the boiler room the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the boiler VENTING General Information You must supply adequate combustion and ventilation air to this unit You must provide minimum clearances for the vent terminal from adjacent buildings windows that open and building openings Follow all requirements set forth in the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building codes Vent installations for connection to gas vents or chimneys must be in accordance with Part 7 Venting of Equipment of the above mentioned standards IMPORTANT
29. the alarm option anytime the safety device senses an abnormal condition An additional wire may be field installed from these safety devices to terminals A3 or B3 as appropriate to activate an alarm if the unit is equipped with the alarm option 22 HeatDem1 HeatDem2 e STAGE1 STAGE2 STAGE3 STAGE 4 1 1NO 2C 2NO 3 4C ONTINUOUS INTERMITTENT Figure 24A Stand Alone Operation Models 985 000 2 065 000 Btu hr Only Remote On NOT USED 1C 1NO 2C 2NO 3C 3NO 4C 4NO CONTINUOUS INTERMITTENT Figure 248 Remote On Off Boiler or Water Heater Models 985 000 2 065 000 Btu hr Only o 2 2 NOT USED 4 1 1NO 2C 2NO 3NO 4C 4NO CONTINUOUS prc 2 A1 A2 B2 B3 e Figure 24 Two Stage High Low Fire Boiler or Water Heater Models 985 000 2 065 000 Btu hr Only HeatDem1 STAGE 1 4 1 5 HeatDem2 STAGE 2 STAGE 3 1 bcc 1C 1NO 2C 2NO 3 4NO CONTINUOUS INTERMITTENT m CONTINUOUSLY INTERMITTENTLY MONITORED EXAMPLE DEVICES HIGH LOW GAS AUX HI LIMIT AUX LIMITS EXT FLOW SWITCH Figure 24D Field Installed Safety Devices Models 985 000 2 065 000 Btu hr Only MONITORED Installation and Service Manual BOILER SYS
30. the building The unit will not operate properly if the reference COMBINATION VALVE hose is removed or a vent to atmosphere is installed DOWNSTREAM Optional gas controls may require routing of bleeds and vents TEST VALVE to the atmosphere outside the building when required by local codes Connecting Gas Piping to Unit TOBURNERS ADDITIONAL VALVES BASED ON UNIT INPUTS All gas connections must be made with pipe joint compound Figure 19 Gas Train Drawing resistant to the action of liquefied petroleum L P and natural gases All piping must comply with local codes and TABLE F ordinances Piping installations must comply with approved Pipe Size for Single standards and practices Btu hr Distance From Meter in feet 1 Make sure gas line is a separate line direct from the meter Input 0 50 51 100 101 200 201 300 301 500 unless the existing gas line is of sufficient capacity Verify som ie pipe size with your gas supplier 495 000 11 4 1 1 4 11 2 2 2 2 Use new properly threaded black iron pipe free from chips If you use tubing make sure the ends are square deburred and clean Make all tubing bends smooth and without deformation Avoid flexible gas connections Internal diameter of flexible lines may not provide unit with proper volume of gas 3 Install a manual main gas shutoff valve at the unit s gas inlet outside of the unit 5 fur 1 435 000
31. the combustion air inlet follow all instructions in this section Outdoor Vent Air Inlet Location Keep venting areas free of obstructions Keep area clean and free of combustible and flammable materials Maintain a minimum clearance of 3 76mm to combustible surfaces and a minimum of 3 76mm clearance to the air inlet To avoid a blocked air inlet or blocked flue condition keep the air inlet flue outlet and drain slot clear of snow ice leaves debris etc Do not install outdoor models directly on the ground You must install the outdoor unit on a concrete brick block or other non combustible pad Do not locate unit so that high winds can deflect off of adjacent walls buildings or shrubbery causing recirculation Recirculation of flue products may cause operational problems bad combustion or damage to controls Locate unit at least 3 feet 0 91m from any wall or vertical surface to prevent wind conditions from affecting performance Multiple outdoor unit installations require 48 1 22m clearance between each vent cap Locate the outdoor cap at least 48 1 22m below and 48 1 22m horizontally from any window door walkway or gravity air intake Locate the unit at least 10 feet 3 05m away from any forced air inlet Locate the unit at least 3 feet 0 91m outside any overhang Clearances around outdoor installations can change with time Do not allow the growth of trees shrubs or other plants to obstruct the
32. the common venting system are located and other building spaces Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued 4 Turn on clothes dryers and any other appliances not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fire place dampers Place in operation the unit being inspected Follow the lighting instructions Adjust thermostat so unit will operate continuously Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe After making sure that each appliance remaining connected to the common venting system properly vents when tested as above return doors windows exhaust fans fireplace dampers and other gas burning appliances to their previous conditions of use Correct any improper operation of the common venting system so that the installation conforms to the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edition of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment When resizing any portion of the common venting system resize to approach the minimum size as determined using the appropriate tables of the latest edition of the National Fuel Gas Code ANSI Z223 1 in Canada the latest edi
33. water temperature of 125 52 Remember no water heating system provides exact temperatures at all times Let the system operate a few days at your desired settings to determine correct settings for your needs 1 These units are equipped with an operating temperature control 2 The control set points are preset to a low test setting when shipped from the factory 3 Reset the temperature set points to the lowest settings which will satisfy hot water demands eliminate a possible condensate problem and prevent a risk of scald injury WARNING Return water temperatures must not be less than 140 F 60 C If lower return wate temperatures are required folllow the instructions for Low Temperature Return Water Systems page 25 The High Fire Offset should normally be adjusted to 0 when supplying potable hot water for domestic use Stage firing can be achieved by adjusting the High Fire Offset to any value other than zero Typically a setting of 3 F is 5 F is suitable for stage firing in a water heater application Stage firing of a potable water heater is normally only used to replace system standby heat loss All stages of burner operation should fire when there is a major draw from the potable hot water storage system This prevents possible condensate problems and ensures a rapid recovery of the hot water used Note The High Fire stage will be delayed by approximately 10 seconds to allow a soft sta
34. 495 000 645 000 745 000 985 000 1 255 000 1 435 000 1 795 000 2 065 000 40 4 0 52 5 1 60 80 5 2 102 116 146 168 80 129 149 1974 2514 2884 360 414 60 30 F AT 40 F AT 50 F FT HD FT HD FT HD GPM FT HD GPMFT HD GPM FT HD 0 6 0 6 0 7 0 8 1 1 1 7 2 4 4 5 20 26 30 40 51 58 73 84 0 7 1 6 2 3 1 4 2 3 3 7 6 2 8 7 16 21 24 32 41 47 58 67 0 6 0 8 1 2 1 0 1 6 2 2 4 2 6 0 27 35 40 53 1 6 3 0 4 0 2 4 68 4 3 78 6 0 97 112 These flow rates exceed recommended flow rates of boiler If these system temperature rises are used an external piping by pass must be installed These foot head calculations exceed the maximum allowable flow rate of the boiler Requires Cupro Nickel heat exchanger Boiler Flow Rate CAUTION The maximum flow rate for models 495 000 745 000 Btu hr is 60 GPM and 90 GPM on 985 000 2 065 000 models Do not exceed the maximum flow rate of the heating boiler If higher flow rates are required through the boiler an optional Cupro Nickel heat exchanger is available When using a Cupro Nickel heat exchanger GPM can be increased by 30 percent Consult the factory for specific application requirements The heat exchanger is generally capable of operating within the design flow rates of the building heating system Should the flow rate exceed the maxi
35. AIN PLUG 4 Figure 3 Draining Unit Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued Freeze Protection for a Heating Boiler System if required Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible N WARNING Do not use undiluted automotive type antifreeze 2 A solution of 50 antifreeze will provide maximum protection of approximately 30 F 3 Follow the instructions from the antifreeze manufacturer Quantity of antifreeze required is based on total system volume including expansion tank volume 4 Glycol is denser than water and changes the viscosity of the system The addition of glycol will decrease heat transfer and increase frictional loss in the boiler and related piping A larger pump with more capacity 1596 to 25 more may be required to maintain desired flow rates and prevent a noise problem in a glycol system 5 Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system COMBUSTION AND VENTILATION AIR 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 Z223 1 in Canada the latest edition of CAN CGA B149 Installat
36. CB CW E I S 07 INSTALLATION AND SERVICE MANUAL WARNING 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 HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 495 000 2 065 000 Btu hr MODELS ab WARNING Improper installation adjustment alteration service or maintenance can cause property damage personal injury exposure to hazardous materials or loss of life Refer to this manual Installation and service must be performed by a qualified installer service agency or the gas supplier This unit contains materials that have been identified as carcinogenic or possibly carcinogenic to humans CERTIFIED _ 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 Do not store or use gasoline or otherflammable vapors and liquids in the vicinity of this or any other appliance WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbors phone Follow the supplier s instructions If you cannot reach your gas supplier call the fire department nstallation and servic
37. Examine the venting system at least once each year Check all joints and vent pipe connections for tightness Also check for corrosion or deterioration If you find any problems correct them at once Venting Support Support horizontal portions of the venting system to prevent sagging Provide an upward slope of at least 1 4 inch per foot 2Imm m on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney The weight of the venting system must not rest on the unit Provide adequate support of the venting system Follow all local and applicable codes Secure and seal all vent connections Follow the installation instructions from the vent material manufacturer Vertical Vent Termination Clearances and Location 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 termination less than 10 feet 3 05m from a parapet wall must be a minimum of 2 feet 0 61m higher than the parapet wall You must locate the air inlet termination elbow at least 12 30cm above the roof or above normal snow levels Keep the vent cap clear of snow ice lea
38. LOW SWITCH OPTIONAL 1 W1 X amp R CONTINUOUS PUMP B PUM 11 DOTTED LINES INDICATE i 1 OPTIONAL EQUIPMENT UNLESS OTHERWISE INDICATED MV SN 1 PS W WHITE T TAN IGNITION M oe o BK BLACK v veLLow MS MODULE u PR PURPLE BR BROWN 280 2 amp f O ORANGE R RED FLAME FAIL RESET BL IGNITION MODULE e sPLicE SPLICE SDISCONNECT POWER BEFORE SERVICING THE UNIT WHEN REPLACING DAMAGED WIRING USE EQUIVALENT TYPE AND GAUGE JUMPERED PROVIDED IF NO OPTIONS ARE ORDERED BK PUMP DELAY RELAY 24VDC COIL CONTROL PAN OPTION BOX C WIRING DIAGRAMS UNIT CONNECTIONS MODELS 495 000 745 000 BTU HR CONTINUED CHASSIS GROUND O G 120VAC Q W SUPPLY 2 2 2 120VA PUMP BK D a BK BLOWER JE v Fe HH PR i LOWAIR gt GR lt INDICATOR 222 S W 5 lt 9 lt BURNER ROUND GROUND VALVE 1 AIRPRESSURE VALVEZ2 SM HOT SURFACE IGNITER SWITCH MAIN UNIT GAS VALVES BLOWER PRESSURE SWITCH BK
39. Location of Cold Water Supply Piping Connections 39 High Water Temperature Limit Control Optional Relief Valve ethernet Thermal Expansion 39 Cathodic Protection aA 39 Cleaning and Maintenance 40 Flue Gas Passageways Cleaning Procedures 40 Burner Removal and Cleaning 40 Heat Exchanger 41 41 Combustion and Ventilation 41 Adjusting Differential Air Pressure 41 Servicing Hot Surface Igniter and Ignition Module 43 Ignition System 44 Sequence of 44 GIOSSALY du C 45 Schematic Wiring Diagrams 47 Revision NOLES 3 on ciet eere yr dents Back Cover GENERAL PRODUCT INFORMATION Special Instructions This manual supplies information for the installation operation and servicing of the appliance Read and understand this manual completely before installing unit Installation and service must be performed by a qualified service installer service agency or the gas supplier Unpacking Upon receiving equipment check for signs o
40. Only supply the gas type specified on the unit s rating plate This unit is orificed for operation up to 2000 feet altitude If installing above 2000 feet elevation consult the appliance manufacturer INLET PRESSURE Measure inlet pressure at the inlet pressure tap located upstream of the combination gas valve s See TABLE E for maximum and minimum inlet pressures Do not exceed the maximum Minimum inlet pressure is for the purposes of input adjustment TABLE Inlet Pressure 495 000 745 000 Btu hr Nat Gas LP Gas 985 000 2 065 000 Btu hr Nat Gas 10 5 w c LP Gas 13 w c 10 5 w c 13 w c MANIFOLD PRESSURE Measure manifold pressure at the pressure tap on the downstream side of the combination gas valves The gas regulator on the unit s combination gas valve is adjustable to supply proper manifold pressure for normal operation See TABLE I for net manifold pressure settings If you must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment page 19 Do not increase regulator pressure beyond the specified pressure setting Gas Pressure Test 1 Disconnect the unit from the gas supply piping system during any piping system pressure testing greater than 1 2 PSIG 3 5kPa Isolate the unit from the gas supply piping system by closing a manual shutoff valve during any piping system pressure testing that is equal to or less than 1 2 PSIG 3 5kPa Test all gas connec
41. Remove the upper front jacket panels from the unit to access the upper chamber 2 Slightly loosen the screws that attach the fan transition box to the metal base see Figure 46 eC ES 3 Locate the air shutter at the rear of the fan duct see Figure 47 Move the air shutter towards the rear of the unit to increase air pressure Move the air shutter towards the front of the unit to decrease air pressure 4 Adjust the air shutter until the differential pressure 1 nominally 1 1 1 3 inches water column Note The air chamber pressure is 1 2 inches water column for liquefied petroleum L P and 1 4 inches water column for natural See Figure 45 for installations up to 2000 feet altitude Contact the factory for high altitude settings Figure 47 Adjusting Air Shutter 5 Once the adjustment procedure is complete reattach the caps to the tees in the hoses to the pressure switch and check all tubing and wire connections for a snug fit Test Servicing Hot Surface Igniter and fire the unit Reinstall upper panels Ignition Module This unit uses a proven hot surface ignition module and a hot surface igniter The hot surface ignition module is not repairable Any modification or repairs will invalidate the warranty WARNING Do not attempt to repair a faulty hot surface igniter or ignition module Any modification or repairs may create hazardous conditions that result in property dama
42. S and the boiler s internal controller Terminal Strip Connection Options Models 985 000 2 065 000 Btu hr Only Figure 24A shows the position of jumpers as shipped from the factory for stand alone operation of boilers or water heaters Figure 24B shows connections to the terminal strip for Remote ON OFF control of the boiler or water heater The 1 1 jumper must be removed when making these wiring connections This remote ON OFF control will provide an Enable Disable signal to the unit and allow the unit to operate based on the stage set points until the remote ON OFF signal is cancelled Figure 24C shows the connections necessary to operate the unit as a two stage High Low Fire boiler or water heater from an Energy Management System EMS The actual set point temperatures are controlled by the EMS The High Fire Offset on the electronic temperature control in the unit must be set to zero and the set point must be set to a value which will function as an upper limit for proper operation under this two stage control from an EMS Figure 24D shows the Continuous and Intermittent terminals External safety devices connected to these terminals will function to protect the unit Devices connected to the Intermittent terminals B1 and B2 are monitored only when there is an active Call for Heat Devices connected to the Continuous terminals A1 and A2 are monitored continuously and will activate an alarm if the unit is equipped with
43. SYSTEM 12 OR 4 PIPE DIAMETERS Figure 28 Boiler with Low Temperature Bypass Piping Installation with a Chilled Water System Pipe refrigeration systems in parallel Install duct coil downstream at cooling coil Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity 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 is satisfied This provides greater economy over maintaining standby heat see Figure 29 EXPANSION TANK HEATING AND COOLING COIL LOW WATER 9 PUMP T V ie FLOW SWITCH p OUT IN GRS CHILLER SUPPLY WATER BOILER SUPPLY Figure 29 Installation with a Chilled Water System TABLE L System Temperature Rise Chart Based Btu hr Input AT 10 F AT 20 F Output 400 950 522 450 603 450 831 600 1 058 400 1 209 000 1 512 000 1 738 800 Input
44. TEM PIPING The drawings in this section show typical boiler piping installations Before beginning the installation consult local codes for specific plumbing requirements Be sure to provide unions and valves at the boiler inlet and outlet so it can be isolated for service You must install an air separation device in the installation piping to eliminate trapped air in the system Locate a system air vent at the highest point in the system The system must also have a properly sized expansion tank installed Typically an air charged diaphragm type compression tank is used You must install the expansion tank close to the boiler and on the suction side of the system pump to ensure proper operation CAUTION This boiler system should not be operated at less than 12 PSIG Provide suitable hangers or floor stands to support hot water piping The boiler alone should not support hot water piping Copper pipe systems are 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 Use padding on rigid hangers installed with a copper system Pipe the boiler pressure relief valve to a suitable floor drain See the relief valve section in this manual CAUTION A leak in a boiler system will cause the system to intake fresh water cause the tubes to constantly which will accumulate a lime scale build up This will cause 23
45. Water Chemistry page 37 2 Excessive pitting and erosion on the inside of the copper Installation and Service Manual tube may be caused by too much water velocity through the tubes and 5 not covered by the appliance manufacturer s warranty see System Temperature Rise Chart on page 26 for flow requirements SAFETY INFORMATION 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 Read this owner s manual carefully and completely before trying to install operate or service this unit Improper use of this unit can cause serious injury or death from burns fire explosion electrical shock and carbon monoxide DANGER Carbon Monoxide poisoning may lead to death IMPORTANT Consult and follow local building and fire regulations and other safety codes that apply to this installation Consult your local gas utility company to authorize and inspect all gas and flue connections 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 unit WARNING To minimize the possibility of serious personal injury fire or damage to your unit never violate the following safety rules 1 Thisunit is only for use wi
46. an before ignition on stages 1 and 2 Hot surface igniter preparing to light burners Burners for stage 1 Burners for stage 2 operating 985 000 2 065 000 Btu hr Remote status light for ignition module Indicates flame failure on the ignition module and will indicate additional alarms if the alarm of any failure option is purchased Figure 40 Operation Diagnostic Lights 35 Hydronic Heating Boilers and Domestic Water Heaters DOMESTIC WATER HEATERS This section applies only to those units used to supply potable hot water for domestic use The hot water supply boiler must be installed with a storage tank 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 Hot water supply heaters are designed for installation with a properly sized storage tank The use of a properly sized pump and the control of water velocity as explained below are important for correct operation of your water heater Water Velocity Control IMPORTANT To ensure proper velocity through the heat exchanger you must regulate the temperature rise across the heat exchanger from inlet to outlet Do this upon initial installation and periodically recheck The correct temperature rise across the heat exchanger ensures proper velocity in the tubes This will yield long li
47. below TABLE Remote Wire Connection Maximum Allowable Length Installation and Service Manual HOT SURFACE IGNITION SYSTEM Hot Surface Igniter and Ignition Control Module This unit has one ignition module and one hot surface igniter Figure 38 Hot Surface Igniter A Caution The igniter is extremely fragile be very careful when removing A faulty or damaged hot surface igniter MUST BE replaced with a Lochinvar PLT3400 igniter Do not use general purpose field replacement igniters LN Ft T Figure 39 Hot Surface Ignition Control Module 33 Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued Hot Surface Ignition Control Module Ignition Module Lockout Functions The ignition module may lockout in either a hard lockout condition requiring pushing of the reset button to recycle the control or a soft lockout condition which may recycle after an approximate five minute waiting period This soft lockout condition is intended to allow self correcting faults to correct themselves and permit normal operation A typical hard lockout fault is a flame failure condition An ignition module that is in a hard lockout condition may only be reset by pushing the reset button next to the ignition
48. blems when exposed to inlet water temperatures below 140 F Lochinvar offers a low temperature protection BOILER PUMP Installation and Service Manual valve LTV that is factory preset to maintain 140 F inlet water to the boiler regardless of the system return water temperature See Table K for available valve kits Table K LTV Valve Kits Input Btu hr LTV Valve Kit 495 000 745 000 VAL3048 985 000 2 065 000 VAL3047 Be sure to install the LTV valve per the piping diagrams included with the kits Alternatively a bypass as shown in FIG 28 may be piped into the system This piping is like a primary secondary boiler installation with a bypass in the secondary boiler piping Inlet water temperatures below 140 F 60 C can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue Condensation can cause operational problems bad combustion sooting flue gas spillage and reduced service life of the vent system and related components The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140 F 60 C This should prevent the products of combustion from condensing in most installations The bypass should be fully sized with a balancing valve to allow for proper adjustment A valve must also be provided on the boiler discharge after the bypass Closing this discharge valve forces water
49. ce 1 8 hex plug in the gas valve and tighten 15 Turn on the gas supply at the manual valve turn L P gas at the tank if required 16 Turn the power switch to the ON position 17 Turn the gas valve knob to the position ae 18 Set the electronic temperature control or thermostat to call VALVE for heat WARNING After completing any testing Figure 20 Measuring Gas Supply Pressure at Combination on the gas system leak test all gas connections Gas Valve Apply a soap water solution to all gas connections while main burners are operating Bubbles forming indicate a leak Repair all leaks at once Do not operate this unit with a leak in the gas Manifold Pressure Adjustment train valves or related piping IMPORTANT The gas valves are referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the front inside portion of the jacket Reference the drawings in this section for component and connection points for pressure measurement The referenced chamber pressure must be subtracted from the Check burner performance by cycling the system while you observe burner response Burners should ignite promptly Flame pattern should be stable see Burner Flames page 40 Turn the system off and allow burners to cool then cycle burners again to ensure prope
50. ce risk of scald injury Operate this high efficiency hot water heater at a temperature setting high enough to prevent condensing of the products of combustion on the unit s heat exchanger or in the attached venting system A water temperature setting that is above the dew point of the gas combustion products should prevent condensate formation WARNING To guard against scald injury you must use a properly sized thermostatic mixing valve to supply domestic hot water at temperatures less than 125 F 52 Storing the water at a higher temperature and thermostatically mixing the water increases the available quantity of mixed hot water greatly reducing the possibility of condensate forming on the heat exchanger or in the venting system and helps prevent water born bacteria growth Some states may require a lower water temperature setting for specific applications Check local codes or your gas supplier for domestic hot water temperature requirements 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
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52. delay operation Location Locate indoor boilers and hot water supply boilers in a room having a temperature safely above freezing 32 F 0 C Installation and Service Manual CAUTION A mechanical room operating under a negative pressure may experience a down draft in the flue of a boiler 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 Hydronic System Antifreeze 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 appliance manufacturers instructions Do not use undiluted or automotive type antifreeze Outdoor Boiler Installation Adequate hydronic system antifreeze must be used A snow screen should be installed to prevent snow and ice accumulation around the unit or its venting system Shut Down and Draining If for any reason the unit is to be shut off the following precautionary measures must be taken 1 Shut off gas supply 2 Shut off water supply 3 Shut off electrical supply 4 Drain the unit completely Remove one threaded plug or bulbwell 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 see Figure 3 5 Drain pump and piping DRAIN PLUG DR
53. e must be performed by a qualified installer service agency or the gas supplier Save this manual for future reference Hydronic Heating Boilers and Domestic Water Heaters Table of Contents hier 3 Safety Information ee dace titt thi ioc tite eet teet 3 Product Identification 5 Installati nzo nude a ero eR eR AE 6 Locating Units eee 6 Clearances from Combustible Construction 6 Base for Combustible Floors 6 Freeze Protection esses eene 7 Pomp Operation i cet enden 7 LOGCatlOori tiec eroe tiet beo pert igo rb vex erae Fern denso id 7 Hydronic System 7 Outdoor Boiler Installation eee 7 Shutdown and Draining 7 Freeze Protection for a Heating Boiler System 8 Combustion and Ventilation 8 Combustion Air Filter enc mentes 8 Combustion Air Options enira 9 Exhaust Fans 10 AV cial Ni gt c oiii d DE EO E IEEE 10 General Information eee 10 Venting iicet ee trit eterne a dese iced 10 Vertical Vent Termination Clearances and Location 10 Vent System Options sss 12 Barometric Damper Location
54. e sizing chart provides the minimum pipe size for common manifold piping to ensure adequate flow circulating pump Mount the pump on the unit s inlet water connection 495 000 745 000 Btu hr Models 1 4 HP 120 VAC 5 8 Amps 985 000 2 065 000 Btu hr Models 1 2 HP 120 VAC 7 4 Amps This pump is 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 is based on the following pipe and fittings from the unit to the storage tank 37 Hydronic Heating Boilers and Domestic Water Heaters DOMESTIC WATER H EAT ERS Continued 6 90 elbows 2 ball valves 2 unions 1 cold water tee Not more than 45 feet of straight pipe Potable Hot Water Temperature Control Settings Domestic Water Temperatures WARNING You must take adequate care to prevent scald injury when storing water at elevated temperatures for domestic use IMPORTANT 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 This is based on heating potable water with a hardness of 5 to 25 grains per gallon and or total dissolved solids not exceeding 350 ppm See Water Chemistry page 37 TABLE 5 BTU hr Input
55. ed a call for heat The process begins with 120VAC power entering the appliance and ends with the appliance going into an idle state after completion of a successful call for heat Note The following descriptions do not include remotely connected devices that may be connected to the appliance Refer to the wiring diagram for actual point to point wiring connections that show power delivery 1 The POWER switch is placed in the position 2 120VAC power is supplied to the control transformer along with L1 and F1 on the ignition module 3 24VAC is supplied to the electronic temperature control the ignition module and the adjustable high limit control 4 24VAC is then supplied to the auxiliary limit control if equipped 5 If equipped 24VAC is supplied to a low water cut off and then to the high and low gas pressure switches 6 24VAC is supplied to the continuous alarm terminals A1 and A2 and then to the remote stage one terminal strip and INO 44 7 24 is supplied to the electronic temperature control 8 The electronic temperature control then calls for heat 9 24VAC is supplied to the intermittent alarm field safety contacts and B2 10 24VAC is supplied to the water flow switch if equipped 11 24VAC 15 supplied to the TH terminals on the ignition module 12 As power is applied to the TH terminals on the ignition module 120VAC is switched from the F2 terminal to start the combustion a
56. ed with the O A Shutdown switch Outdoor Air Max The O A Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting When the outdoor air temperature is above the specified setting the unit will not function in the O A Reset Mode but will continue to run at the selected set point temperature Note that the set point knob will now indicate the minimum boiler temperature Target temperature is determined by the ratio and outdoor air temperature below the O A Max setting Ratio The Ratio knob allows the control over the reset ratio to be used during Outdoor Air Reset The allowable ratios are as low as 0 5 1 or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 F for every 1 0 F drop in outdoor air temperature up to the maximum set point temperature Selecting the 1 5 1 ratio will increase the set point 1 5 F for every 1 0 F drop in outdoor air temperature up to the maximum set point temperature See Figure 37 for an outdoor air reset chart example 31 Installation and Service Manual SENSOR ENABLE DISABLE O A SHUTDOWN Figure 36 Optional Outdoor Air Reset Control Hydronic Heating Boilers and Domestic Water Heaters OPERATION Continued Temperature Control Sensors This is a two stage temperature control that controls the burner ignition pump and alarm functions This
57. eed 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 The termination of the vent limited opening on the combination gas valve regulator complies with the safety code requirements of CSD 1 CF 190 a as shipped from the appliance manufacturer without the installation of additional vent lines Checking Gas Supply Pressure Use the following procedure to check gas supply pressure 1 Turn the main power switch to the OFF position 2 Turn gas valve knobs to the OFF position 3 Shut off gas supply at the field installed manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank 4 Remove the 1 8 hex plug located on inlet side of the gas valve You may also use a tapping on the field installed main manual gas cock or gas piping Install a fitting in the inlet pressure tapping suitable to connect to a manometer or magnahelic gauge Range of scale should be 14 w c or greater to check inlet pressure 5 Turn gas supply at the manual gas cock turn on L P gas at tank if required Turn the power switch to the ON position Turn the gas valve knobs to the ON position Set the electronic temperature control or thermostat to call for heat 8 Observe the gas supply pressure as all burners are firing Ens
58. eeze Protection page 7 Hydronic Heating Boilers and Domestic Water Heaters N ST A L L AT 2 Outdoor Installation Venting Continued This option uses the installation of special air inlet and vent caps on the unit See page 13 for venting details All units are shipped from the factory equipped for conventional TABLE a B negative draft venting All other optional vent systems require Flue Pipe Sizes the installation of specific vent kits and venting materials Input Flue The following is a detailed explanation of the installation requirements for each venting system components used and part numbers of vent kits for each model 495 000 645 000 745 000 Barometric Damper Location 985 000 Any venting system option that requires a barometric damper must adhere to the following directions for optimum 1 255 000 performance 1 435 000 1 795 000 The preferred location for the barometric damper is in a tee or 2 065 000 collar installed in the vertical pipe rising from the unit s flue outlet The barometric damper MUST NOT be installed in a bull head tee installed on the unit s flue outlet The tee or collar containing the barometric damper should be approximately Vent System Options three feet vertically above the connection to the unit s flue s outlet This location ensures that any positive velocity pressure This unit has two venting options from the unit s internal combustion fan is dissipated and the 1 Conventional N
59. egative Draft Venting flue products are rising due to buoyancy generated from the temperature of the flue products Adjust weights on damper This option uses a vertical rooftop flue termination Combustion P v to ensure that draft is maintained within the specified ranges air is supplied from the mechanical room See page 13 for detailed information Minimum Recommended Combustion Air Supply Boiler Room Combustion Air Source Boiler Input Outside Air 2 Openings Outside Air 1 Opening Inside Air 2 Openings 495 000 125 in 806 cm 167 in 1077 cm 500 in 3226 645 000 163 in 1052 cm 217 in 1400 cm 650 in 4194 cm 745 000 188 in 1213 cm 250 in 1613 cm 750 in 4839 cm 985 000 248 1 600cm 330 in 2 129cm 990 6 388cm 1 255 000 315 in 2 032cm 420 in 2 710cm 1260 in 8 130cm 1 435 000 360 in 2 323 480 10 3 097cm 1440 in 9 291cm 1 795 000 450 in 2 903cm 600 in 3 87 1800 in 11 614cm 2 065 000 518 in 3 342cm 690 in 4 452 2070 in 13 356cm 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 The above requirements are for the boiler only additional gas fired units in the boiler room will require an inc
60. f shipping damage Pay particular attention to parts accompanying the boiler 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 the carrier Codes The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made These shall be carefully followed in all cases Authorities having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Where required by the authority having jurisdiction the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers ASME CSD boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code Section IV Warranty Factory warranty shipped with unit does not apply to units installed or operated improperly In most cases improper installation or system design causes most operating problems 1 Excessive water hardness causing a lime build up in the copper tube is not the fault of the equipment and is not covered under the appliance manufacturer s warranty see Water Treatment page 28 and
61. fe and economical operation from your hot water heater Excessive lime build up in the tube is caused by too low of velocity through the tubes Excessive pitting or erosion in the tube is caused by too high of velocity through the tubes Take care to measure temperature rise and maintain a velocity as follows 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 2 Turn the water heater and allow time for the temperature to stabilize Record the difference between the inlet and outlet temperatures This difference will be the temperature rise 3 Compare the temperature rise on the heater with the required temperature rise in TABLE Q Should adjustment be needed proceed as follows If the temperature rise is too high the water velocity is too low Check the following 2 Be sure all valves are open between the water heater and the tank Check for restrictions in the outlet of the water heater 36 Check the pump to be sure it is running properly and that the pump motor is running in the proper direction see arrow on volute housing Be sure the installed circulation pipes between the water heater and storage tank are not less than 2 1 2 in diameter on models 985 000 2 065 000 Btu hr Common manifold piping for multiple unit installations will require larger mi
62. five minutes with the fan running before beginning the adjustment procedure Note Retain the plastic caps removed from the tees for reinstallation when complete Figure 45 Combustion Air Adjustment with a Manometer to set Differential Pressures Adjustment Procedure 495 000 1 255 000 Btu hr Models 1 Remove the upper front jacket panels from the unit to access the upper chamber 2 Locate the air shutter on the side of the fan housing see Figure 44 Turn the adjustment screw on the air shutter to open or close the shutter Increase air shutter opening to increase air pressure Decrease air shutter opening to decrease air pressure 3 Adjust the air shutter until the differential pressure is nominally 1 2 1 35 inches water column for models 495 000 745 000 Btu hr and 1 1 1 3 inches water column for models 985 000 1 255 000 Btu hr Note The air chamber pressure is 1 2 inches water column for liquefied petroleum L P and 1 4 inches water column for natural See Figure 45 on installations up to 2000 feet altitude Contact the factory for high altitude pressure settings 4 Once the adjustment procedure is complete reconnect the caps to the tees in the hoses to the pressure switches and check all tubing and wire connections for a snug fit Test fire the unit Reinstall upper panels 42 Installation and Service Manual Adjustment Procedure 1 435 000 1 795 000 and 2 065 000 Btu hr Models 1
63. ge personal injury fire explosion and or toxic gases TRANSITION BOX SCREWS Figure 46 Loosening the Transition Box Screws 1 435 000 1 795 000 and 2 065 000 Btu hr Models Only 43 Hydronic Heating Boilers and Domestic Water Heaters CLEANING AND MAINTENANCE A faulty hot surface igniter or ignition module must be replaced with an identical part specification igniter and ignition module for this specific unit is available from your local distributor Do not use general purpose field replacement ignition modules or igniters Ignition System Checkout Turn off gas supply to unit 2 Turn electric power on 3 Adjust the set point on the temperature control to a setting above water temperature or to the highest safe setting 4 The igniter will cycle on trial for ignition 5 The ignition module will lock out and turn the alarm light on 6 Adjust the Set Point Differential and High Fire Offset to the desired settings 7 Turn on gas supply 8 Press the module reset button to reset the ignition module This 1s a red button beside the ignition module or on the diagnostic panel on the header end of the unit 9 Ifignition system fails to operate properly repair work must be performed by a qualified service person or installer SEQUENCE OF OPERATION OVERVIEW This sequence of operation can be considered the order of events in sequential order that occur after the appliance has receiv
64. ication 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 Placement of Sensors Inlet Temperature Sensor The inlet water temperature sensor is placed into the inlet bulbwell on the boiler This sensor is installed by the factory in new units 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 not read accurately System Sensor This is used for boiler applications This sensor will control the boiler operation based upon the water temperature within the building loop Tank Sensor This is used in water heating applications Place the sensor in the water storage tank to measure water temperature For more information on mounting the sensor see Remote Mounting of Sensors page 33 Outside Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems The outside air sensor is optional You must purchase the sensor from the appliance manufacturer The sensor comes with a housing that helps protect the sensor from the elements Mount the air sensor housing under the eve of the roof Make sure the housing is out of direct sunlight This will ensure that the sensor will accurately read the true outdoor temperature For more informatio
65. in proximity to the gas line when bleeding air from the gas line Gas may be present 17 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued Water heater models do not have downstream test valves but the rest of the gas train is represented by Figure 19 Combination Gas Valves These units fire in up to 2 stages of burner input Each stage of burner operation has a combination gas valve or series of gas valves to cycle the gas supply on and off and regulate gas to the burners Each combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves The valve has a gas control knob that must remain in the open position at all times when the unit is in service The gas control valve has pressure taps located on the inlet and discharge sides of the valve Manifold pressure is adjusted using the regulator located on the valve A manifold gas pressure tap for each burner stage is located on the discharge side of the valve The manifold pressure is preset at the factory and adjustment is not usually required If you must adjust regulator pressure follow the instructions under Gas Manifold Pressure Adjustment page 19 Venting of Combination Gas Valves The combination gas valve regulator used on all units is equipped with an integral vent limiting orifice per ANSI Z21 78 The vent limiter ensures that the volume of gas emitted from the valve does not exc
66. in this tap that is suitable for connection of a hose to a manometer or 7 side of a magnahelic gauge CO N N E CT G T O WAT E R see Figure 21 SU PPLY 8 Turn the power switch to the T or ON position 9 Push the reset button s for the ignition control s if In let an d ut let Co nnect io ns necessary E For ease of service install unions the water inlet and water outlet of the unit The connection to the unit marked Inlet on the header should be used for return from the system The 11 Once the unit is firing the manometer magnahelic will connection on the header marked Outlet is to be connected reflect the net manifold gas pressure Compare this reading to the supply side of the system the respective value in TABLE I for Natural Gas or Propane Gas 10 Set the temperature control to call for heat see Setting Temperature Control page 29 20 WATER CONNECTIONS Models 495 745 2 NPT Models 985 2065 2 1 2 NPT WATER OUTLET WATER INLET INSPECTION PLUGS Figure 22 Water Connections Relief Valve This unit is supplied with a relief valve s sized in accordance with ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The relief valve s is installed in the vertical position and mounted in the hot water outlet Place no other valve between the relief valve and the unit To prevent water damage pipe the discharge from the relief va
67. ion Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes Provide properly sized openings to the equipment room to assure adequate combustion air and proper ventilation when the unit is installed with conventional venting or sidewall venting Combustion Air Filter The 985 000 2 065 00 Btu hr models have a standard air filter s located behind the combustion air inlet panel s This filter helps ensure clean air is used for the combustion process Check this filter every month and replace when it becomes dirty The filter size 15 12 x 16 x 1 30 5cm x 40 6cm x 2 5cm You can find this commercially available filter at any home center or HVAC supply store Installing Combustion Air Filter To install the filter s remove the combustion air inlet panel s The 985 000 1 435 000 Btu hr models have one combustion air inlet panel located on the left front of the unit see Figure 4 The 1 795 000 and 2 065 000 Btu hr models have two combustion air inlet panels located on the left and right front of the unit see Figure 5 1 Loosen knurled knob at the bottom of the control panel cover 2 Pull the bottom of the panel s out and down to remove 3 Place filter s in opening s 4 Replace combustion air inlet panel s Figure 4 Installing Combustion Air Filter 985 000 1 435 000 Btu hr Models Figure 5 Installing Combustion Air Filters 1 795 000 and 2 065 000 Bt
68. ir fan at full speed on the 495 000 745 000 Btu hr models and at low speed on the 985 000 2 065 000 Btu hr models 13 24VAC is supplied to the C terminal of the air pressure switch As the low air switch makes power is supplied to the ignition module 14 24VAC is then supplied to the PS terminals on the ignition module as the air pressure switch makes to prove fan operation The combustion air fan operates for the pre purge period At the end of the pre purge 120VAC is applied to the hot surface igniter and the trial for ignition light The hot surface igniter proves 1800 F 982 C ignition temperature by current draw through the ignition module The ignition module supplies voltage to the MV terminals on to the gas valve s 15 16 17 18 F9 SINGLE STAGE FIRING 19 gas valves on the 495 000 745 000 Btu hr models and approximately half of the valves on the 985 000 2 065 000 Btu hr models open supplying gas to the orifice and burner inlet to pre mix The gas air mixture 1s forced into the burner and out of the burner ports under pressure The hot surface igniter lights the gas air mixture and then serves as a flame sensor to prove main burner flame by rectification After a time delay of 10 seconds the remaining gas valves on the 985 000 2 065 000 Btu hr models open supplying gas to the remaining burners The gas air mixture is forced out of the burners and out of the burner ports under
69. just the fan if a continuous Low Air Status Code occurs Check for proper installation and draft in the venting system Correct as required Adjusting Differential Air Pressure The following is a recommended method for setting the differential air pressure A P for the fan Hydronic Heating Boilers and Domestic Water Heaters CLEANING AND MAINTENANCE continuen Turn the adjustment screw on the air shutter to open or close shutter Figure 44 Adjusting Air Shutter Set Up Procedure To the left of the fan 15 an air pressure switch with a large and a small tube delivering pressure from points inside the unit see Figure 43 The pressure in the large tube is the chamber pressure The pressure in the small tube is the burner pressure They act together to make the pressure switch By disconnecting the caps from the tees in the pressure switch hoses and connecting them to either side of a manometer you can read the differential pressure to the switch The connection on the manometer connects to the tee in the tubing from the units front chamber and the connection on the manometer connects to the tee in the small tubing from the burner Upon a call for heat the fan will run for about 90 seconds before going into soft lockout If necessary turn the power to the unit OFF and then back ON again to recycle the fan Note If the unit has been firing recently allow the unit to cool for
70. l are for Set Point Differential and High Fire Offset see Figure 35 Maximum Set Point Determination The maximum set point for the control is factory set Boilers are set to 230 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 not cutting cutting the and OJ2 jumpers located on the right side of the temperature controller see Figure 35 The maximum set point is determined as shown in TABLE M 30 orr 240 SETPOINT DIFFERENTIAL TST2314 HIGH FIRE Maximum Set Point Determination Max OJ2 Set Point 230 F 190 F 200 F 160 F Connected Connected Cut Connected Cut Connected Cut Cut Note Anytime that OJ1 is the only jumper cut a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190 F Anytime the OJ2 jumper is cut with or without OJ1 a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200 F Set Point The Set Point knob specifies the target water temperature in degrees Fahrenheit After the water temperature reaches the set point the temperature control shuts off the burners Differential The Differential specifies the number of degrees below the set point that the control will allow the water te
71. lso activates the pump relay If more heat 15 needed it activates the high fire stage Ignition Module Controlled by Electronic Temperature Controller One ignition module is provided on the unit Upon sensing the 24V AC delivered to it by the electronic temperature controller the ignition module checks for a shorted pressure switch and then provided the air switch isn t shorted supplies 120VAC to its blower output relay and waits for a pressure switch signal Two Speed Blower Controlled by Ignition Module and Relay Board A single 2 speed blower on the 985 000 2 065 000 Btu hr models single 1 speed blower on the 495 000 745 000 Btu hr models provide combustion air to the unit The blower is provided with a high and low speed tap The blower operates in tandem with the ignition module when a call for heat signal is received Depending upon the number of stages in operation the blower s speed may increase or decrease accordingly Switch Activated by Blower Turning n One pressure switch is provided to monitor the blower On Off operation Upon a call for heat 24V AC is delivered to the pressure switch If the blower generates adequate air pressure the pressure switch closes to deliver 24VAC to the ignition module pressure switch monitoring input terminal Prepurge Ignition Module Function Once the ignition module sees a 24VAC input from the pressure switch it runs the blower for approximately 15 seconds in order t
72. lve to a suitable floor drain for disposal when relief occurs Do not install any reducing couplings or other restrictions in the discharge line The discharge line will allow complete drainage of the valve and line Manually operate the relief valves at least once a year CAUTION Avoid contact with hot discharge water Water Flow Switch A water flow switch is factory installed The flow switch is wired in series with the 24 VAC safety control circuit at the units terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition The factory supplied flow switch is installed in the outlet side of the front header These units require a minimum flow of 26 GPM to make the flow switch and start burner operation Ensure that the pump installed on the unit will supply adequate flow to make the flow switch contacts and operate the unit A water flow switch meets most code requirements for a low water cut off device on appliances requiring forced circulation for operation 21 Installation and Service Manual Low Water Cutoff If Equipped If installing this unit above radiation level you must install a low water cut off device at the time of appliance installation Electronic or float type low water cutoff controls are available as a factory supplied option on all units Inspect the low water cutoff every six months including flushing of float types The
73. mperature 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 while Low Fire operates approximately one half of the burners The High Fire knob specifies the number of degrees below set point that the High Fire stage shuts down At that point the unit will continue to operate at the Low Fire stage until the set point is reached The High Fire offset knob has settings between 0 F and 20 F If set at O F the High Fire offset is disabled and the unit will operate at the High Fire stage until the set point is reached and the temperature control shuts the unit off When the High Fire offset knob is set to 0 or 1 the unit will light at Low Fire and operate for approximately 10 seconds before the High Fire stage actuates When set to 2 or above the unit will operate at Low Fire for 2 minutes before the High Fire stage actuates Outdoor Air Reset Option For boilers ordered with the Outdoor Air Reset option there is an additional control see Figure 36 There are three setting knobs for Shutdown Outdoor Air Max and Ratio There is also a switch to turn the outdoor air sensor On or Off An O A Sensor is also included Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the unit from operating This feature can be enabled disabl
74. mum allowable flow rate through the boiler an external bypass must be installed The bypass should be fully sized with a balancing valve to allow for proper adjustment of flow Flow rate can be determined by measuring the temperature rise through the boiler Boiler Bypass Requirements The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise It is recommended that this boiler be installed with a bypass in the piping if the maximum recommended flow rate is exceeded The bypass will help to ensure that the boiler can be supplied with adequate water flow Flow rates exceeding the maximum recommended flow will result in erosion of the boiler tubes A typical bypass with a valve is shown in Figure 30 will allow control of boiler flow Temperature Pressure Gauge This boiler is equipped with a dial type temperature pressure gauge This gauge 1 factory installed in the outlet side of the heat exchanger The gauge has one scale to read system pressure and a separate scale to read water temperature in degrees Fahrenheit Installation and Service Manual MAKE UP WATER TO SYSTEM E We RY Es QY SYSTEM PUMP AIR SEPARATOR J 4 BY PASS VALVE FROM SYSTEM Figure 30 Boiler Bypass Piping for High Flow Systems Filling the System air must be purged from the system for proper operation An air scoop and air vent must be located close to the boiler
75. n on mounting the sensor see Remote Mounting of Sensors page 33 Remote Mounting of Sensor You must mount the outside air temperature sensor outside the building To mount 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 common mode rejection of some types of electrical interferences 1 Do not route temperature sensor wiring with building power wiring 2 Do not locate temperature sensor wiring next to control contactors 3 Do not locate temperature sensor wiring near electric motors 4 Do not locate temperature sensor wiring near welding equipment 5 Make sure good mechanical connections are made to the sensor any interconnecting wiring and the controller 6 Do not mount sensor with leadwire end pointing up in an area where condensation can occur 7 Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists Shielded cable is recommended on all cable runs of more than 25 feet in length Note Ground the cable shield at the connection to the boiler temperature control only Do not ground the shielded cable at the sensor end To maintain temperature accuracy sensor wires should be at least 18 AWG see Table N
76. ng of 200 F 93 If water temperature exceeds the set point the limit will break the control circuit and shut down the unit The limit control will only be reset after the water temperature has cooled below the set point of the limit The high water temperature limit control is mounted in the outlet side of the front header A manual reset high water temperature limit control is available as an optional control Optional Relief Valve This water heater 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 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 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 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 which is extremely flammable can be produced in a hot water system that has been unused for a long period of time
77. nifold from gas train using union s just below each gas valve s Remove mounting screws from manifold mounting brackets Pull the manifold orifice assembly away from burners Repeat for each manifold assembly Remove two mounting screws from burner and slide burner out toward front of unit Use caution to prevent damage to burners refractory hot surface igniter or wiring Remove soot from burners with a stiff bristle brush Dirt may be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installing Damaged burners must be replaced When installed in a dusty and dirty location the burners may require cleaning on a 3 to 6 month schedule or as needed 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 The standard inlet air filter will help eliminate dust and dirt from entering the unit Use extreme care when operating a unit for temporary heat during new construction The burners could require a thorough cleaning before the unit is placed in service Heat Exchanger Cleaning 1 While burners are removed check the heat exchanger surface for sooting If present heat exchanger must be cleaned and problem corrected Proceed as follows Remove gas manifold s orifice assemblies as described in steps 1 thr
78. nimum pipe sizes and tank circulating tappings to ensure proper flow See TABLE R If the temperature rise is too low the water velocity is too high Adjust as follows 1 Slowly throttle the valve on the outlet side of the water heater until the temperature rise 1s steady at the required temperature rise as noted in TABLE Q 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 Based on heating potable water with a hardness of 5 to 25 grains per gallon and or total dissolved solids not exceeding 350 ppm see Water Chemistry page 37 TABLE Q Temperature Rise Chart Btu hr Input 495 000 645 000 745 000 985 000 1 255 000 1 435 000 1 795 000 2 065 000 Temperature Rise F Water Chemistry The required temperature rise and the standard pump sizing are based on the heating of potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids not exceeding 350 ppm Consult the appliance manufacturer when heating potable water exceeding these specifications Heating of high hardness and or high total dissolved solids water will require a larger circulating pump an optional cupro nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water t
79. ntrol draft Multiple unit installations with combined venting or common venting with other Category I negative draft appliances require each boiler to have a barometric damper installed to regulate draft within the proper range Do not connect vent connectors serving appliances vented by natural draft negative draft to any portion of a mechanical draft system operating under positive pressure Connecting to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury 13 Installation and Service Manual Flue Outlet Piping With this venting option you must use Type B double wall or equivalent vent materials Vent materials must be listed by a nationally recognized test agency for use as vent materials Make the connections from the unit vent to the outside stack as 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 Follow the vent manufacturer s instructions when installing Type B vents and accessories such as firestop spacers vent connectors thimbles caps etc Provide adequate clearance to combustibles for the vent connector and firestop When planning the venting system avoid possible contact with plumbing or electrical wiring inside walls ceilings and floors Locate the unit as close as possible to a chimney or gas vent Avoid long horizontal r
80. o be heated Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non warrantable damage to the heater pump and associated piping Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions COLD WATER SUPPLY EXPANSION TANK IF REQUIRED MIXING VALVE HOT WATER Installation and Service Manual TABLE Pipe Sizing Chart 495 000 745 000 Number Common of Pipe Units Size Min 985 000 2 065 000 Number Common of Pipe Units Size Min 2 1 2 Circulating Pump The water heater must be connected to a properly sized pump that circulates water between the heater and storage tank SUPPLY 4 2 The pump is sized to heater input and water hardness Care ME should be taken to size the pump correctly See Water Chemistry on this page NA 3 The water heater is equipped with factory supplied pump LGGKETEMP delay system in accordance with the requirements of the dios latest edition of ASHRAE 90 1 4 Lubricatethe pump to the manufacturer s recommendations DRAIN N Pump damage due to inadequate lubrication is non warrantable BUILDING 5 Standard water heaters are furnished with the following RETURN Figure 41 Typical Water Heater Piping with Storage Tank Pipe Size Requirements Table R pip
81. o purge the combustion chamber of any unburned fuel air mixture Trial for Ignition Ignition Module Function Once the ignition module has completed its prepurge period it turns on the hot surface igniter Once the hot surface igniter s current draw reaches a proper level the ignition module begins a trial for ignition period of approximately 25 seconds to allow time for the igniter to reach the ignition temperature necessary to ignite the fuel air mixture Igniter Controlled by Ignition Module One igniter is provided in order to ignite the fuel air mixture and its on off operation is controlled by the ignition module 46 Relay Board Controlled by Electronic Temperature Controller and Ignition Module A small relay board is provided on the 985 000 2 065 000 Btu hr models to switch the blower from low to high speed and to deliver power from the low fire stage Stage 1 to the high fire stage Stage 2 depending upon the electronic thermostat s settings Ignition Ignition Module Function Once the trial for ignition period has been completed the ignition module sends 24V AC to the gas valves on the low fire stage Stage 1 Gas valves should open and allow gas to flow to the burners in Stage 1 being energized The fuel air mixture should ignite from the hot surface igniter Once this voltage has been sent to the valves the hot surface igniter 1s turned off The ignition module then monitors the status of the flame and will
82. or blocks Place a 1 2 fireproof millboard over the top of the tile or block base Place a 20 gauge sheet metal cover over the fireproof millboard Center the unit on the base Also follow this procedure if electrical conduit runs through the floor beneath the unit This base must meet all local fire and safety codes TABLE COMBUSTIBLE FLOOR Input Btu hr Kit Number 495 000 CFK3302 645 000 CFK3303 745 000 CFK3304 FREEZE PROTECTION Although these units are CSA International design certified for outdoor installations such installations are not recommended in areas where the danger of freezing exists You must provide proper freeze protection for outdoor installations units installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower If freeze protection is not provided for the system a low ambient temperature alarm is recommended for the mechanical room Damage to the unit by freezing is non warrantable Anytime the temperature measured at any of the sensors except the outside air temperature sensor drops below 40 F the control turns on the pump contact and the alarm relay The pump will shut off when both sensors are above 50 F Pump Operation This unit is equipped with a pump delay of 30 seconds If continuous operation of the pump is desired the pump must be electrically connected to another circuit Connection of the pump to this unit will provide intermittent pump
83. ough 5 in Burner Removal and Cleaning page 40 Disconnect wiring from the hot surface igniter and hose from the burner pressure tap Remove inner jacket panel mounting screws and slide door assembly out toward front of the unit Use caution to prevent damage to the refractory and hot surface igniter Check baffles and frame runners along front and back edges of heat exchanger Remove and clean if necessary Remove soot from heat exchanger with a stiff bristle brush Use a vacuum to remove loose soot from surfaces and inner chamber The heat exchanger can be removed by sliding towards the front of the unit Once the heat exchanger is removed from the unit a garden hose can be used to wash the tubes to ensure that all soot is removed from the heat exchanger surfaces Note Do not wet the unit s refractory Ensure that all burner ports are cleaned to remove any soot See Burner Removal and Cleaning page 40 Carefully reinstall the heat exchanger baffles and frame runners if removed from the unit Note Make sure frame runners seal securely where they contact the front and rear compartment refractory 10 Carefully reinstall inner jacket panels burners manifolds wires and hoses Use new gasket material to ensure a proper air seal 11 12 13 Reassemble all gas and water piping Test for gas leaks Reassemble outer jacket panels Cycle unit and check for proper operation Electrical This unit u
84. outlet and there should be a minimum distance between the cold water feed and the system purge valve 1 Close all drain cocks and air vents 2 Open the makeup water valve and slowly fill the system 3 Ifa makeup water pump is employed adjust the pressure to provide a minimum of 12 psi at the highest point in the system If a pressure regulator 5 also installed in the line it should be adjusted to the same pressure 4 Close all valves Purge one circuit at a time as follows A Open one circuit drain valve and let the water drain for at least five minutes Ensure that there are no air bubbles visible in the water stream before closing the drain valve B Repeat this procedure for each circuit 5 Open all valves after all circuits have been purged Make sure there are no system leaks N CAUTION Do not use petroleum based stop leak products All system leaks must be repaired The constant addition of make up water can cause damage to the boiler heat exchanger due to scale accumulation Scale reduces flow and heat transfer causing overheating of the heat exchanger 6 Run the system circulating pump for a minimum of 30 minutes with the boiler turned off 7 Open all strainers in the system and check for debris 27 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION OPERATION onines FOR YOUR SAFETY READ 8 Recheck all air vents as described in step 4 BEFORE OPERATING 9 Inspect the liquid le
85. phone 14 Verify system pressure with the boiler pressure gauge before beginning regular operation 15 Within three days of startup recheck and bleed all air vents and the expansion tank using these instructions Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department C Use only your hand to turn the gas control lever Never use WATER TREATMENT tools If the lever will not turn by hand don t try to repair it In hard water areas water treatment should be used to reduce call a qualified service technician Force or attempted repair the introduction of minerals to the system Minerals in the may result in a fire or explosion water can collect in the heat exchanger tubes and cause noise D Do not use this boiler if any part has been under water on operation Excessive build up of minerals in the heat Immediately call a qualified service technician to replace exchanger can cause a non warrantable failure the boiler 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 Lighting Instructions 1 STOP Read the safety information 2 Set the temperature control to the desired settings see Setting Temperature Control page 29 3 Loosen the knurled knob at the bottom of the control panel cover see Figure 31 4 Grasp the bottom of the control panel cover and pull out and down 5
86. proper operation of the outdoor vent system Do not install in locations where rain from building runoff drains will spill onto the unit TABLE D Outdoor Vent Kits Kit without Pump Cover ODK3014 ODK3015 ODK3015 ODK3043 ODK3044 ODK3044 ODK3045 ODK3045 These kits include an outdoor vent cap air inlet hood s and gasket Kit w Pump Input Btu hr Cover ODK3023 ODK3024 ODK3024 ODK3046 ODK3047 ODK3047 ODK3048 ODK3048 495 000 645 000 745 000 985 000 1 255 000 1 435 000 1 795 000 2 065 000 15 Installation and Service Manual Flue gas condensate can freeze on exterior walls or on the vent cap Frozen condensate on the vent cap can result in a blocked flue condition Some discoloration to exterior building or unit surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate The Outdoor Vent Kit The optional outdoor vent kit is available from the appliance manufacturer The outdoor kit part numbers are listed by unit size See TABLE D for kit numbers You can install the outdoor vent cap and combustion air inlet panel s on the unit see Figures 15 and 16 Figure 15 Outdoor Vent Cap Installed on 495 000 1 435 000 Btu hr Models Figure 16 Outdoor Vent Cap Installed on 1 795 000 and 2 065 000 Btu hr Models Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued CONNECTING TO GAS SUPPLY
87. r ignition and flame characteristics manifold pressure to obtain actual net manifold pressure for normal operation A manometer or magnahelic gauge legible in 0 1 increments up to 10 inches w c is required to check and adjust the manifold pressure The regulator cover screw on the gas valve must be in place and tight for the unit to operate properly Remove screws that fasten the control panel access door and remove the door 19 Hydronic Heating Boilers and Domestic Water Heaters 5 12 If adjustment is necessary remove the regulator cover screw Continued on the gas valve Note If the gas valve under adjustment is located on a manifold assembly monitored by an igniter the unit may shut down and recycle when the regulator cover O screw is removed This is normal 5 13 Turn the regulator adjustment screw clockwise to raise the regulator gas pressure Turn the regulator adjustment screw M counterclockwise to lower the regulator gas pressure 14 Replace the regulator cover screw and make sure it is tight for proper operation PEE 15 Read the value on the manometer magnahelic and compare it ADJUSTMENT to the values in TABLE I UNDER CAP SCREW 16 Repeat this adjustment procedure for each gas valve as CHAMBER _ BARBED 5 necessary to adjust to the proper manifold gas pressure PRESSURE GAS VALVE
88. rease in the net free area to supply adequate combustion air for all units Combustion air requirements are based on the latest edition of the National Fuel Gas Code ANSI 7223 1 in Canada refer to CAN CGA B149 Installation Code Check all local code requirements for combustion air 12 1 Conventional Negative Draft Venting IMPORTANT Before installing a venting system follow all venting clearances and requirements found in the Venting General Information section page 10 Figure 14 Conventional Negative Draft Vertical Venting with Combustion Air Louvers This option uses Type B double wall flue outlet piping The blower brings in combustion air The buoyancy of the heated flue products cause them to rise up through the flue pipe The flue outlet terminates at the rooftop Negative Draft The negative draft in a conventional vent installation must be within the range of 0 02 to 0 08 inches w c to ensure proper operation Make all draft readings while the unit is in stable operation approximately 2 to 5 minutes Connect the flue vent directly to the flue outlet opening on the top of the unit No additional draft diverter or barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the specified range of 0 02 to 0 08 inches w c If the draft in a dedicated stack for a single unit installation exceeds the maximum specified draft you must install a barometric damper to co
89. res for domestic use 8 This unit must have an adequate supply of fresh air during operation for proper gas combustion and venting 9 Make sure all exhaust venting is properly installed and maintained Improper venting of this unit could lead to increased levels of carbon monoxide 10 Do not use this boiler if any part has been under water Immediately call a qualified service technician to replace the boiler 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 11 Do not alter this unit in any way Any change to this unit or its controls can be dangerous Installation and Service Manual PRODUCT IDENTIFICATION Front View HT HI Rear View Figure 1 Front and Rear View Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION This unit meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas fired units ANSI Z21 13 CSA 4 9 and ANSI Z21 10 3 CSA 4 3 LOCATING UNIT Maintain all clearances from combustible construction when locating unit See Clearances from Combustible Construction this page 2 Locate the unit so that if water connections should leak water damage will not occur When such locations cannot be avoided install a suitable drain pan that is well drained under the unit The pan must not
90. restrict combustion air flow The appliance manufacturer is not responsible for water damage in connection with this unit or any of its components 3 Install indoor units so that the ignition system components are protected from any water while operating or during service 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 1 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 6 You must install unit on a level non combustible floor 7 Do not install unit directly on carpet or other combustible material A concrete over wood floor is not considered non combustible Maintain required clearances from combustible surfaces If installing unit in an area with a combustible floor you must use a special combustible floor base See Base for Combustible Floors this page 8 For outdoor models you must install an optional vent kit Instructions for mounting the vent kit are included in the venting section Do not install outdoor models directly on the ground You must install the outdoor unit on a concrete brick block or other non combustible
91. rt of the water heater IMPORTANT When water 1 stored temperatures above 125 F 52 C a thermostatic mixing valve must be installed on the hot water outlet from the storage tank to supply lower temperature water and prevent the risk of a scald injury Note This water heater when set at a lower temperature setting is not capable of producing hot water of sufficient temperature for sanitizing purposes Location of Cold Water Supply Piping Connections 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 You must install the cold water supply piping 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 Figure 41 and typical installation drawings provided with the unit for correct piping Higher water temperatures reduce condensate formation Installation and Service Manual 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 unit 39 High Water Temperature Limit Control The unit is equipped with an adjustable setting auto reset high water temperature limit control The hot water heater temperature limit control has a maximum limit setti
92. s been corrected Diagnostic Status Indication The ignition module has an LED which indicates the status of the safety circuits remote Ignition Module Status indicating light is wired from the ignition module Status LED and mounted on the side diagnostic panel The flashing operation of this light indicates the diagnostic status of the ignition control module The status LED mounted on the ignition module flashes a code sequence from the Ignition Module to indicate the status of the ignition process See TABLE N for the flashing diagnostic status codes as signaled by the ignition module 34 Ignition and Control Timings Proven Pilot Hot Surface Ignition System F9 15 standard on models 495 000 through 2 065 000 Btu hr and 9 is optional on models 495 000 through 2 065 000 Btu hr with One Hot Surface Ignition Module Hot Surface Ignition Module Timings Nominal Prepurge 15 Seconds Hot Surface Igniter Heat up Time 25 35 seconds Main Burner Flame Establishing Period 4 Seconds Failure Response Time 0 8 Seconds at less than 0 5 pA flame current Flame Current 5 15 Time Delay Between Stages 1 amp 2 10 Seconds Post purge 30 Seconds Pump Delay Timing 30 Seconds after burner shutdown OPERATION AND DIAGNOSTIC LIGHTS The diagnostic control panel has up to 6 indicating and diagnostic lights to show all major steps of operation and control sensed malfunctions This panel is located on the left end of the unit
93. ses a transformer to supply a low voltage control circuit The voltage on the secondary side should be 24 to 28V AC when measured with a volt meter Larger models have a 7AMP circuit breaker provided on the secondary side of the transformer tripped circuit breaker indicates a short in the 24V AC controls that must be corrected 41 Installation and Service Manual Combustion and Ventilation Air Combustion Air Filter Models 985 000 2 065 000 Btu hr Only This unit has a standard air filter s located behind the combustion air inlet panel s This filter helps ensure clean air is used for the combustion process Check this filter every month and replace when it becomes dirty The filter size 15 12 x 16 x 1 30 5cm x 40 6cm x 2 5 You can find this commercially available filter at any home center or HVAC supply store To install filter see Combustion Air Filter page 8 Air Flow Check frequently to be sure the flow of combustion and ventilation air to the unit is not obstructed Combustion Air Fan These units use a fan assisted combustion process These units have one fan to supply combustion air to the burners Fan Cleaning Check each combustion air fan every six months Clean fan as required when installed in dusty or dirty location Oiling 15 not required Combustion Air Fan Adjustment The combustion air fan is factory preset and should not need adjustment in most cases Follow the steps below to ad
94. sted from the unit END OF SEQUENCE 38 Set point for the high fire on the electronic temperature control is satisfied 39 Power to all valves is turned OFF on F9 systems and power to the high fire gas valves is turned OFF on M9 systems 40 The water temperature continues to rise and the set point for low fire is satisfied M9 41 Power to the low fire gas valves is turned OFF M9 42 The combustion air fan runs for a 30 second post purge timing and turns OFF 43 The appliance is now in a Standby Mode waiting for the next call for heat GLOSSARY Power Supply AC120VAC 60Hz 120VAC 60Hz 1PH power connects to black line and white neutral wires located within an electrical wiring box located on the left side of the unit A green chassis grounding wire is also provided for connection to earth ground ON OFF Rocker Switch The black line voltage wire runs directly to a single pole single throw On Off rocker switch located behind the front cover accessible by a thumb screw Turning ON the rocker switch delivers line voltage to the low voltage transformer and ignition module Note The On Off switch does not provide for disconnection of power being supplied to any remotely connected devices that may be connected to the unit 1 e pumps louvers power Installation and Service Manual venters etc As such it may be necessary to locate and turn off power to these items before attempting to service the unit
95. stion chamber The pump then turns off to prevent the heat in the water from going back into the combustion chamber and up the flue Idle Electronic Thermostat Function After completion of the post purge cycle the unit will go into an idle state whereby the electronic thermostat continuously monitors the water temperature until the water temperature drops to levels that require additional heat SCHEMATIC DIAGRAM MODELS 495 000 745 000 BTU HR YO NOILdO HO NOlLdO lt i DADOS oL H91IMS SNIAO3d 4 a 19 H 4 ors ES gt i OM TE Ut MB i J 2250 8 5 gt i Rove woo Avz 479 IN H G pos yg o POs Wavy 2VAVZ ON un aincow Ex TWNOILdO 5 4 H a HOLIMS 1531 1 39NVHO O s31volaNI 139440 yiinauadaia LNIOdLIS AVHO AD INId d 29 angaia 321146 ana NMOUS 4a 3 Idifd Hd 1 MOTHBA AJ2V18 1NIOd
96. temperature controller can measure up to three different sensor inputs depending upon how the unit is set up They are as follows l 2 Multi Purpose Temperature Sensor Inlet Water Temperature Sensor 3 Outside Air Temperature Sensor Inlet Water Temperature Sensor This sensor measures the inlet water temperature coming into the unit Multi Purpose Temperature Sensor Depending upon how your unit is set up this sensor can be used as a system sensor or a tank sensor Outdoor Air Temperature Sensor This sensor is only available on boiler units with an outdoor air reset option This allows you to tie boiler operation to the outdoor air temperature As outside temperatures drop the control will increase the temperature setting of the boiler As outdoor temperatures rise the control will decrease the temperature to the selected set point of the boiler You can set the control to shut the boiler off when a desired outdoor air temperature level is reached SP MAX SETPOINT RATIO 1 5 1 0 RATIO 0 5 SETPOINT lt TEMP 0 A MAX Figure 37 Outdoor Air Reset Chart Example 32 Boiler Application Standard boiler units are shipped with two sensors the inlet water temperature sensor and the multi purpose temperature sensor The multi purpose sensor should be used as a system sensor Boilers with the outdoor air reset option also have an outside air temperature sensor Water Heater Appl
97. th the type of gas indicated on the rating plate 2 Ifyou smell gas shut off gas supply do not try to light any appliance do not touch any electrical switch do not use any phone in your building immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions if you cannot reach your gas supplier call the fire department Hydronic Heating Boilers and Domestic Water Heaters 3 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 Follow all clearances from combustibles contained in this manual 4 Never cover your unit 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 5 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 6 Appliance surfaces become hot during operation Be careful not to touch hot surfaces Keep all adults children and animals away from an operating hot unit Severe burns can occur 7 You must take adequate care to prevent scald injury when storing water at elevated temperatu
98. the electrical wiring box In addition to providing a means to externally stage fire the unit these terminals also provide for remote shutdown and override by routing through dry contacts from external devices Connection of the external dry contacts to these terminals requires the removal of one or more factory installed jumpers located on the terminal strip Safety Device Terminals The safety device terminals ensure that no power can be delivered to the ignition module unless factory field installed safety devices such as flow switches and gas pressure switches are closed These safety device terminals are located below the EMS Sequencer Remote Aquastat terminals located within the electrical wiring box Two types of connections are offered Continuous terminals provide for connection of safety devices that are desired to be constantly monitored Intermittent terminals are provided for devices that are only monitored during a call for heat cycle Connection to either of these terminals requires the removal of a factory installed jumper located on the terminal strip Hydronic Heating Boilers and Domestic Water Heaters Electronic Temperature Controller Operator A 2 stage electronic temperature controller is provided on the unit and it serves to maintain a user selectable temperature set point Ultimately the temperature controller delivers 24 to the ignition module and pressure switch when it senses heat mode is desired It a
99. the outer jacket at the burners or in the areas between the fins on the copper heat exchanger indicates a need for cleaning The following cleaning procedures must only be performed by a qualified serviceman or installer Proper service is required to maintain safe operation Properly installed and adjusted units seldom need flue cleaning IMPORTANT gaskets on disassembled componenis must be replaced with new gaskets on reassembly Gasket kits are available from your distributor long shutdown periods or at least every six months Burner viewports are located on the right and left sides of the unit Normal Flame Yellow Tips Yellow Flames Lifting Flames Figure 43 Flame Pattern Illustration WARNING The areas around the burner viewports are hot Direct contact with unit could result in burns Normal Flame A normal flame is blue with slight yellow tips has a well defined inner cone and displays no lifting flames Yellow Tips The usual causes for yellow tips on the burner flame are burner air flow blockage or partial obstruction Yellow Flames The usual causes for yellow flames are primary air flow blockage to the burner s or excessive gas input Correct this condition immediately 40 Burner Removal and Cleaning 1 Turn off main power to unit Turn off main manual gas shutoff to unit 2 3 Remove the front outer jacket panels 4 Disconnect ma
100. the relay allowing the control relay to cycle the pump on each call for heat The field installed boiler pump using the optional factory supplied pump control system must not exceed 10 AMPS at 120VAC As shipped from the factory the optional control system is set to cycle the boiler pump on at each call for heat before the burners fire and run the pump for a 30 second period after the thermostat is satisfied This will remove any residual heat from the combustion chamber before turning the pump off See Wiring Diagrams page 47 Pump Installation and Maintenance For installation and maintenance information on the circulator pump refer to pump manufacturers instructions included in the instruction package Primary Secondary Boiler Piping Boiler installations with a primary secondary piping system as shown in Figure 26 are recommended This type of system uses a dedicated pump to supply flow to the boiler only This secondary pump is sized based on desired boiler flow rate boiler head loss and head loss in the secondary system piping only A properly sized system pump provides adequate flow to carry the heated boiler water to radiation air over coils etc The points of connection to the primary system should be a maximum of 12 or 4 pipe diameters apart to ensure connection at a point of zero pressure drop in the primary system Multiple boilers may also be installed with a primary secondary manifold system as shown in Figure 27 The
101. 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 temperature range operator is recommended to control the boiler operation based on the lower system temperature See Terminal Strip Connection Options starting on page 22 Radiant Floor and Snow Melt Heating Systems This type of heating boiler application operates in a low temperature range which requires a boiler bypass as described under Low Temperature Bypass Requirements A non metallic rubber or plastic tubing installed in a radiant in floor system must have an oxygen barrier to prevent oxygen from entering the system through the walls of the installed tubing Excessive oxygen absorption into the system will result in an accelerated rate of corrosion causing a sludge buildup This excessive corrosion will also damage the boiler and system components 25 Hydronic Heating Boilers and Domestic Water Heaters INSTALLATION Continued Sludge formed as the result of excessive oxygen in the system can restrict water flow resulting in a premature boiler failure Any boiler damage due to excessive oxygenation 1 non warrantable MAKE UP WATER 2 EXPANSION TANK TO SYSTEM SECONDARY BOILER PUMP AIR SEPARATOR 1 SS BYPASS FROM
102. tion of CAN CGA B149 Installation Code for Gas Burning Appliances and Equipment Masonry Chimney Installations A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems Exterior masonry chimneys with one or more sides exposed to cold outdoor temperatures are more likely to have venting problems The temperature of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft This will result in condensing of flue products damage to the masonry flue tile insufficient draft and possible spillage of flue products into an occupied living space Carefully inspect all chimney systems before installation Inspection of a Masonry Chimney A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products A clay tile lined chimney must be structurally sound straight and free of misaligned tile gaps between liner sections missing sections of liner or any signs of condensate drainage at the breeching or clean out If there is any doubt about the condition of a masonry chimney it must be relined with a properly sized and approved chimney liner system An unlined masonry chimney must not be used to vent flue products from this high efficiency unit
103. tions for gas leaks before placing unit in operation Gas Piping To safely operate this unit you must properly size the gas supply piping See TABLES F G amp H for piping and fitting requirements Gas pipe size may be larger than heater connection The gas connection for models 495 000 to 745 000 Btu hr is 1 1 4 NPT and on models 985 000 to 2 065 000 Btu hr the gas connection to these units 1 2 For ease of service install a union Install a manual main gas shutoff valve outside of the unit gas connection within six feet of the unit in accordance with the requirements of the National Fuel Gas Code ANSI Z223 1 You must provide a sediment trap drip leg in the inlet of the gas connection to the unit FRONT VIEW GROUND JOINT MANUAL MAIN SHUTOFF VALVE GAS INLET P SEDIMENT TRAP DRIP LEG ELECTRICAL JUNCTION BOX CONTROL WATER INLET ACCESS INSPECTION PLUGS WATER OUTLET Figure 17 495 000 745 000 Btu hr Gas Line Connection Example GROUND MANUAL MAIN SHUT USE WRENCH TO HOLD PIPING Figure 18 985 000 2 065 000 Btu hr Gas Line Connection Example IMPORTANT Do not block access to the electrical cover plate when installing the sediment trap The sediment trap must be a minimum of 12 inches from the appliance Installation and Service Manual The combination gas valves have an integral vent limiting device and does not require venting to atmosphere outside
104. u hr Models Combustion Air Options CAUTION Under no circumstances should the mechanical room ever be under a negative pressure Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc take away air from the unit 1 Outside Combustion Air No Ducts You can direct outside combustion air to this unit using either one or two permanent openings One Opening The opening must have a minimum free area of one square inch per 3000 Btu input 7cm per kW You must locate this opening within 12 30cm of the top of the enclosure Figure 6 Outside Combustion Air Single Opening Two Openings The combustion air opening must have a minimum free area of one square inch per 4000 Btu input 5 5cm per kW You must locate this opening within 12 30cm of the bottom of the enclosure The ventilation air opening must have a minimum free area of one square inch per 4000 Btu input 5 5cm per kW You must locate this opening within 12 30cm of the top of the enclosure Installation and Service Manual Figure 7 Outside Combustion Air Two Openings 2 Outside Combustion Air Using Ducts You can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room Each of the two openings must have a minimum free area of one square inch per 2000 Btu input 11cm per kW _
105. uns of the vent pipe 90 elbows reductions and restrictions No additional draft diverter or barometric damper is required on single unit installations with a dedicated stack and a negative draft maintained between 0 02 to 0 08 inches w c Common Venting Systems You can combine the flue with the vent from any other negative draft Category I appliance Using common venting for multiple negative draft appliances requires you to install a barometric damper with each unit This will regulate draft within the proper range You must size the common vent and connectors from multiple units per the venting tables for Type B double wall vents in the latest edition of the National Fuel Gas Code ANSI Z223 1 and or CAN CGA B149 Installation Code Common venting systems may be too large when an existing unit 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 Sealany unused opening in the common venting system 2 Visually inspect the venting system for proper size and horizontal pitch Make sure there is no blockage or restriction leakage corrosion and other unsafe conditions 3 Ifpossible close all building doors and windows Close all doors between the space in which the appliances remaining connected to
106. ure that inlet pressure is within the specified range See Connecting To Gas Supply page 16 for minimum and maximum gas supply pressures TABLE H Multiple Unit Installations Gas Supply Pipe Sizing Nominal Iron Pipe Size Inches A Length of Pipe In Straight Feet 100 125 150 175 20 369 BECUN ECC EH Maximum capacity of pipe thousands of BTU s per hour for gas pressures of 14 Inches Water Column 0 5 PSIG or less and a total system pressure drop of 0 5 Inch Water Column Based on NAT GAS 1025 BTU s per Cubic Foot of Gas and 0 60 Specific Gravity Installation and Service Manual 9 If gas pressure is out of range contact your gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control 10 If gas supply pressure is within normal range remove the gas manometer and replace the pressure tap fittings in the gas control as indicated in the following steps 11 Turn the power switch to the OFF position uat 12 Turn gas valve knob to the OFF position 13 Shut off gas supply at the manual gas cock in the gas piping to the unit If fuel supply is L P gas shut off gas supply at the tank 1 8 HEX INLET PRESSURE TAP 14 Remove the manometer and related fittings from the inlet side of the gas valve repla
107. vel in the expansion tank The system must WARNING If you do not follow these be full and under normal operating pressure to ensure proper instructions exactly a fire or explosion may water level in the expansion tank Ensure that diaphragm type result causing property damage personal injury expansion tanks are properly charged and not water logged or loss of life 10 Start the boiler according to the operating instructions in this manual Operate the system including the pump boiler and This appliance does not have pilot It is equipped with an radiation units for one hour ignition device which automatically lights the burner Do not try to light the burner 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 11 Recheck the water level in the expansion tank If it exceeds half the tank volume open the tank to reduce the water level Recheck pressure charge on diaphragm type tanks 12 Shut down the entire system and vent all radiation units and high points in the system 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 13 Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris Reopen the water makeup valve Immediately call your gas supplier from a neighbors
108. ves and debris to avoid blocking the flue 10 OR LESS 2 MIN 3 MIN RIDGE CHIMNEY et Figure 10 Vent Termination from Peaked Roof 10 or Less From Ridge IMPORTANT Vent terminations are not shown in Figures 10 11 12 and 13 Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer RIDGE CHIMNEY Figure 11 Vent Termination from Peaked Roof More Than 10 From Ridge Installation and Service Manual 10 ORLE 10 ORLESS i i 2MIN 2 MIN 42 LA Li CHIMNEY WALL OR CHIMNEY PARAPET Figure 12 Vent Termination from Flat Roof 10 or Less from Parapet Wall I 10 OR LESS i i NOTE NO HEIGHT 4 ABOVE PARAPET 4 REQUIRED WHEN DISTANCE FROM WALLS OR PARAPET IS MORE THAN 10 LA CHIMNEY WALL OR PARAPET Figure 13 Vent Termination from Flat Roof More Than 10 from Parapet Wall CAUTION Units which are shut down will not operate may experience freezing due to convective air flow in the flue pipe through the air inlet or from negative pressure in the mechanical room In cold climates operate pump continuously to help prevent freezing of boiler water Provide proper freeze protection See Fr

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