Lochinvar Copper-Fin II Commercial Gas Boilers Instruction Manual

Lochinvar Copper-Fin II Commercial Gas Boilers

Product Information

Specifications

• Model: CFA-I-S_100160907_2000001336_Rev P
• Installation & Service Manual Models: 90,000 – 500,000 Btu/hr

Product Usage Instructions

Installation

Before proceeding with the installation, it is strongly recommended to review the entire manual completely. Failure to comply with the instructions could result in severe personal injury, death, or substantial property damage.

1. Perform installation steps in the order given.
2. This gas appliance should only be installed by a licensed electrician and/or certified gas supplier.
3. Ensure that the appliance is not installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is designed to eliminate the probable ignition of gasoline or flammable vapors.
4. Check for signs of shipping damage upon receiving the equipment. Pay close attention to parts accompanying the appliance for any signs of mishandling or damage. Verify the total number of pieces received matches the packing slip. If there is any damage or shortage, immediately notify the carrier.

Service

Service of the appliance must be performed by a qualified service installer, service agency, or the gas supplier.

1. Follow the instructions provided in this manual for assistance or additional information.
2. For any alterations, installations, adjustments, or maintenance, consult a qualified installer, service agency, or the gas supplier to avoid injury or property damage.

FAQs

• Q: Can I install this appliance myself?
  • A: No, this gas appliance should be installed by a licensed electrician and/or certified gas supplier.
• Q: Can I install the appliance in a location with gasoline or flammable vapors?
  • A: No, unless the installation is designed to eliminate the probable ignition of gasoline or flammable vapors.
• Q: What should I do if there is shipping damage or a shortage?
  • A: Immediately notify the carrier if there is any damage or shortage upon receiving the equipment.

CFA-I-S_100160907_2000001336_Rev P

Installation & Service Manual Models: 90,000 – 500,000 Btu/hr

WARNING:
This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an installation. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
Save this manual for future reference.

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION NOTICE

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

2

Installation & Service Manual

Please read before proceeding

NOTICE

This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier. Service must be performed by a qualified service installer, service agency or the gas supplier.

WARNING If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury, or death.
This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.
What to do if you smell gas ­

· Do not try to light any appliance.

WARNING

Improper alteration,

installation, adjustment, service or maintenance can

cause injury or property damage. Refer

to this manual for assistance or additional

information, consult a qualified installer,

service agency or the gas supplier.

Checking equipment ­

Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on the packing slip with those actually received. In case there is damage or a shortage, immediately notify the carrier.
Do not use this appliance if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

· Do not touch any electric switch; do not use any phone in your building.
· Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.
· If you cannot reach your gas supplier, call the fire department.

The installer must verify that at least one carbon monoxide alarm has been installed within a residential living space or home following the alarm manufacturer’s instructions and applicable local codes before putting the appliance into operation.
Owner warning ­
NOTE: Retain this manual for future reference.

Installation and service must be performed by a qualified installer, service agency, or the gas supplier.
Warranty ­

The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers. Consult your local expert for proper installation or service procedures.

Installation and service must be performed by a qualified service installer, service agency or the gas supplier.
Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

IMPORTANT

Consult and follow all local Building and Fire Regulations and other Safety Codes that apply to this installation. Consult your local gas utility company to authorize and inspect all gas and flue connections.

Experience has shown that improper installation or system design, rather than faulty equipment, is the cause of most operating problems.

Your conventionally vented gas appliance must have a supply of fresh air circulating around it during burner operation for proper gas combustion and proper venting.

1. Excessive water hardness causing a lime/scale build-up in the copper tube is not the fault of the equipment and is not covered under the manufacturer’s warranty (see Water Treatment and Water Chemistry).
2. Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer’s warranty (see Boiler Flow Rates and Temperature Rise for flow requirements).

WARNING

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect the electrical supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

3

Installation & Service Manual

Please read before proceeding

WARNING

To minimize the possibility of serious personal injury, fire, or damage to your

appliance, never violate the following safety

rules:

1. Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components.

2. Never cover your appliance, lean anything against it, store trash or debris near it, stand on it or in any way block the flow of fresh air to your appliance.

3. UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance, vent-air intake system or any location from which fumes could reach the appliance or vent-air intake system.

Codes ­
The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1. Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-1. All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code, Section IV. Where required by the authority having jurisdiction, the installation must comply with the Canadian Association Code, CAN/CGA- B149.1 and/or local codes.
This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.

Boiler water ­
Thoroughly flush the system to remove debris. Use an approved pre- commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.
Prevention of freezing ­
Heat exchangers and headers damaged by freezing are not covered by warranty.
See Section 6, Start-Up – Freeze Protection for more information.

4

Ratings

Installation & Service Manual

Model Number
Note: Change “N” to “L” for L.P. gas models
CBN315 CBN360 CBN399 CBN500

Copper-Fin AHRI Rating

Input MBH
(Note 4)

MIN

MAX

157.5

315

180

360

199.5

399

250

500

Gross Output MBH
(Note 1)
258 295 327 410

Net AHRI Ratings Water, MBH
(Note 2)
224
257
285
357

Other Specifications

Boiler Water Content Gallons

Water

Gas

Connections Connections

Vent Size (Note 3)

1.2

2″

1.2

2″

1.3

2″

1.4

2″

3/4″

8″

1″

9″

1″

10″

1″

10″

NOTICE Maximum allowed working pressure is located on the rating plate.

Notes:
1. The ratings are based on standard test procedures prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

3. Copper-fins require special gas venting. Use only the vent materials and methods specified in the Installation and Service Manual.

4. The Copper-fin is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation.

Figure A High Altitude Label Location

5. Ratings have been confirmed by AHRI.

UNIT EQUIPPED FOR
HIGH ALTITUDE
UP TO 2000 FT.

5

Ratings

Installation & Service Manual

Model Number
Note: Change “N” to “L” for L.P. gas models
CWN090 CWN135 CWN180 CWN199 CWN201 CWN225 CWN270 CWN315 CWN360 CWN399 CWN500

Input MBH
90 135 180 199 201 225 270 315 360 399 500

HLW

LOW LEAD CONTENT

Copper-fin Specifications

Water Content Gallons

Water Connections

Gas Connections

1.0

2″

1/2″

1.0

2″

1/2″

1.1

2″

3/4″

1.1

2″

3/4″

1.1

2″

3/4″

1.1

2″

3/4″

1.1

2″

3/4″

1.2

2″

3/4″

1.2

2″

1″

1.3

2″

1″

1.4

2″

1″

Vent Size (Note 1) 5″ 6″ 7″ 7″ 7″ 7″ 8″ 8″ 9″ 10″ 10″

NOTICE Maximum allowed working pressure is located on the rating plate.
Notes: 1. Copper-fins require special gas venting. Use only the vent
materials and methods specified in the Installation and Service Manual.
2. The Copper-fin is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation.

UNIT EQUIPPED FOR
HIGH ALTITUDE
UP TO 2000 FT.

Figure B High Altitude Label Location

6

Installation & Service Manual

The Copper-fin – How it works…

1. Control panel cover

15. Water inlet

The control panel cover provides access to the thermostat,

The water inlet is a 2″ pipe connection that receives water from the

ignition module, and transformer.

system and delivers it to the heat exchanger.

2. Drain port (not shown) Location from which the heat exchanger can be drained.

16. Water outlet The water outlet is a 2″ pipe connection that supplies water to

3. Flue outlet The flue outlet allows the connection of the vent pipe to the unit.

the system . 17. Burner (not shown)

4. Gas connection pipe The gas pipe connection on this appliance should be connected to

The burner is a cylindrical stainless steel tube used to regulate burner flame.

the incoming gas supply for the purpose of delivering gas to the

appliance.

18. Pilot (not shown)

5. Gas valve The gas valve allows the proper amount of gas to pass into the burner for combustion.

( F9 and M9 models only) The pilot is a spark ignition device is used to light a pilot flame which in turn is used to light the main burners. ( F1 models only)

6. Heat exchanger

The pilot uses a standing flame to light the main burner.

The heat exchanger allows system water to flow through specially

designed tubes for maximum heat transfer. The glass lined headers and copper finned tubing are encased in a jacket that contains the combustion process.

19. Sight Glass (not shown) The sight glass provides a view of the burner surface, burner flame, and the pilot flame.

7. High limit sensor Device that monitors the outlet water temperature to ensure safe operation. If the temperature exceeds its setting , it will break the control circuit, shutting the appliance down.
8. Ignition module (F9 and M9 models only) The ignition module responds to a call for heat signal to provide burner operation .
9. Junction box The junction box contains the connection points for the line voltage power and the pump.
10. Relief valve The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Water heaters are supplied with a temperature and pressure relief valve.

20. Temperature and pressure gauge (CB models only) The temperature and pressure gauge monitors the outlet temperature of the boiler as well as the system water pressure.
21. Pump (shipped with CW models only) The pump ensures adequate flow to operate the unit.
22. Pump relay The pump relay energizes the pump on a call for heat.
23. Temperature sensor This sensor monitors inlet water temperature. If selected as the controlling sensor, the appliance will maintain the setpoint at this sensor.

11. Terminal strip The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection to contact points on the unit.

12. Thermostat
The thermostat monitors the water temperature via a temperature sensor and will initiate a call for heat when the water temperature drops below the setpoint plus the differential on the thermostat.

13. Temperature gauge (CW models only) The temperature gauge monitors the inlet temperature of the water heater as well as the outlet temperature.
14. Transformer The transformer reduces 120 VAC supply voltage to 24 VAC for the control circuit.
7

The Copper-fin – How it works…
3

Installation & Service Manual
3

10

1

10

16

21

15

5

Models CWN270 Front View

9 11

16

9

21

11

5

15

Model CWN399 Front View

6

1
6

7
13
23 22
4 Model CWN270 (inside unit)

8

12 14

13

7 23 4
Model CWN399 (inside unit)

14 22

8

12 8

The Copper-fin – How it works… (continued)
3

Installation & Service Manual 3

20

1

20

1

10

10

16

15

9

11 5
Model CBN399 Front View

16
15 9
11 5 Model CBN500 Front View

6

6

7
23 4

14 22

Models CBN399 (inside unit)

12 8
7
23 4

14 22

12 8

Model CBN500 (inside unit)

9

Determine unit location

Location of unit

Installation & Service Manual

1. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

2. The appliance must be installed indoors where it is protected from exposure to wind, rain and weather.

3. The appliance must be installed so that the ignition system components are protected from water (dripping, spraying, rain, etc.,) during appliance operation and service (circulator replacement, control replacement, etc.,).

4. Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18″ (46cm) above the floor. The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle.

5. DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present.

6. All units have been approved for alcove installation (an ALCOVE is a closet enclosure without a front door).

7. The appliance must not be installed on carpet.

8. All units have been approved for use on combustible surfaces.

9. Allow sufficient space for servicing pipe connections, pump and other auxiliary equipment, as well as the appliance.

NOTICE

Clearances from combustible construction are noted on the appliance rating plate.

14 ” TOP

6 ” REAR

6″ RIGHT

24″ FRONT

24″ LEFT

Figure 1-1_Alcove installation, 90,000 – 180,000 Btu/hr

29″ TOP

6″ REAR
24″ FRONT

24″ LEFT

6 ” RIGHT

Figure 1-2_Alcove Installation, 225,000 – 500,000 Btu/hr

10

Installation & Service Manual
1 Determine unit location (continued)
Combustion and ventilation air requirements for conventionally vented appliances
Provisions for combustion and ventilation air must be in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting.
Figure 1-4_Combustion Air Through Ducts
2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11cm2 per kW) (see FIG. 1-4).

Figure 1-3_Combustion Air Direct from Outside
1. If air is taken directly from outside the building with no duct, provide two permanent openings (see FIG. 1-3):

(a) Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12″ (30 cm) of the floor.
(b) Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12″ (30 cm) of the ceiling.

Figure 1-5_Combustion Air from Interior Space
3. If air is taken from another interior space that is adequately ventilated, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/ hr (22cm2 per kW) of input, but not less than 100 square inches (645cm2) (see FIG. 1-5).

11

Installation & Service Manual

1 Determine unit location

CAUTION

Under no circumstances should the room where the appliance is installed ever be under a negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the appliance.

Figure 1-6_Combustion Air from Outside Single Opening
4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12″ (30 cm) of the top of the enclosure (see FIG. 1-6).
Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada refer to National Standard CAN B149.1. Check all local code requirements for combustion air.
All dimensions are based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12″ (30 cm) of the ceiling and one must be within 12″ (30 cm) of the floor of the room where the appliance is installed. Each opening must have a net free area as specified in Table 1B (on page 13). Single openings shall be located within 12″ (30 cm) of the ceiling.

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as freon, tricholorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger finned tubes, headers, flue collectors, and the vent system. The result is improper combustion and a non-warrantable, premature appliance failure.
The result is improper combustion and a non-warrantable, premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected. If a fan is used to supply combustion air to the equipment room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance.

12

1 Determine unit location (continued)

Installation & Service Manual

TABLE – 1B MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM

Input Btu/hr

*Outside Air from

*Outside Air from

2 Openings Directly from *Outside Air from 2 Ducts Delivered from

Outdoors

1 Opening Directly

Outdoors

Top

Bottom from Outdoors, in2

Top

Bottom

Opening, in2 Opening, in2

Opening, in2 Opening, in2

90,000

23 (148 cm2)

23 (148 cm2)

30 (194 cm2)

45 (291 cm2)

45 (291 cm2)

135,000

34 (220 cm2)

34 (220 cm2)

45 (291 cm2)

68 (439 cm2)

68 (439 cm2)

**Inside Air from 2 Ducts Delivered from
Interior Space

Top

Bottom

Opening, in2 Opening, in2

100 (646 cm2)

100 (646 cm2)

135 (871 cm2)

135 (871 cm2)

180,000

45 (291 cm2)

45 (291 cm2)

60 (388 cm2)

90 (581 cm2)

90 (581 cm2)

180 (1,162 cm2)

180 (1,162 cm2)

199,000/ 201,000 225,000 270,000 315,000 360,000 399,000 500,000

50 (323 cm2)
57 (368 cm2)
68 (439 cm2)
79 (510 cm2)
90 (581 cm2)
100 (646 cm2)
125 (807 cm2)

50 (323 cm2)
57 (368 cm2)
68 (439 cm2)
79 (510 cm2)
90 (581 cm2)
100 (646 cm2)
125 (807 cm2)

67 (433 cm2)
75 (484 cm2)
90 (581 cm2)
105 (678 cm2)
120 (775 cm2)
134 (865 cm2)
167 (1,078 cm2)

100 (646 cm2)
113 (730 cm2)
135 (871 cm2)
158 (1,020 cm2)
180 (1,162 cm2)
200 (1,291 cm2)
250 (1,613 cm2)

100 (646 cm2)
113 (730 cm2)
135 (871 cm2)
158 (1,020 cm2)
180 (1,162 cm2)
200 (1,291 cm2)
250 (1,613 cm2)

200 (1,291 cm2)
225 (1,452 cm2)
270 (1,742 cm2)
315 (2,033 cm2)
360 (2,323 cm2)
400 (2,581 cm2)
500 (3,226 cm2)

200 (1,291 cm2)
225 (1,452 cm2)
270 (1,742 cm2)
315 (2,033 cm2)
360 (2,323 cm2)
400 (2,581 cm2)
500 (3,226 cm2)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.
*Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of ”Tight Construction”. For buildings of *”Tight Construction”, provide air openings into the building from outside.

No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of ”Tight Construction”.

• “Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

Vent installations for connection to gas vents or chimneys must be in accordance with “Venting of Equipment,” of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes.

Adequate combustion and ventilation air must be supplied to the room where the appliance is installed in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

13

Installation & Service Manual

Venting

The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.

Vent connection is made directly to the top of the appliance. This appliance is designed with a built-in draft diverter. No additional external draft hood is required. The connection from the appliance vent to the common vent or chimney must be made as direct as possible.

A Conventional Negative Draft Venting System
The negative draft in a conventional vent installation must be within the range of a negative 0.02 to 0.05 inches water column to ensure proper operation. All draft readings are made while the appliance is in stable operation (approximately 2 to 5 minutes).
Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have draft within the proper range. If the draft measured above the appliance’s built-in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances, a barometric damper must be installed to control draft.

Figure 2-1_Conventional Negative Draft Vertical Venting

TABLE – 2A VENT PIPE SIZES

Input Btu/hr

Flue Size

90,000

5″

135,000

6″

180,000

7″

199,000/201,000

7″

225,000

7″

270,000

8″

315,000

8″

360,000

9″

399,000

10″

500,000

10″

On a conventionally vented, negative draft appliance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type “B” double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter. To properly size all double wall vent connectors and stacks, use the venting tables in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment. The Type “B” vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer’s listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes.

Any vent materials used must be listed by a nationally recognized test agency for use as vent material.

14

2 Venting (continued)
Locate appliance as close as possible to a chimney or gas vent.
Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions. Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm/m) from the appliance to the vent terminal. Follow manufacturer’s instructions.
Do not use an existing chimney as a raceway for a flue pipe if another appliance or fireplace is vented through the chimney. A water heater shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.
The weight of the venting system must not rest on the appliance. Adequate support of the venting system must be provided in compliance with local codes and other applicable codes. All connections should be secured with rustproof sheet metal screws.
Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure. Connection to a positive pressure chimney may cause flue products to be discharged into the living space causing serious health injury.
Common venting systems may be too large when an existing appliance is removed. At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to the common venting system are not in operation.
(a) Seal any unused opening in the common venting system.
(b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.
(c) Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

Installation & Service Manual
(e) Test for spillage at the draft hood/relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
(f) After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.
(g) Any improper operation of the common venting system should be corrected so that the installation conforms to the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 in the latest edition of the National Fuel Gas Code, ANSI Z223.1. In Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.
15

2 Venting
Vertical Vent Termination Clearances

10′ OR LESS

CHIMNEY

2′ MIN RIDGE

3′ MIN

Installation & Service Manual

10′ OR LESS

10′ OR LESS

2′ MIN

2′ MIN

3′ MIN

Figure 2-2_Vent Termination from Peaked Roof 10′ or Less from Ridge

CHIMMEY WALL OR PARAPET

CHIMMEY

Figure 2-4_Vent Termination from Flat Roof 10′ or Less from Parapet Wall

10′ OR MORE

MORE THAN 10′

10′

3′

2′ MIN

CHIMNEY

RIDGE

3′ MIN

NOTE: NO HEIGHT ABOVE PARAPET REQUIRED WHEN DISTANCE FROM WALLS OR PARAPETS IS MORE THAN 10′.

Figure 2-3_Vent Termination from Peaked Roof More than 10′ from Ridge
The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof within a 10 foot (3.05m) radius of the termination. The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.
A vertical terminal less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet wall.
The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot (1.22m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.
The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m) below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above any door, window or gravity air inlet into any building.
Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area.
16

WALL OR PARAPET

CHIMNEY

Figure 2-5_Vent Termination from Flat Roof More Than 10′ from Parapet Wall

The vent can not terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above grade.
To avoid a blocked vent condition, keep the vent cap clear of snow, ice, leaves, debris, etc.
Flue gases will form a white plume in winter. Plume could obstruct window view.
Flue gas condensate can freeze on exterior surfaces or on the vent cap. Frozen condensate on the vent cap can result in a blocked vent condition. Flue gas condensate can cause discoloration of exterior building surfaces. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

NOTICE

Examine the venting system at least once a year. Check all joints and vent pipe connections for tightness. Also check for corrosion or deterioration. Immediately correct any problems observed in the venting system.

Installation & Service Manual

2 Venting (continued)

Masonry Chimney Installation
A masonry chimney must be properly sized for the installation of a gas fired appliance. Venting of an appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry chimneys, with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature of the flue gases from an appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft. This will result in condensing of flue gases, damage the masonry flue/tile, insufficient draft and possible spillage of flue gases into an occupied living space. Carefully inspect all chimney systems before installation. If there is any doubt about the sizing or condition of a masonry chimney, it must be relined with a properly sized and approved chimney liner system.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to determine its suitability for the venting of flue gases. A clay tile lined chimney must be structurally sound, straight and free of misaligned tile, gaps between liner sections, missing sections of liner or any signs of condensate drainage at the breaching or clean out. If there is any doubt about the condition of a masonry chimney, it must be relined. An unlined masonry chimney must not be used to vent flue gases from this appliance. An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it. Metallic liner systems (Type “B” double wall or flexible or rigid metallic liners) are recommended. Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney.
Sidewall Venting
This appliance is NOT approved for sidewall venting with the negative draft venting system as shipped from the factory. An induced draft fan MUST be used if the installation requires that the flue gases be vented out a sidewall. A properly sized and installed induced draft fan may also be used to vent the flue gases vertically if required by job site conditions. The induced draft fan must be listed by a nationally recognized test agency, be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements. Use care to ensure that the mechanically supplied draft does not exceed the range of a negative 0.02 to 0.05 inches water column to ensure proper operation. If draft exceeds the specified range, the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft.

fan manufacturer and provide proper clearances from any combustion or ventilation openings, windows, doors or other openings into the building. All induced draft fan installations must comply with local code requirements. See FIG. 2-7 for minimum sidewall venting clearances. Fan Assisted Venting
A Power Venter kit is available on models 90,000 – 135,000 Btu/hr, water heaters only.

TABLE 2B – VENT MATERIALS

Kit Number

Input Btu / hr

Material

100157734

90,000 135,000

CPVC Rated CPVC Rated

Minimum Vent Length = 12 Equivalent Feet * (ALL UNITS)

Maximum Vent Length = 25 Equivalent Feet (ALL UNITS)

*Equivalent Feet: 90° Elbow = 5 Feet 45° Elbow = 3 Feet

CAUTION

DO NOT use Radel or cellular (foam) core PVC or CPVC pipe.

NOTE: In Canada, CPVC and PVC vent pipe, fittings and

cement/primer must be ULC-S636 certified.

WARNING

DO NOT insulate PVC or CPVC venting materials. Use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

NOTICE

All CPVC and PVC vent pipes must be glued, properly supported, and the exhaust

must be pitched a minimum of 1/4″ per foot back to the water

heater (to allow drainage of condensate). Horizontal runs

shall have supports suitable for non-metallic vent piping that

do not clamp tightly onto vent allowing for vent expansions or

contraction. Supports shall be as close to joints and fittings as

practical and no more than 5 ft. apart.

NOTICE

When available, follow all vent manufacturer’s installation instructions.

Figure 2-6_CW135 with Fan Assisted Venting

An induced draft fan MUST be interlocked into the appliance’s

control circuit to start when the appliance calls for heat. The

induced draft fan MUST also be equipped with a proving

switch, properly interlocked into the appliance’s control circuit

to prove fan operation before the main burners are allowed

to fire. A vertical or sidewall vent termination for an induced

draft fan MUST be installed per the recommendations of the

17

2 Venting
Figure 2-7 Other than Direct Vent Terminal Clearances

Installation & Service Manual

Table 2C Other than Direct Vent Terminal Clearances

Canadian Installations¹

A =

Clearance above grade, veranda, porch, deck, or balcony

12 in (30 cm)

US Installations²
12 in (30 cm)

6 in (15 cm) for appliances < 10,000 Btuh

B =

Clearance to window or door that may be opened

(3 kW), 12 in (30 cm) for appliances > 10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW), 36 in (91 cm) for appliances >

4 ft (1.2 m) below or to side of opening; 1 ft (300 mm) above opening

100,000 Btuh (30 kW)

C =

Clearance to permanently closed window

Vertical clearance to ventilated soffit

D =

located above the terminal within a horizontal distance of 2 ft (61 cm) from

the center line of the terminal.

E =

Clearance to unventilated soffit

F =

Clearance to outside corner

G =

Clearance to inside corner

Clearance to each side of center line

H =

extended above meter / regulator

3 ft (91 cm) within a height 15 ft (4.6 m)

assembly

18

Installation & Service Manual

2 Venting (continued)

Table 2C Other than Direct Vent Terminal Clearances (continued)

I =
J =
K =
L =
M = *

Clearance to service regulator vent outlet

3 ft (91 cm)

Clearance to nonmechanical air supply inlet to building or the combustion air
inlet to any other appliance

6 in (15 cm) for appliances < 10,000 Btuh (3kW), 12 in (30 cm) for appliances

10,000 Btuh (3 kW) and < 100,000 Btuh (30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)

4 ft (1.2 m) below or to side of opening; 1 ft (300 mm) above opening

Clearance to a mechanical air supply inlet

6 ft (1.83 m)

3 ft (91 cm) above if within 10 ft (3 m) horizontally

Clearance above paved sidewalk or paved driveway located on public property

7 ft (2.13 m)

7 ft (2.13 m) for mechanical draft systems (Category I appliances). Vents for
Category II and IV appliances cannot be located above public walkways or other areas where condensate or vapor can
cause a nuisance or hazard

Clearance under veranda, porch, deck,

12 in (30 cm)

or balcony

Clearance in accordance with local installation codes and the requirements of the gas supplier. A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings and serves both dwellings. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he floor.

NOTES:

In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

19

Installation & Service Manual

2 Venting
Automatic Vent Damper
This heating boiler is design certified for use with the automatic vent damper (FIG. 2-8) part number printed on the boiler’s rating plate. A vent damper is optional on heating boilers above 360,000 Btu/hr. Automatic vent dampers are not required or furnished on potable water heaters. Water heaters with inputs of 360,000 Btu/hr and less may be ordered with the vent damper as an option. A vent damper is a useful tool for saving energy when installed inside the living space where air can circulate freely around the appliance. The vent damper will not save as much, if any, energy if it is installed in locations such as:

Figure 2-8_CB with Vent Damper and Vent Damper Terminal Block
VENT DAMPER

– Unheated garage – Attic – Crawlspace – Mechanical room that is vented outdoors

For installation and maintenance on the vent damper, refer to the instructions supplied with the vent damper.
Larger input heating boilers and water heaters will have a jumper plug installed in the terminal block to allow operation without a damper. Remove the jumper plug from the terminal block to connect an optional vent damper wire harness (water heater shown in FIG. 2-9). The jumper plug MUST be in place if an optional vent damper is not used on water heaters and larger input heating boilers.

TERMINAL BLOCK
Figure 2-9_CW with Vent Damper
VENT DAMPER

WARNING

Do not install the vent damper within 6″ (152 mm) of combustible materials.

DANGER

Install the vent damper to service only the single appliance for which it is intended. If improperly installed, a hazardous condition such as an explosion or carbon monoxide poisoning could result.

The damper position indicator must be in a visible location with access for service following installation. The damper must be in an open position when appliance main burners are operating.
The part number for the automatic vent damper required on this heating boiler is printed on the rating plate. Vent damper regulations are design certified per the latest edition of ANSI Z21.66.

WARNING

The vent damper must be installed directly on the flue outlet located on the top of the draft hood (see FIG. 2-8). Do not alter the wire harness supplied with the vent damper. Follow the instructions supplied with the vent damper.

CAUTION

An appliance which is shut down or will not operate may experience freezing due to convective air flow down the flue pipe connected to the unit. Proper freeze protection must be provided, see Freeze Protection in the Startup Section of this manual.

20

Installation & Service Manual

Gas connections

Gas Supply

Gas Pressure Test

Verify that the appliance is supplied with the type gas specified on the rating plate. This appliance is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation. Field conversions for operation at high altitude must be performed by certified personnel only. The appliance will be marked to indicate suitability for high altitude operation.
GAS SUPPLY PRESSURE: Measured at the inlet pressure tap located upstream of the combination gas valve(s) see FIG.’s 3-5 and 3-6, page 25.

1. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5kPa).
2. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5kPa).
3. The appliance and its gas connection must be leak-tested before placing it in operation.
Gas Connection

TABLE – 3A
GAS SUPPLY PRESSURE

Natural Gas

Max. (Inches Water Column) Min. (Inches Water Column) Min. (Inches Water Column)

14 *4.5 **5.0

LP Gas 14 11 11

1. Safe operation of the appliance requires properly sized gas supply piping.
2. Gas pipe size may be larger than appliance gas connection.
3. Installation of a union is suggested for ease of service, see FIG. 3-1 on page 22.
4. Install a manual main gas shutoff valve, outside of the appliance gas connection and before the gas valve or manifold connection, when local codes require.

*Models 90,000 – 360,000 Btu/hr Only **Models 399,000 – 500,000 Btu/hr Only
Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.
MANIFOLD PRESSURE: Measured at the pressure tap on the downstream side of the combination gas valve(s) (see FIG.’s 3-5 and 3-6, page 25). The gas regulator settings for single stage and two stage operation are factory set to supply proper manifold pressure for normal operation. To check manifold pressure, see Manifold Adjustment Procedure. Do not increase manifold pressure beyond specified pressure settings shown below in Table 3B.

5. A trap (drip leg) MUST be provided by the installer in the inlet of the gas connection to the appliance, see FIG. 3-1 on page 22.
6. The combination gas valve has an integral vent limiting device and does not require venting to atmosphere, outside the building.
7. Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes.
TABLE – 3C
FITTINGS TO EQUIVALENT STRAIGHT PIPE
Diameter Pipe (inches)

TABLE – 3B MANIFOLD PRESSURE

Input Gas Btu/hr

Single and Two-Stage

Two Stage

Full or High Fire Settings Low Fire Settings Natural Gas LP Gas Natural Gas LP Gas

90,000 – 180,000 3.5″

10″

0.9″

2.5″

199,000/201,000 2.9″

7.5″

0.9″

2.5″

215,000 – 399,000 3.5″

10″

0.9″

2.5″

500,000

3.5″

10″ (two valves)

N/A

N/A

3/4 1 1 1/4 1 1/2 2 3 4 5 Equivalent Length of Straight Pipe (feet)
2 2 3 4 5 10 14 20

TABLE – 3D
GAS CONNECTIONS

Btu/hr INPUT

Pipe Size

90,000 – 135,000

1/2″

180,000 – 315,000

3/4″

360,000 – 500,000

1

21

3 Gas connections

Installation & Service Manual

Pipe Size (Inches) 1/2 3/4
1 1 1/4 1 1/2
2 2 1/2
3
4

TABLE – 3E Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 specific gravity, 0.30″ w.c. pressure drop)
Length of Pipe in Straight Feet

10 20 30 40 50 60 70 80 90 100 125 150

131 90 273 188 514 353 1,060 726 1,580 1,090 3,050 2,090 4,860 3,340 8,580 5,900 17,500 12,000

72 151 284 583 873 1,680 2,680 4,740 9,660

62 129 243 499 747 1,440 2,290 4,050 8,270

55 114 215 442 662 1,280 2,030 3,590 7,330

N/A 104 195 400 600 1,160 1,840 3,260 6,640

N/A 95 179 368 552 1,060 1,690 3,000 6,110

N/A 89 167 343 514 989 1,580 2,790 5,680

N/A 83 157 322 482 928 1,480 2,610 5,330

N/A 79 148 304 455 877 1,400 2,470 5,040

N/A 70 131 269 403 777 1,240 2,190 4,460

N/A 63 119 244 366 704 1,120 1,980 4,050

175
N/A 58 109 224 336 648 1,030 1,820 3,720

200
N/A N/A 102 209 313 602 960 1,700 3,460

Gas Piping
GAS VALVE GAS SHUTOFF

2. Use new, properly threaded black iron pipe free from chips. If tubing is used, make sure the ends are cut squared, deburred and clean. All tubing bends must be smooth and without deformation. Avoid flexible gas connections. Internal diameter of flexible lines may not provide proper volume of gas.
3. Run pipe or tubing to the gas valve or manifold inlet. If tubing is used, obtain a tube to pipe coupling to connect the tubing to the gas valve or manifold inlet.

TRAP ( DRIP LEG )

UNION

4. DO NOT OVER TIGHTEN. Over tightening may result in damage to the gas valves. Valve distortion or malfunction may result if the pipe is inserted too deeply into the gas valve.

5. Apply a moderate amount of good quality pipe compound

Figure 3-1_Gas Line Connection

(DO NOT use Teflon tape) to pipe only, leaving two end

All gas connections must be made with pipe joint

threads bare.

compound resistant to the action of liquefied petroleum and natural gas. All piping must comply with local codes. Tubing

Remove seal over gas valve or manifold inlet.

installations must comply with approved standards and

practices. Reference FIG. 3-1 for a typical installation.

7. Connect pipe to gas valve or manifold inlet. Use wrench

to square ends of the gas valve (FIG. 3-2).

Install Piping to Control

8. For L.P. gas, consult your L.P. gas supplier for expert

1. The gas line should be a separate line direct from the

installation.

meter unless the existing gas line is of sufficient capacity.

Verify pipe size with your gas supplier.

22

Installation & Service Manual

3 Gas connections (continued)
WHEN FLANGE IS USED

APPLY WRENCH TO FLANGE ONLY

WHEN FLANGE IS NOT USED

APPLY WRENCH FROM BOTTOM OF GAS CONTROL
TO EITHER SHADED AREA

Figure 3-2_Wrench

IMPORTANT

Upon completion of any piping connections to the gas system, leak test all gas connections with a soap solution while system is under pressure. Immediately repair any leaks found in the gas train or related components. Do Not operate an appliance with a leak in the gas train, valves or related piping.

Gas Manifold Pressure Adjustment Procedure

INLET PRESSURE
TAP

PRESSURE REGULATOR ADJUSTMENT
(UNDER SCREW CAP)
OUTLET PRESSURE TAP

2. Turn gas valve control knob to “PILOT” position on standing pilot models. Ensure that the standing pilot remains on. If the pilot goes out, follow the “Lighting Instructions” in Section 6 – Startup for standing pilot models to light the pilot. Turn gas valve control knob to “OFF” position on spark ignition models.
3. Remove the 1/8″ hex plug located on the outlet side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge. See FIG. 3-3. Minimum range of scale should be up to 5″ w.c. for Natural gas models and 10″ w.c. for L.P. gas models.
4. The 500,000 Btu/hr model will have two gas valves with a pressure regulator on each valve. Repeat the following adjustment procedure to set the manifold pressure on each gas valve.
5. Remove the pressure regulator adjustment cap screw on the gas valve. See FIG. 3-3 for location.
6. Turn the power “ON” at the main disconnect switch.
7. Turn gas valve control knob to “ON” position.
8. Set the thermostat(s) to call for heat.
9. Observe gas regulator pressure when all burners are firing. See Table 3B, Manifold Pressure (page 21) for proper regulator pressure settings.
10. If adjustment is necessary, turn regulator adjustment screw clockwise to raise regulator gas pressure, counterclockwise to lower gas pressure, to proper setting.
Note: Adjustment fitting is plastic and may require slightly greater turning force than a metal fitting.
11. Turn the power “OFF” at the main disconnect switch.

MANOMETER

PILOT OUTLET GAS CONTROL KNOB RED RESET BUTTON

NOTICE

Do not increase regulator pressure beyond specified pressure setting.

12. Turn gas valve control knob to “PILOT” position on standing pilot models. Turn gas valve control knob to “OFF” position on spark ignition models.

13. Remove fitting from the gas valve and replace the 1/8″ hex plug that was previously removed and tighten.

14. Repeat the adjustment procedure for the second gas valve on the 500,000 Btu/hr model.

UNION GAS VALVE

15. Turn the gas valve control knob(s) to “ON” position.
16. Turn the power “ON” at the main disconnect switch. The appliance is now ready to operate.

Figure 3-3_Manifold Pressure Adjustment 1. Turn the power “OFF” at the main disconnect switch.

If manifold pressure can not be properly adjusted, use the procedure on page 24 to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control.
23

Installation & Service Manual

3 Gas connections

Checking Gas Supply Pressure
MANOMETER
GAS SUPPLY PRESSURE
GAS VALVE
UNION
Figure 3-4_Gas Supply Pressure 1. Turn the power “OFF” at the main disconnect
switch. 2. Turn gas valve control knob(s) to the “OFF” position. 3. The 500,000 Btu/hr model will have two gas valves.
Turn the gas valve control knob on each valve to the “OFF” position. 4. Shut off gas supply at the manual valve in the gas piping to the appliance. If fuel supply is L.P. gas, shut off gas supply at the tank. 5. Remove the 1/8″ hex plug, located on the “inlet” side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge. On two gas valve models, remove the hex plug from the gas valve closest to the gas supply connection. Range of scale should be 14″ w.c. or greater to check inlet pressure. See FIG.’s 3-3 and 3-4 for location. 6. Turn on gas supply at the manual valve, turn on L.P. gas at tank if required. 7. Turn the power “ON” at the main disconnect switch. 8. Turn gas valve control knob to “PILOT” position on standing pilot models. Follow the “Lighting Instructions” in Section 6 – Startup for standing pilot models to light the pilot . Turn gas valve control knob to the “ON” position when the pilot is established. Turn gas valve control knob(s) to the “ON” position on spark ignition models.

9. Set the thermostat(s) to call for heat.
10. Observe the gas supply pressure with all burners firing. Ensure inlet pressure is within specified range. Check gas supply pressure with all other gas fired appliances in operation to ensure proper gas volume during periods of peak gas usage.
11. If gas pressure is out of range, contact gas utility, gas supplier, qualified installer or service agency to determine necessary steps to provide proper gas pressure to the appliance.
12. If the gas supply pressure is within the specified range, proceed with the following steps to return the appliance to service.
13. Turn the power “OFF” at the main disconnect switch.
14. Turn gas valve control knob to “PILOT” position on standing pilot models. Turn gas valve control knob(s) to “OFF” position on spark ignition models.
15. Shut off gas supply at the manual valve in the gas piping to the appliance. If fuel supply is L.P. Gas, shut off gas supply at the tank.
16. Remove the manometer and related fittings from the “inlet” side of the gas valve, replace 1/8″ hex plug in gas valve.
17. Turn on gas supply at the manual valve, turn on L.P. Gas at tank if required.
18. Turn the power “ON” at the main disconnect switch.
19. Turn the gas valve control knob(s) to the “ON” position. If the pilot is not burning, follow the “Lighting Instructions” in Section 6 – Startup for standing pilot models to light the pilot. Spark ignition models will automatically light the pilot on a call for heat.
20. Set the thermostat to call for heat. The appliance is now ready to operate.

IMPORTANT

Upon completion of any testing on the gas system, leak test all gas connections with a soap solution while main burners are operating. Immediately repair any leak found in the gas train or related components. Do Not operate an appliance with a leak in the gas train, valves or related piping.

Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly. Flame pattern should be stable, see the “Maintenance Section -Normal Flame Pattern”. Turn system off and allow burners to cool, then cycle burners again to ensure proper ignition and flame characteristics.

24

3 Gas connections (continued)
Combination Gas Valves
PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)

INLET PRESSURE TAP

OUTLET PRESSURE TAP

RED RESET BUTTON

PILOT OUTLET GAS CONTROL KNOB

Figure 3-5_F1 Gas Valve, standing pilot

PRESSURE REGULATOR ADJUSTMENT (UNDER CAP SCREW)

WIRING TERMINALS

OUTLET PRESSURE TAP

INLET PRESSURE TAP
GAS CONTROL KNOB
Figure 3-6_F9 Gas Valve, spark ignition

PILOT OUTLET

Installation & Service Manual
Each unit has a combination gas valve(s) to control the gas supply to the burners. The 500,000 Btu/hr model has two combination gas valves to supply gas to the burners. The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves. The valve has a gas control knob that must remain in the open position at all times when the appliance is in service. Each gas valve has pressure taps located on the inlet and outlet sides. Manifold pressure is adjusted using the regulator located on the valve. The manifold pressure is preset at the factory and adjustment is not usually required. If the manifold pressure is to be adjusted, follow the “Gas Manifold Pressure Adjustment Procedure”, page 23 for proper adjustment.
Venting of Combination Gas Valves
The combination gas valve regulator used on all models is equipped with an integral vent limiting orifice. The vent limiter ensures that the volume of gas emitted from the valve does not exceed the maximum safe leakage rate allowed by agency requirements. Combination gas valve/regulators equipped with integral vent limiters are not required to have vent or relief lines piped to the outdoors. A dust cap is provided at the vent termination point on the valve to prevent blockage of the vent limiter by foreign material. The combination gas valve regulator with an integral vent limiter complies with the safety code requirements of CSD-1, CF-190(a) as shipped from the manufacturer without the installation of additional vent lines.
Two Stage Burner Control System
The 315,000 through 399,999 Btu/hr boiler models (M9) will be equipped with a two stage gas valve to control high/low burner operation. The 500,000 Btu/hr boiler model achieves two stage burner firing by staging the operation of the two combination gas valves.

25

Hydronic piping

Relief Valve

Installation & Service Manual
Water Flow Switch (if equipped)

RELIEF VALVE

FLOW SWITCH

Figure 4-1_Relief Valve – CBN315-500

Figure 4-2_Water Flow Switch – CBN315-500

This appliance is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). The relief valve(s) is mounted directly into the heat exchanger inside the header (see FIG.’s 4-1 and 4-2). To prevent water damage, the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs. No reducing couplings or other restrictions shall be installed in the discharge line. The discharge line shall allow complete drainage of the valve and line. Relief valves should be manually operated at least once a year.
CAUTION Avoid contact with hot discharge water.

A water flow switch is available as a factory supplied option on all heating boilers and water heaters (see section 7). The flow switch should be wired between terminals X and B. Remove the jumper between the X and B terminals on the terminal strip. This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition. A flow switch installed with the factory supplied minimum adjustment setting requires a specific minimum flow to make the switch and start burner operation. The flow rate required is a function of the diameter of pipe and tee used for installation. Ensure that the pump installed on the boiler will supply adequate flow to make the flow switch contacts and operate the appliance.

26

Installation & Service Manual

4 Hydronic piping (continued)
A water flow switch meets most code requirements for a low-water cut off device on boilers requiring forced circulation for operation.

Typical Heating Boiler Installations
General Plumbing Rules

Low Water Cutoff (if equipped)

1. Check all local codes.

2. For serviceability of the boiler, always install unions.

A hot water boiler installed above radiation level must be provided with a low water cutoff device either as part of 3. Always pipe pressure relief valves to an open drain.

the unit or installed at the time the boiler is installed. An electronic low water cutoff is available as a kit on all units.

Locate system air vents at the highest point of the system.

Low water cutoffs should be inspected every six months, 5. Expansion tank must be installed near the boiler and on

including flushing of float types.

the suction side of the pump.

TABLE – 4A MINIMUM REQUIRED FLOW
FOR HEATING BOILER

Input Btu/hr

GPM Flow

315,000

13

360,000

14.9

399,000

16.5

500,000

20.7

6. Support all water piping.
Placing the Boiler in Operation
Filling the System: All air must be purged from the system for proper operation. An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve.
1. Close all drain cocks and air vents.
2. Open the makeup water valve and slowly fill the system.

NOTICE

Minimum flow is based on a 40°F temperature rise across the boiler. Minimum flow may not prove a flow switch installed in the boiler piping. Use care when operating a boiler at or near the minimum recommended flow because conditions unique to the installation (system pressure, operation of multiple zone valves, glycol, variations in flow, etc.,) may result in overheating of the boiler water causing noise or nuisance operation of safety limit controls. Typical heating boiler applications will operate with a 20°F to 30°F temperature rise across the boiler.

3. If a makeup water pump is employed, adjust the pressure to provide a minimum of 12 psi at the highest point in the system. If a pressure regulator is also installed in the line, it should be adjusted to the same pressure.

4. Close all valves. Purge one circuit at a time as follows:

A. Open one circuit drain valve and let the water drain for at least five minutes. Ensure that there are no air bubbles visible in the water stream before closing the drain valve.

B. Repeat this procedure for each circuit.

5. Open all valves after all circuits have been purged. Make sure there are no system leaks.

NOTICE

Do not use petroleum based stop leak products. All system leaks must be repaired. The constant addition of make-up water can cause damage to the boiler heat exchanger due to scale accumulation. Scale reduces flow and heat transfer, causing overheating of the heat exchanger.

6. Run the system circulating pump for a minimum of 30 minutes with the boiler turned off.

7. Open all strainers in the system and check for debris.

8. Recheck all air vents as described in step 4, General Plumbing Rules.

27

Installation & Service Manual

4 Hydronic piping

9. Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged and not water logged.
10. Start the boiler according to the Section 6 – “Start-Up Instructions” in this manual. Operate the system, including the pump, boiler and radiation units, for one hour.
11. Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. Recheck pressure charge on diaphragm type tanks.
12. Shut down the entire system and vent all radiation units and high points in the system.
13. Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris. Reopen the water makeup valve.
14. Verify system pressure with the boiler pressure gauge before beginning regular operation.
15. Within three days of start-up, recheck and bleed all air vents and the expansion tank using these instructions.

Piping of the Boiler System

The drawings in this section (see FIG’s 4-4 through 4-6) show typical heating boiler piping installations. Before beginning the installation, consult local codes for specific plumbing requirements. The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for service. The boiler circulating pump, air separator, expansion tank and other components required for proper installation must be purchased locally. An air separation device must be supplied in the installation piping to eliminate trapped air in the system. Locate a system air vent at the highest point in the system. The system must also have a properly sized expansion tank installed. Typically, an air charged diaphragm-type expansion tank is used. The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year. Install a Y-strainer or equivalent multi-purpose strainer just before the boiler pump at the inlet of the heat exchanger. This item is used to remove system debris from older hydronic systems and to protect newer systems.

CAUTION

This boiler system should not be operated at less than 12 PSIG (83 kPa) (Non- metallic system piping must have an oxygen barrier to be considered a closed loop).

Input 315,000 360,000 399,000 500,000

Btu/hr

TABLE – 4B SYSTEM TEMPERATURE RISE CHART
Based on Boiler Output in Btu/hr

20°F rT

30°F rT

Output

GPM

Ft/hd

GPM

Ft/hd

258,000

26.0

4.1

17.3

2.2

295,000

29.7

5.4

19.8

2.5

327,000

—

—

22.0

3.6

410,000

—

—

27.6

6.6

40°F rT

GPM

Ft/hd

13.0

1.3

14.9

1.5

16.5

2.0

20.7

3.5

28

Installation & Service Manual

4 Hydronic piping (continued)

Hot water piping must be supported by suitable hangers or

floor stands, NOT by the boiler. Copper pipe systems will

be subject to considerable expansion and contraction. Rigid

pipe hangers could allow the pipe to slide in the hanger

resulting in noise transmitted into the system. Padding

is recommended on rigid hangers installed with a copper

system. The boiler pressure relief valve must be piped to a

suitable floor drain. See the relief valve section on page 26

of this manual.

CAUTION

A leak in a boiler system will cause the system to intake fresh water constantly,

which will cause the tubes to accumulate

a lime/scale build up. This will cause a

NON-WARRANTABLE FAILURE.

Water Connections Heating Boilers Only

All water heaters and heating boilers with inputs of 315,000 500,000 Btu/hr have 2″ NPT.
CAUTION Field installed reducing bushings may decrease flow resulting in boiler noise or flashing to steam.

Circulator Pump Requirements
This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation. The boiler circulating pump must be purchased locally. The boiler circulator pump must operate continuously while the boiler is firing. Pump selection is critical to achieve proper operation. A pump should be selected to achieve proper system design water temperature rise. A heat exchanger pressure drop chart (Table 4C) is provided to assist in proper pump selection. Also provided is a System Temperature Rise Chart (Table 4B). This table provides GPM and boiler head-loss at various temperature rises for each boiler based on Btu/ hr input. Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing. Example: The boiler inlet temperature is 160°F and the boiler outlet temperature is 180°F, this means that there is a 20°F temperature rise across the boiler.

3. Cast iron circulators may be used for closed loop systems.
4. A properly sized expansion tank must be installed near the boiler and located on the suction side of the pump.
TABLE – 4C HEAT EXCHANGER PRESSURE DROP CHART

77 CCBB 55000
66
CCBB3360 55

44

CCBB33115

CCBB 339999

33

FFT/T/HDHD

2

1

0

0

5

10

15

20

25

30

35

Gallons per Minute

Circulator Pump Operation (Heating Boilers Only)
Boilers are equipped with a relay for controlling the circulation pump for the hot water loop. The relay turns ON and OFF in response to the “W” input from the wall thermostat or zone control.
The field installed boiler pump MUST NOT exceed 1 h.p. For continuous pump operation, wire the system pump to the 120V supply. The pump should be connected at the junction box as shown in FIG. 4-3.
120V SUPPLY

Circulator Pump Specifications
1. Maximum operating pressure for the pump must exceed system operating pressure.
2. Maximum water temperature should not exceed nameplate rating.

TO UNIT

TO CIRCULATION
PUMP
Figure 4-3_Boiler Wiring – Circulation Pump to Junction Box
29

4 Hydronic piping
PUMP INSTALLATION AND MAINTENANCE: The boiler circulating pump must be purchased locally. For installation and maintenance information on the circulator pump, refer to the pump manufacturers instruction package included with the pump.
Primary/Secondary Boiler Piping
Heating boilers with inputs of 315,000 – 500,000 Btu/hr or larger installed on multiple zone systems are recommended to be installed with a primary/secondary piping system as shown in FIG. 4-4. A primary/secondary piping system uses a dedicated pump to supply flow to the boiler only. This pump is sized based on desired boiler flow rate, heat exchanger head loss and head loss in the secondary system piping only. The secondary pump, installed in the boiler piping, ensures a constant water flow rate to the boiler for proper operation. Boiler installation with a primary/secondary piping system can prevent noise problems caused by low system water flows. A primary/secondary piping system is recommended on any boiler where low water flow conditions may present an operational problem.
A primary/secondary piping system is ideal for systems filled with a propylene glycol and water mixture. A glycol and water mixture is more dense than water only and may result in a lower boiler flow rate. A lower boiler flow may cause noise on operation or short cycling of the burners. A larger secondary pump may be used on a primary/secondary system to provide an increased boiler flow rate. A glycol and water system may require from 10 to 20% more flow to compensate for the increased density of the glycol and its effect on the heat transfer process in the boiler. The exact increase in flow that may be required is based on the type and percentage of glycol added to the boiler system. Consult the manufacturer of the glycol for additional recommendations when using a glycol and water fill for your boiler system.

Installation & Service Manual

The installer must ensure that the boiler has adequate flow without excessive temperature rise. The temperature rise on a multiple zone system should be made when only the zone with the longest length and/or highest head loss is open. Low system flow can result in overheating of the boiler water which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. System noise may also indicate an oversized boiler.

CAUTION

At no time should the system pressure be less than 12 PSIG (83 kPa) (Non- metallic system piping must have an oxygen barrier to be considered a closed loop).

NOTICE

A boiler operated with an inlet temperature of less than 140°F (60°C) must have a low temperature bypass to prevent problems with condensation. A 1 1/2″ LTV Valve Kit may be used. Follow the piping diagram in FIG. 4-5 to complete installation.

30

Installation & Service Manual

4 Hydronic piping (continued)

Low Temperature Bypass Requirements

Boiler Flow Rates

This piping is like a primary/secondary boiler installation with a bypass in the secondary boiler piping. Inlet water temperatures below 140°F (60°C) can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue. Condensation can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system and related components. The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140°F (60°C). This should prevent the products of combustion from condensing in most installations.
The bypass should be fully sized with a balancing valve to allow for proper adjustment. A valve must also be provided on the boiler discharge, after the bypass. Closing this discharge valve forces water through the bypass. Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open. A small amount of the higher temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature. A remote low temperature range operator is recommended to control the boiler operation for temperatures lower than 100°F. This remote operator should be wired across the R and W terminals (see Room Thermostat Connection and Terminal Strip Instructions in Section 5 of this manual).
Three Way Valves

TABLE – 4D
MAXIMUM FLOW FOR HEATING BOILER

The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following:

Model 90,000 – 500,000

Maximum

Flow

Maximum Flow for CuNi Heat Exchanger

30 GPM

38 GPM

The heat exchanger is generally capable of operating within the flow rates of a residential heating system. Should the flow rate exceed the maximum allowable flow rate through the boiler 30 GPM) an external bypass must be installed. The bypass should be fully sized with a balancing valve to allow for proper adjustment of flow. Flow rate can be determined by measuring the temperature rise through the boiler.

The basic guide for minimum flow in this boiler is based on a 40°F temperature rise in most installations. Lower flow and a higher temperature rise is acceptable if the boiler system is specifically designed for the characteristics of a higher temperature rise. A system not specifically designed for a higher temperature rise may experience overheating of the boiler water. This can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. These conditions can lead to operational problems and non-warrantable failures of the boiler. High temperature rise systems must be designed by a qualified engineer.

The installation of a three way valve on this boiler is not generally recommended because most piping methods allow the three way valve to vary flow to the boiler. This boiler is a low mass, high efficiency unit which requires a constant water flow rate for proper operation.

Low flow rates can result in overheating of the boiler water which can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. These conditions can cause operational problems and non-warrantable failures of the boiler. If a three way valve must be installed, please pipe in a primary/secondary system. Based on boiler sizing and system flow requirements, this piping may still result in boiler short cycling.

31

4 Hydronic piping
Primary / Secondary Piping
Figure 4-4_Primary / Secondary Piping of a Single Boiler

Installation & Service Manual

DIRT SEPARATOR (RECOMMENDED)
MAY SUBSTITUTE LOW LOSS HEADER
AIR SEPARATOR
DRAIN POINT (TYPICAL)
SYSTEM SUPPLY SENSOR (WHEN USED)
SYSTEM CIRCULATOR

FROM SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART BALL VALVE (TYPICAL)

TO SYSTEM
MAKE UP WATER WATER METER
BACK FLOW PREVENTER PRESSURE REDUCING VALVE

PRESSURE GAUGE EXPANSION TANK
Y-STRAINER
FLOW CHECK VALVE (TYPICAL) BOILER CIRCULATOR

DIR #2000570578_000

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

FLOW SWITCH DRAIN

BOILER UNION (TYPICAL)

NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

32

4 Hydronic piping (continued)
Primary / Secondary Piping

Installation & Service Manual

Figure 4-5_Single Boiler – Primary / Secondary with Low Temperature Bypass

MAY SUBSTITUTE LOW LOSS HEADER

DIRT SEPARATOR (RECOMMENDED)

FROM SYSTEM

AIR SEPARATOR DRAIN POINT
(TYPICAL) SYSTEM SUPPLY SENSOR
(WHEN USED) SYSTEM CIRCULATOR
TO SYSTEM
MAKE UP WATER WATER METER
BACK FLOW PREVENTER PRESSURE REDUCING VALVE

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12″ APART
BALL VALVE (TYPICAL)

PRESSURE GAUGE
EXPANSION TANK
FLOW CHECK VALVE (TYPICAL)

LOW TEMPERATURE BYPASS

Y-STRAINER

PRESSURE RELIEF VALVE
TEMPERATURE / PRESSURE GAUGE

FLOW SWITCH DRAIN

DIR #2000570577_000

BOILER CIRCULATOR

BOILER

UNION (TYPICAL)

NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

33

4 Hydronic piping
Primary / Secondary Piping
Figure 4-6_Multiple Boilers Zoned with Circulators
TEMPERATURE LOOP 3
TEMPERATURE LOOP 2
TEMPERATURE LOOP 1

Installation & Service Manual

TO SYSTEM

FROM SYSTEM

MAKE UP WATER

AIR SEPARATOR
PRESSURE GAUGE

WATER METER
BACK FLOW PREVENTER

PRESSURE REDUCING
VALVE

EXPANSION TANK

SYSTEM SUPPLY SENSOR
( WHEN USED )
DRAIN POINT (TYPICAL)

NOT EXCEED 12″ APART

MAY SUBSTITUTE LOW
LOSS HEADER

PRESSURE RELIEF VALVE

INDIRECT DHW TANK
ANTI-SCALD MIXING VALVE
HOT WATER OUT
COLD WATER IN

FLOW CHECK VALVE

DRAIN

BALL VALVE (TYPICAL)

DIRT SEPARATOR (RECOMMENDED)
Y-STRAINER (TYPICAL)
FLOW CHECK VALVE (TYPICAL)

BOILER CIRCULATOR
DRAIN ( TYPICAL )

BOILER 2
TEMPERATURE / PRESSURE GAUGE ( TYPICAL)
PRESSURE RELIEF VALVE (TYPICAL)

BOILER 1
UNION (TYPICAL) DOMESTIC HOT WATER CIRCULATOR

DIR #2000570579_000

NOTICE

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

34

Installation & Service Manual

Electrical connections

This appliance is wired for 120 VAC service. The appliance, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the National Electrical Code ANSI/NFPA No. 70. When the unit is installed in Canada, it must conform to the CSA C22.1, Canadian Electrical Code, Part 1 and/or local Electrical Codes.
1. All wiring between the appliance and field installed devices shall be made with type T wire [63° F(35° C) rise].

Remove the jumper between the R and W terminals on the terminal strip. Refer to the chart in this section (Table 5A) to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the R and W terminals on the terminal strip. Connection to the terminal strip will allow the room thermostat to make and break the 24 VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requirements. Set the boiler operating temperature control as described in this section.

2. Line voltage wire exterior to the appliance must be enclosed in approved conduit or approved metal clad cable.

3. The pump must run continuously when the appliance is being fired.
4. To avoid serious damage, DO NOT energize the appliance until the system is full of water. Serious damage may result.

B
DETAIL
A

5. Provide the unit with proper overload protection.
6. Install a wall thermostat on the inside wall. DO NOT install the thermostat in an area affected by drafts, sunlight, light fixtures, hot or cold water pipes or near a fireplace. See “Terminal Strip Connection of a Room Thermostat” (this page), for proper wiring connection.
Boiler Operating Temperature Control
The operating temperature control is located in the control panel, behind the control panel front access door. The sensing element for the operator is placed in a bulbwell installed in the heat exchanger. Carefully observe the inlet water temperature on the initial boiler on cycles. The exact temperature set point is based on your system’s requirements. Turn the control set point dial to the desired operating water temperature. Observe the boiler discharge temperature after each set point adjustment to ensure proper operation.
Room Thermostat or Remote Thermostat Connection to Terminal Strip
A room thermostat or remote temperature control may be connected to the boiler. The room thermostat should be installed on an inside wall, away from the influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sun rays or fireplaces. Follow the manufacturers instructions supplied with the thermostat for proper installation and adjustment. The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection (FIG. 5-1).

Figure 5-1_Terminal Strip Connections

TABLE – 5A TERMINAL STRIP WIRING

Wire Gauge Allowable Length
12 GA

Maximum 100 ft.

14 GA

75 ft.

16 GA

50 ft.

18 GA

30 ft.

Power Venter Connection to Terminal Strip
A terminal connection strip is provided for ease of connection for Power Venting Systems, see FIG. 5-1, inset A.
A field supplied powered venter or powered louver/damper may be connected to the boiler via a terminal strip located on the left side of the unit, see FIG. 5-1, inset B.
A 24 VAC relay can be powered from this location when a call for heat has been established. A proving switch can be interlocked back to the appliance to ensure its operation before the appliance is allowed to fire.
Reference the wiring diagrams on pages 65 through 68 of this manual.

35

5 Electrical connections
Pump Wiring for a Heating Boiler

The heating boiler circulating pump must be purchased locally. The maximum load for the pump switched by the internal pump relay must not exceed 1 HP. The current draw for a field installed 120 VAC pump MUST be added to the boiler’s current draw to determine the minimum wire size for 120 volt service.

TABLE – 5B

AMP DRAW DATA FOR

STANDARD FIRING CODES

Maximum

Firing Control

Model

Total AMPs / 120VAC

CB315

.5

M9

CB360

.5

CB399

.5

CB500

.5

CW90

1.5

CW135

1.5

*F1

CW180

1.5

CW199/201

1.5

CW225

1.5

CW270

1.5

CW315

1.5

*F9

CW360 CW399

1.5 1.5

CW500

1.5

• 1.0 AMPs added for “PM” water heaters

IGNITION MODULE
TEMPERATURE CONTROL PUMP RELAY

Installation & Service Manual

TEMPERATURE CONTROL

IGNITION MODULE
PUMP RELAY
MANUAL RESET HIGH LIMIT (IF EQUIPPED) TRANSFORMER

Figure 5-3_Intermittent Pilot System 500,000 Btu/hr Control Panel

Temperature Adjustment

Operating Temperature Control

NOTICE

The temperature controller is pre-set at the factory with test settings. You may need to adjust the settings to meet your specific needs.

WARNING

Return water temperatures must not be less than 140°F. If lower return water temperatures are required, follow the instructions for Low Temperature Bypass Requirements or Three-Way Valves, see page 31.

TRANSFORMER

MANUAL RESET HIGH LIMIT (IF EQUIPPED)

INTERMITTENT PILOT SYSTEM M9 CONTROL PANEL

Figure 5-2_Control Panel Assembly 90-135,000 BTU/hr

36

Installation & Service Manual

5 Electrical connections (continued)

Locating Temperature Control
Remove the control panel door on the front of the unit in order to locate and access the temperature control.
Temperature Control Settings
Remove the control panel door on the front of the unit unless your unit is specified as a boiler only with an outdoor air reset option. If your unit is a boiler only with an outdoor air reset option, there are additional controls for this option. They are explained under Outdoor Air Reset Option, page 39.

NOTICE Set Point

Anytime that OJ1 is the only jumper cut, a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190°F.
Anytime the OJ2 jumper is cut (with or without OJ1), a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 200°F.

The three setting knobs on the temperature control are for Set point, Differential, and High-Fire Offset (see FIG. 5-4).

The Set Point knob specifies the target inlet (or system sensor, if used) water temperature in degrees, Fahrenheit. After the water temperature reaches the set point, the temperature control shuts off the burners.

Differential
The Differential specifies the number of degrees below the set point that the control will allow the water temperature to drop before it brings the unit back on again.

Figure 5-4_Temperature Control
Maximum Set Point Determination
The maximum set point for the control is factory set. Boilers can be set to 240°F max., water heaters are set to 190°F max., and specialty state and local codes to 200°F.
These maximum set points are established by cutting the OJ1 and OJ2 jumpers located on the right side of the temperature controller. The maximum set point is determined as shown below in Table 5C.

TABLE – 5C MAXIMUM SET POINT DETERMINATION

OJ1

OJ2

MAX. SET POINT

Connected

Connected

240°F

Cut

Connected

190°F

Connected

Cut

200°F

Cut

Cut

160°F

High-Fire Offset
The temperature control operates a two-stage firing system. The two stages are High-Fire and Low-Fire. High-Fire operates all burners at full rate while Low- Fire operates the burners at approximately one-half rate.
The High-Fire Offset knob specifies the number of degrees below set point that the High-Fire stage shuts down. At that point, the unit will continue to operate at the Low-Fire stage until the set point is reached.
The High-Fire Offset knob has settings between 0°F and 20°F. If set at 0°F, the High-Fire Offset is disabled and the unit will operate the High-Fire stage until the set point is reached and the temperature control shuts the unit off.
If the High Fire Offset knob is set to 0 or 1, the delay will be 10 seconds; if set to 2 or above the delay will be 120 seconds.
Boiler Application
Standard boiler units are equipped with one inlet water temperature sensor. An optional sensor is also provided for use as a remote system sensor. Boilers with the outdoor air reset option also have an outside air temperature sensor.
Water Heater Application
Water heater units are shipped with an inlet water temperature sensor and a multi-purpose temperature sensor to be used as a tank sensor. The inlet water temperature sensor is factory installed on all water heaters.

37

5 Electrical connections
Temperature Control Sensors This is a two-stage temperature control (M9/F9) that controls the burner ignition and pump functions. This temperature controller can measure up to three different sensor inputs, depending upon how the unit is set up. They are as follows: 1. Inlet Water Temperature Sensor 2. Multi-Purpose Temperature Sensor 3. Outside Air Temperature Sensor
Inlet Water Temperature Sensor This sensor measures the inlet water temperature coming into the unit.
The inlet water temperature sensor is placed into the inlet bulbwell on the boiler. This sensor is installed by the factory.
Multi-Purpose Temperature Sensor Depending upon how your unit is set up, this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications. Connect this sensor to the two blue wires in the upper left-hand corner of the control panel.
Outdoor Air Temperature Sensor The outside air temperature sensor will only be used for boiler systems. The outside air sensor is optional. This sensor allows you to tie boiler operation to the outdoor air temperature. As outside temperatures drop, the control will increase the temperature setting of the boiler. As outdoor temperatures rise, the control will decrease the temperature to the selected set point of the boiler. You can set the control to shut the boiler off when a desired outdoor air temperature level is reached.
You must purchase the sensor from the appliance manufacturer. The sensor comes with a housing that helps protect the sensor from the elements. Mount the air sensor housing outdoors, under the eve of the roof. Make sure the housing is out of direct sunlight. This will ensure that the sensor will accurately read the true outdoor temperature. Connect the outdoor air temperature sensor to the terminal block on the outdoor air reset board. For more information on wiring the sensor, see Wiring of Remote Sensors, this page.
Installation of Remote Sensors Make sure to insert the sensor all the way into the bulbwell, leaving no air pocket between the front surface of the sensor and the back of the bulbwell. Air pockets are thermally non-conductive and will cause sensors to read inaccurately.
System Sensor The system sensor must be installed when piping the boiler in Primary – Secondary fashion when using the Pump Delay option.
38

Installation & Service Manual

Tank Sensor
Water heaters are provided with an extra temperature sensor that MUST be field installed. The sensor is shipped loose in the I & O packet. This remote mounted sensor will be the primary temperature sensor which will inform the appliance’s built-in thermostat control. For domestic water heating, the sensor MUST be installed into a bulbwell on the storage tank. This is required to maintain the desired temperature in the tank and reduce cycling of the heater.
In both applications be sure to insert the sensor all the way into the bulbwell, leaving no air pockets between the front surface of the sensor and the back of the bulbwell. Air pockets are thermally non-conductive and will cause sensors to read inaccurately.

Wiring of Remote Sensors
To wire remote sensors, follow the guidelines below. Take care to correctly wire sensors to the unit. Erratic temperature readings can be caused by poor wiring practices. Twist the wires between the unit and the remote sensor. Turn wires at least three or four turns per linear foot of wiring. This provides protection against some types of electrical interferences.
1. Do not route temperature sensor wiring with building power wiring.
2. Do not locate temperature sensor wiring next to control contactors.
3. Do not locate temperature sensor wiring near electric motors.
4. Do not locate temperature sensor wiring near welding equipment.
5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller.
6. Do not mount sensor with leadwire end pointing up in an area where condensation can occur.
7. Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists. Shielded cable is recommended on all cable runs of more than 25 feet in length.

NOTICE

Ground the cable shield at the connection to the boiler temperature control only. Do not ground the shielded cable at the sensor end.
To maintain temperature accuracy, sensor wires should be 18 AWG two conductor (18/2). Use shielded wire if required.

Installation & Service Manual

5 Electrical connections (continued)

Installation of a Remote Sensor (Boiler Application)

1. Turn OFF the main electrical power and the main manual gas shutoff to the appliance.
2. Remove the side access panel from the appliance to gain access to the thermostat.
3. Locate the sensor in the kit. Determine the location of the remote sensor and measure the amount of wire needed to connect the sensor to the thermostat. See Wiring of Remote Sensors on page 38 for guidelines.
4. Use twisted pair wire, minimum 18 gauge or larger. See Table 5A, page 35 regarding distance versus wire gauge. Ensure all wire insulation is trimmed to reveal at least 3/8″ of exposed wire.
5. Connect the measured wire to the sensor wire using wire caps (see FIG. 5-5). Install .250 x .032 insulated female quick connect terminals to the end of the wires. Feed the wires through the access hole located on the back of the unit and secure the connectors to the thermostat connections (Sys/Tank) CN5 and CN6 located in the upper right-hand of the thermostat.
6. Turn on the electrical power and the main manual gas shutoff to the appliance.
7. Replace the side access panel.
8. Fire the appliance and resume operation.

ACCESS HOLE
CONNECT THE MEASURED WIRE TO THE SENSOR WIRE
Figure 5-5_Installation of Remote Sensors
Outdoor Air Reset Option
For boilers ordered with the Outdoor Air Reset option, there is an additional control (FIG. 5-6). There are three setting knobs for Shutdown, Outdoor Air Max., and Ratio. There is also a switch to turn the outdoor air shutdown feature On or Off. An O.A. Sensor is also included.

Installation of a Tank Sensor (Water Heater Application)
1. Turn OFF the main electrical power and the main manual gas shutoff to the appliance.
2. Remove the side access panel from the appliance to gain access to the wire harness.
3. Locate the two blue wires with a tag notating the remote thermostat sensor. Feed the blue wires through the access hole located on the back of the unit.
NOTE: It will be necessary to add additional wire to reach from the appliance to the remote water source. Use twisted pair wire, minimum 18 gauge or larger. See Table 5A, page 35 regarding distance versus wire gauge. Ensure all wire insulation is trimmed to reveal at least 3/8″ of exposed wire.
4. Connect the wires to the sensor wire using wire caps.
5. Turn on the electrical power and the main manual gas shutoff to the appliance.
6. Replace the side access panel.
7. Fire the appliance and resume operation.

(c)2002 L.C.

55

CN1

CN7

50

60

CN2 CN3 OJ1

C10

D4

CN8

45

O.A. SENSOR

65

ON ENABLE

CN4

VR3

40

70

W1 SHUTDOWN

SW1
DISABLE O.A. SHUTDOWN

CN5 OJ2

R6 R4 C7

C9

55

50

60

0.9 1.01.1

0.8

1.2

CN6

J4

45

65 0.7

1.3

0.6

1.4

W3

R8

CN1
160 140

VR1

40

70

O.A. MAX.

200

VR2

0.5

1.5

RATIO

9 11

8

12

7

13

W1

W2

10 5

CN9
15

R15 R16

120

220 6

14

5 VR2 15

(F-)0 VR3 20

OFF

240 DIFFERENTIAL

HIGH-FIRE

SETPOINT

TST2314

OFFSET

Figure 5-6_Optional Outdoor Air Reset Control

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5 Electrical connections
Shutdown The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the unit from operating.

Outdoor Air Max (O.A. Max)
The O.A. Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting. When the outdoor air temperature is above the specified setting, the unit will not function in the O.A. Reset Mode, but will continue to run at the selected set point temperature.

Note that the set point knob will now indicate the “minimum” boiler temperature. Target temperature is determined by the ratio and outdoor air temperature below the O.A. Max setting.
Ratio
The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset. The allowable ratios are as low as 0.5:1 or as high as 1.5:1. Selecting the 0.5:1 ratio will increase the set point 0.5° for every 1.0° drop in outdoor air temperature up to the maximum set point temperature. Selecting the 1.5:1 ratio will increase the set point 1.5° for every 1.0° drop in outdoor air temperature up to the maximum set point temperature. If the outdoor design and boiler design temperatures are known, the Ratio setting can be calculated using the following formula:
Ratio = (boiler design temperature – operator set point) (O.A. Max. setting – outdoor design temperature)
Note that the reset set point cannot exceed the maximum set point of the boiler thermostat.
These settings are illustrated graphically in FIG. 5-7.

Figure 5-7_Outdoor Air Control Example Chart
Outdoor Air Shutdown Enable/Disable Switch The Outdoor Air Shutdown Enable/Disable switch turns the outdoor air shutdown feature On and Off. Disabling the Outdoor Air Shutdown feature allows the unit to operate regardless of the outdoor air temperature. This is needed for indirect domestic hot water systems for example.
Additional Temperature Controls
High Water Temperature Limit Control
The appliance is supplied with a fixed setting, auto-reset high water temperature limit control. The setting of this control limits maximum discharge water temperature. If water temperature exceeds the setting, the limit will break the control circuit and shut down the appliance. The limit control will only be reset after the water temperature has cooled well below the setting of the limit. The auto-reset high water temperature limit control is mounted in the outlet side of the front header.

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Installation & Service Manual

5 Electrical connections (continued)

Manual Reset High Water Temperature Limit Control (Standard Fixed Settings on Boilers and Water Heaters with Optional Adjustable Settings)
Water heaters are supplied with a fixed setting, manual reset high water temperature limit control. This manual reset temperature limit control has a fixed limit setting of 230°F (110°C). If water temperature exceeds this setting, the limit will break the control circuit and shut down the unit. The limit control can only be reset after the water temperature has cooled well below the setting of the limit. Reset of the limit control is accomplished by pushing the Red Reset Button (Manual Reset High Limit) (see FIG.’s 5-2 and 5-3 on page 36) located on the front side of the control panel. A label on the control panel indicates the exact location of the manual reset high water temperature limit control.
Blocked Vent and Flame Roll-Out / Flame Interlock Switch

BLOCKED VENT SWITCH INVERTED TO SHOW RESET UNDERNEATH
DRAFT HOOD

FRONT OF UNIT

UPPER FRONT JACKET PANEL
DETAIL FLAME ROLL-OUT SWITCH / INTERLOCK SWITCH LOWER FRONT JACKET PANEL
HEX FILLER BRACKET
Figure 5-9_Flame Roll-Out / Flame Interlock Switch Location
All units are equipped with manual reset blocked vent and flame roll-out / flame interlock switches. These temperature switches are located in the controls compartment and in the relief opening of the boiler’s built-in draft hood. Each switch has a red reset button. In the event the system has actuated to shut off the main burner gas supply, wait for the boiler to cool, then press the red reset to return the boiler to operation. Operation of a blocked vent and/or flame roll-out / interlock switch usually indicates a problem with the venting system, obstruction of the heat exchanger flue gas passageway and/or a combustion air supply problem. The cause for operation of the blocked vent and/or flame roll-out / interlock switch must be determined and corrected. If the boiler cannot be restored to normal operation, contact a qualified service installer, service agency or the gas supplier.

Figure 5-8_Blocked Vent Switch Location

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Installation & Service Manual

Start-up

Initial Start-up
Follow the Lighting Instructions on the label applied to the appliance.
A. On water heaters and boilers with the system pump delay option, the operating temperature control will energize the pump relay which energizes the pump on a call for heat. The operating temperature control will de-energize the pump relay approximately 30 seconds after the call for heat ends. If either the inlet sensor or the optional multi-purpose temperature sensor reads below 40°F, the pump relay will turn ON. When the temperature rises above 50°F the pump relay will turn OFF.
On boilers, the pump will operate whenever the “W” terminal is energized.
B. Location – The appliance should be located within a room having a temperature safely above freezing [32°F(0°C)].
C. Shutdown and Draining – If, for any reason, the appliance is shut off, the following precautionary measures must be taken:
1. Shut off gas supply, 2. Shut off water supply. 3. Shut off electrical supply. 4. Drain the heat exchanger completely. Remove one
3/8″ NPT plug or bulbwell from the inlet side and one from the outlet side of the front header of the heat exchanger. 5. Drain the pump. Remove the 3/4″ plug in the bypass loop.
Pre-start Checklist
1. Inspect the burners to be sure they are properly aligned.
2. Inspect the pilot gas line, thermocouple leads, ignition leads and wire connections to the gas valve to be sure none were damaged during shipment.
3. Check to ensure that gas connections have been made properly and the gas line is purged of air.
4. Check to ensure that water connections are tight and the appliance and piping system have been properly filled.
5. Ensure that discharge from the relief valve has been piped to a floor drain.
6. Verify that properly sized combustion and ventilation air openings are provided and not obstructed in any way.

7. Check carefully for gas leaks.
8. Read the appliance’s safety warnings, lighting instructions and check out procedure carefully, before firing the system.
Lighting Instructions for Standing Pilot Models (F1) Models (F1) Models 90,000 through 270,000 Btu/hr Input

FORYOURSAFETYREADBEFOREOPERATING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result

causing property damage, personal injury

or loss of life.

A. This appliance has a pilot which must be ignited by hand. When lighting the pilot, follow these instructions exactly.

B. BEFORE OPERATING, smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.
Do not touch any electric switch; do not use any phone in your building.
Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

42

Installation & Service Manual

6 Start-up (continued)
Lighting Instructions
1. STOP! Read the safety information (page 42).
2. Remove the control panel door.
3. Set the thermostat to the lowest setting (OFF).
4. Turn off all electrical power to the appliance.
5. Turn the gas control knob on the gas valve clockwise to the “OFF” position.
Figure 6-1_Gas Valve 90,000 – 270,000 Btu/hr Models F-1 GAS VALVE
90,000 -270,000 BTU MODELS

Figure 6-2_Pilot Location
Pilot Location
Main Burner
TOP OF FLAME SPREADER TO BE FLUSH WITH TOP OF BURNER
9. Turn the control knob on the gas valve counterclockwise to the “PILOT” position.

Figure 6-3_Lighting Wand

TOP

FLOW

SIDE

OUTLET

6. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. If you smell gas, STOP! Follow the steps in the”What To Do If You Smell Gas” section in the safety information on page 42. If you do not smell gas go on to the next step.

7. Remove the lower panel door to gain access to the pilot.

8. Find the pilot – Follow the metal tube from the gas valve to the pilot. The pilot is located on the right side of the burner approximately centered in the burner tray.

USE A FIELD SUPPLIED LIGHTER OR THE FACTORY SUPPLIED LIGHTING WAND TO LIGHT THE STANDING PILOT

NOTICE

The information package shipped with the appliance contains a wire lighting wand. The loop end of the wand will hold a match. The wand extends your reach to the pilot and makes lighting the pilot easier (see FIG. 6-3).

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Installation & Service Manual

6 Start-up

10. Use the loop end of the wire lighting wand, shipped with the instruction package, to hold the match and reach the pilot. An access slot is provided in the lower front jacket panel, beside the burner, to insert the lighting wand and match to the pilot. Lift the pilot cover (FIG. 6-3) to access the pilot. Push down and hold in the red button on the gas valve. This should start gas flow to the pilot. Continue to hold the red button in for about one (1) minute after the pilot is lit. Release the button and it will pop back up. The pilot should remain lit. If the pilot goes out, repeat steps 5 through 10.

Safety Shutoff Test For Standing Pilot Ignition System

If the red button does not pop up when released, stop and immediately call your gas supplier.

If the pilot will not stay lit after several tries, turn the gas control to “OFF” and call your service technician or gas supplier.
11. Turn the gas control knob on the gas valve counterclockwise to the “ON” position.
12. Turn on all electric power to the appliance.
13. Re-install the lower panel door.
14. Set the thermostat to the desired setting.
15. Re-install the control panel door.

TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to the OFF position.
2. Turn off all electric power to the appliance if service is to be performed.
3. Turn the gas control knob on the gas valve clockwise to the “OFF” position. Do not force.

WARNING

Should overheating occur or the gas fail to shut off, turn off the external manual

gas valve to the appliance.

PILOT WITH THERMOCOUPLE

PILOT WITH SPARK IGNITION

Figure 6-4_Pilot with Thermocouple and Spark Ignition

1. With the main burners on and firing, unscrew the thermocouple connection from the gas valve (FIG. 6-4) and remove from the fitting.
2. The main gas valve should extinguish the burners immediately after removal of the thermocouple.
3. If burners do not extinguish, immediately follow steps in “To Turn Off Gas To Appliance”.
4. Immediately call a qualified serviceman or installer to repair an ignition system that fails to operate properly and shut down the burners.
5. After successful completion of test, turn the control knob on the gas valve clockwise to the “OFF” position. Do not force.
6. Carefully reconnect the thermocouple to the gas valve.
7. Follow the Lighting Instructions to relight the pilot and establish normal operation.

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Installation & Service Manual

6 Start-up (continued)
Lighting Instructions for Spark Ignition Pilot Models (F9/M9) Models 90,000 through 500,000 Btu/hr Input

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 is equipped with an ignition device which automatically lights the pilot. Do not try to light the pilot by hand.

B. BEFORE OPERATING, smell around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle to the floor.

WHAT TO DO IF YOU SMELL GAS
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 nearby phone. Follow the gas supplier’s instructions.
If you cannot reach your gas supplier, call the fire department.
C. Use only your hand to turn the gas control knob. Never use tools. If the knob will not turn by hand, don’t try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Operating Instructions
1. STOP! Read the safety information first.
2. Remove the control panel door.
3. Set the thermostat to the lowest setting (OFF).
4. Turn off all electrical power to the appliance.
5. This appliance is equipped with an ignition device which automatically lights the pilot. DO NOT try to light the pilot by hand.
6a. 90,000 – 135,000 and 399,000 – 500,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the “OFF” position.
6b. 180,000 – 360,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob. Depress the knob and continue rotation to the “OFF” position.
7. Wait five (5) minutes to clear out any gas, then smell for gas, including near the floor. If you smell gas, STOP! Follow the steps in the “What To Do If You Smell Gas” section in the safety information, this page. If you do not smell gas go on to the next step.
8a. 90,000 – 135,000 and 399,000 – 500,000 Btu/hr models, rotate the gas control knob on the gas valve counterclockwise to the “ON” position.
8b. 180,000 – 360,000 Btu/hr models, rotate the gas control knob on the gas valve counterclockwise to the line on the collar around the knob. Allow the knob to “pop” up, and continue rotation to the “ON” position.
9. Turn on all electric power to the appliance.
10. Set the thermostat to the desired setting.
11. Re-install the control panel door.
12. If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

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Installation & Service Manual

6 Start-up

To Turn Off Gas to Appliance

1. Set the thermostat to the OFF position.

2. Turn off all electric power to the appliance if service is to be performed.
3a. 90,000 – 135,000 and 399,999 – 500,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the “OFF” position. Do not force.

3b. 180,000 – 360,000 Btu/hr models, rotate the gas control knob on the gas valve clockwise to the line on the collar around the knob. Depress the knob and continue rotation to the “OFF” position. Do not force.

WARNING

Should overheating occur or the gas fail to shut off, turn off the external manual

gas valve to the appliance.

Safety Shutoff Test for Spark Ignition Pilot System

1. Turn “OFF” gas supply to the appliance.
2. Turn thermostat to highest setting.
3. Turn electric power “ON”.
4. Pump relay pulls in to start pump.
5. The ignition will begin sparking at the pilot.
6. The ignition module will lock out after the trial for ignition period.
7. Immediately call a qualified serviceman or installer to repair an ignition system that fails to lock out and properly shut down burner operation.
8. After successful completion of the test, readjust the thermostat to normal setting.
9. Turn “ON” gas supply.
10. Turn power “OFF” then “ON” to reset ignition module.
11. If ignition system fails to operate properly, repair work must be performed by a qualified serviceman or installer.

Intermittent Pilot Spark Ignition System (F9/M9)
The ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases. A faulty ignition module must be replaced with a new module.
Freeze Protection
1. For water heaters and boilers that utilize the pump delay option, if either the inlet sensor or the optional multipurpose temperature sensor reads below 40°F, the pump relay will turn ON. When the temperature rises above 50°F the pump relay will turn OFF.
2. Location – Heating boilers and water heaters must be located in a room having a temperature safely above freezing [32°F(0°C)].
3. Caution – A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing. The cold outside air pulled down the flue may freeze a heat exchanger. This condition must be corrected to provide adequate freeze protection.
4. Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Follow the manufacturers instructions. DO NOT use undiluted or automotive type antifreeze.
5. A snow screen should be installed to prevent snow and ice accumulation around the appliance venting system in cold climates.
6. Shut-down and Draining – If for any reason, the appliance is to be shut off, the following precautionary measures must be taken:
(a) Shut off gas supply.
(b) Shut off water supply.
(c) Shut off electrical supply.
(d) Drain the unit completely. Remove one threaded plug or bulbwell from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger. Blow all water out of the heat exchanger.
(e) Drain pump and piping.

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Installation & Service Manual

6 Start-up (continued)

Pre-Commissioning Cleaning

Boiler water

1. Prior to fill and start-up, flush the entire heating system.
2. Clean the entire heating system with an approved precommissioning cleaner (comparable to Sentinel X300 or Fernox F3) in accordance with the manufacturer’s recommendation to remove debris and prolong the life of the heat exchanger.
3. Clean all water filtering devices in the system.
4. Flush the cleaning solution out of the entire system and refill.
Fill water
Check/control fill water chemistry

IMPORTANT

Conduct water quality testing prior to installing the appliance. Various solutions

are available to adjust water quality.

The manufacturer recommends the following for properly filling your boiler with the appropriate water chemistry for closed loop boilers. Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and corrosion in closed loop systems.
Hardness between 5 and 15 grains per gallon

1. Consult local water treatment companies for hard water areas (above 15 grains per gallon hardness).

2. Hardness levels that are above 15 grains/gallon can lead to lime scale buildup throughout the boiler system. If the fill water is below 5 grains/gallons, usually due to use of a water softener, it is recommended to mix in some potable water at the inlet to increase the hardness of the water to above 5 grains/gallons.

CAUTION

Do not use petroleum based cleaning or sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.
DO NOT use “homemade cures” or “boiler patent medicines”. Serious damage to boiler, personnel, and/or property may result.

Table 6A Boiler Water Chemistry

BOILER WATER CHEMISTRY

Specification

Range

Dissolved Solids

< 2000 ppm

pH Level

6.5 to 9.5

Chloride

< 150 ppm

· Monitoring pH, chlorides, TDS, and hardness levels can prolong the life of the appliance by reducing lime scale buildup, corrosion, and erosion. Check for leaks to ensure that fresh water is not entering the system.

· Continual fresh makeup water will reduce boiler life.

· Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.

· The addition of oxygen carried in by makeup water can cause internal corrosion in system components.

pH between 6.5 and 8.5
1. pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale buildup.
Total Dissolved Solids (TDS) less than 350 ppm
1. Total dissolved solids are all minerals, salts, metals, and charged particles that are dissolved in water.
2. The greater the amounts of TDS present, the higher the corrosion potential due to increased conductivity in the water.
Chlorine concentration less than 150 ppm
1. Do not fill boiler or operate with water containing chlorine in excess of 150 ppm.
2. Filling with fresh drinking water should be acceptable.
3. Do not use the boiler to directly heat swimming pool or spa water.

· Leaks in the boiler or piping must be repaired at once to prevent excessive makeup water. For this purpose, it is recommended to install a water meter to easily check the amount of makeup water entering the system. Makeup water volume should not exceed 5% of the total system volume per year. NOTE: When makeup water is added, make sure the chemical additives are added to maintain the correct level.
· An approved multi-metal corrosion inhibitor (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner recommended by the manufacturer.
Freeze protection for a heating boiler system (if required)
WARNING Ethylene glycol is toxic, DO NOT use as your freeze protection. Ethylene glycol has a sweet aroma which children and pets could mistake as food and ingest; leading to death.
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Installation & Service Manual

6 Start-up
1. Use glycol only if needed for freeze protection.

Fill and test water system

2. Propylene glycol is the recommended freeze protection.
3. Make sure to flush the boiler system before adding glycol.
4. Determine the freeze protection fluid quantity using system water content, following the fluid manufacturer’s instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.
5. Local codes may require a backflow preventer or actual disconnect from city water supply.
6. When using freeze protection fluid with automatic fill, it is suggested to install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing the concentration to drop, which reduces the freeze protection level.

1. Fill system only after ensuring the water meets the requirements of this manual.
2. Close automatic and manual air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary with each application. a. The minimum cold water fill pressure for a system is 12 psi. b. Pressure will rise when the boiler is turned ON and system water temperature increases.
4. At initial fill and during boiler startup and testing, check the system thoroughly for any leaks. Repair all leaks before proceeding further.

7. The freeze protection set points may be lowered when freeze protection fluid is used (see the Copper-Fin Service Manual).

8. Consult the glycol manufacturer for details on the suggested mix of glycol and water for the desired freeze protection level and the de-rate effect it will have on the boiler output.

Test / replace freeze protection fluid

1. For systems using freeze protection fluids, follow the fluid manufacturer’s instructions.

2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time.

3. It is recommended to test the glycol concentration annually and adjust within the desired set points.
Oxygen prevention

CAUTION

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Dissolved oxygen can have a negative effect on the boiler system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion on non-stainless steel parts of the system. A low pH level combined with oxygen further enhances its corrosive effects. After boiler installation, check for air leaks in the following areas:

· Suction gasket · Pump · Air valve · O-ring gaskets

Purge air from water system
1. Purge air from system: a. Connect a hose to the purge valve (see purge/drain valve in the piping diagrams on pages 32 through 34). Route the hose to an area where water can drain and be seen. b. Close the boiler or system isolation valve between the purge valve and fill connection to the system. c. Close zone isolation valves. d. Open the quick-fill valve on the cold water makeup line. e. Open purge valve. f. Open the isolation valves one zone at a time. Allow water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged. g. Close the quick-fill water valve and purge valve and remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure. h. After the system has operated for a while, eliminate any residual air by using the manual air vents located throughout the system. i. If purge valves are not installed in the system, open the manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder type expansion tank systems only) one turn.
3. Open other vents: a. Starting on the lowest floor, open air vents one at a time until water squirts out. b. Repeat with remaining vents.
4. Refill to correct pressure.

Precautions include installing a water meter to evaluate the fresh water volume entering the system (should be no more than 5% system volume). Additional volumes of fresh water could indicate that a leak is present.

48

6 Start-up (continued)

Check for gas leaks

WARNING

Before starting the boiler, and during initial operation, smell near the floor and

around the boiler for gas odorant or any

unusual odor. Remove the top access

panel and smell the interior of the boiler

enclosure. Do not proceed with startup

if there is any indication of a gas leak.

Use an approved leak detection solution.

Repair any leaks at once.

WARNING

Propane boilers only ­ Your propane supplier mixes an odorant with the propane

to make its presence detectable. In some

instances, the odorant can fade, and the gas

may no longer have an odor. Before startup

(and periodically thereafter), have the

propane supplier verify the correct odorant

level in the gas.

WARNING

DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct

outlet pressure. This setting is suitable

for natural gas and propane, requiring

no field adjustment. Attempting to

alter the gas valve outlet pressure could

result in damage to the valve, causing

potential severe personal injury, death, or

substantial property damage.

Installation & Service Manual

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Installation & Service Manual

Domestic water heaters

Domestic Water Heaters 90,000 500,000 Btu/hr Models
This section applies only to those units used to supply direct fired domestic hot water and installed with a storage tank(s). The use of a properly sized pump and the control of water velocity, as explained in the Water Velocity Control section, are important for correct operation of your hot water heater.
This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and service sections apply to these instructions. Water heaters are designed for installation with a storage tank. The use of a properly sized pump and the control of water velocity, as explained below, is important for correct operation of your water heater.
Water Velocity Control
IMPORTANT – To ensure proper velocity through the heat exchanger, it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet. This must be done on initial installation and periodically rechecked. With the correct temperature rise across the heat exchanger, you may be assured of the proper velocity in the tubes. This will yield long life and economical operation from your water heater. Excessive lime build-up in the tube is a result of too little velocity in the tubes. Excessive pitting or erosion in the tube is caused by too much velocity through the tubes. Care should be taken to measure temperature rise and maintain a velocity as follows:
1. The pump must run continuously when the burners are firing.
2. With the pump running and the water heater off, the inlet and outlet thermometers should read the same temperatures. If they do not, an adjustment must be made to your final calculation.
3. Turn the water heater on and allow time for the temperature to stabilize. Record the difference between the inlet and outlet temperatures. This difference will be the “temperature rise.”
4. Compare the temperature rise on the heater with the required temperature rise in Table 7A. Should adjustment be needed, proceed as follows:
If the temperature rise is too high, the water velocity is too low. Check the following:
1. Check for restrictions in the outlet of the water heater.
2. Be sure all valves are open between the water heater and the tank.
3. Check the pump to be sure it is running properly and that the pump motor is running in the proper direction.
50

4. Be sure the circulation pipes between the water heater and storage tank are not less than 2″ diameter for a single unit installation.
5. Common manifold piping for multiple unit installations will require larger minimum pipe sizes to tank tappings to ensure proper flow. See Table 7B on page 49.
6. Multiple unit installations may also require a larger circulating pump to achieve the specified flow against the increased head loss of multiple unit common manifold piping.
If the temperature rise is too low, the water velocity is too high. Adjust as follows:
1. Slowly throttle the valve on the outlet side of the water heater until the temperature rise is steady at the required temperature rise as noted in Table 7A.
2. Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchanger. This is a non- warrantable failure. Temperature rise must be properly adjusted to achieve the specified flow rate.

TABLE – 4D
MAXIMUM FLOW FOR HEATING BOILER

The maximum flow rate through the boiler with a copper heat exchanger must not exceed the following:

Model 90,000 – 500,000

Maximum

Flow

Maximum Flow for CuNi Heat Exchanger

30 GPM

38 GPM

Required Temperature Rise

Temperature rise is based on the hardness of the potable water to be heated. The temperature rise specified is for water with a hardness of 5 to 20 grains per gallon. The total dissolved solids shall not exceed 350 ppm.

TABLE – 7A REQUIRED TEMPERATURE RISE

Btu/hr INPUT
90,000 135,000 180,000 199,000/201,000 225,000 270,000 315,000 360,000 399,000 500,000

Flow Rate GPM
30 30 30 30 30 30 30 30 30 30

Temperature Rise °F
5 7 10 11 12 15 17 20 22 28

Installation & Service Manual

7 Domestic water heaters (continued)

Water Chemistry

The required temperature rise and the standard pump sizing are based on the heating of potable water with chemistry within the specified limits. Caution should be used when heating water sof

References

• National Institute for Occupational Safety & Health | NIOSH | CDC

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