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H Series Manual

1. m 7 757 tre Jon Ad OX 0X0 gt DXX d OO 9 9 o m F 525055555555 33 osorno P N NO Pin Combustion chamber H HW HP DHW coil double wall with gasket 2400 234 Gasket flameholder burner blower Gasket DHW coil 1 036 6 Flameholder assembly with gaskets 2400 040 Gauge pressure temperature 2400 114 7 Gas balance line 2400 026 Pressure relief valve 30 PSIG 2400 112 2400 028 Thermostatic union assembly H M2 2400 030 31 32 33 34 5 3 7 Transfer tank less coil 2400 034 Gasket ignitor gasket kit Transfer tank less coil Stainless Steel 2400 238 Gasket blower intake gasket kit 8 Transfer tank amp assem single wall 2400 240 Transfer tank amp coil assem Stainless 2400 242 Blower intake duct assembly 1 236 Fitting boiler discharge 1 164 Tube boiler discharge 1 278 Jacket front removable 2400 256 Air duct hose 1 458 Jacket lower front HW M2 only 2400 258 1 1 1 1 1 1 1 1 Jacket top 2400 260 Pipe 3 flue AL29 4C S S 2 4 2400 342 7 74 i Boiler control 2400 224 Pipe 5 air Stainless Steel 2 2400 336 Elbow Set 3 amp 5 AL29 4C S S 2400 330 Vent terminal horizontal venting only 2400 276 49a Carton B Direct Vent Standard 2400 326 49b Carton B Direct Vent Alternate 2400 328 G
2. TEMPERING TANK TO OTHER HEATMAKERS NOTE WIRE AQUASTAT OR CONTROL CONTACTS IN SERIES WITH PARALLEL WIRED ZONE CONTROL END SWITCHES OR PUMP RELAY CONTACTS ELECTRICAL CONNECTIONS CONTROL VOLTAGE T T LINE VOLTAGE 120 VAC ELECTRICAL CONNECTIONS All electrical wiring must conform to local codes and or the 1 National Electric Code or 2 Canadian Electrical Code Part 1 The unit must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirement with the 1 National Electrical Code ANSI NFPA NO 70 latest edition or the CSA Standard C22 1 Canadian Electrical Code Part 1 Single pole switches including those of safety controls and protective devices must not be wired in a grounded line All electrical connections are made in the field wiring box which is located on the right side of the unit NOTE Allinternal electric components have been pre wired No attempt should be made to connect electric wires to any other location except the wiring box as described below 1 Main power Connect a 15 amp fused 120 volt supply to the main power switch illustrated hot leg is connected directly to switch Neutral leg to white wire Ground wire can be connectd to the grounding screw in the box or on the switch 2 For single zone installations connect room thermostat T T wires to the red and white red wires Connect circulator 120 vol
3. 6 BOILER FEED WATER PREFERRED SYSTEM SUPPLY AIR VENT PIPING B IEE amp BOI FOR SYSTEM PURGING OPTIONAL POSITION AUTO FILL CONTRACTOR SUPPLIED VALVE 12 PSI MIN BOILER DRAIN Figure 15 Hydronic Piping with Indirect Sree Y ORAIN 1 2 BY PASS FOR RESET CONTROL OR HIGH VOLUME SYSTEMS SYSTEM 5 SYSTEM SUPPL Y i THERMOSTAT Indirect UNION ASSY Domestic SUPPLIED ZONE RELAY ORY CONTACT OR ZONE ENO SWITCHES TANK AQUASTAT H OR HP T T CONNECT IONS H OR HP T T RAB32A CONNECT I ONS OR EQUIV 120 VAC 2 SUPPLY e 6 RELAY OR EQUIV 120 T TO DHW SUPPL Y CIRCULATOR TO SYST CIRCULATOR Figure 16 Hydronic Piping H P Models SYSTEM SUPPLY PIPING AIR PURGER DIAPHRAGM EXPANSION TANK GJE amp BOILER DRAIN FOR SYSTEM PURGING ROO BALL vave Sm ve 9 O 49 BOILER d FEED WATER B n T BACKFLOW CA OPTIONAL POSITION PR VENTER AUTO FILL Iy CONTRACTOR SUPPLIED 12 cs SYSTEM CIRCULATOR ae OPTIONAL BALL VALVE 4 BYPASS ON SYSTEMS w pa LARGE WATER VOLUME d ER EHAN MAINS Buy PEN UNION SUPPLIED BOILER DRAIN AUTO WIRE TO ZONEVALVE BACKFLOW FILL END SWITCH OR RELAY PREVENTER VLVE CONTACTS BOILER FEED WATER DIAPHRAGM EXPANSION TANK THERMO 5 STATIC S I BUFFER ED
4. fan max capacity from B vent tables See page 5 for vent table excerpts National Fuel Gas Code ANSI 2223 1 NFPA 54 CGA Refer to page 4 for Alternate Venting Method Relay Enclosure Relay ELECTRICAL CONNECTIONS If the installation is new wire the unit per the applicable wiring diagram for line voltage 120VAC and control 24VAC wiring connections Do not connect an external voltage source to the HP 24 volt T T wires Install an isolation relay if required per diagram Fig 20 Where a HP M2 Series in a Paloma Pak Hytech retrofit is connected to a single zone system the original transformer relay control pak should be removed all field wiring connected to the unit electrical connection junction box on the right side of the unit The 120VAC power input 120VAC system circulator output and thermostat should be wired as outlined in figure 18 Be sure to set the thermostat heat anticipator to 0 9 amp for single zone connection If a retrofit installation includes multiple zones any one of the options provided in this manual may be used or the existing transformer relay control pak may be utilized and re wired according to the diagram below Where two wire or three wire zone valves are used this is the preferred wiring method on retrofits HP WIRING BOX 02 2 lt p O NUN m PALOMA PAK HYTECH TRANSFORMER RELAY CONTROL PAK SYSTEM Transformer PUMP S
5. BOILER CONTROL BY SWITCHING POWER OFF FOR 15 SECONDS AND THEN ON AGAIN WITH A CALL FOR HEAT HOT WATER AFTER APPROX TWO SECONDS GREEN LIGHT COMES ON AND BLOWER STARTS YES NO AFTER FIVE MINUTES RED AFTER 45 SECONDS RED PURGE LIGHT FLASHES PURGE LIGHT FLASHES YES SHUT OFF POWER DISCONNECT WIRES TO STACK SWITCH TURN ON POWER AFTER TWO SEC ONDS BLOWER STARTS STACK SWITCH CONTACTS NOT CLOSING CHECK FOR FLUE BLOCKAGE SNOW CYCLE BOILER MANY TIMES TO TRY TO CREATE A MALFUNCTION LEAVES ETC AGAINST VENT TERMINAL BLOCKAGE EXISTS NO BLOCKAGE RECONNECT STACK SWITCH WIRES CLEAR BLOCKAGE AND RECYCLE BOILER CHECK STACK SWITCH PAGE 30 CHECK BLOWER PAGE 29 CHECK STACK SWITCH PAGE 30 28 CHECKING BLOWER YOU MUST COMPLETE PAGE 28 FIRST RESET BOILER CONTROL BY SWITCHING BOILER SWITCH OFF FOR 15 SECS THEN BACK ON WITH A CALL FOR HEAT HOT WATER AFTER TWO SECONDS DOES GREEN POWER LIGHT COMES ON YES NO REFER TO GENERAL TROUBLE SHOOTING SECTION PAGE 22 BLOWER STARTS CONNECT MANOMETER TO PRESSURE TAP CHECK FOR VOLTAGE 120 VAC ON GAS VALVE PRESSURE DURING BLOWER AT BLOWER WIRE CONNECTOR OPERATION WITHOUT GAS FLOW VALVE WITHIN 5 MINS AFTER GREEN FLAME LIGHT NOT LIT IS 2 5 IN W C LIGHT YES 0 VOLTS 120 VAC BLOWER O K CHECK FOR FLUE OBSTRUCTIONS CHECK TT LIMITS REPLACE BLOWER STACK SWITCH OK OPEN OBSTRUCTED CLEAR
6. Catagory I Appliance Wall Flue Connector Serving a Single Category Appliance Vent and Connector Diameter A amp D Type B Double Connector Diameter to be used with chimney areas within the size limits at bottom Height Lateral 5 6 Height Lateral Appliance Rating in MBH Fan Assist Fan Assist Cw m pe ue oe D ne 0 59 151 85 249 126 373 2 85 156 123 231 4 55 1 3j 6 0 58 164 83 273 123 412 5 77 102 107 168 gt 0 57 174 82 293 120 444 5 76 1i1 105 185 710197 102 0 56 190 80 325 116 499 2 157 136 80 225 115 337 5 75 128 102 216 10 95 116 128 201 0 54 200 78 346 114 537 Minimum Internal Area of Chimney 5 73 140 100 239 e 10 93 129 125 23 0 53 211 76 372 110 584 Square inches 5 72 157 98 271 NOTE DERATE FAN MAX CAPACITY IN TABLE 2 BY 20 10 91 144 122 255 WHEN SIZING FLEXIBLE METAL FLUELINERS 45 5 3 NOTE TABLES APPLY TO MODEL H W M2 130 CATAGORY 1 APPLIANCES ONLY Figure 5 Tile Lined Chimney Masonry Chimney Serving a Single Catagory Appliance See Table 2 INSTALLING STAINLESS STEEL HORIZONTAL VERTICAL VENTING NON CONCENTRIC Stainless Steel Special Gas Vent listed to U L Sta
7. Outside air is drawn through the air orifice located in the air induction system and mixed with the gas drawn in downstream of the air orifice The gas is metered through an orifice located in the gas orifice union All the air required for complete combustion comes into the system in this manner Adjusting the input is limited to changing the gas orifice to achieve the proper input The air orifice cannot be altered and the gas valve pressure setting cannot be changed Before changing the gas orifice to correct input service representatives should make the following checks 1 The pressure on the inlet side of the gas valve is between 4 and 13 water column 2 The pressure on the outlet side manifold of the gas valve and T above air orifice is between negative 05 and negative 35 water column with the unit operating To increase the input install larger diameter gas orifice Each size will change the input approximately 5 C F H Once the correctinputhas been achieved the burner should be checked with an oxygen O2 or carbon dioxide CO2 gas analyzer The unit should be in operation 5 minutes before adjusting input or taking CO2 or O2 readings This time will allow for pre heating of the intake air Insert the probe of the O2 or CO2 tester at least 6 into the vent through the vent terminal If COz is being measured the readings should be between 8 0 and 8 5 for natural gas and 9 0 and 9 8 for propane If O2 is bei
8. VALVE FLAME SEE PAGE 31 2 NO CALL FOR HEAT REPLACE TRANSFORMER HOT WATER AND RUN BOILER THROUGH A FEW CYCLES POOR SWITCH CONTACT ON RELAYS ZONE VALVES OR THERMOSTATS CAN CAUSE A FLASHING GREEN LIGHT ON JOHNSON CONTROLS G856DBG 5201 26 TESTING LIMIT CIRCUIT YOU MUST COMPLETE PAGE 26 FIRST VIOLET 1 SWITCH BOILER ON 2 CHECK FOR 24V AT PIN 6 CONTROL NOTE PLUG ORIENTATION MAY DIFFER FROM DIAGRAM NO UNPLUG CN6 FROM YES BOILER CONTROL AND TEST AS INDICATED ALL LIMITS OK CHECK FOR CONTINUITY ACROSS BOILER SHOULD CYCLE PROPERLY PRESSURE SWITCH CONTACTS ON A CALL FOR HEAT OR HOT WATER BOILER PRESSURE ABOVE 12 PSI CONTINUITY NO CONTINUITY CHECK FOR CONTINUITY ACROSS REPLACE YES SAFETY LIMIT CONTACTS PRESSURE PUMP OPERATES SWITCH CONTINUITY NO CONTINUITY CHECK FOR CONTINUITY ACROSS OPERATING CONTROL LIMITS CHECK PUMP PAGE 32 REPLACE SAFETY LIMIT CONTINUITY NO CONTINUITY LIMIT CIRCUIT APPEARS OK RECYCLE BOILER A FEW TIMES AFTER REPLACE OPERATING PLUGGING IN CONTROL PLUG CONTROL NOTE AFTER COMPLETEING LIMIT CIRCUIT TESTING RECYCLE BOILER A FEW TIMES IF BOILER DOES NOT RECYCLE CONNECT A JUMPER TEMPORARILY BETWEEN THE RED WIRES IF BOILER STARTS REMOVE JUMPER AND TEMPORARILY JUMP EACH SAFETY CONTROL UNTIL THE DEFECTIVE CONTROL IS LOCATED NEVER LEAVE A SAFETY CONTROL JUMPED 27 RED PURGE LIGHT FLASHING YOU MUST COMPLETE PAGE 26 FIRST RESET
9. VENT 02SVEPXX030 SEE FIGURE 9 Apply 1 4 bead of Silicone sealer GE 108 or Novagard 400 to the 3 inch 3 flue outlet of the Heatmaker approximately one inch 1 from the end Slide pipe over the Heatmaker flue outlet and push down to stop do not force pipe beyond stop Apply another bead of silicone around this joint and smooth out SECURING SPECIAL GAS VENT Attach Heatmaker part number 2400 372 to 5 collar on appliance or end of five inch 5 combustion air duct and tighten large clamp Form tabs on part number 2400 372 onto Special Gas Vent pipe and secure tabs with the 3 clamp After the clamp has been tightened fold the end of the tabs down over the clamp DO NOT use screws in any portion of the 3 Special Gas Vent For vertical venting see instructions in the Vertical Vent Kit pertaining to use of raincaps and condensate drip tee s Part 2400 372 COMBUSTION FOL TABS DOWN AFTER AIR DUCT TIGHTENING CLAMP VENT TERMINAL PART NO 2400 277 OPTIONAL PART NO 2400 350 FOLD TABS DOWN AFTER TIGHTENING CLAMP PART NO 2400 352 OR Z VENT O2SVEPXXOSO ADAPTER INCLUDED WITH 2400 350 Figure 8 amp 9 NEN rM lt THE DIRECT VENT KITS PART NUMBERS 2400 326 or 2400 328 When using the Direct Vent Kit the Heatmaker is a sealed combustion unit All of its air is drawn in from the outside thro
10. a fire or explosion Do not use this appliance if any part has been under water Immediately call a qualified service technician 10 inspect the appliance and to replace any part of the control system and any gas control which has been under water OPERATING INSTRUCTIONS STOP Read the safety information above on this label Make sure system has been properly filled with water and thoroughly bled of air set the thermostat to lowest setting Turn off all electric power to the appliance This appliance is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand GAS CONTROL KNOB SHOWN IN ON POSITION Remove control access panel Push in gas control clockwise x to OFF NOTE Knob cannot be turned to OFF unless knob is pushed in slightly Do not force knob slightly and turn Wait five 5 minutes to clear out any gas Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If you don t smell gas go to the next step Turn gas control knob counterclockwise C to ON Replace control access panel Turn on all electric power to the appliance Set thermostat to desired setting If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier TO TURN OFF GAS TO APPLIANCE 1 Set th
11. damaged LOCATING THE HEATMAKER The Heatmaker design is certified by the AGA and CGA for installation on combustible flooring in alcoves basements closets or utility rooms It must not be installed on carpeting IF INSTALLED IN A FINISHED AREA PROVISION SHOULD BEMADE FORDRAINAGE OF ANY ACCIDENTAL SPILLAGE ORLEAKAGE The location for the unit should be chosen with regard to venting dimensions convenient access to piping ventilation of operating components and accessibility for service and cleaning The boiler shall be installed so that the gas ignition system components are protected from water dripping spraying rain etc during appliance operation or service circulator replacement control replacement etc CLEARANCES The following dimensions and criteria should be followed when choosing the location for the unit Vent Direct Vent Chimney Connect Alternate 3 Minimum clearance from combustible construction to meet AGA CGA requirements Recommended clearance for accessibility and venting Z gt O0OZ2 50 P vC gt p O O r K KK 70 O0Z 1zm LOCATING UNIT WITH RESPECT TO VENTILATION While the Heatmaker when direct vented requires no interior air for combustion adequate airflow around the unit and to the enclosed room must be provided for proper cooling of elec trical components CHIMNEY VENTING USA Only Model H W M2 130 is a category l boiler and may be vented i
12. off disconnect switch before changing TDR DHW COIL REPLACEMENT Shut off boiler feed water domestic water supply to coil and electrical power to boiler Valve off system and drain the water from the tank Disconnect boiler discharge union from coil fitting remove relief valve discharge piping and cut the horizontal hot and cold water pipes about 6 inches away from plate Disconnect and remove low limit sensor Remove the Six coil retaining nuts and take out coil Remove the old coil gasket and clean gasket sealing surface on tank Remove the pressure relief valve from old coil and install in new coil assembly with thread sealing tape or pipe joint compound Install new gasket in recess on tank if it doesn t fit snugly in tank recess remove it and stretch it Place new coil in tank and Screw on coil retaining nuts Tighten nuts evenly to seat gasket properly Do not over tighten Make up boiler discharge union fill boiler and check around gasket for leaks If the coil plate is leak tight make up hot and cold water pipes with slip couplings and reassemble relief valve discharge piping Connect and reinstall low limit sensor Turn on domestic water supply and electrical power Bleed air from coil bleed petcock and recycle boiler Boiler fill pressure is 12 PSI minimum TANK REPLACEMENT The tank can be replaced by disconnecting the DHW coil as explained above and unbolting the lower pump flange bolts Access to the tank is possible by remov
13. orifice and connect the sampling tube of the analyzer to the tee Run boiler and check CO If there is any measurable cross contamination exists somewhere in the flue system If the boiler will not operate long enough to get a CO2 sample it is possible to check for cross contamination in another way Loosen the top clamp on the air duct coupling and remove the gas balance line from the Tee fitting Lift up the air induction elbow and twist it to the side so that air from the space around the boiler can be drawn into the air duct coupling do not disturb the air orifice in the coupling Cover the air induction elbow with your hand or plug it with a rag and restart the boiler If no short cycling occurs there is a leak in the 3 flue pipe which must be corrected Do not leave the boiler operating in this manner Reassemble the air duct after removing plug rag and connect the balance line and stack switch tubes Disassemble flue and fix leak LOCK OUTS Integrated Boiler Control Lock Outs Possible Causes a Cross Contamination Moisture in Combustion Chamber Gas Valve Malfunction Poor combustion Boiler control malfunction Control contact failure 1 Stack Switch 2 Operating Control Failure of air source Ignitor failure a If cross contamination is suspected see Cross Contamination and check for it One percent CO2 in the air duct can cause nuisance lockouts b Moisture in the combustion chamber will also cause
14. replace perform the same operations in reverse Push the sensing bulb as far into the fitting as possible before tightening sealing nut No more than 1 2 of sensing bulb should be visible after installation Fill the boiler and be sure to bleed the coil at the coil bleed petcock Turn on disconnect switch and check boiler operation OPERATING CONTROL The Operating Control maintains boiler discharge temperature between 170 210 F during the space heating cycle It has a fixed set point of 210 F HW M2 Series only and a differential of 40 F therefore its contacts open at 210 F and they reclose at 170 F If replacement is necessary shut off the 120 volt power and disconnect the wires to the sensor Valve off and drain 1 or 2 gallons of water from the boiler and remove sensor Install new sensor refill boiler and bleed coil at coil bleed petcock Check boiler operation after installation of new Operating Control The Operating Control on the H P M2 series has a fixed set point of 185 F Its contacts open at 185 F and they reclose at 160 F IGNITER The igniter is a glow bar type silicon carbide unit It is energized whenever there is a call for heat and the red IGNITER light on the boiler control is lit After the igniter is Switched off andthe boiler continues to run the igniterfunctions as a flame sensor for the boiler control If the ignitor fails and must be replaced always install a new igniter gasket with the replac
15. supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1 2 psig 3 5kPa boiler and its gas connection must be leak tested before placing the boiler in operation J Purge all air from gas lines K Note Heatmaker s are certified for 4 to 13 W C We find on L P the unit performs better when the low pressure regu lator is not set over 9 W C Use an appliance regulator maxitrol RV48 or equivalent if more than 3 lock up occurs in gas supply DOMESTIC WATER PIPING Figure 13 1 Connect hot water tempering valve 12 HOT port to hot water outlet from unit This valve should be mounted 3 to 6 below the outlet and set for 120 F mixed delivery temperature or as local codes dictate HEATMAKER RECOMMEND ANTI SCALD VALVE SUCH AS SPARCO OR DANFOSS 2 Connect gate or shutoff valve 13 to tempering valve 12 MIX port and cold water inlet 3 Install supplied flow restrictor 14 ahead of mix valve tee 4 Connect pressure relief valve 1 if required by codes maximum 150 PSI as close to the unit as possible No other valves or restrictions may be installed between the Heatmaker and the relief valve DO NOT USEATEMPERATURE PRESSURE RELIEF VALVE AS THIS IS NOT A STORAGE HOT WATER HEATER Model 60 is not recommended for larger hot water demands Warning Failure to install a hot wate
16. to which it is connected Figure 11 _ 9 VENT INTAKE AIR SCREEN H HP or HW with Separate Air Source ALTERNATE TO 1 3 ABOVE GAS CONNECTION TO HEATMAKER A The Heatmaker requires an inlet gas pressure of at least 4 W Candnogreaterthan 13 W C Check with yourlocal gas utility or supplier for availability of this pressure range B Referring to Table 4 size supply piping to minimize pres sure drop between meter or regulator and unit C Run gas supply line in accordance with all applicable codes IF UNIT IS INSTALLED ABOVE GAS SUPPLY RUN PIPIING UP TO A POINT ABOVE VENT CENTER LINE AND BACK DOWN TO UNIT THIS WILL PREVENT WATER FROM ENTERING GAS SUPPLY SHOULD A LEAK DEVELOP IN THE BOILER SECTION See Figure 12 D Locate and install manual shutoff valves in accordance with state and local requirements E Install drip leg ground joint union and drip cap to trap sediment and for test gauge access Figure 12 F Support all piping with proper hangers G All threaded joints should be coated with piping compound resistant to action of liquified petroleum gas whether LPG is used or not H The boiler and its individual shutoff valve must be discon nected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 1 2 psig 3 5kPa The boiler must be isolated from the gas
17. 4 x4 Electrical Junction Box MANUFACTURED HOME MOBILE HOME APPLIANCE INSTALLATION INSTRUCTIONS These appliances are design certified to conform to the requirements of ANS Z21 10 3 for installation in manuafactured homes mobile homes when installed in conformance with this manual supplement and the manual APPLIANCE MOUNTING Model HP Series appliances are provided with a wall mounting bracket Model H Series appliances are provided with mounting holes in the base Either lag bolts or through bolts must be used for secure attachment of the appliance to the structure Model HW Series appliances are attached to the structure by attaching angle brackets from the structure to the secured clearance brackets See Figure 22 Figure 22 sure SECURE CLEARANCE BRACKET AT THIS POINT ON EACH SECURE ANGLE BRACKET TO CLEARANCE BRACKET AT THIS POINT ON EACH SIDE CHECK TEST amp START UP FILLINGSYSTEM 1 Open all supply and return valves 2 Fill heating system to minimum operating pressure 12 psig 3 Open bleed pet cock and bleed air from boiler coil until a good stream of water comes out H P M2 series Item 8 on page 33 4 Purge all lines by opening vents or with flushing valves 5 Close gas valve 6 Turn on 120 volt power and listen for unit circulator to start Unit will cycle off on lockout 7 Open all vents again to discharge any additional air and close off after air is elimin
18. ES GAS VALVE CLICK CHECK WIRES TO GAS VALVE OK DOES BURNER IGNITE AND APPEAR TO RUN PROPERLY YES NUISANCE LOCKOUT CAUSED FLASHING CHECK IGNITER REPLACE CORRECT LITE CHECK COMBUSTION IGNITER OK INTEGRATED WIRING 50 200 OHMS BOILER NO CRACKS CONTROL P N 2400 224 YES NO CHECK FOR GAS FLOW IS REPLACE METER MOVING GAS IGNITER PRESSURE IS OK YES NO CHECK GAS AND AIR ORIFICE REPLACE GAS VALVE FOR PROPER SIZE INCORRECT CORRECT INSTALL CORRECT BOILER CYCLES THROUGH THREE CYCLES AFTER RESETTING AND VALVE FLAME LITE FLASHES ORIFICES REPLACE INTEGRATED BOILER CONTROL P N 2400 224 CHECKING PUMP WITH A CALL FOR HEAT RESET BOILER CONTROL BY SWITCHING OFF BOILER SWITCH FOR 15 SECS AND THEN ON AGAIN AFTER TWO SECONDS DOES GREEN POWER LIGHT COME ON YES NO REFER TO GENERAL TROUBLE SHOOTING SECTION PAGE 26 PUMP OPERATES YES AFTER FIVE MINUTES ARE ANY RED LIGHTS FLASHING 120 VOLTS AT PUMP PLUG N 24 VOLTS AT CONTROL YES NO CN6 PLUG PIN 7 YES PURGE SEE PAGE 28 LIMIT CIRCUIT OPEN YES NO VALVE FLAME SEE SEE PAGE 27 REPLACE NO CALL 2400 224 FOR HEAT PAGE 31 120 VOLTS AT PUMP MOTOR YES NO REPLACE CHECK PUMP WIRES TO CARTRIDGE PUMP 32 Ma OIL x ag X INDUCER x XFRM PRI IGN 120 vac goog CIRCULATOR 5 o d
19. Heatmaker H HP and HW Operating Installation TRIANCO amp Maintenance Instructions HEATMAKER THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH STATE AND LOCAL CODES BY A QUALIFIED INSTALLER To the Installer After installation these instructions must be given to the homeowner or left on or near the boiler To the Homeowner This booklet contains important information that will help you in maintaining and operating this boiler Please retain it for future reference HW M2 Series H M2 Series HP M2 Series HW M2 130 H M2 130 HP M2 130 HW M2 100 H M2 100 HP M2 100 HW M2 60 H M2 60 HP M2 60 Integrated Hydronic Heating and Domestic Hot Water Appliance For Natural or Propane Gas Field conversion only Hydronic Heating Only For Natural or Propane Gas Hydronic Heating Only For Natural or Propane Gas Wall Hung INSTALLATION SERVICE Introduction Cleaning Combustion Chamber Coil Schematic Diagram HW M2 Series Boiler Components Descriptions Schematic Diagram H P M2 Series Domestic Water Coil Replacement Unpacking Tank Replacement Venting Options Delayed Ignition Horizontal Vertical Venting Noisy Operation Direct Venting amp Air Source High Gas Consumption Gas amp Domestic Water Piping Insufficient Hot Water Hydronic Heat Piping Short Cycling Electrical Connections Cross Contamination HP Installation Lock Outs Modular Home Installation Sequence of Operation Check Test amp Start Up
20. Ignitor off 39 sec Gas valve energized 39 43 sec Quick Reference Trouble Shooter S9301A CONTROL MODULE NORMAL SEQUENCE FAILURE TO COMPLETE THIS CYCLE Control Funtion Verified Integrated boiler control S9301A 1 Internal Pump Starts 2 Low limit HW only operating control safety limit system pressure switch stack switch 3 Blower starts Igniter via S9301A Gas valve opens Igniter air amp gas source oroor zo Envent Confirmed Green POWER light on Note If internal pump is running unit may be in lockout Reset power switch Red PURGE light on Note If unit in purge mode without light stack switch is not proving air flow Red IGNITER light on Red PURGE light off Blower continues to run Red VALVE FLAME light on Ignitor monitors flame via flame rectification to ground Light Event Unconfirmed 1 No 120 VAC supply 2 Defective 24 VAC transformer 3 Defective S9301A module 1 Internal pump defective or air bound 2 Defective low limit operating control safety limit or differential presssure switch 3 Defective inducer blower Igniter does not heat up look for heat up at ignitor base 1 Stack switch does not confirm air flow 2 Gas valve has short Unit transfer to purge 12 15 secs after valve flame light is on and repeats sequence Action for Diagnosis 1 Read voltage between black amp white wires at back of 120 VAC pl
21. REMOVE REPLACE REPLACE BOILER REFER TO PAGE 27 OBSTRUCTION BLOWER CONTROL 2400 224 REFER TO PAGE 30 29 CHECKING STACK SWITCH YOU MUST COMPLETE PAGE 29 FIRST TURN OFF BOILER SWITCH 2 REMOVE BOTH TUBES FROM STACK SWITCH AND DISCONNECT ELECTRICAL WIRES CHECK FOR CONTINUITY ACROSS SWITCH TERMINALS CONTINUITY NO CONTINUITY 0 OHMS COOHMS 2 1 TUBES DISCONNECTED FROM STACK SWITCH U TUBE MANOMETER TURN ON BOILER TO OPERATE BLOWER MANOMETER INDICATES 1 5 W C OR GREATER RECONNECT STACK SWITCH TUBES AND CHECK FOR CONTINUITY BETWEEN CHECK FOR VENT OBSTRUCTIONS STACK SWITCH TERMINALS WITH BLOWER OPERATING CLEAR OBSTRUCTED CHECK BLOWER CLEAR OBSTRUCTIONS amp PAGE 29 RECONNECT TUBES amp ELECTRICAL WIRES TO CONTINUITY 0 OHMS NO CONTINUITY coOHMS STACK SWITCH OK STACK SWITCH START BOILER amp RUN THROUGH A FEW CYCLES REPLACE STACK SWITCH P N 2400 110 NOTE CHECK TUBES ON STACK SWITCH FOR PROPER CONNECTIONS 30 RED VALVE FLAME LIGHT FLASHING YOU MUST COMPLETE PAGE 26 FIRST ARE GAS VALVES AND GAS METER TURNED ON IS THERE GAS IN LP TANK LP UNITS YES NO RESET BOILER BY INTERUPTING POWER FOR TURN ON VALVES FILL LP TANK ON LP 15 SECONDS WHEN VALVE FLAME LITE UNIT RESET BOILER BY SWITCHING LIGHTS IS THERE 24 VAC BETWEEN ORANGE POWER OFF FOR 15 SECONDS RUN AND YELLOW WIRES ON GAS VALVE AND OR THROUGH TWO TO THREE CYCLES DO
22. Trouble Shooting Flow Charts Maintenance Parts List amp Order Information Electrical Diagrams INTRODUCTION ZOo 40C00J4Z HW SERIES Model HW D M2 130 HW D M2 100 HW D M2 60 H P SERIES Model H M2 130 H M2 100 H M2 60 HEATMAKER MARK II boiler is a low pressure hot water boiler that is available in two 2 design configurations The HW series provides domestic hot water as well as hydronic space heating It includes an insulated storage tank through which boiler water is circulated A heat exchanger within the tank transfers heat from the boiler to the domestic hot water The H and HP series boilers are designed to provide hot water for space heating and can be plumbed to an indirect water heater to supply domestic hot water Figure 1 HW M2 By replacing the air and the gas orifices the basic Heatmaker boiler has the flexibility to operate on either natural or LP gas and may be fired at 60 000 100 000 or 130 000 BTU HR input The Heatmaker can be direct vented by utilizing an optional concentric vent system that will provide outside air for com bustion H W P 60 100 amp 130 appliances may also be vented with 3 or 4 diameter stainless steel horizontal vertical venting as described on page 6 The maximum length shall not exceed 50 equivelant feet of 3 diameter or 100 equivelant feet of 4 diameter H W P M2 130 appliances may also be connected to a lined int
23. as orifice in LP unit occurs on startup a High lock up pressures on LP fuel systems are the most common cause of delayed ignitions on Heatmaker boilers The high LP supply pressure results from improper second stage regulator selection or a faulty regulator It can be detected by measuring the gas supply pressure to the unit at the inlet pressure tap on the gas valve Use a water manometer or pressure gage with a scale reading of at least 25in W C or 15 oz in2 Installthe pressure tap inthe 1 8 NP TF plugged port located above the gas inlet port on the gas valve The gas supply to the boiler must be shut off before making this connection The Heatmaker boiler is designed to operate with supply pressures of 4 13 in W C 2 3 7 5 oz in If supply pressure exceeds 13 in W C 7 5 oz in with the boiler not operating it is likely that this is the cause of the delayed ignition Lock up pressures must be measured when the boiler is not operating and preferably immediately after boiler shutdown b Gas valve regulation problems can also cause delayed ignitions To detect gas valve regulation problems it is necessary to have an inclined manometer or a Magnehelic pressure gage The normal gas valve regulator setting is 0 2 in W C It is measured between the 1 8 NPTF plugged port marked PRESS TAP on the gas valve and the barbed fitting above the air orifice coupling The pressure will be about 2 5 IN W C when the blower is runnin
24. as valve neg pressure White 2400 014 Rodgers Safety Limit 215 F 2400 024 39 40 41 42 43 44 45 6 4 2 2 0 2 Switch 120 volt 1 506 Hamess wiing WM sees 134 Harness wiring seres 50 24225 B 2 2 2 2 2 1 2 3 4 5 6 7 8 1 3 4 5 6 7 Installer Date of Installation Serial Number NOTES FOR YOUR SAFETY READ BEFORE OPERATING WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life A This appliance does not have a pilot It is equipped with an ignition device which automatically lights the burner Do not try to light the burner by hand BEFORE OPERATING smell all around the appliance area for gas Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electric switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Use only your hand to push in or turn the gas control knob Never use tools If the knob will not push in or turn by hand don t try to repair it call a qualified service technician Force or attempted repair may result in
25. at the unit be checked with a standard CO or O tester Insert tester probe at least 6 into exhaust pipe through outside vent terminal Readings should be CO2 8 to 8 5 nat gas O2 7 to 47 9 to 9 8 LP gas 6 Check Burner Input other equipment off a Measure the time in seconds it takes to use one cubic foot of gas b Divide the number of seconds into 3 600 c Multiply the result by the heating value of the gas to obtain BTU HR input Example If it takes 36 seconds to use one cubic foot of gas and the heating value of the gas is 1 000 BTU CU FT approx natural gas value INPUT 3 600 36 x 1 000 100 000 BTU HR Input Ranges H W M2 130 127 400 TO 132 600 BTU HR H W M2 100 98 000 TO 102 000 BTU HR H W M2 60 58 800 TO 61 200 BTU HR Because of the altitude and other minor variations it is possible the input will not fall within this range and the gas orifice must be replaced See chart in an orifice kit CHECK LIMIT CONTROL OPERATION OPERATING AND LOWLIMIT CONTROLHW M2 a When water temperature reaches low limit set point 180 F with no call for heat Heatmaker will shut down b Turn up the room thermostat Boiler pump inside jacket will now run c If water temperature is below operating control cut out temperature 210 F burner will fire d When operating control cut out temperature is reached 210 F burner will go off blower will post purge for 30 seconds and the boiler
26. ated 8 System is now ready for operation FIRINGBURNER 1 Be sure that system has been filled properly see above and is leak tight 2 Open gas cock s Open manual gas shutoff valve by turning to on position 3 Turn on main switch and set thermostat to call for heat In approximately 2 seconds blower will come on NOTE Burner may not ignite on first attempt because of air in gas lines In this case blower will stop after 5 minutes Should this happen turn off main switch Wait 5 minutes and turn on main switch again 4 If burner fails to ignite after three attempts refer to Trouble Shooting Section 2 Service Manual or call service for trouble shooting CAUTION SHOULD ANY PRONOUNCED ODOR OF GAS BE DETECTED ORIF THE GAS BURNER DOES NOT APPEAR TOBE FUNCTIONING IN A NORMAL MANNER CLOSE MAIN SHUTOFF VALVE DO NOT SHUT OFF SWITCH AND CON TACT YOURHEATING CONTRACTOR GAS COMPANY OR FACTORY REPRESENTATIVE 5 You MUST check flame monitoring control ignition system safety shutoff device a Close gas cock with burner operating b In 3 seconds FLAME indicator light will go out and blower will continue to run on post purge cycle Two additional attempts to light will follow including pre purge igniter on valve flame on and post purge Ignition will not occur gas off c Open gas cock Switch unit OFF and then ON again Burner should start after about 45 seconds It is recom mended th
27. by installer Lift the HP M2 onto the wall brackets and re assemble the bolts nuts and washers to affix the unit onto the wall brackets NOTE DONOTREINSTALL THEU CHANNEL SPACER ETS WHEN MOUNTING THE WALL BRACKETS DIRECTLY TO AWALL HYDRONIC SYSTEMS CONNECTIONS The HEATMAKER HP M2 Series is supplied with the neces sary fittings to match the Paloma Pak supply and return piping If the original wall bracket is compatible with the slotted mounting holes on the rear of the HP M2 the supply and return pipe unions attach directly to the existing piping If the installation is new or if the old bracket is incompatible or unusable the return and supply connections will require re piping to match the HP M2 connections PLUMBING ACCESSORIES INSTALLATION 1 Attach boiler drain plumbing accessory to the labeled return on the bottom of the HP M2 2 Separate Thermostatic Union Assembly halves and thread the 1 nipple side to the labeled supply on the bottom of the HP M2 Attach the remainder of the union assembly onto the top half of the union Be sure to use appropriate thread sealers to assure leak tight joints Where the HP M2 is a direct replacement for a Paloma Pak Hytech the installation is completed by connecting union halves together If the installation is new refer to the piping schematics and instructions on page 10 12 GAS SUPPLY CONNECTION If the installation is a direct retrofit the gas
28. d Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remain ing connected to the common venting system properly vents when tested as outlined above return doors windows ex haust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the 1 National Fuel Gas Code ANSI Z223 1 latest edition 2 Can CGA B149 When re sizing any portion of the common venting system the common venting system should be re sized to approach the minimum size as determined using the appropriate tables in Part 11 in the National Fuel Gas Code ANSI Z223 1 latest edition LIGHTING AND SHUTDOWN INSTRUCTIONS A LIGHTING 1 Ensure that boiler is filled with water air is bled from boiler coil and that boiler water pressure is at a minimum of 12 psi 2 Open main gas cock 3 Open gas cock on gas valve 4 Turn ON disconnect switch on right side of unit 5 After 45 seconds ignition will occur if there is a call
29. e thermostat to lowest setting 4 Push in gas control knob slightly and turn clockwise X to OFF Do not force 2 Turn off all electric power to the appliance if service is to be performed 5 Replace control access panel 3 Remove control access panel LEGEND Figure 23 H P Wiring Diagram CK BLK INTEGRATED BOILER CONTROL Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify Proper Operation After Servicing Figure 24 H P Ladder Diagram CIRCULATOR TIME DELAY RELAY CNI 2 CN4 3e 5 3 eo2802029260 69909 e e CN6 3 SAFETY LIMIT STACK SWITCH CA PRESSURE BLOCK FLUE SEN GAS VALVE SWITCH OPERATING CONTROL Figure 25 HW Wiring Diagram Caution Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify Proper Operation After Servicing Figure 26 HW Ladder Diagram CIRCULATOR BLOWER CNI 2 CN4 3 5 3 VALVE 120 VOLT ES RM THERMOSTAT C3 PRESSURE BLOCK FLUE SEN GAS VALVE SWITCH OPERATING CONTROL ODAH A Power switch on B Prepurge if low limit or Thermostat calling 2 17 secs C Igniter heats up and remains on 17 39 sec D Gas valve energized 37 43 secs E
30. egulator setting gas flow must be adjusted by changing the gas orifice To remove the gas valve shut off 120 volt power and the master gas cock in gas line loosen the nut on the gas orifice union and remove the orifice union plus piping to the gas valve Disconnect the wires from the gas valve The valve may now be unscrewed from the inlet piping It may be necessary to deflect the inlet piping somewhat in order to clear the boiler jacket After the valve has been removed replace with a new valve in the reverse order in which the old valve was removed Do not over tighten the fittings into the valve body as this may cause damage to the valve NOTE Whenfueled byLP gas HeatMakers perform best with 9 10 in W C supply pressure If no other appliances are being supplied by the LP supply set the low pressure regulator to 9 10 in W C CUZ 2 fo 4 2 20 2500 zmrm Oou 6ZO 1 0 30o0muog SAFETY LIMIT SWITCH The Safety Limit Switch has a fixed set point at 215 F It will reset automatically To replace the switch shut off the 120 volt power and valve off the boiler drain 1 or 2 gallons of water from the boiler and remove the nut which holds the safety limit bulb in the boiler discharge fitting Remove the bulb from the fitting and remove the 2 screws which hold the switch assembly to the electrical control box Disconnect the 2 wires from the quick connects at switch and remove the safety limit assembly To
31. ement igniter CAUTION Ignitor gets hot PRESSURE DIFFERENTIAL SWITCH The Pressure Differential Switch is a normally open single pole switch which is designed to detect pump operation and water flow To replace turn off electrical power amp boiler feed water Valve off and drain 1 or 2 gallons of water from the boiler unplug wires from the switch and remove switch Install new Switch in reverse order Refill boiler and bleed air from the coil bleed petcock Turn on electrical power and recycle system TRANSFORMER The control transformer accepts 120 VAC power and provides 40 VA of 24 VAC power for the boiler control only It is not capable of supplying control power for external devices such as zone valves They must have their own separate power supply LOW LIMIT HW M2 Series Only The Heatmaker Mark 2 may be equipped with a strap on Low Limit The Low Limit control performs two functions It controls the temperature ofthe water in the transfer tank and it prevents the house circulator from operating when insufficient tank water temperature causes the domestic hot water delivery temperature to drop below 140 F The Low Limit Control has a fixed differential of 15 F and is set to turn the burner on at 140 F tank water temperature and to turn it off when the sensor reaches 155 F Because of the thermal lag in the sensor the tank water temperature will reach about 180 F before the burner actually is turned off The boiler te
32. equate air flow or if the flue is blocked so as to prevent sufficient air flow for proper combustion the contacts of the stack switch will open and the unit will shut down After 5 minutes purge light will flash Close all covers Reset room thermostats and place these instructions in a place convenient to the unit Please be sure that the warranty card is mailed to TRIANCO HEATMAKER INC by either you or the property owner COMMON VENT TEST Required only if Heatmaker is not being chimney connected Atthe time of removal of an existing boiler the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common vent ing system are not in operation a Sealany unused opening in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restric tion leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and win dows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maxi mum spee
33. er the gas valve is deenergized the blower will continue to run for a 30 second post purge If normal burner operation during a heating cycle is interrupted by any of the limit controls the unit pump will continue to run and the blower will continue to operate for a 30 second post purge TROUBLE SHOOTING DETAILED FLOW CHARTS ON PAGES 26 32 If the burner locks out for any reason the cause will be indicated by one of the following lights CODE GREEN POWER No light no power or Light on see trouble shooting section RED PURGE Light flashing blower or stack switch failure or possible flue blockage RED VALVEYFLAME Light flashing valve igniter or flame sense failure combustion related problem NORMAL p OPERATION y NOTE Ifthe stack switch contacts ES are closed for any reason when the blower isn t operating sequence will not occur and after 45 seconds the control will lock out and the PURGE light will flash If the stack switch contacts are open and do not close during purge period after 5 minutes the tus control will lock out and the PURGE light will flash Ifthe boiler does not operate the green power light is on and no indicatorlights are flashing check for an open pressure switch low limit switch on HW M2 series operating control or safety limit switch on either series For additional troubleshooting information refer to the trouble shooting flow charts on the
34. ere are two basic causes for the noise rich mixture and cross contamination To check for a rich mixture it will be necesary to measure the percent O or CO in the flue products O readings lower than 472 or CO readings higher than 97496 natural gas and 10 896 LP will often cause combustion noise To eliminate the noise it will be necessary to install a smaller gas orifice so that the will rise above 47296 or the CO will drop to 87 natural or 97296 LP Sometimes the readings are influenced by cross contamination and a check for cross contamination should be done before changing orifices if itis suspected A strong smell from the flue products is generally an indication Check for cross contamination using the procedure listed in the index If there is no cross contamination reorificing should be done b Boiling kettling may occur at boiler discharge temperatures from 170 F to 210 F The temperature at which it starts will vary from one installation to another The primary cause of the problem is poor heat transfer on the inside of the boiler coil This may be caused by foaming of antifreeze in the system or scaling from the boiler water if no antifreeze is present There are many manufacturers of plumbing and boiler antifreezes Plumbing antifreezes should never be used in a boiler system because they have no antifoamants in them Not all boiler antifreezes have an effective antifoamant either so the noise may exist w
35. ernal chimney The Heatmaker features a forced draft pre mixed combus tion system All air for combustion is supplied with the gas to the burner flameholder Both the intake air and the gas are metered through separate orifices before entering the com bustion air blower The blower forces the air fuel mixture through the flameholder and into the combustion chamber The mixture is ignited from the hot surface igniter and burns Hot gases are forced out between the passes of the heat exchanger into the flue collector Flue gases are discharged into the outside atmosphere through the vent terminal a chimney horizontal or vertical alternate vent Model H W M2 60 amp H W M2 100 UNITS MUST NOT BE CHIMNEY CONNECTED INSTALLATIONS WITH WATER CONTAINING 10 GRAINS OF HARDNESS OR HIGHER MUST BE INSTALLED WITH APPROPRIATE WATER TREATMENT TO THE INSTALLER BEFORE YOU BEGIN The Heatmaker is uniquely different from any heating boiler you have installed in the past It is important for you to take a few minutes to review the contents of the Installation and Operating section of this manual before you begin installa tion This will avoid making mistakes and causing confusion when installing and operating the unit Gas Burner Sealed Combustion w P N 2400 236 or 2400 238 Outside Vent Wall Outside Air For Combustion Copper Coil Heat Exchanger T
36. etainer 5 Remove the igniter 6 Clean the finned tubing with a wire brush and vacuum all loose material from the combustion chamber 7 Replace all parts in the reverse order in which they were removed 8 Restart the unit as indicated by the lighting instruction label UNIT PUMP The unit pump operates whenever there is a call for heat or hot water Itis a wetted rotor type pump and should always be filled with water when it is operating so that it will cool properly If a pump change is required for any reason valve the boiler and drain approximately 1 or 2 gallons of water from the unit Turn off the main disconnect switch and unplug the pump wires remove the pump motor The pump housing need not be removed The replacement pump motor should be installed in the reverse order from which the old pump motor was removed After filling the system be sure to bleed the coil NOTE If the pump motor is not defective the pump cartridge alone may be changed Taco Pumps Only GAS VALVE The gas valve is a solenoid operated negative pressure regulated valve The outlet pressure is regulated at minus 0 2 inches w c It is designed to operate with supply pressures of 4 13 inches w c Within that range of supply pressures the regulated discharge pressure may vary from minus 05 to minus 35 inches w c The regulator is not adjustable and the effect of this variation in discharge pressure is not significant Because of the fixed r
37. foamant USING IN A COMBINED HOT WATER HEATING AND CHILLED WATER COOLING SYSTEM When the Heatmaker is used in connection with a refrigera tion system it must be installed so that the chilled medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium from entering it The boiler piping system of a Heatmaker boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle Figure 14 Hydronic Piping HW 4 2 If codes require install suit able back flow preventor 11 between automatic fill valve and city main ZONE VALVES TO PREVENT THERMAL CIRCULATION 3 To ensure sufficient expan sion volume of the hydronic system water due to heat up and cool down during normal opera tion a 30 or larger expansion tank must be used on all HW series applications HYDRONIC PIPING HW SERIES HW M2 boilers are installed in single and multiple zone sys tems using either zone valves or zone circulators in the same manner as any other residential boiler Systems with zone circu lators or single zone systems require the installation of a hy dronic flow check 6 to prevent gravity circulation of heating sup ply water when no heat is HYORONIC FLOw CHECK S OR BALL VALVE 9 Q
38. for a short time when that zone is operating alone before the return water comes back to the boiler at a temperature which will cause the operating control contacts to open If this situation causes very rapid cycling it may be necessary to only operate the small output zone when another zone is calling This can be done most simply on Systems using zone valves by disconnecting the end switch wire on the small output zone one so that the boiler will not be started unless another zone is calling This approach eliminates the need for time consuming repiping If the on cycles are at least 172 minutes long then the short cycling will not be a problem CROSS CONTAMINATION AND COMBUSTION RELATED SHORT CYCLING UNITS INSTALLED WITH QUICK VENT Boiler short cycling nuisance lockouts and objectionable flue gas odors may be caused by leakage of flue products into the combustion air stream This results from poorly sealed joints inthe inner 3 pipe The symptom of this problem is continual restarts without a lockout occurring The VALVE FLAME lite will be on for only a short time but more than 6 seconds before the post purge starts This condition is generally seen on new installations however it is possible that a poorly assembled flue pipe could come apart and cause the same effect Cross contamination can best be detected with a CO2 analyzer Bacharach kit for example Remove the stack Switch tube from the tee fitting above the air
39. for heat B SHUTDOWN 1 Turn OFF disconnect switch 2 Close gas cock on gas valve 3 Close main gas cock MAINTENANCE OWNER CARE AND MAINTENANCE 1 Inspect venting system Annually remove screws on vent terminal and remove terminal Inspect interior with flashlight 2 General Housekeeping Keep boiler area clear and free from combustible materials gasoline and other flammable vapors and liquids Keep boiler jacket louvers clear for proper cooling of internal components Do not obstruct boiler room ventilation screens or grills SERVICEMAINTENANCE Cleaning Heat Exchanger to be done by qualified service person 1 Turn off electric and gas supplies and remove the jacket 2 Remove the vent assembly and top cover 3 Remove the top half of the combustion chamber by remov ing the three screws and nuts that clamp the top half to the bottom half the clamp on the induction tube and the 1 8 diameter balance lines 4 Remove the top insulator cap by spreading the retainer 5 Remove the igniter to avoid damage during cleaning 6 Clean the finned tubing with a wire brush and vacuum all loose material from the combustion chamber Wipe flameholder burner with a clean dry rag 7 Replace all parts in the reverse order in which they were removed 8 Restart the unit as indicated by the operating instructions plate ADJUSTING BURNER INPUT The HeatMaker burner system is a pre mixed forced combustion system
40. g prepurge before the gas valve opens When the gas valve is energized and the solenoid opens the pressure should rise to 0 2 IN W C This should happen smoothly without allowing the pressure to go positive above 0 IN W C If the pressure spikes positive when the solenoid opens then the gas valve regulator is faulty and may be the cause of the delayed ignition assuming inlet tested OK C A defective burner flameholder can cause a delayed ignition however not often If the gas supply pressure and the gas valve are functioning properly and the air and gas orifices are correct the burner should be inspected To inspect remove the blower and the burner will drop out of the bottom of the chamber There should be no perforations other than the punched holes When replacing the burner the insulating pad must be on the top of it If none was on the burner when it was removed check to see if it fell off during burner removal and has stayed in the combustion chamber Never leave an insulating pad lying in the combustion chamber as this can cause burner overheating and perforation NOISY OPERATION There are two principal sources of noisy operation a Combustion high pitched noise whistle or hoot b Boiling kettling lower frequency noise which varies with temperature moan a Combustion noise occurs at any boiler discharge temperature and is heard the loudest at the flue outlet especially on units with side wall venting Th
41. hermostatic Union H M2 Domestic Hot Water Coil HW D M2 Heating System Water Outlet Heating System Water Return Gas Supply See Figure 1 Figure 2 2 CODES amp STANDARDS All installations must be made in accordance with 1 the National Fuel Gas Code ANSI Z223 1 latest edition or 2 CAN CGA B149 Installation Codes for Gas Burning Appliances and Equipment or with the requirements of the local utility or other authorities having jurisdiction Such applicable requirements take pre cedence over the general instructions contained herein All electrical wiring is to be done in accordance with 1 the National Electrical Code ANSI NFPA70 latest edition or 2 the CSA standard C22 1 Canadian Electrical Code Part 1 and local codes All vent installations must be made in accordance with 1 Part 7 Venting of Equipment of the National Fuel Gas Code ANSI 223 1 latest edition or applicable provisions of the local building codes or 2 CAN CGA B149 When required by the jurisdiction authority the installations must conform to the American Society of Mechanical Engi neers Safety Code for Controls and Safety Devices for Automatically fired Boilers No CSD I UNPACKING THE HEATMAKER Remove all packing and tie down materials On HW models remove three 3 shipping bolts from underside of base Make immediate claims to carrier if unit is
42. ic hot water through the domestic hot water DHW coil immersed in it The DHW coil may be removed from the tank if either tank or the DHW coil must be replaced The coil is securedtothe tank with 6 3 8 16 bolts which are replaceable if they are broken or stripped THERMOSTATIC UNION H P M2 Series Boilers Only The themostatic union is 172 NPTF union which has thermostatic element on the inside The element has two small bypass holes to allow some water to flow into the System when the element is closed When the boiler first starts and cold system water is returning the element is closed and boiler water is recirculated back to the return until the supply water reaches 160 F and the element opens To replace the element shut off and drain the section of the System that the thermostatic union is installed in Open the union and replace the element with a new one The element should be installed so that its spring and actuator are on the system side Close union open valves refill and bleed system bleed coil at coil bleed petcock and restart boiler TIME DELAY RELAY TDR H P M2 Series boilers only The Time Delay Relay controls the unit pump and keeps it operating for approximately one minute after the blower post purge stops Control voltage on the TDR is 24 volts from the limit circuit The contacts to supply pump power are 120 VAC They delay on open one minute after the 24 volt control voltage is interrupted Turn
43. iler the cold water in the bottom of the tank will be mixed with the hot water at the top and mix temperature will be too low to provide adequate domestic hot water and it will turn cold If this is the suspected cause feel the temperature of the piping after the flow check when the heating system has not been calling for awhile If the piping is hot there is flow past the flow check which may be causing the problem e Coil scaling may occur in some areas of the country where there are high concentrations of minerals in the water These minerals may cause fouling of the domestic hot water coil over an extended period of time lime build up or they may in rare instances cause a problem in less than a year of operation The minerals which react quickly mostly magnesium in well systems cause a slime on the inside of the coil which prevents adequate heat transfer These minerals must be filtered out by a special incoming water filter or inhibited to protect the coil and also to provide acceptable water quality The minerals contained in public water systems which accumulate in the coil over long periods of time may be removed when necessary by flushing the coil with cleaner such as Unlime or Sizzle These products are also effective in cleaning a coil that is fouled by magnesium HIGH GAS CONSUMPTION SEE ALSO CROSS CONTAMINATION Improper burner operation caused by incorrect air fuel ratio CO2 or O2 out of the specified range wil
44. ing the jacket lower front panel This is done by removing the screws that hold the panel atthe base and by cutting an aluminum pop rivet on each side at the top approximately 2 inches down These rivets hold the lower front panel to the jacket back A flat bladed tool like a putty knife is ideal forthis purpose Drive the blade down from the top in the crease between the jacket back and the lower front panel This will cutthe rivets Remove the four screws that hold the electrical box and move it aside The lower front panel may now be lifted up above the base and removed When the boiler is shipped from the factory there are shipping bolts which hold the tank and the base together The installer was instructed to remove these bolts before installing the boiler If this was done nothing will be holding the tank in place at this time except the hydronic piping at the rear of the appliance Remove the supply and return connections and remove the tank Installation of the new tank is done in the reverse order If the tank alone is being replaced it is easier to remove tank and coil together and change the coil from the old tank to the new one when both are free of the jacket C r gt lt m DELAYED IGNITION Possible Causes Time of occurance High lockups on LP occurs on start up Gas valve regulation problem occurs on start up Defective burner flameholder occurs primarily on burner shutdown Natural g
45. ith boiler antifreezes also The cure for the boiling noise is the same regardless of the cause However if antifreeze in the system is suspected of being the cause the concentration and type should be investigated before attempting to eliminate the noise The most eefective means of cleaning the combustion coil utilizes the siphon cleaning method Instructions for this method may be obtained from Trianco as Service Bullitin SB 9701 Concentrations of antifreeze should be kept as low as possible because antifreeze will reduce heat transfer and efficiency Many times it is difficult to determine if the noise is combustion or boiling related The best clue is when in the cycle the noise appears and if its frequency changes with boiler discharge temperature Combustion noises always have the same frequency however their volume may change from the time that the burner first fires to the time that it shuts off Boiling noises have a frequency that varies with boiler discharge temperature and sometimes they will disappear completely at higher temperatures just before the boiler goes off on limit Vibration of the boiler pressure gage needle may also occur with boiling noises INSUFFICIENT HOT WATER HW M2 Series Only Possible Cause No Flow Restrictor Low limit Failure Incorrect Wiring of System Circulator No Flow Check in System Supply Coil Contamination a The most common cause for insufficient hot water complaints results fro
46. l cause high gas consumption It is most noticeable on LP fired units with low CO or high O2 however units operating on LP or natural gas with incorrect air fuel ratios will not provide their best efficiency If no combustion analyzing equipment CO or O2 is available an indication ofthe air fuel ratio can be gotten by briefly sniffing the flue gases When running properly the Heat Maker s flue gases should have little smell If they have a strong piercing smell the gas orifice is probably too small Do not attempt to do reorificing without an O2 CO kit SHORT CYCLING H M2 HP M2 Series Only SEEALSO CROSS CONTAMINATION Possible Causes a No system circulator low system water flow b Small zones high zone return temperature a The most common causes of short cycling of HeatMaker H P M2 Series and other low mass boilers is insufficient hydronic system water flow or small zones With HeatMakers this is sometimes caused by the installer s failure to install a System circulator as required in the Installation and Operating Instructions The result of low flow is very rapid temperature rise in the boiler Sometimes the rise is so fast that the operating control will not operate before the safety limit operates Boiler will reset following cool down of safety limit thermo element b Another cause of short cycling is a result of system design If one zone in a zoned system has a very small output the boiler will only be on
47. let on the unit and the adaptor DO NOT use plastic vent pipe in any part of the chimney vent connection Install vent connector between elbow if used and chimney Pitch vent connector up toward chimney 74 per foot of lateral run Secure all joints with sheetmetal screws ALTERNATE VENTING METHOD Canada Only The Heatmaker may be vented vertically up thru a masonary chimney using a 4 diameter ULC Certification Flexible Stain less Steel Vent Observe the following requirements 1 The flexible vent must be run from the boiler up thru the entire chimney 2 The chimney must terminate with a suitible vent cap 3 If chimney is exposed the vent pipe should be insulated 4 The vent pipe must be installed with a 74 per foot upward slope from the boiler to the chimney 5 The vent pipe must be supprted every 3 to prevent sagging 6 All joints in the vent must be secured with at least two corrosion resistant screws and sealed with an approved silicone sealant and checked for gas tightness 7 The vent system should be checked once a year by a qualified serviceman Note Boiler may not be vented in common with another gas appliance or be vented using B vent Figure 4 H M2 Terminal Extension Optional 24 Ud Table 1 Table 2 Capacity of Type Double Wall Vents with Single Wall Capacity of Masonary Chimney Flue with Type B Double Metal Connectors Serving a Single
48. lock outs by weakening the flame signal to the boiler control It should be suspected if the boiler temperature does not rise above 160 F during long periods of operation This condition can be caused by a defective thermostat in the thermostatic union of H P M2 series boilers or the omission of the thermostatic union at installation or an improperly wired system circulator on HW M2 series boilers sidewall vented units moisture can get into the combustion chamber from a flue pipe that is pitched incorrectly back toward the boiler without a condensate trap Quick Vented systems should always pitch down from the boiler c A defective gas valve one that doesn t always open properly can cause a nuisance lockout however occurences of this are rare d A more common cause of nuisance lockouts is poor combustion If there is an odor in the flue gases this should be suspected Check CO2 or O2 to determine if combustion is within limits Poor combustion causes a weak flame signal to the burner control and lock outs may result e If combustion is within limits and none of the causes mentioned above seems to be the cause of the lockout it is possible that the boiler control may be defective SEQUENCE OF OPERATION On a call for heat from the room thermostat on H W M2 series boilers or the low limit on the HW M2 series the pump operates and the boiler control is energized through the operating control pressure switch and the
49. m failure to install a flow restrictor If there is no flow restrictor water passes through the coil at a greater volume than the boiler output is capable of heating to the desired temperature rise b Failure of the low limit to operate within its normal calibration points will have the same effect as incorrect system circulator wiring Incorrect wiring for the system circulator can also cause the problem If the blue wire in the field wiring box is not used to control the circulator or circulators then the low limit cannot prevent boiler water temperature from dropping to a point that is insufficient to provide enough heat for the domestic hot water coil The blue wire interrupts power to the system circulator through the priority relay R 1 R 1 is controlled by the low limit which should limit minimum tank temperature to 140 F d Flow checks in single zone systems and multizone systems with zone circulators prevent gravity circulation of heated boiler water from the transfer tank If no flow check exists or if an existing flow check is left in the manual open position heatleaves the bottom of the tank by gravity circulation Because of stratification in the tank when the pump is off the water around the low limit sensor will remain hot and the boiler will not replace the heat that is lost When domestic hot water is turned on there will be a short draw of domestic hot water and then when the unit pump comes on to start the bo
50. mperature may reach operating temperature due to this thermal lag If replacement is necessary shut off the 120 volt power Simply remove and attach wire for wire Clamp the new Low Limit to the hot outlet pipe as close to the domestic exchanger plate as possible and cover area with tank insulation blanket Return boiler to service BLOWER The Combustion Air Blower is a high head centrifugal blower Itis designed to provide about 2 w c of suction at 30 CFM This performance is necessary to operate the gas valve reliably to overcome induction system friction losses and to eliminate any sensitivity to wind striking the vent terminal It is powered by a 120 volt motor which draws about 1 3 amps at rated load It is powered by the integrated boiler control whenever there is a call for heat and 30 seconds thereafter If a blower change is required turn off the 120 volt power and unplug the power wires from the blower motor Remove the three nuts from the blower discharge flange and the four nuts from the blower inlet flange The blower may now be deflected enough to permit its removal Install the new blower using new gaskets in the reverse order from which the old blower was removed The four inlet flange nuts however should only be finger tight initially and then tightened with a wrench after all other operations have been completed The combustion should be checked for correct air fuel ratio whenever the blower is replaced see Burner Adj
51. n chimneys subject to the following requirements Model H W M2 60 and H W M2 100 MUST NOT BE CHIM NEY OR B VENT CONNECTED Chimney mustbe internally lined or B vent type External or unlined chimneys may serve as a chase for utilization of stainless steel alternative venting providing no other equip ment is vented into it or the chimney may have an approved liner installed into the flue B Two 2 or more vent connectors from either power or natural draft units may enter a common gas vent providing they conform to the requirements and tables of the National Fuel Gas Code ANSI 7223 1 54 latest edition or applicable provision of the local building code None may be connected to equipment with a positive vent pressure C Locate unit as close to chimney as possible for shortest vent connector Figure 3 HW M2 SUPPLY DOMESTIC TT 30i 32 RETURN INSTALLATION Determine height of chimney or B Vent and length of lateral run Select vent connector diameter from 1 Table 1 or 2 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 latest edition see excerpts or 2 Table G 3 of the Can CGA B149 Installation Code Install an adaptor at the flue outlet of the unit to step up to the diameter of the vent connector Install elbow for vent connec tor if required This elbow should be full size of the vent connector DO NOT install a three 3 inch elbow between the flue out
52. ndard 1738 and U L C Standard 636 may be used to vent all Heatmaker H W P and DH P models Vent pipe and fittings are manufactured to these Standards by Heat Fab Inc under the trade name of Saf T Vent and by Z Flex under the trade name of Z Vent Follow the Special Gas Vent manufacturers instructions regarding design location and assembly of the vent system Table 3 Appliance Design Data single pipe only Minimum clearance from combustibles vent EG Max flue gas temp 325 F Max equiv ft of venting any 50 equiv ft combination of horiz or vert 3 diameter Max equiv ft of venting any 100 equiv ft combination of horiz or vert 4 diameter The Heatmaker appliance may be vented with any number of elbows or fittings provided that the maximum equivalent feet of venting is not exceeded 90 elbows in the vent system shall be considered to be 10 equivalent feet When vented with Special Gas Vent the Heatmaker must not be common vented with any other appliance CONNECTING SPECIAL GAS VENT TO HEATMAKER Heatmaker part number 2400 372 Figure 6 is used to secure the Special Gas Vent to the flue outlet of the Heatmaker Heat Fab pipe or fittings Heatmaker part numbers 2400 350 or 2400 352 or the male end of Z Vent pipe Z Vent 02 SVEPXX030 may be installed over the flue outlet of the Heatmaker duct is used around the Special Gas Vent to bring in combustion air from another location the connecti
53. nection of Blue wire required on HW only p O Z O m r m Ur 42 05 0 Z g g The Model HP M2 Series may be used as either a Paloma Pak Hytech boiler replacement or as a new wall mount instal lation Carefully unpack HP unit Read all installation instructions before starting the installation Remove the Front removable jacket and find the plumbing accessories pack age inside the unit WALL MOUNTING INSTRUCTIONS PALOMA HYTECH REPLACEMENT Hang the HP M2 as assembled from the manufacturer onto the existing wall bracket Do not remove the brackets which are attached to the new unit If the existing wall bracket does not align with the slotted mounting holes on the rear of the HP M2 remove the old bracket from the wall and follow instructions for new wall mount below NEW WALL MOUNT INSTALLATION Remove the bolts nuts and washers that secure the two mounting brackets to the bottom and rear of the HP M2 cabinet Remove the U channel spacer bracket from each wall bracket and discard Spacer brackets are used only with original bracket in Paloma Pak Hytech retrofit installations Attach the included mounting template to the selected wall location Mark and drill holes for appropriate mounting hard ware at the template specified locations Remove template from the wall and securely affix the two wall brackets to the wall surface with appropriate mounting hardware provided
54. ned spaces in buildings infiltration may be adequate to provide air for combustion and ventilation however in buildings of unusu ally tight construction or when locating the unit in a confined space additional air should be provided and the following guidelines must be followed 1 Ifthe space is in a building of unusually tight construction air should be obtained from outdoors or from spaces which freely connect with outdoors 2 For boilers in confined rooms two permanent openings shall be provided one within 12 of the ceiling and one within 12 of the floor of each room Each opening shall be at least one square inch per 1 000 BTU HR boiler input but not be less than 100 square inches These openings shall freely connect with areas having adequate infiltration from outside 3 When all air is provided from outdoors the confined space shall be provided with two openings as outlined above These openings shall connect directly or by ducts with outdoors or spaces crawl or attic that freely connect with the outdoors and shall be of the size listed below for that particu lar arrangement a One square inch of free area per 4 000 BTU HR of boiler input for direct outdoor air supply through an outside wall or through vertical ducting directly to outside One square inch of free area per 2 000 BTU HR of boiler input for direct outdoor air through horizontal ducting All ducting shall be of the same size as the opening
55. ng measured the readings should be between 7 and 6 Measuring CO2 When operating on narural gas readings below 8 0 generally indicate a lean mixture not enough gas Readings above 9 25 generally indicate a rich mixture too much gas Inputs should be increased or decreased to correct lean or rich mixtures NOTE If the mixture is very rich not enough air for complete combustion it is possible to get low readings on CO2 analyzer This situation does not occur often but it can be detected if reading continues to go lower as the input is increased If this condition is suspected a CO test should be taken at the vent outlet Inputs must be reduced to correct high CO reading and to bring CO2 readings to proper levels The following numbers apply to natural gas only The range of operation for LP is 9 0 to 9 8 Measuring O2 Readings above 7 indicate a lean mixture not enough gas Readings below 4796 indicate a rich mixture Input should be increased or decreased to correct lean or rich mixtures CLEANING COMBUSTION CHAMBER COIL 1 Turn off electric and gas supplies and remove the jacket 2 Remove the vent assembly and top cover 3 Remove the top half of the combustion chamber by removing the 3 screws and nuts that clamp the top half to the bottom half the clamp on the air orifice hose and the two clear plastic lines connected to the T on the air induction elbow 4 Remove the top insulator cap by spreading the r
56. on of that duct to the appliance must be secured with sheetmetal Screws Each joint between the appliance and the last joint before the location where the Special Gas vent exits the duct must also be secured with sheetmetal screws In this application part number 2400 372 is not used at the boiler flue collar It is used and must be used to secure the Special Gas Vent at the point where the Special Gas Vent exits the duct The combustion air supply should be protected from debris entering the duct This may be done with a Heatmaker Vent Terminal part number 2400 277 as shown in Figure 7 or with a large mesh screen Follow the Special Gas Vent manufacturer s instructions for cleaning and sealing all parts before assembling APPLIANCE JOINT PROCEDURE WITH HEATMAKER PART 2400 350 SEE FIGURE 8 Apply 1 4 bead of silicone sealer GE108 or Novagard 400 to the 3 inch 3 flue outlet of the Heatmaker approximately one inch 1 from the end Slide flue adapter over the Heatmaker flue outlet flared up end and push down to stop do not force adapter beyond stop Apply another bead of silicone around this joint and smooth out Apply 1 4 bead of silicone to the straight end of the 2400 350 pipe approximately 1 4 from the end Slide the pipe into the adapter until it bottoms in the adapter Apply another bead of silicone around this joint and smooth out APPLIANCE JOINT PROCEDURE WITH HEATMAKER PART 2400 352 OR Z
57. pages that follow CIRCULATOR AIR PROVING SWITCH COMBUSTION AIR BLOWER PURGE LED IGNITER PROOF OF FLAME IGNITER LED GAS CONTROL VALVE FLAME LED A POWER LED BLINKS ONCE WHEN 24V POWER APPLIED ANO WHEN THERMOSTAT CALLS FOR HEAT Aon AS LONG AS CONTROL IS POWERED ANO OPERATING PROPEALY A IF EITHER SWITCH OPENS DURING THE RUN CYCLE BURNER WILL STOP FOLLOWED BY POSTPURGE CIRCULATOR WIL RUN AS LONG AS THERMOSTAT IS CALLING FOR HEAT BURNER IGNITION SEQUENCE WILL RESTART SWITCH CLOSES GENERAL TROUBLE SHOOTING RESET BOILER CONTROL BY INTERUPTING POWER AT SIDE OF UNIT FOR 15 SECONDS YES 1 IS SERVICE SWITCH ON GREEN LIGHT COMES ON 2 1S CIRCUIT ON 3 ARE FUSES OR CIRCUIT BREAKER OK CHECK FOR VOLTAGE DID BOILER RUN THROUGH 120 VAC BETWEEN CORRECT AND A COMPLETE CYCLE AS BLACK AND WHITE RECYCLE BOILER DESCRIBED IN SEQUENCE WIRES AT BACK OF 120 THROUGH A FEW OF EVENTS ON PAGE 25 VAC CONNECTOR ON CYCLES BOILER CONTROL PUMP OPERATES REFER TO 120 V TO PUMP PAGE 32 0 VOLTS HAVE QUALIFIED ELECTRICIAN REPAIR FAULT IN WIRING TO THE BOILER REFER TO FLOW CHECK FOR VOLTAGE 24 CHART FOR SPECIFIC VAC BETWEEN YELLOW PROBLEM WIRES AT BACK OF VAC 24 XFMR CONNECTOR AFTER 5 MINUTES ARE ANY ON BOILER CONTROL RED LIGHTS FLASHING REPLACE BOILER CONTROL 2400 224 1 LIMIT CIRCUIT OPEN PURGE SEE PAGE 28 SEE PAGE 27
58. pply line at or above pipe height Install automatic float type air vent 3 on air purger Connect diaphragm type expansion tank 5 to air purger Install a boiler drain valve 8 adjacent to unit in return line Connect system return to 1 return connection B Install a properly sized circulator 9 with optional isolation valves 10 CAUTION All hot water pipes must be installed with a mini mum 1 clearance from combustible materials NOTE H HP boilers installed in radiant in floor systems and other low mass systems should be provided with a buffer tank to assure constant supply temperature without excessive boiler short cycling Figure 17 FEEDWATERMAKE UP 1 Connect boiler feed water supply with shut off valve to inlet connection of automatic fill valve desired To minimize heat loss from the storage tank HW during standby periods it is recommended that the piping between the Heatmaker up to and including the vertical leg be insulated with 72 34 of insulation CAUTION Unless equipped with optional stainless steel tank the HW model must not be direct connected to a heating system utilizing oxygen permeable tubing see warranty Provide a water to water heat exchanger between systems to prevent corrosion of tank or other components Nontoxic heating system antifreeze may be added to the hydronic system provided that the concentration does not exceed 35 and the antifreeze contains an anti
59. pump and system circulator will continue to operate until room thermostat is satisfied e When water temperature drops below low limit cut in temperature 150 F and there is a continued call for heat the System circulator will go off The boiler pump will continue to operate and the burner will remain on When low limit cut out temperature is reached 180 F the system circulator will come on OPERATING CONTROL 2 a Burner will run until operating control cut out temperature 185 F is reached b When Operating Control cut out temperature is reached burner will go off and boiler pump will continue to run and blower will post purge for 30 seconds c When temperature reaches Operating Control cut in tem perature 160 F burner will start and continue to run until a call for heat is satisfied or Operating Control cut out tempera ture is reached again SAFETY LIMIT OPERATION H W M2 If boiler water temperature exceeds operating control cut out temperature for any reason the safety limit will interrupt power to the gas valve at approximately 215 F the blower will post purge for 30 seconds and the unit will shut down The safety limit will reset at 195 F Note temperature of limit operations are all approximate allow for gauge and tolerance variations gt 40 X AOMIO moz gt zm 4z gt 3 STACK SWITCH OPERATION H W M2 If for any reason the combustion air blower fails to provide ad
60. r tempering valve 12 creates a scalding hazzard with potential for serious bodily injury Some brands of tempering valves are not designed as anti scold valves INSTALLATIONS WITH WATER CONTAINING 10 GRAINS OF HARDNESS OR HIGHER MUST BE INSTALLED WITH APPROPRIATE WATER TREATMENT Figure 12 THIS RETURN BEND MUST HIGHER THAN THE VENT CENTERLINE OF THE HORIZONTAL SECTION OF THE 3 FLUE PIPE WHEN THE BOILER IS LOCATED ABOVE THE GAS SUPPLY SUCH AS ON A FLOOR ABOVE A METER LOCATED IN THE BASEMENT PIPE THE GAS SUPPLY TO THE BOILER AS SHOWN k gt FLOOR FROM GAS A Table 4 of 6 Specific Gravity a F hepe a 175 360 Additional length to be added for each tee or bend WATER SOFTENER AMAYPSAPMI 2 2 OPTIONAL RETURN LINE PIPING or per valve manufacturers instructions mms O jAOMZOO0 Z g gt O ZOJO lt I Z g HYDRONIC HEAT PIPING H SERIES Hydronic Connections Fittings and Accessories Refer to Fig 16 page 12 NOTE ASEPARATEHEATING CIRCULATORMUSTBEPRO VIDEDINSYSTEMPIPING FORALLMODELS 1 Connect system supply to 1 supply connection A 1a Install thermostatic union supplied on H HP boilers 2 Pipe the discharge of the relief valve full size to a drain or in a manner to prevent injury in the event of pressure relief Install an air purger 2 in su
61. s fired at 130 000 BTU only E 2 2 CHIMNEY Vent to lined chimney only or use B Vent See table 11 3 amp 11 2 Pg 4 5 3 4 HYDRONIC HEAT Properly sized expansion tank HW must have 30 in supply piping Pg 10 ELECTRICAL Pg 13 Fig 18 21 Pg 13 Fig 20 3 ISET THERMOSTAT ANTICIPATOR 9 amp for single loop systems or Taco Zone Valves 24 pa IMPORTANT 1 SHIPPING BOLTS Removed from tank base on HW units see below Pg 3 2 WARRANTY CARD Completed and returned to T H l Leave Service Manual with unit EN 1 BLUE WIRE field wiring box Wired to power system circulator s 2 THREE WIRE ZONE VALVES i e Taco Watts Sparco wired with isolation relay TRIANCO HEATMAKER Inc 111 York Avenue Randolph Massachusetts 02368 Part No 1 510 Telephone 781 986 9100 2M 11 19 97 Fax 781 986 9907
62. safety limit It checks to ensure that the stack switch contacts are open and then energizes the blower The blower starts and the air pressure increases until the stack switch contacts close and the red PURGE light lights The pump and blower continue to run and for 15 seconds the red PURGE light stays on Following that the red PURGE light goes out the red igniter light lights and the igniter heats for 20 seconds At the end of the 20 seconds the red VALVE FLAME light is lit and the gas valve is energized For 2 seconds the valve and igniter are energized and burner will ignite Following this the igniter is deenergized and the red IGNITER light goes out and the pump and blower continue to run and the burner operates under the supervision of the boiler control If for any reason the full sequence is completed and the burner doesn t ignite the sequence will be repeated after a blower on time of 45 seconds 30 seconds post purge and 15 seconds prepurge for the next cycle During this part of the sequence the igniter remains on for 30 seconds and the balance of the sequence is unchanged If no ignition occurs again a third cycle will follow with the same sequence as the second After the third trial for ignition if the burner does not ignite the system will lock out and reset can only be accomplished by momentarily switching the power off At the end of a heating cycle either space heating or domestic water heating aft
63. supply will require re piping to connect to the HP M2 gas inlet If the gas is supplied from below the unit be sure to run supply pipe to a point higher than the vent center line before connection to the unit gas valve On new installations refer to the gas piping section for gas pipe sizing and related information VENTING THE HP M2 SERIES The HP M2 may be vented using any of the venting options available to the H W M2 Series These options include Direct Vent Outside Air vented Alternate horizontal vertical venting using Special Gas Vent or internal lined or B Vent type chimneys MODEL HP M2 60 amp HP M2 100 MUST NOT BE CHIMNEY CONNECTED OR B VENT CONNECTED AGA When used as a retrofit boiler vented into a chimney or B Vent be sure to check current vent and vent connector sizing tables Only units fired at 130MBTU hr may be vented with this option Under no circumstances shall the HP M2 60 be chimney connected or B vented using vent or vent connec tors The unit 3 vent collar must be increased to a size which will accommodate the chimney system for the appropriate BTU hr input of the boiler In the event the unit firing rate and masonry chimney param eters do not fall within the recommendations in the latest N F G C chimney sizing tables a flexible chimney liner may be utilized in the chimney Sizing capacity for metal chimney liners may be obtained by 20 de rating or 80 of the
64. t 5 amps maximum between the blue wire and the white wire neutral per Fig 18 Set thermostat anticipator to 0 9 amps 3 Zone Valves and Thermostats 19 Fig 20 for 3 wire zone valve such as TACO or DC magnatrol valves Install external 24 volt transformer of sufficient V A to power combined load of zone valves Consult zone valve manufacturer s instructions Connect circulator 120 volt 5 amp maximum between the blue wire and the white wire neutral 4 Multi Zone Multi Relay Circulator Installations Fig 21 Multiple circulators must not exceed 5 amps when connected to blue wire Blue wire must be used on all HW series NOTE On zone valve systems such as Taco Automag and others which do not have isolated dry contact end switches a single pole isolating relay must be utilized Fig 20 LEGEND 1 Disconnect Switch 24 Volt Thermostats _5 Tee THs ct Zone Circulators 2 Zone Relays s s 21 202 23 Honeywell R845A or equivelant Zone Valves Honeywell V8043 or equivelant Figure 18 Single Zone FIELD WIRING BOX P eee Set Thermostat Anticipator to 0 9 amp T1 24 Volt Transformer Sufficient VA for All zone valves ALL COMPONENTS SUPPLIED BY OTHERS Figure 20 Zoning with 3 wire Zone Valves EXTERNAL TACO ZONE V CIRCULATOR ue pae ir 21 HME 21 LI A ALL COMPONENTS SUPPLIED BY OTHERS Note Con
65. uch as doors win dows etc Units terminating below the top of the boiler must reduce allowable vent length by 1 for every foot of vertical drop below the top Vent opening should be well away from shrubbery or other obstructions that would prevent free air flow to and from vent terminal Do not terminate vent under decks stairways or car ports When ever possible locations under windows should be avoided NOTE Should it be impossible to locate opening center line 16 74 above grade use optional Vent Terminal Extension Part Number 2400 278 Fig 4 Vent terminals must also be at least 3 above any forced air inlet located within 10 and at least 7 above grade when located adjacent to a public walkway and cannot terminate in a location where condensate or vapor may be a nuisance hazard or could be a detriment to other equipment Vent terminals must have a minimum clearance of 4 feet horizon tally from and in no case above or below electrical meters gas meters regulators and relief equipment unless a 4 foot horizontal distance is maintained Do not locate the vent terminal where blockage by snow is a possibility or where flue products could strike against build ing materials and cause degradation AIR SOURCE FOR COMBUSTION WHEN NOT DIRECT VENTED When using these venting methods the Heatmaker draws all combustion air through the top of the unit and from the space around the boiler When locating the unit in unconfi
66. ug 2 Read voltage between yellow wires at back of VAC 24XFMR plug 3 Replace S9301A part 2400 224 1 Check for 120 VAC at module pins marked circulator opposite brown and white 2 Jump control wires one control at a time to identify open circuit control no continuity 3 Check for 120 VAC at module pins marked inducer opposite gray and white wires Check for 120 VAC at pins marked IGNR blue wires during ignitor light on Check for 24 VAC between orange and yellow wires on gas valve when red VALVE FLAME light is on See trouble shooting section under cross contamination amp short cycling in service manual QUICK REFERENCE TROUBLE SHOOTER FOR MORE INFORMATION SEE INDEX mr sc Od A SHORT CYCLING Unit shuts down before reaching limit Restarts within one minute without resetting Cross contamination in air source remove air elbow from top of air orifice hose coupling and utilize air from space Do not vent both 3 and 5 pipe to chimney Wrong air or gas orifice combination for size or fuel source Refer to Heatmaker gas orifice chart only Limits operating intermittently or calibration out of specification B HEATMAKER OVERHEATS QUICKLY boiling noise in combustion chamber Air in combustion coil or in pump purge system 02 400rI0 Pump failure or control failure C DELAYED IGNITION Unit starts or stops with a pop Wrong gas orifice for fuel or air orifice si
67. ugh the 5 outer pipe Flue gases are vented through the 3 vent pipe positioned inside the 5 intake pipe The hot flue gases are surrounded by the intake flow of cooler outdoor air This vent system may be installed through and be in contact with combustible materials INSTALLING DIRECT VENT KITS The Direct Vent Heatmaker is certified with a maximum of 15 linear feet of vent pipe and one set of elbows Systems may be vented with a maximum of three sets of concentric elbows providing the maximum length is reduced by three linear feet for each additional elbow set Provide a minimum of 16 above the top of the boiler for vent installation and servicing There are two vent kits available Part numbers 2400 326 and 2400 328 provides all of the required materials Part number 2400 326 for vent installations which require adjustable height and horizontal run This kit will permit vertical and horizontal lengths of pipe from 2 or 4 One foot extensions and 2 to 4 extentions are available to increase vent lengths to the maxi mum allowed Additional sets of elbows are also available Part number 2400 328 provides all of the required materials for vent installations which may have a fixed height of 11 inches and an adjustable horizontal run of 2 4 Accessories for P N 2400 326 also fit P N 2400 328 LOCATING THE VENT ON AN OUTSIDE WALL Exterior vent should terminate 167 above grade and least 13 77 from any other building opening s
68. ustment PRIORITY RELAY R1 HW M2 Series Only The Priority Relay is a normally open single pole relay which accepts a 24 VAC signal from the low limit aquastat and the T T wires to provide 120 VAC power to the system circulator when the tank temperature remains above 150 F BOILER CONTROL The Integrated Boiler Control Module controls the combustion process the gas valve the igniter the blower the unit pump and the system circulator It provides blower prepurge as well as burner flame sensing When replacing the boiler control turn off disconnect switch and press in tabs on each end of plugs to remove from control All plugs are color coded and it is not possible to miswire the control STACK SWITCH The Stack Switch is a normally open single pole switch which is operated by the pressure difference across the air orifice It is set to close when a static pressure difference of 1 in w c is generated by the combustion air blower Its function is to prove airflow and to inhibit burner operation in the event of flue or chimney stoppage The switch is wired directly to the boiler control It is located on the inside of the jacket back panel adjacent to the boiler bracket TRANSFER TANK AND DOMESTIC HOT WATER COIL HW N2 Series Only The transfer tank contains approximately 20 gallons of boiler water It functions as an energy storage vessel to reduce boiler cycling on small output heating zones and to provide heat for domest
69. ze LP Gas regulator lock up 3 or greater above run pressure correct regulator and check gas pipe sizing against piping chart in installation manual Set regulator for maximum run pressure of 9 W C Remove blower and inspect flame holder burner for hole Check that blower flanges and gas piping are sealed D OCCASIONAL LOCK OUTS Requires interruption of power to restart Air in system causes safety limit to open Vent air from system and determine source of air Cross contamination in direct vent piping measure CO in air supply above air orifice 1 or greater will cause lock out and unit damage Condensing of moisture in combustion chamber a H M2 units No thermostatic union in system supply piping or thermostat does not close below 160 F b HW M2 units System circulating pumps not wired to Heatmaker blue wire See field wiring prints in installation manual c Improper pitch of vent pipe allowing moisture to return to combustion chamber or vent cap installation problem Occasional failure of blower red PURGE light will be flashing May also be caused by defective contact on strap on operating control Zone control short cycling or voltage problem Operate thermostats in various sequences to create suspect problem Note TACO zone valves must have isolating relay between end Switch and Heatmaker Installer s Leave It Right Check List VENTING 1 DIRECT Horizontal pitched down away Vertical unit

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