Laars JVH075NCSS Mini-Therm® Residential Gas Boiler 75 MBH Natural Gas Installation manual
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Installation and Operation Instructions Document 1254D
JVH
Installation and
Operation Instructions for
M
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Residential
Gas-Fired
Hydronic Boilers
Models JVH, JVS
JVS
Sizes 50-225
U.S. Patent No. 1,609,692
Canada Patent No. 383,318
Vent damper is optional in some provinces of Canada..
These instructions are to be stored next to the boiler for reference purposes.
FOR YOUR SAFETY:
This product must be installed and serviced by a professional service technician, qualified in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.
Improper installation and/or operation will void the warranty.
WARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical 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.
Installation and service must be performed by a qualified installer, service agency, or gas supplier.
AVERTISSEMENT
Assurez-vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort.
Ne pas entreposer ni utiliser d’essence ni d’autres vapeurs ou liquides inflammables dans le voisinage de cet appareil ou de tout autre appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d’allumer d’appareils.
• Ne touchez à aucun interrupteur. Ne pas vous servir des téléphones dansle bâtiment où vous êtes.
• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le sservice des incendies.
L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualifié ou par le fournisseur de gaz.
Page 2
TABLE OF CONTENTS
LAARS Heating Systems
SECTION 1.
General Information
1A. Introduction ....................................................3
1B. Warranty ........................................................3
1C. Model Number and Nomenclature .................
4
SECTION 6.
6A. Electrical Wiring ...........................................
21
6B. Outdoor Reset .............................................
21
6C. Wiring Diagrams .....................................
22-25
SECTION 2.
Boiler Assembly & Placement
2A. Field Assembly ..............................................
4
2B. Boiler Placement ...........................................
5
2C. Flooring ..........................................................
5
2D. Dimensional Information ................................6
2E. Clearance / Closet Installations .....................8
SECTION 7.
7A. Filling the System ........................................26
SECTION 8.
Operating Procedures
8A. System Start-up ...........................................
27
8B. Sequence of Operation ................................28
8C. Operating Instructions, JVH .........................28
8D. Operating Instructions, JVS .........................29
8E. Operating Temperature Control ...................30
SECTION 3.
Air and Venting
3A. Combustion Air Supply ..................................9
3B. Venting .........................................................
10
3C. Vertical Venting - Category I ........................
11
3D-
1
Horizontal Venting - Category III
..................
12
3D-
2
Venting Connections
....................................
12
3D-
3
Vent Terminations
........................................13
3E. Common Venting System ............................13
SECTION 9.
9A. Maintenance ................................................32
9B. Electrical Troubleshooting ...........................33
SECTION 10. Replacement Parts
10A. Glossary of Terms ........................................36
10B. Parts List JVH ..............................................37
10C. Parts List JVS ..............................................39
SECTION 4.
Gas Connections
4A. Gas Supply and Piping ................................
14
4B. Special Precautions for LP .........................
15
SECTION 5.
Water Connections
5A. Water Piping ................................................
15
5B. By-pass Piping .............................................16
5C. Adjusting the bypass ...................................16
5D. Alternate Auto-Bypass Operation ................16
5E. Flow Requirements ......................................18
5F. Chilled Water Systems ................................18
5G. Oxygen Permeable Systems .......................18
5H. Anti-Freeze ..................................................18
5 I. Low Water Cut Off (LWCO) ........................19
5J. Typical Plumbing Diagrams .........................
20
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SECTION 1.
General Information
1A. Introduction
This manual provides information necessary for the installation, operation, and maintenance of the
Laars Mini-Therm model JV low pressure, copper tube hydronic boilers. These boilers are available in two configurations; the JVH has a hot surface pilot ignition system and the JVS has an electronic intermittent ignition device (I.I.D.). Look for the model designation on the rating plate, which can be found on top of the boiler.
All application and installation procedures should be reviewed completely before proceeding with the installation. Consult the Laars factory, or local factory representative, with any problems or questions regarding this equipment. Experience has shown that most operating problems are caused by improper installation.
WARNING
This hydronic boiler must be installed in accordance with the procedures detailed in this manual, or the Laars warranty will be voided. The installation must conform to the requirements of the local jurisdiction having authority, and, in the
United States, to the latest edition of the National
Fuel Gas Code, ANSI Z223.1. In Canada, the installation must conform with the latest edition of
CAN/CGA B149.1 OR .2 installation codes for gas burning appliances, and/or local codes.
Any modifications to the boiler, its gas controls, gas orifices, wiring or draft inducer assembly may void the warranty. If field conditions require modifications, consult the factory representative before initiating such modifications.
ATTENTION
L' eau chaude chaudière doit être installé en conformité avec les procédures détaillées dans ce manuel, ou le Laars garantie sera annulée.
L'installation doit être conforme aux exigences de la juridiction locale ayant l'autorité, et, aux
ÉTATS-UNIS , à la dernière édition du National gaz carburant Code, ANSI Z223.1. Au Canada, l'installation doit être conforme à la plus récente
édition de la norme CAN/CGA B149.1 ou .2 codes d'installation gaz pour appareils de combustion et/ ou codes locaux.
1B. Warranty
The Laars Mini-Therm model JV boilers are covered by a limited warranty. The owner should complete the warranty registration online by going to
www.Laars.
com
. and select the 'Support' pull-down to find the new product warranty registration form.
All warranty claims must be made to an authorized
Laars representative or directly to the factory. Claims must include the boiler serial number and model
(this information can be found on the rating plate), installation date, and name of the installer. Shipping costs are not included in the warranty coverage.
Some accessory items are shipped in separate packages. Verify receipt of all packages listed on the packing slip. Inspect everything for damage immediately upon delivery, and advise the carrier of any shortages or damage. Any such claims should be filed with the carrier. The carrier, not the shipper, is responsible for shortages and damage to the shipment whether visible or concealed.
The warranty does not cover damage caused by improper assembly installation, operation or field modification.
WARNING:
Cancer and Reproductive Harm www.P65Warnings.ca.gov.
As required by the State of California Proposition 65.
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LAARS Heating Systems
1C. Model Number and Nomenclature
The rating plate on the side of your Mini-Therm shows your Model Number. The original characteristics of your unit can be identified using this nomenclature from your Model Number.
1 2
3
4 5
6
7
8 9
10 11 12
J V U 2
MODEL
J V
IGNIT
SYST
S
H
SIZE
0 5 0
0 7 5
1 0 0
1 2 5
1 6 0
2 2 5
FUEL
N
P
FIRING
SYST
C
D
CONST
OPTION
S
I
J
ALTITUDE
S
H
I
J
COUNTRY
U
REVISION
2
Table 1. Nomenclature.
JVH
1st and 2nd Characters (Series Name)
JV = Mini-Therm
3rd Character (Ignition System)
H = Hot Surface Pilot
4th thru 6th Characters (Size)
Input MBTU / H
7th Character (fuel)
N = Natural Gas
P = Propane Gas
8th Character (Firing System)
C
= On / Off
9th Character (Construction Option)
S = Standard
10th Character (Altitude in Feet)
S = (0 - 2,000) Natural or (0 - 5,000) Propane
H = (2,001 - 5,000) Natural
I = (5,001 - 8,000) Natural and Propane
J = (8,001 - 10,000 Natural and Propane
11th Character (Country)
U = USA & Canada
12th Character (Revision)
2 = Second Revision
JVS
1st and 2nd Characters (Series Name)
JV = Mini-Therm
3rd Character (Ignition System)
S = Spark Ignition
4th thru 6th Characters (Size)
Input MBTU / H
7th Character (fuel)
N = Natural Gas
P = Propane Gas
8th Character (Firing System)
D
= on / off
9th Character (Construction Option)
I = (Standard)
J = Pump (050-125 only)
10th Character (Altitude in Feet)
S = (0 - 2,000) Natural or (0 - 5,000) Propane
H = (2,001 - 5,000) Natural
I = (5,001 - 8,000) Natural and Propane
J = (8,001 - 10,000 Natural and Propane
11th Character (Country)
U = USA & Canada
12th Character (Revision)
2 = Second Revision
SECTION 2.
Boiler Assembly and Placement
2A. Field Assembly
The Mini-Therm JV is available in two configurations.
The JVH has a hot surface ignition pilot and integral draft fan, and the JVS has an electronic intermittent ignition device (I.I.D.). Look for the model designation on the rating plate, which can be found on right side of the boiler, just above the drain.
The Laars automatic vent dampers are standard on all JVS models. The Laars side wall power venters can be used on JVS models. Special instructions for their installation are included in the vent damper and power venter package. Read them carefully before installation.
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Vent Damper (JVS only):
1. Mini-Therm JVS boilers have built-in draft diverter for natural draft operation.
2. Find the vent damper box which is located in the boiler package.
3. Install the vent damper directly to the top of the draft diverter outlet with the damper operator facing to the front of the boiler, and with the flow direction arrow pointing upward. Use the vent damper wire harness provided with the boiler to connect the vent damper to the boiler. The bracket end of the harness should be connected to the vent damper actuator.
4. For Model JVS only: Install the metal plug provided with the vent damper onto the damper plate hole.
5. Do not modify the automatic vent damper device.
It is very important that no other vents are closed.
Provide at least six inches clearance between the automatic vent damper and combustible construction, and be sure to allow access for servicing the damper.
Temperature/Pressure Gauge:
Install the temp/ pressure gauge provided in the parts box.
2B. Boiler Placement
1. The boiler must be placed to provide clearances on all sides for maintenance and inspection. There must also be minimum distances maintained from combustible surfaces. Avoid locations which can be damaged by water or moisture.
2. A minimum of 15" (381mm) access must be available in front of the boiler for burner tray removal. Consult local codes for clearances to hot water pipes and accessories.
3. If the boiler is to be installed in a garage, all burners and burner ignition devices must have a minimum 18" (457mm) clearance
4. Boilers can be installed in a closet as long as the minimum clearances shown in
Table 2
are observed. Special attention should be paid to clearances between the front of the boiler and the closet door when it is closed
(see Figure 2)
.
WARNING
This boiler is intended for indoor installation only.
Do not install this boiler in a location subject to negative pressure, or improper operation will occur.
Avertissement
Cette chaudière est destiné pour une installation intérieure uniquement. Ne pas installer cette chaudière dans un endroit soumis à pression négative, ou fonctionnement incorrect se produira
2C. Flooring
JVS model boilers can only be installed on noncombustible flooring.
JVH model boilers are designed and certified for installation on a combustible floor.
All boilers must be installed on a level floor and must NEVER be installed on carpeting.
NEVER store objects on or around the boiler.
Noncombustible flooring
is defined as flooring material and surface finish not capable of being ignited and burning and with no combustible materials against the underside. Acceptable materials are those consisting entirely of a combination of steel, iron, brick, tile, concrete, slate, glass or plaster.
The JVS model boilers can be installed on a combustible floor if a noncombustible base assembly, available from Laars, is used.
See the JVS
Parts List at the back of this manual for the appropriate
Noncombustible Base Kit part number.
Figure 1. Typical Combustible Floor Installation.
As an alternative to the Laars Noncombustible Base
Kit, in the United States the National Fuel Gas
Code allows a heater to be placed on a combustible surface when there is a platform under the heater made of hollow masonry no less than 4 inches (102 millimeters [mm]) thick, covered with sheet metal at least 24 gauge thick and extending beyond the full
Caution
Do not force motor operation when operator is fastened to the damper by moving the damper blade, turning the shaft or by turning the position indicator.
Attention
Ne pas tourner le registre manuellement avec ou sans courant électrique ou le moteur sera endommagé.
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2D. JVH Dimensional Information
Dimensions in inches
mm
C B
7
180
6
152
LAARS Heating Systems
25
635
24
610
50
75
100
125
160
225
Size A B C
in.
mm
in.
mm
in.
mm
13-3/8
13-3/8
16-7/8
16-7/8
20-3/8
25-5/8
340
340
429
429
518
651
3-1/8
2-1/4
5-3/4
5-1/2
7-1/4
10
79
57
146
140
184
254
2-7/8
2
2-7/8
2
2
2
73
51
73
51
51
51
Water
Connection
Gas
Connection
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1-1/4
1/2
1/2
1/2
1/2
1/2
3/4
JVH Dimensions
7
180
9 -1/4
240
C B
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2D. JVS Dimensional Information
Dimensions in inches
mm
7
180
6
152
2.4
61
25
635
Page 7
24
610
7
180
9 -1/4
240
Water
Conn
Gas
Conn
Size A B C D E V in. mm in. mm in. mm in. mm in. mm in. mm
1-1/4 1/2
50
13-3/8 340 27-3/4
710
23-5/8 600 21-3/4
550
26-1/2
670
4 10
1-1/4 1/2
75
13-3/8 340 27-3/4
710
24-1/8 610 21-3/4
550
27-1/2
700 5
13
100
16-7/8 430 28-3/4 730 24-1/8 610 22-3/4 580 27-1/2
700 5
13
125
16-7/8 430 28-3/4 730 23-5/8 600 22-3/4 580 27-1/2
700
6
15
160 20-3/8 518 28-3/4 730 23-5/8 600 22-3/4 580 27-1/2
700
6
15
225
25-5/8 651 31-1/2 800 23-1/4 590 23-3/4 630 27-1/2
700 7
18
1-1/4 1/2
1-1/4 1/2
1-1/4 1/2
1-1/4 1/2
1-1/4 3/4
JVS Dimensions
Page 8 width and depth of the heater by at least 12 inches
(305mm) in all directions. The masonry must be laid with ends unsealed, and joints matched to provide free circulation of air from side to side through the masonry (see Figure 1). If the boiler is installed in a carpeted alcove, the entire floor of the alcove must be covered by a noncombustible platform.
2E. Clearance / Closet Installations
All Mini-Therm JV's can be installed in a closet as long as the minimum clearances are observed.
See
Table 2JVH and Figure 2JVH
for clearances required for the Mini-Therm JVH.
See
Table 2JVS and Figure 2JVS
for clearances required for the Mini-Therm JVS
LAARS Heating Systems
Special attention should be paid to clearances between the front of the boiler and the closet door when it is closed.
Consult the American National Standard Z21.13 for more information concerning closet installations. In
Canada, refer to the latest edition of CSA-B149.1.
Boiler Sizes
Clearances
Left side
Right side
Rear
Front
Flue
(using B-vent)
Top
50 - 225 in
cm
2
5
5
15
2
5
4
10
6
15
23
58
Boiler Sizes
Clearances
Left side
Right side
Rear
Front
Flue
Top
50 - 125 in
cm
6
15
6
15
6
15
4
10
6
15
23
58
160 - 225 in
cm
6
15
6
15
6
15
4
10
6
15
36
91
Table 2JVH Minimum Boiler Clearances Table 2JVS Minimum Boiler Clearances
Note:
Clearances listed are manufacturer’s tested values. These are given as minimum values. Where local and national codes apply, and values are different than those listed use the greater value to ensure safe operation.
Minimum Boiler Clearances from Combustible Surfaces.
Dégagements Minimaux à Assurer Entre Ics Parois de L’appareil et leo Constructions Combustibles
A
2
(51)
2
(51)
Air
Openings
6
(152)
MIN
TOP
VIEW
6
(152)
5
(127)
B
SIDE
VIEW
Figure 2JVH. Closet Installation.
Dimensions in inches (mm).
6
15
4*
10
6
15
Dimensions in inches
cm
.
*6" for models JV160 to JV225.
Figure 2JVS.
Closet Installation
6
15
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SECTION 3.
Air and Venting
3A. Combustion Air Supply
The boiler location must provide sufficient air supply for proper combustion, and ventilation of the surrounding area as outlined in the latest edition of U.S. ANSI standard Z223.1 or in Canada, CAN/
CGA-B149.1 or .2, and any local codes that may be applicable.
In general, these requirements specify that the boiler rooms which represent confined spaces should be provided with two permanent air supply openings; one within 12 inches (305mm) of the ceiling, the other within 12 inches (305mm) of the floor.
NOTE:
In Canada, follow Canadian Standard,
CAN/CGA-B149 or local codes.
Outside Air Supply:
When combustion air is supplied directly through an outside wall, each opening should have a minimum free area of one square inch per 4,000 BTU/h (6 sq. cm per 1.2 kW) input of the total input rating of all appliances in the enclosed area.
Inside Air Supply:
When combustion is supplied from inside the building, each opening should have a minimum free area of one square inch per 1,000
BTU/h (6 sq. cm per 0.3 kW) input of the total input rating of all appliances in the enclosed area. These openings should never be less than 100 square inches
(645 sq. cm).
Boiler Size
50
75
Outside Air Area
sq. in
sq. cm
15
20
97
129
Inside Air Area
sq. in.
sq. cm
100
100
645
645
100
25
161
100
645
125
160
32
40
206
258
125
160
807
1032
225
60
387
225
1452
*Area indicated is for one of two openings: one at floor level and one at the ceiling, so the total net free area would be double the figures shown. For special conditions, refer to
NFPA54 ANSI Z223.1. In Canada, refer to the National
Standard CAN1-B149.1 or .2, which differs from this table.
NOTE: Check with louver manufacturers for Net Free Area of
Louvers. Correct for screen resistance to the Net Free Area if a screen is used.
Table 3. Minimum Recommended
Air Supply to Boiler Room
Exhaust Fans or Vents: Any equipment which exhausts air from the boiler room can deplete the combustion air supply or reverse the natural draft action of venting system. This could cause flue products to accumulate in the boiler room. Additional air must be supplied to compensate for such exhaust.
The information in
Table 3
is not applicable in installations where exhaust fans or blowers of any type are used. Such installations must be designed by qualified engineers.
NOTE: Because the boiler control reduces the Boiler
Target Temperature when outdoor temperature rises (to improve efficiency), there may be condensation forming in the vent or vent connectors at some times.
If a blower or fan is used to supply air to the boiler room, the installer should make sure it does not create drafts which could cause nuisance shutdowns. If a blower is necessary to provide adequate combustion
CHIMNEY
CHIMNEY
LINER
THIMBLE
1/4"
PER FT.
(20mm PER M)
SLOPE
LINER
1/4"
PER FT.
(20mm PER M)
SLOPE
CLEANOUT
BOILER
THIMBLE
CLEANOUT
12" (305mm)
BOILER
Figure 3. Chimney Venting.
Figure 4. Vertical Venting.
Page 10
LAARS Heating Systems
10 (3.0) OR
LESS MORE THAN 10
(3.0)
RIDGE
2 (0.6) MIN.
WALL OR
PARAPET
CHIMNEY
10 (3.0)
OR LESS
2 (0.6)
MIN.
CHIMNEY
Figure 5. Vertical Vent Termination.
3 (0.9)
MIN.
3 (0.9)
MIN.
3 (0.9)
MIN.
TERMINATION
10 FT. (3.0m)
OR LESS FROM RIDGE,
WALL OR PARAPET
NOTE: NO HEIGHT
ABOVE PARAPET
REQUIRED WHEN
FROM WALLS OR
PARAPET IS MORE
THAN 10 FT. (3.0m)
WALL OR
PARAPET
CHIMNEY
RIDGE
MORE THAN 10
(3.0)
10 (3.0)
3 (0.9)
MIN.
Dimensions in feet (m).
2 (0.6)
MIN.
CHIMNEY air to the boiler, a suitable switch or equivalent must be wired into the boiler control circuit to prevent the boiler from firing unless the blower is operating.
The boiler must be completely isolated and protected from any source of corrosive chemical fumes such as those emitted by trichloroethylene, perchloroethylene, chlorine, etc.
3B. Venting
Vent Categories:
The Mini-Therm JVS is a natural draft appliance for Category I venting only. The
Mini-Therm JVH is a fan-assisted product that can be vented vertically in a properly-designed Category I system, or can be vented horizontally as a Category III appliance, per this installation manual.
When venting as a Catagory I, the boiler vent collar must be fastened directly to an unobstructed vent pipe with rustproof sheet metal screws no longer than
1/2” (13mm) and located to prevent interference with the inducer damper. Do not weld the vent pipe to the boiler collar. The weight of the stack must not rest on the boiler. The boiler top must be easily removable for normal boiler service and inspection.
When venting as a Category III horizontal, the venting requires a stainless steel system that is in compliance with the requirements of UL 1738 in the United States or ULC–S636 in Canada and in accordance with this section and with the venting system manufacturer’s instructions. Plastic venting of any kind is not permitted. The venting system must be attached to the boiler vent collar, using the appropriate
Boiler Adapter. DO NOT ATTACH WITH SCREWS.
WARNING
This boiler must be vented in accordance with
Part 7, Venting of Equipment, of the latest edition of the National Fuel Gas code, NFPA 54/ANSI
Z223.1 and all applicable local building codes. In
Canada, follow CAN/CGA B149 Installation codes.
Improper venting of this appliance can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
AVERTISSEMENT
Cette chaudière doit être ventilé, conformément aux dispositions de la partie 7, de la ventilation de l'équipement, de la dernière édition du National gaz carburant code, NFPA 54/ANSI Z223.1 et tous les codes du bâtiment locaux. Au Canada, CAN/
CGA B149 codes d'installation. Une mauvaise ventilation de cet appareil peut entraîner des niveaux excessifs de monoxyde de carbone qui peut entraîner de graves blessures ou la mort!
IMPORTANT
Only JVH (induced draft) models may be side-wall vented without the addition of a properly sized and installed power venter.
JVS must be connected only using Category Type
I methods. JVH may be connected per Category I or III methods and materials. See fuel gas code for more information regarding your venting application.
IMPORTANT
Seulement JVH (tirage induit) modèles peuvent
être ventilés de la paroi latérale sans l'ajout d'une taille appropriée et puissance installée venter.
JVS doit être connecté à l'aide de méthodes de
Type I de la catégorie. JVH peut être connecté par catégorie I ou III Méthodes et matériaux. Voir code de gaz combustible pour plus d'informations concernant votre demande de ventilation
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Avoid terminating boiler vents near air conditioning or air supply fans. The fans can pick up exhaust flue products from the boiler and return them to the building, creating a possible health hazard.
Avoid oversized vent pipe or extremely long runs of the pipe, which may cause excessive cooling and condensation.
3C. Vertical Venting - Category I
(JVS and JVH)
All venting must comply with fuel gas code and be installed by a licensed professional.
The Mini-Therm JVS or JVH series boilers can be vented into a masonry chimney, (see Figures 3 and 4) provided several conditions are met:
1. The chimney must have an appropriate tile lining that is clean, properly constructed and properly sized.
2. The chimney passage way shall be examined to ascertain that it is clear and free of obstructions.
3. If a chimney rebuild is required, it shall conform to nationally recognized standards (see National
Building Code or ANSI/NFPA 211).
4. The boiler must not be connected to a fireplace, wood stove or other solid fuel burning equipment.
5. When the boiler and a hot water heater are to be connected to the same chimney, they must have their own vent connector and enter the chimney at least 6” (152mm) apart.
IMPORTANT NOTE
: Always provide a minimum clearance of 6” (152mm) between Type C (single wall) vent pipe and any combustible materials.
Page 11
WARNING
Do not store any chemical, cleaners, or other corrosive material near combustion air openings or in the room. Avoid locating dryer vents in the vicinity of combustion air openings. Failure to prevent corrosive materials from mixing with combustion air can result in reduced boiler life and unsafe boiler operation.
AVERTISSEMENT
N’entrepposer aucun produit chimique, produit nettoyant ou produit corrosif à proximité des bouches d’air de combustion ou dans la pièce.
Éviter de placer des tuyaux de ventilation pour sécheuse à proximité des bouches d’air de combustion. Le fait de laisser des maitières corrosives se mélanger à l’air de combustion risque de réduire le cycle de vie de l’appareil de chauffage et de compromettre son fonctionnement.
WARNING
Single wall vent pipe must NEVER pass through interior walls or through floors or ceilings! Failure to comply with this warning could result in a fire causing property damage, personal injury, or death!
AVERTISSEMENT
Paroi simple tuyau d'évent doit jamais passer par l'intérieur les murs ou par planchers ou plafonds
! Le non-respect de cet avertissement peut provoquer un incendie causant des dommages matériels ou corporels, ou de mort!
When installing the vent system, all applicable
VENT
TERMINAL
4 (1.2)
MIN.
12 (3.7)
MIN.
4 (1.2)
MIN.
VENT TERMINAL
3 (0.9)
MIN.
Dimensions in feet (m).
Figure 6. Horizontal Vent Termination.
VENT TERMINAL
CAULK JOINTS
ANCHORED
FASTENER
SEAL ENTIRE
CIRCUMFERENCE
OF JOINT
LESS THAN
10
(3.0)
6 (1.8) MIN.
GRADE
THIMBLE
SHEET METAL
SCREWS
FORCED
AIR INLET
VENT TERMINAL DETAIL
CAULK JOINTS
ANCHORED
FASTENER
EXHAUST
HOOD
Page 12
LAARS Heating Systems
national and local codes must be followed! The use of thimbles, firestops and other protective devices, when penetrating combustible or noncombustible construction, must be in accordance with all applicable national and local codes.
Vertical vents of the induced draft JVH boilers must be installed in accordance with the code requirement for Category 1, Fan Assisted Appliances. Follow the requirements as indicated in the latest edition of ANSI
Z223.1/NFPA 54, sizing of Category I Venting System and Annex F, or in Canada, follow the instruction of
CAN/CGA-B149 installation code.
An unused lined chimney can be used as a raceway for single wall vent pipe,
(see Figure 3)
. Never run vent pipe through a flue that has another appliance attached to it.
the manufacturers of products that comply with the requirements of UL 1738 / ULC-S636 and the part numbers of component parts. Do not mix venting suppliers and models in venting systems. Failure to comply could result in personal injury, property damage, or death.
Installations must comply with applicable national, state and local codes. The entire vent system must not exceed the size specified in Table 2.
The following criteria must be observed:
1. If the horizontal run exceeds 5 ft (1.5 m) attach a vertical section of not less than 12 in. (305 mm) to the boiler vent collar using the appropriate adapter listed above.
2. Support the vent runs with overhead hangers at intervals specified in the vent system manufacturer’s instructions.
3D-1.
Horizontal Venting - Category III
(JVH only)
Category III horizontal venting requires a stainless steel venting system that is in compliance with the requirements of UL 1738 in the United States or
ULC–S636 in Canada and in accordance with this section and with the venting system manufacturer’s
Instructions. Plastic venting of any kind is not permitted. The venting system must be attached to the boiler vent collar, using the appropriate Boiler Adapter.
DO NOT ATTACH WITH SCREWS.
Common venting is not allowed in Category III systems unless designed and certified by a licensed
Professional Engineer.
3. Pitch the vent run down toward the vent terminal ¼ in. per foot (20mm per m).
The venting system must be attached to the boiler vent collar, using the appropriate Boiler Adapter listed above. DO NOT ATTACH WITH SCREWS.
All JVH models are to be vented with a 4” diameter venting system of the equivalent length specified in
Table 4. The venting system of the JVH-225 may be increased to 6” diameter to permit the longer equivalent length indicated in Table 4. When installing the 6” diameter system, install the Boiler Adapter to the boiler flue collar and an Increaser or Increasers to the Boiler Adapter to transition to the 6” diameter
3D-2
Venting Connections (JVH only)
system.
Refer to venting supplier’s instructions for complete
ALLOWABLE SINGLE WALL STAINLESS STEEL VENT SUPPLIERS AND PART NUMBERS
parts list and method of installation. Table 1 lists
MFR MODEL NUMBER (ABBREVIATED)
Selkirk NovaFlex
Example Components
DuraVent
Trade Name / Model
Safe-
T Vent EZ Seal FasNSeal Z Flex
90° Elbow
Pipe
9x14
9x07
FSELB90xx
FSVLxxxx
2SVEExx90
2SVEPxxxx
Boiler Adapter 5x01BOI FSAAUx
2SVSAxx (OD)
2SVSTTAxx (ID)
Horizontal Termination (bird screen)
Vertical Termination (rain cap)
Inlet Air Termination
Adapter SS to CPVC
9x92
5X00CI
9xTERM
9x5xCPVC
FSBSx
FSRCx
FSAIHXX*
FSAxxFNSM
xPVCF
2SVSTPXxx
2SVSRCxx
2SVSTEXxx90
Adapter SS to PP
FSAAUxxPP 2ZDCPVCx**
*4", 6" & 7" only **up to 6"
NOTE: “x”, “xx”, and “xxxx” refer to variations in nominal size. See manufacturer’s catalog for a particular application.
Table 1.
Allowable Single Wall Stainless Steel Vent Manufacturers and Part Numbers
Size
50 -
160
Diameter in.
mm
4
102
No. of
Elbows
4
Horizontal Run Length ft.
m
35
10.7
225
225
4
6
102
152
2
4
10
35
3.0
10.7
Horizontal Venting Configuration
ALLOWABLE SINGLE WALL STAINLESS STEEL VENT SUPPLIERS AND PART NUMBERS
MFR MODEL NUMBER (ABBREVIATED)
Selkirk NovaFlex
Example Components
DuraVent
Trade Name / Model
90° Elbow
Pipe
Safe-
T Vent EZ Seal
9x14
9x07
FasNSeal
FSELB90xx
FSVLxxxx
Z Flex
2SVEExx90
2SVEPxxxx
Boiler Adapter 5x01BOI FSAAUx
2SVSAxx (OD)
2SVSTTAxx (ID)
Horizontal Termination (bird screen)
Vertical Termination (rain cap)
Inlet Air Termination
Adapter SS to CPVC
Adapter SS to PP
9x92
5X00CI
9xTERM
9x5xCPVC
FSBSx
FSRCx
FSAIHXX*
FSAxxFNSM
xPVCF
FSAAUxxPP
*4", 6" & 7" only
2SVSTPXxx
2SVSRCxx
2SVSTEXxx90
2ZDCPVCx**
**up to 6"
M
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HERM
JV
Size
50 -
160
225
225
Diameter in.
mm
4
102
4
6
102
152
No. of
Elbows
4
2
4
Horizontal Run Length ft.
m
35
10
10.7
3.0
35 10.7
Table 2.
Horizontal Venting Configuration
Horizontal Venting Configuration
Section 3D-3 Vent Termination (JVH only)
3E. Common Venting System
The sidewall vent terminal and thimble are a part of the vent system and must be selected from the chosen vent system Model numbers listed with the other vent system component parts in Section 3D-2. It provides a means of installing vent pipe through the building wall and must be located in accordance with ANSI
Z223.1/NFPA 54, or in Canada CAN/CGA-B149 and applicable local codes (See Figure 6).
The location of the vent terminal should be chosen so that exiting flue products don’t come in contact with nearby shrubbery. In accordance with ANSI Z223.1/
NFPA 54, or CAN/CGA-B149, the terminal must be located 12” above grade or the anticipated snow level in areas where snow is expected. Follow any additional local codes when choosing the location.
WARNING
Operation of appliances with a blocked common vent may lead to serious injury or death. Safety devices must be implemented to prevent blocked common vent operation. If safe operation of all appliances connected to a common vent cannot be assured, including prevention of spillage of flue gasses into living spaces, common venting should not be applied, and appliances should each be vented separately.
AVERTISSEMENT
Le fonctionnement des appareils avec un système d’évacuation bloqué peut provoquer des blessures graves, voire la mort. Des dispositifs de sécurité doivent être installés pour éviter le blocage des systèmes d’évacuation. Si le fonctionnement de tous les appareils connectés
à un système d’évacuation commun ne peut pas être assuré, y compris la prévention de la dispersion des gaz toxiques dans les espaces habités, on ne devrait pas installer un système d’évacuation commun et chaque appareil devrait
être ventilé séparément.
Page 13
When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it.
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
3. Insofar as it 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 gas burning appliance not connected to the common venting system. Turn bathroom exhausts, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate continuously.
5. Test for spillage at the burner opening after five minutes of main burner operation.
6. 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 any other gas burning appliance to their previous conditions of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code,
ANSI Z223.1. When re-sizing any portion of the common venting system, the common venting system should be re-sized to approach the minimum size as determined using the appropriate tables in Appendix G in the National
Fuel Gas Code, ANSI Z223.1/NFPA 54
.
Page 14
SECTION 4.
Gas Connections
4A Gas Supply and Piping
1.
Gas piping installation must be in accordance with the latest edition of ANSI Z223.1 and all local codes. In Canada, the installation must be in accordance with CSA-B149.1 and all local codes that apply.
Supply Pressure
Natural Gas
LP Gas
Minimum Maximum
5.5 Inches WC 10.5 Inches WC
(1.3 kPa) (2.5 kPa)
10.0 Inches WC 13.0 Inches WC
(2.4 kPa) (3.1 kPa)
Table 5. Gas Supply Pressure Requirements.
NOTE:
The maximum inlet gas pressure must not exceed the specified value. The minimum value listed is for the purpose of input adjustment. Refer to
Table 5.
2.
Check the gas supply to be sure that it is the same as the gas indicated on the boiler’s plate.
Mini-Therm JVS and JVH boilers, as shipped from the factory, are certified to operate within the altitude range indicated on the rating plate.
If a field conversion to a different altitude range or different gas should be necessary, conversion parts are available. Contact a Laars representative or the factory for the correct part numbers to order for conversions
3. Use the figures in Table 6 to size the gas inlet piping from the gas meter to the heater. Check all local codes for compliance before installing the heater.
Boiler Size
Distance
From Gas
Meter
50 75 100 125
160
225
Pipe Size
0-50
0-15m
50-100'
15-30m
100-200'
30-60m
1/2
3/4
3/4
3/4
3/4
1
3/4
3/4
1
3/4
1
1
1
1
1-1/4
1
1-1/4
1-1/4
*
Note:
These figures are for Natural Gas (.65 Sp. Gr.), and are based on 1/2" water column pressure drop. Check supply pressure with a manometer, and local code requirements for variations. For LPG, reduce pipe diameter one size, but main
tain a 1/2" minimum diameter. A 'normal' number of Tees and elbows have been taken into allowance.
Table 6. Natural Gas Pipe Size Requirements*
Caution
Permanent damage to the gas valve will occur if the following procedures are not followed.
Attention
Vous endommagerez la soupape de gaz si vous ne respectez pas les procédures suivantes.
HORIZONTAL
DROP
3" (76mm)
MIN.
LAARS Heating Systems
TO BOILER
RISER
TO BOILER
SEDIMENT TRAP
OR DRIP LEG
Figure 8. Gas Supply Piping.
3" (76mm)
MIN.
Gas Supply
Inlet
Tee
Fitting
To Equipment
Inlet
3 in.
(76mm) Min.
Nipple
Cap
Figure 9. Typical design for a sediment trap/drip leg.
M
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JV
Page 15
WARNING
The Mini-Therm JVS and JVH boilers are designed for use with either natural gas or LP gas. Check the rating plate to be sure that the boiler is designed to use the type of gas being supplied.
DO NOT ATTEMPT TO CONVERT
THIS HEATER FOR USE WITH ANY OTHER
TYPE OF FUEL.
AVERTISSEMENT
Les appareils de chauffage à faibles sont conçus pour être utillsés avec du gaz naturel ou du gaz de pétrole liquéfié (GPL). Vérifiez l’information inscrite sur la plaque signalétique du pour vous assurer que l’appareil est conçu pour le type de gaz fourni.
NE PAS ESSAYER DE CONVERTIR
CET APPAREIL À UN AUTRE TYPE DE GAZ.\
Caution
Some leak test solutions (including soap and water) may cause corrosion or stress cracking.
Rinse the piping with water after testing.
Attention
Certaines solultions d’essai d’étanchéité (y compris l’eau et le savon) peuvent causer de la corrosion ou de la fissuration. Rincez les tuyaux à l’eau apprès l’essai d’étanchéité.
4. A sediment trap (drip leg) must be installed ahead of the gas controls
(see Figure 8)
. Fit the trap with a threaded cap which can be removed for cleaning.
5. Install a manual gas shutoff valve for service and safety. Do not use a restrictive gas cock. Flexible gas connectors, if used, must be CSA rated for the total input rating of the boiler.
6. Disconnect the boiler and its individual shutoff valve from the gas supply system during pressure testing of the system at pressures higher than 1/2 pounds per square inch (psi) (3.45 kilopascals
[kPa]). If the test pressure is equal to or less than
1/2 psi (3.45 kPa), close the manual shutoff valve on the heater during the piping pressure test.
7. If the gas supply pressure is less than required, check for undersized pipe between the meter and the boiler, a restrictive fitting, or an undersized gas meter. Gas supply pressures to the heater are listed in Table 5.
NOTE
: The boiler and all other gas appliances sharing the boiler gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure.
Low gas pressure could be an indication of an undersize gas meter and/or obstructed gas supply line.
8. The correct high fire burner manifold gas pressure is stamped on the rating plate. The regulator is pre-set at the factory, and normally requires no further adjustment. For two-stage units (JVS 100-225) be sure unit is able to fire at both high and low fire.
9. Before operating the boiler, the complete gas supply system and all connections must be tested for leaks using a leak detector solution. Do not use an open flame.
4B Special Precautions for LP Gas
LP Gas is heavier than air and can therefore more readily collect or “pool” in enclosed areas if provision for proper ventilation is not made. Be sure to pay special attention to proper ventilation for LP gas.
Locate boilers a safe distance from LP gas cylinders and filling equipment. In the United States, consult the “National Fuel Gas Code” ( NFPA 54 / ANSI
Z223.1, latest edition ) or in Canada, the Propane
Installation Code ( CSA-B149.2 ), any local codes and fire protection authorities about specific installation restrictions in your area.
SECTION 5.
Water Connections
5A. Water Piping
Figure 10. shows ‘typical’ plumbing installations.
Be sure to provide
unions
and
isolation valves
at the boiler inlet and outlet so it can be isolated for service.
Check local codes for specific plumbing requirements before beginning the installation.
An ASME pressure relief valve is supplied on all JV boilers, and is pre-set at 30 PSI. The valve outlet piping must discharge to a drain. Under no circumstances should the relief valve piping be a closed circuit.
A pressure reducing valve (automatic feed) must be used to maintain the system at constant proper pressure
(see Figure 10)
. Supply properly installed purge valves to eliminate air from each circuit.
A drain valve is supplied with the boiler, and can be found in the plastic bag shipped with each boiler. This valve is to be installed on the lower right side of the boiler and is used for draining the unit.
To drain the boiler completely, open the drain valve and remove
Page 16
LAARS Heating Systems
the two drain plugs located on the lower left side of the boiler.
Be sure to include air vent devices located at the highest point in the system to eliminate trapped air, and an air elimination device near the outlet side of the
JV boiler. Manual vent valves are recommended.
Hot water piping should be supported by suitable hangers or floor stands, NOT by the boiler. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers used. Rigid hangers could transmit noise through the system caused by the piping sliding in the hangers.
It is recommended that padding be used when rigid hangers are installed.
Gas piping should also be supported by suitable hangers or floor stands, not the boiler.
A properly sized expansion tank must be included in the system.
5B By-pass Piping
The following information and suggestions are made on by-pass piping as it affects the temperature rise at the boiler. A boiler temperature rise must be taken on all JV boiler installations. If the temperature rise exceeds 30°F (17°C) at full rate, it is an indication that the boiler is not receiving adequate water flow. Check the pump for any obstruction, replace the pump with a larger size where necessary, or install a system by-pass as indicated in
Figures 10 and 11.
A full sized, 1¼" bypass with balancing valves is strongly recommended for all systems, and required when: 1) the boiler is installed without primarysecondary piping in a multiple zone system; 2) when the return water temperature can be expected to be lower than 120°F (44°C); or 3) whenever the system piping on the outlet side of the boiler may allow reduced flow through the heat exchanger, causing excessive temperature rise..
Note:
Laars strongly recommends a primary/ secondary piping system for all installations, especially sizes 125, 160 and 225. In this system, a circulator is dedicated to pumping the boiler only. This circulator should be sized for the boiler head loss and flow rate.
All precautions must be taken by the installer to insure that a maximum temperature rise through the boiler does not exceed 30°F (17°C). The temperature rise on boilers installed in multi-zone systems using zone valves must be taken when the zone of the longest length and/or the zone of the highest head loss is open.
A full size, 1¼" diameter by-pass with balancing valve must be installed if a return water temperature below 120°F (44°C) is expected under operating conditions regardless of boiler size. This may be expected in many systems, including infloor radiant and snow melt systems.
5C Adjusting the bypass:
Refer to
Figure 11
. Provide a means of measuring temperature on the inlet pipe to the boiler such as using a strap on or infrared thermometer. Starting with both balancing valves fully open, start the boiler.
Adjust the balancing valve on the return to the system slowly to provide 120°F (44°C) water at the inlet to the boiler, leaving the bypass balancing valve fully open. As the system warms up, this valve may need to be adjusted open. In rare cases, this valve will have to be kept fully open, and the bypass balancing valve adjusted toward closed to prevent heated bypass water from satisfying the call for heat when the system is up to temperature.
5D Alternate Auto-Bypass Operation
Use of the Laars thermostatic union, p/n 2400-030, can provide automatic bypass operation in primary
- secondary piped systems (but cannot be used when primary - secondary piping is not used). The thermostatic union is installed on the outlet piping, after the bypass assembly. It can be used in place of a balancing valve. It opens fully at 140°F
(see Figure 11)
. Contact the factory for more information.
Size Flow Rate
gpm
l/s
50 5.3
0.3
15°F 8°C ft
Headloss
0.3
m
gpm
20°F 11°C
Flow Rate
l/s
0.1
4
0.3
ft
Headloss
0.2
m
0.1
75
100
125
160
225
8
10.7
13.3
17
24
0.5
0.7
0.8
1.1
0.6
1.3
2.2
2.5
0.2
0.4
0.7
0.8
1.5
5
1.5
6
8
10
12.8
18
0.4
0.5
0.6
0.8
1.1
0.3
0.7
1.3
1.8
3.1
0.1
0.2
0.4
0.5
0.9
Flow Rate
gpm
3.2
4.8
6.4
8
10.2
14.4
25°F 14°C
Headloss
l/s
0.2
0.3
0.4
0.5
0.6
0.9
ft
0.1
0.2
0.5
0.8
1.2
1.9
m
0
0.1
0.2
0.2
0.4
0.6
gpm = Water Flow in gallons per minute.
l/s = Water flow in liters per second.
ft = Pressure drop (headloss) through the boiler in feet of water.
m = Pressure drop (headloss) through the boiler in meters of water.
Notes: 1. Shaded area is the recommended flow and temperature rise.
2. Temperature rise and associated flow rates are based on high fire operation at the Normal Input Rate from the rating plate.
Table 7. Temperature Rise °F °C.
M
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HERM
JV
Multi-Zone
Pump
System
JV
Single Circuit System
Multi-Zone
Valve System
JV
JV
Primary
Secondary
Multi-Zone
Pump System
JV
Page 17
JV
Primary/Secondary Multi-Zone Valve System
Low Temperature Installation
KEY: PUMP CHECK VALVE
Figure 10. Typical Plumbing Installations.
VALVE
JV
Primary/Secondary Multi-Zone Valve System
ZONE VALVE UNION AUTO AIR BLEEDER
Page 18
From
System
Balancing
Valve
In
(Return)
Out
(Supply)
To
System
Balancing Valve or optional thermostatic union, Laars P/N
2400-030. (Primary/
Secondary only)
Left Side View
A full size by-pass must be installed.
Figure 11. By-pass Piping.
Drip
Leg
5E Flow Requirements
All high recovery, low volume water boilers must have adequate flow for efficient operation. Pump selection is critical to this goal, and pumps should be selected to provide for system design water temperature rise.
Table 7
details temperature rise and water flow (GPM) for the Mini-Therm boilers.
Damage from improper flow is not warranteed.
Failure to insure proper water flow through the heat exchanger of the boiler will void the Laars warranty.
Flow can be verified by measuring the difference in water temperatures between the boiler inlet and outlet. For example: For a JV-100 installation, the inlet water temperature is 160°F (71°C), and the outlet temperature is 180°F (82°C) at Normal Input Rate from the rating plate. That means there is a 20° (11°C) temperature rise through the boiler. According to
Table 7
, that would indicate a flow rate of 8 GPM
(0.5L/S). Temperature rise must be measured with the longest (highest head) zone calling for heat alone.
Other factors to be considered before selecting a pump are pipe size, the number of fittings throughout the system, smoothness of the interior surface of the pipe, the quantity of water flowing through the pipe, whether a glycol solution is being used, and the total length of piping in the system.
Table 8
provides example pump selection criteria using Type L copper
LAARS Heating Systems
piping, one zone valve and up to eight elbows for single zone systems. Consult the factory or a qualified system designer if you have more fittings or different size or type of pipe.
1/2" Pipe
Size Pump
H.P.
3/4" Pipe
Pump
H.P.
1" Pipe
Pump
H.P.
1-1/4" Pipe
Pump
H.P.
1/25 1/12 1/25 1/12 1/6 1/25 1/12 1/6 1/25 1/12 1/6
50 50 99 390 680
75
* * * * * * *
*
35 160 300 460 640
* * * * *
100
125
* *
77 150 260 330 620
* * * *
* *
27 80 140 170 360 600
* * *
160
* * *
25 72 57 160 330 190 480
*
225
* * * * * * *
110
*
69 330
*A circulator and/or primary/secondary piping are required. Consult factory.
1. Chart is based on 30°F (17°C) maximum temperature rise.
2. Calculations are based on Type L copper tubing with one zone valve and eight elbows.
3. Typical circulating pumps:
1
/
25
HP=Taco 007, B&G LR-20 or
SLC-25, Grundfos UP15-42F, or equivalent.
1
/
12
12, Grundfos UP26-42F, or equivalent.
Grundfos UP43-75, or equivalent.
1
/
6
HP=B&G LR-
HP=B&G series HV,
Table 8. Maximum Suggested Circuit Length in Feet.
5F Chilled Water Systems
If the boiler is installed in conjunction with refrigeration systems, it shall be installed so that the chilled medium is piped in parallel with the heating boiler with appropriate valves to prevent the chilled medium from entering the heating boiler.
When boiler piping is connected to heating coils, which are in close proximity to refrigerated air circulation, there must be flow control valves or other automatic methods to prevent gravity circulation of the boiler water during the cooling cycle.
5G Oxygen Permeable Systems
The JV boiler must not be direct connected to a heating system utilizing oxygen permeable tubing.
Provide a water-to-water heat exchanger between systems to prevent corrosion of ferrous metals such as the boiler’s piping wet walls, etc. Air elimination devices are not sufficient protection, and corrosion damage is not covered under the limited warranty.
5H Anti-Freeze
Non-toxic HVAC anti-freeze may be added to the hydronic system provided the concentration does not exceed 50%, and the anti-freeze contains an anti foamant and rust inhibitor. Follow the anti-freeze manufacturer’s recommendations for yearly or biannual replacement of system anti-freeze. Never use automotive anti-freeze in a boiler system.
M
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HERM
JV
5 I Low Water Cut Off (LWCO)
When this boiler is installed above radiation level, it is required that a Low Water Cut-Off (LWCO) be installed unless this requirement is superceded by
Jurisdictional requirements. Specific instructions for the installation are the following:
Locate the appropriate wiring diagram within this manual. There are two diagrams, one for the JVH
Series and one for the JVS Series. These boilers are available for operation on 115/60 Hz or 220/50 Hz power. If this boiler is to be operated at 220/50 HZ use only a 24 VAC LWCO device. Depending upon the Voltage requirements of the chosen LWCO device
(24 VAC or 120 VAC) wire the power wires for the device in the following manner: For 120 VAC LWCO devices, wire the power wires in parallel with the incoming supply power to the boiler. For 24 VAC
LWCO devices, wire the power wires in parallel with the 24 VAC output from the boiler’s transformer.
On the appropriate wiring diagram, locate the HI
LIMIT. Connect the switch contact wires from the
LWCO device in series with the blue wire (JVH) or
Orange wire (JVS) to the HI LIMIT. Follow LWCO device Manufacturer’s Wiring Instructions for identification of power wires and switch contact wires.
Mechanically, install the LWCO device in a tee fitting in the supply piping above the highest point of the boiler. Follow LWCO Manufacturer’s Instructions for minimum pipe sizing.
Perform a test of the Low Water Cut Off device according to its Manufacturer’s Instructions before leaving the boiler unattended.
Note: This boiler is a water tube boiler that requires water flow through the heat exchanger for proper operation. It does not have an operating water level and must be full at all times. In accordance with ANSI/
ASME CSD-1 Section CW-210 and The National
Fuel Gas Code ANSI Z223.1/NFPA 54 Section 10.3.5 a water tube boiler shall have a water flow proving device in lieu of a Low Water Cut Off.
Page 19
Page 20
5 J Typical Plumbing Diagrams
LAARS Heating Systems
The preferred piping configuration for JV boilers is always using primary/secondary piping.
There are some applications that are acceptable without primary/secondary piping, see below.
To
System
Pump
Tempering
Valve
Isolation Valve
LOW TEMP SYSTEMS
To
System Pump
JV
From
System
Tempering
Valve
Pump Isolation
Primary/Secondary
Valve
System Loop with Tempering Valve and Pump with Boiler Loop with Tempering Valve and Pump
Isolation
Valve
Auto
By-Pass
Valve
From
System
Pump Isolation
Valve
Primary/Secondary Piping with Automatic By-Pass
JV
To
System
Pump
Balancing
Valve
Balancing
Valve
Isolation Valve
JV
To
System
Pump
Balancing
Valve
Isolation
Valve
Balancing
Valve
JV
Pump Isolation
From
System
Valve
Primary/Secondary Piping with Field Balancing
(for Fixed Low Return Temperatures)
To
System
Pump
Variable Speed
Control
Isolation Valve
JV
From
System
To
System
Pump Isolation
Valve
Primary/Secondary Piping with By-Pass
(for Fixed Low Return Temperatures)
Laars
Thermostatic
Union
PN 2400-030
Isolation
Valve
Pump
Balancing
Valve
JV
120°+
From
System
Pump Isolation
Valve
Primary/Secondary Piping with Variable Speed Injection
To
System
Pump
From
System
Pump Isolation
Valve
Primary/Secondary Piping with Laars
Thermostatic Union as an Automatic Bypass
Tempering
Valve
NON-LOW TEMPERATURE SYSTEMS
(120°F+ Return Temps)
Isolation Valve
To
System Pump
JV
Isolation
Valve
JV
From
System Pump
Tempering Valve with System Loop
Valve
and Boiler Loop Pump
Isolation
From
System
Pump Isolation
Valve
Simple Primary/Secondary Piping - Hydronic - Not Low Temp
NOTE: All closed loop systems should include air elimination, expansion tank and feed water inlet. Place at point of lowest pressure (typically at the inlet of pump).
NOTE: Ball valves should not be used as balancing valves. Only use for shutoff apps.
M
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Page 21
SECTION 6.
6A. Electrical Wiring
Follow these instructions to make the necessary initial electrical connections.
1. Remove the two screws attaching the front cover of the control box.
2. There are wires coiled in the area on the right side of the control box, supplied with wire nuts: black wires and white wires.
3. Follow the schematic in
Figures 14A. and 14B
.
Remove the wire nut from the two sets of wires, and connect the hot lead from the 115V power supply to the black wires and the neutral lead to the white wires.
4. Attach the leads from the wall thermostat to the terminal strip, located on the left side of the control box.
5. Check the boiler wiring and pump for correct voltage, frequency and phase. If the pump circuit is other than 115V, be sure there is an appropriate transformer or relay installed. The pump relay is suitable for pumps of 1/3 HP or less (max 5A).
6. For systems with multiple zone pumps or valves
(see Figure 17).
A means of disconnecting the electrical supply must be provided within sight of the boiler. The pump and boiler must be wired as shown to insure that the pump is running whenever the boiler is firing.
Flow Switch:
If the system includes a flow switch, it should be wired in series with the high-limit switch.
The boiler will not fire unless the pump is running and the flow switch is closed.
Field installed safety devices and operating controllers, such as valve end switches, relays, timers, can be connected to the boiler through the wall thermostat circuit. Do not exceed a draw of 40VA on the transformer secondary. A 2-Amp fuse is here to protect the transformer.
Terminals
Figure 13A
WARNING
The boiler 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 70, in the U.S. and with the latest edition of CSA C22.1 Canadian Electrical
Code, Part 1, in Canada. Do not rely on the gas or water piping to ground the metal parts of the boiler.
Plastic pipe or dielectric unions may isolate the boiler electrically. Service and maintenance personnel who work on or around the boiler may be standing on wet floors and could be electrocuted by an ungrounded boiler.
AVERTISSEMENT
La chaudière doit être mis à la terre conformément aux prescriptions de l'autorité ayant juridiction ou, en l'absence de telles exigences, avec la dernière
édition du national Electrical Code, ANSI/NFPA
70, aux ÉTATS-UNIS et à la dernière édition de la norme CSA C22.1 Code électrique canadien, partie
1, au Canada. Ne pas compter sur le gaz ou l'eau tuyauterie à la masse des pièces métalliques de la chaudière. Tuyau en plastique ou diélectrique les syndicats peuvent isoler la chaudière électrique.
Figure 13B
6B. Outdoor Reset.
To comply with Federal Law, the Mini-Therm JV automatically sets water temperature based on outdoor temperature. A sensor (E2347400) supplied must be located outdoors yet out of direct sunlight. If not connected, the boiler may not be fully functional.
Connect the sensor to the terminals labeled "COM" and "OUTDOOR" located on the left side of the control box, using outdoor rated min 24 gauge wire.
(See Figures 13A and 13B)
Page 22
6C Wiring Diagrams
NEUTRAL NE GROUNDING CON
LAARS Heating Systems
FIELD WIRING
BOILER SEN
CONTROLLER SV9501,
FLAME ROL
HI LIMIT
M
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JV
Page 23
4 3 1 2
FIELD WIRING
BK R
Page 24
JVH
110 VAC
R
TEMP CONTROL
CONTROL
RLY
CONTROL
RLY
BK
R
BL
BOILER
PUMP
BR
INDUCER
FAN
TRANSFORMER
110V
FUSE
R
24V
TEMP CONTROL
4 2
GAS VALVE
1 3
TEMP
CONTROL
1
HI LIMIT
N
FAN
PROVING
ROLLOUT
SW
GAS
VALVE
4
GND
Figure 15A. JVH Ladder Diagram
JVH PILOT
1.25
(32)
0.16
(4)
110 VAC
BK
TEMP
CONTROL
R
BK
R
FUSE
2A
R
P
LAARS Heating Systems
JVS
N
PUMP
5A MAX
TRANSFORMER
TEMP CONTROL
4 2
DAMPER
HI LIMIT
BL
TEMP
CONTROL
1
POWER VENTER
BK
BLOCKED
VENT
BK
ROLLOUT
SW
BK
GND
MAIN BURNER
FLAME PATTERN
IGNITION CONTROL
6 5
BR
MV
Y
C
O
PV
TEMP CONTROL
3
BK
GAS VALVE
MV
MV/PV
PV
H 2nd STAGE ONLY
Figure 15B. JVS Ladder Diagram
1.25
(32)
JVS PILOT
0.10 TO 0.35
(3 to 9)
MINIMUM FLAME
LENGTH
0.50
(13)
Figure 16. Main Burner/Pilot Flame Pattern.
Dimensions in inches (mm).
MINIMUM FLAME
LENGTH
0.50
(13)
M
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Page 25
COM
HEAT
Wiring with Taco
Zone Valves
COM
HEAT
COM
HEAT
Wiring with
Honeywell
Zone Valves
Wiring with Multiple
Zone Pumps
Figure 17. Multiple Zone Wiring.
Page 26
SECTION 7.
7A Filling the System
It is crucial to the efficient operation of the system that all air be removed from the circuit. For this reason, an air scoop and vent should be located close to the boiler outlet, and there should be a minimum distance between cold water feed and system purge valve.
1. When the system has been completely installed, close all air vents and open the makeup water valve. Allow the circuit to fill slowly.
2. If a make-up water pump is employed, adjust the pressure to provide a minimum of 12 psi (83kPa) at the highest point in the circuit. If a pressure regulator is also installed in the line, adjust it to the same pressure.
3. Close all valves. Purge one circuit at a time as follows: a. Open one circuit drain valve and let water drain out for at least 5 minutes. Be certain there are no air bubbles visible in the water stream before closing the drain valve.
b. Repeat this procedure for each circuit.
4. Open all valves after all circuits have been purged.
5. Run the system circulating pump for a minimum of 30 minutes with the boiler shut off.
6. Open all strainers in the system, and check for debris.
LAARS Heating Systems
7. Recheck all air vents as described in Step 3.
8. If a Diaphragm Expansion Tank is utilized in the system, proceed to Step 13.
Inspect the liquid level in the expansion tank, with the system full of water, and under normal operating pressure, to ensure proper water level in the expansion tank.
9. Start up boiler according to the procedures described in Section 2 and operate the system, including the pump, boiler, and radiation units, for one hour.
10. Recheck the water level in the expansion tank. If it exceeds 1/2 of the volume of the tank, open the tank drain and reduce the water level.
11. Shut down the entire system, and vent all radiation units and high points in the system.
12. Close the water makeup valve and check the strainer in the pressure reducing valve for sediment or debris. Reopen the water makeup valve.
13. Verify system pressure with the boiler pressure gauge before beginning regular operation.
14. Within 3 days of start-up, recheck and bleed all air vents and the expansion tank using these instructions.
M
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HERM
JV
SECTION 8.
Operating Procedures
Before placing the boiler in operation, check and reset the safety shutoff devices. Once the boiler is connected to the gas and water piping and after all the requirements in previous pages have been met, follow these procedures:
8A. System Start-up
1. Verify that the pump system is operating properly: a. Shut off the manual gas valve located outside the boiler.
b. Raise the wall thermostat high enough to call for heat.
c. The pump should come on immediately. If it does not, test the electrical circuits.
2. Pilot and Main Burner Lighting: a. The JV boiler does not require manual lighting. The pilot is controlled by the automatic ignition system.
b. Different models of the JV boiler utilize various gas valves. Although the gas valves may have different control knobs, they are all similar in operation.
c. Understand and follow the operating instructions that are applicable to the type of ignition system installed on the boiler.
3. The pilot and main burners will automatically ignite when there is a call for heat.
Note: Manual gas valve must be turned back on for this to happen.
Page 27
8B. Sequence of Operation
1. Wall thermostat will call for heat.
2. Pump relay will turn on the circulating pump.
3. If water temperature is below the limit setting, the inducer motor relay will turn on the draft inducer (JVH).
4. Pressure switch will sense the fan (JVH only) operation and send 24 volts to the flame rollout switch.
5. In normal conditions, the flame rollout switch will be in a closed position. 24 volts will be sent to the gas valve/controller, the igniter will glow/spark and the pilot valve will open, lighting the pilot.
6. After pilot is proven to be lit, the main gas valve will open, the main burners will ignite and continue until either the primary control, hi-limit or wall thermostat opens.
7. When the wall thermostat is satisfied, the burners will shut off. The relays will turn off the draft inducer (JVH only) and the circulating pump, unless pump purge is selected. If selected, the pump will continue to run for 3 minutes. When the room temperature falls below the wall thermostat setting, the cycle will repeat.
Page 28
LAARS Heating Systems
8C. Operating Instructions
Mini-Therm JVH
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Page 29
8D. Operating Instructions
Mini-Therm JVS
Page 30
Control Access
Panel
1.
2.
Figure 18A.
8.E Operating Temperature Controls
Note: The Temperature Controllers, the Dip switch panel, and the LED panel can be found under the
Control Access Panel after removing the bolts.
Two temperature controls are now standard on all
JVS and JVH boilers.
1. The primary temperature controller
maintains all normal heating operations.
2. A secondary, mechanical high-limit aquastat
provides safe shutdown, should the primary controller fail.
Important:
If the secondary controller
(See Figure
18A and Figure 18B)
dial is set below 220F, it may inhibit proper operation of the primary controller.
Prior to calling for technical support, please ensure high limit control is set for at least
220F
.
Figure 18B.
Secondary, mechanical high-limit aquastat
Pump Operation.
When a call for HEAT and/ or DHW is present the boiler pump will turn on. Post purge can be selected via dip switch #5, Pump Post
Purge Inactive (Off) /Active 3 min. (On). In the On position the pump will continue to run for 3 min after the last call has been satisfied. When the dip switch is
LAARS Heating Systems
Off there is no post purge of the pump, the pump turns off immediately after the last call is removed. Laars strongly recommends using a pump post purge. During
WWSD and a call for HEAT is present the pump will remain off.
Pump Exercising
The control exercises the boiler pump every 3 days of inactivity. While the control is exercising the pump all LEDs will turn off and the power LED will flash for 10 seconds.
Staging (where applicable – factory setting
):
Dip #1 is used to select the number of stages: 2-Stage
(Off) / Single Stage (On).
Note:
Use of 2-Stage operation may reduce efficiency.
For 2-stage operation, the first stage is cycled on
Proportional error and the second stage is cycled based on PI according to a fixed algorithm. No user adjustment is necessary.
Note:
All stages are turned off when the water outlet temperature reaches the Maximum setting that is elected via dip switch #4, Boiler Maximum 210°F
(Off) / 190°F (On).
Auto Boiler Target Setpoint: Space Heating:
The boiler target temperature is automatically determined from Space Heating and DHW requirements. Space heating is based on outdoor reset.
When both a Heat Call and a DHW Call are present at the same time, the control operates to provide the higher boiler target temperature.
Heating Curve (Outdoor Temperature Reset)
The control uses a linear heating curve to calculate a target setpoint. The following data are used to calculate the target setpoint from the outdoor temperature.
1. The heating curve or reset ratio (RR) is set by the potentiometer with a range of 0.4 to 3.6.
2. The room temperature is fixed at 70 deg F.
Outdoor
Temp F
-30
-20
Heating Curve=Reset Ratio (RR)=
1.0
2.0
Boiler Target
°
F
3.0
170
160
210
-10
210
0
10
20
150
190
170
30
190
40
150
50
150
60
70
WWSD OFF
Reset Ratio Calculation:
Boiler Target =
70 + RR *(70 - Actual Outdoor)
Table 9
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Page 31
DHW Operation
The boiler target for DHW calls is fixed at 180 deg F.
Note: There is no control of a DHW pump, so the boiler pump runs with the call for DHW.
Limiting
The boiler target is limited to a minimum and a maximum target to ensure that the water temperature does not exceed the limits.
1. Target Min
- The boiler target minimum is the point at which the stages will start to turn on to maintain a minimum water temperature. The Boiler
Minimum water temperature is 150 deg F, regardless of other calculated targets. To ensure that the water temperature is greater than the Boiler Minimum water temperature the target is increased to allow the stages to cycle on by the Boiler Minimum water temperature,
Boiler Minimum target is set to Boiler Minimum + differential/2.
2. Target Max
- The boiler target maximum is the point at which the stages will start to turn off to maintain a maximum water temperature. The Boiler
Maximum water temperature is set by setting dip switch #4: Boiler Maximum 210°F (Off) / 190°F
(On).
To ensure that the water temperature is less than the
Boiler Maximum water temperature the target is decreased to allow the stages to cycle off by the Boiler
Maximum water temperature, Boiler Maximum target is set to Boiler Maximum - differential/2.
Summary of Dip Switch Settings:
#1 Two Stage (Off) / Single Stage (On)
(Note: Efficiency may be reduced with 2-stage operation.)
#2 (Off) / Outdoor Reset (On) (Note: Outdoor Reset is required for residential operation)
#3 WWSD Inactive (Off) / Active 70°F (On)
#4 Boiler Maximum 210°F (Off) / 190°F (On)
#5 Pump Post Purge Inactive (Off) / Active 3 min.
LEDs Status & Description
1. Power
2. Heat – On = call for heat; Flashes for Boiler
3. DHW – On = call for DHW; Flashes for
4. WWSD – On = Outdoor Reset AND WWSD
Summary of Input Sensors:
1. Outdoor sensor - monitors the outside air temperature for outdoor reset mode
2.
(On) sensor error outdoor sensor error
Active AND control in WWSD; Flashes for outdoor sensor error, operation continues with fixed boiler target of 140°F.
Boiler outlet sensor -monitors the water temperature of the boiler outlet supply
3. System Supply sensor - monitors the water
NOTE: If the outdoor sensor is not installed or is inoperative, the Target Max is automatically set at
140°F regardless of the Dip Switch #4 setting. This to comply with the requirements of the U.S. Department of Energy.
Auto Differential
The control automatically adjusts differential to prevent short cycling and maximize the lifetime of components.
WWSD Operation
Warm Weather Shutdown -
WWSD feature is selected via dip switch #3, WWSD
Inactive (Off) / Active 70°F (On).
WWSD point is fixed at 70 deg
F. Control exits WWSD when the outdoor temp falls to 65 F. When there is a call for HEAT and the control is in WWSD the HEAT call will be ignored. When there is a call for DHW and the control is in WWSD the DHW call will be satisfied. WWSD LED turns on when control detects WWSD.
Model
Number
JVH050
JVH075
JVH100
JVH125
JVH160
JVH225
JVS050 system supply sensor is optional and utilizes primary
/ secondary piping. If the system supply sensor has a fault then the control flashes an error message and operates using the boiler outlet sensor (system supply
= boiler outlet).
Input, MBH Heating Capacity,
50
75
100
125
160
225
50 temperature of the system supply
The boiler outlet sensor is required at all times. If the boiler outlet sensor has any fault then the control will flash an error and turns all stages off. The
MiniTherm Series Boiler Natural Gas
MBH
41
62
82
102
131
184
43
Net AHRI Rating
Water, MBH
36
54
71
89
114
160
37
AFUE, %
83
83
82
82
82
82
85
Table 10. Efficiencies
JVS075
JVS100
JVS125
JVS160
JVS225
75
100
125
160
225
64
85
106
136
191
56
74
92
118
166
85
85
85
85
85
Page 32
SECTION 9.
9A. Maintenance
1.
Lubricate the water circulating pump per the instructions on the pump.
2. If a strainer is employed in a pressure reducing valve or the piping, clean it every six months.
3. At start-up, and periodically thereafter, the burner and pilot flames should be observed. If the flame has the appearance of “sooting” tips, check for debris near the orifices and call the service technician.
4. Ensure proper operation of the mechanical damper, mounted in the flue collar, by observing the damper handle. Be sure the handle swings when the draft inducer starts (depending on the boiler size, swing may be as little as 30°).
Remove any obstructions and clean around the pivot rod (handle) holes.
5. Inspect the venting system for obstruction, leakage or corrosion at least once a year.
6. Keep the boiler area clear and free from combustible materials, gasoline, and other flammable vapors and liquids.
7. Be sure that all combustion air and ventilation openings are unobstructed.
8. Upon completion of the installation, inspect the external surfaces of the heat exchanger for fouling based on the following schedule:
24 hours - 7 days - 30 days - 90 days
Once every six months thereafter.
9. If the boiler is not going to be used for long periods of time in locations where freezing occurs, it should be completely drained of all water. To accomplish this, there is a drain valve on the right side of the boiler which can be opened. This will drain the right side of the boiler. There are two plugs located on the left side of the heater which must be removed to drain that side.
BOTH SIDES MUST BE
DRAINED.
LAARS Heating Systems
10. The gas and electric controls on the boiler are engineered for long life and dependable operation, but the safety of the equipment depends on their proper functioning. It is strongly recommended that the basic items listed below be inspected by a qualified service technician every year. a. Water temperature controls.
b. Pilot safety system.
c. Automatic gas valves.
d. Fan proving switch.
e. Inducer/Blower assembly.
f. Mechanical flue damper operation.
WARNING
The Warranty does not cover damage caused by lack of required maintenance, lack of water flow, or improper operating practices.
AVERTISSEMENT
La garantie ne couvre pas les dommages causés par l'absence d'entretien, absence de débit d'eau, ou pratiques de fonctionnement irrégulières
Fouling on the external surfaces of the heat exchanger is caused by incomplete combustion, and is a sign of venting and/or combustion air problems. The heat exchanger can be inspected by using a flashlight and placing a mirror under the burners. An alternate method is to remove the venting and top panel to inspect the exchanger from above. The vent system should be inspected at the same time. If cleaning is required: a. Shut off all power to the boiler.
b. Remove the venting top, flue collector, draft inducer assembly, and heat exchanger baffles.
c. Remove the burner tray.
d. Use a hand-operated spray bottle filled with water, and a wire brush to clean soot and loose scale from the underside of the heat exchanger. DO NOT USE COMPRESSED
AIR, HIGH PRESSURE WATER, OR A
GARDEN HOSE.
e. Clean any fallen debris from the bottom of the unit.
f. Check to make sure the burner ports and pilot assembly are free of debris before returning the burner tray to its original position.
g. Reassemble the boiler in reverse order, making sure to replace the heat exchanger baffles.
M
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JV
9B. Electrical Troubleshooting
1. Remove the control box cover on the front of the boiler.
2. Verify that 115 volts is reaching the boiler by testing across the black wire and the white wire on the transformer.
3. Verify 24 volts transformer output by placing the meter leads on the yellow and red wires. If
24 volts is not evident, replace the transformer.
Perform the following series of tests with one meter lead attached to the yellow wire on the transformer.
4. Place the second lead on the “HEAT” connection on the terminal board. Turn the wall thermostat high enough to call for heat. If the meter fails to register 24 volts, the thermostat or its circuit may be defective.
5. Place the second lead on the purple wire terminal on the hi-limit switch. If no voltage across the switch, check for defective hi-limit, open circuit due to excessive water temperature, or a low temperature setting.
6. For JVH only, place the second lead on the blue wire terminal on the fan proving switch. If voltage is present, skip to step 8. If voltage isn’t present, connections or the draft inducer/motor could be defective.
7. Verify the voltage across the roll-out safety switch.
8. If it is determined that there is voltage to the gas valve, the pilot is lit and the pilot sensor is properly positioned, and the thermostat is set high enough to call for heat, the gas valve or the pilot assembly may be defective.
9. See Section 8E for
LED's, Status &
Description.
What the LED's on the temperature controller mean. .
Caution
Page 33
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.
Étiquette
de mise en garde tous les fils avant le débranchement lors de l'entretien. Les erreurs de câblage peut causer le mauvais et dangereux.
Vérifier le fonctionnement correct après l'entretien
WARNING
Follow local regulations with respect to installation of carbon monoxide (CO) detectors and manufacturer’s maintenance schedule of the boiler.
AVERTISSEMENT
Conformez-vous aux réglementations locales pour ce qui est de l'installation de détecteur de monoxyde de carbone (CO) et du programme de maintenance du fabricant de la chaudière.
Page 34
#
1
2
3
4
5
6
7
8
9
10
11
12
LAARS Heating Systems
Symptom
Pump not operating
Pilot outage
Flame roll-out on start-up
Flame has lazy yellow tip
Not enough heat
Pump noisy
Boiler pounding or knocking
Boiler condensing
Pump cavities or low water pressure at boiler gauge or bubbles in system at high temperature
Pressure relief valve opens
Pilot is lit but main burners will not come on
Boiler short cycles
Cause Remedy
No power . . . . .
Pump defective . . . . .
Incorrectly wired . . . . .
Inlet gas pressure too low . . . . .
Check circuit breakers and power source. Replace. Recheck wiring diagrams.
Consult gas utility company. Inlet gas pressure to boiler should be 5.5" (1.4 kPa) to 9.0" (2.2 kPa) water column on natural gas. 10.0" (2.5k Pa) to 14.0" (3.4 kPa) on propane gas.
Pressure should be regulated within limits shown above.
Inlet gas pressure to high causing an unstable blowing pilot. . . . .
Damaged pilot. . . .
Dirty pilot. . . .
Replace.
Blow dust or lint out of pilot.
Plugged or undersized pilot. .
No power from ignition control.
Replace pilot orifice.
If OK check ignition control.
Blocked outlet
Pilot out of position (delayed ignition) . . . .
Check flue damper operation.
Correct pilot position.
Blocked heat exchanger or flue . . Clean and correct as necessary.
Refractory tile out of place . . . . .
Correct or replace tile as necessary.
Low primary air . . . . Correct manifold pressure according to rating plate. Correct orifice size if necessary (see parts list). Clean burner ports if dirty.
Inadequate gas supply . . . . .
Gas meter too small. Gas line from meter to boiler too small.
Low manifold gas pressure . . . . . Gas pressure on boiler manifold, with Modusnap valve wide open. Should be adjusted to 4.0" (1.0 kPa) W.C. natural gas
9.0" (2.2 kPa) W.C. propane.,
Boiler size inadequate . . . . .
Air in volute . . . . .
Replace with boiler of higher input.
Bleed air from volute. Check pump alignment.
Worn coupling or bearings . . . . .
Replace worn parts.
Too low water flow through boiler
. . . . .
Check temperature rise between inlet and outlet boiler piping. 15°F (8°C) to 25°F (14°C) temperature rise is recommended. If temperature rise is over 25°F (14°C), increase pipe size or pump capacity or locate obstruction.
Check for stuck closed zone valves. Check for zone pumps not operating. Check for closed valve in system.
Low water temperature . . . . .
Defective fill valves or pressure regulator .
Flue product moisture will condense at the start-up until the boiler water temperature reaches the normal operating conditions.
Replace.
Oversized expansion tank . . . . .
Replace.
Expansion tank piped incorrectly
. . . . .
Re-pipe expansion tank to suction size of pump at high temperature.
Waterlogged expansion tank . . . . Drain 2/3 of the water from the expansion tank.
Boiler off on hi-limit control . . . . .
Check for low water flow or hi-limit setting.
Boiler incorrectly wired . . . . .
On single or multiple zone systems with zone valves, room thermostat should be wired to T-T terminals. For multiple zone systems with ozone pumps, thermostats for extra zones should be wired to R&A terminals.
Broken wire in thermostat circuit or defective thermostat . . .
Check continuity through thermostat circuit with
Heat anticipator in room thermostat set too low . . . . .
Increase setting (1.0 is usually satisfactory)
Low water flow through boiler . . Increase size of pump or increase piping size.
Hi-limit switch may be set too low . . . .
Increase setting to at least 20°F (11°C) over outlet water temperature.
M
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JV
START
• TURN GAS SUPPLY OFF
• SET THERMOSTAT TO
CALL FOR HEAT
SV9501/SV9601 IS
POWERED
(24 VAC NOMINAL)
Troubleshooting Honeywell SV9501/SV9601
Hot Surface Pilot System (JVH only)
NO
CHECK:
• LINE VOLTAGE POWER
• LOW VOLTAGE TRANSFORMER
• LIMIT CONTROLLER
• THERMOSTAT
• WIRING
• FAN PROVING SWITCH
ON COMBUSTION AIR BLOWER
YES
NO
UNPLUG IGNITER
MEASURE VOLTAGE AT
TWO BOTTOM TERMINAL OF
SV9501/SV9601
(24 VAC NOMINAL)
IGNITER WARMS UP
AND GLOWS RED
YES
NO
PILOT VALVE
OPENS
NO
REPLACE IGNITER
REPLACE SV9501/SV9601
YES
TURN GAS ON.
PILOT BURNER LIGHTS?
YES
MAIN VALVE OPENS?
NO
NO
MEASURE VOLTAGE TO
SV9501/SV9601.
VOLTAGE MUST BE AT LEAST
19.5 VAC.
YES
NO
REPLACE IGNITER
REPLACE IGNITER SENSOR AND
RETAIN: RESTART TROUBLE-SHOOTING
SEQUENCE. DOES MAIN VALVE OPEN?
NO
YES
YES
SYSTEM OK
NO
DISCARD OLD IGNITER SENSOR
Page 35
REPLACE
SV9501/
SV9601
CHECK
TRANS-FOR
-
MER, LINE
VOLT SUP
-
PLY
REPLACE
SV9501/
SV9601.
SAVE OLD
IGNIT
-
ER-SENSOR
FOR
SERVICE.
Page 36
LAARS Heating Systems
SECTION 10. Replacement Parts
10A Glossary of Terms
Air Vent
A device used to purge air from the Circuit. Should be located at the highest point in the Circuit.
Branch
The section(s) of supply and return piping, including the heat distribution units connected directly to the trunk. Also referred to as a “zone”.
By-Pass
A section of pipe (including an adjustable valve) that diverts part of the water flow from undersized piping to the boiler. Adjusted to maintain minimum flow requirement (GPM) through the boiler.
Circuit
Entire water circulation piping, beginning and ending at the boiler (Series Loop System).
Expansion Tank (Compression Tank)
Installed in the circuit to accommodate excess water produced by heat expansion.
Diaphragm Expansion Tank
Used instead of Expansion Tank (Compression Tank).
Internal bladder separates air and water.
Heat Distribution Units
Transfers heat from the water supplied by the boiler to the area to be heated through the use of baseboard, convector, radiator, finned tube. Also known as
“radiation”.
Isolation Valve
Used to isolate the boiler from the circuit. It minimizes the amount of water drained from the system.
Primary-Secondary Piping
Two or more interconnecting circulating loops, each with its own pump. Primary =System Circuit;
Secondary=Boiler Circuit.
Reverse-Return Piping
Balanced, equal flow (first in, last out) piping. Utilized with multiple boilers and/or radiation. Applied with single system pumps, or primary-secondary pump.
System Purge Valve
A device used to purge air from the circuit. Should be located as close as possible to the cold water feed, but not immediately after the cold water feed.
Temperature Controllers
The primary temperature controller
maintains all normal heating operations.
A secondary, mechanical high-limit aquastat
provides safe shutdown, should the primary controller fail.
Trunk
The section of piping which connects the boiler return and supply with the branch(es). Also known as a
“main” or “header”. Should be same size as boiler inlet/outlet connections.
Zone Pump
Circulators installed in branch piping that divert hot water coming from the boiler into various areas
(zones) of a building.
Zone Valve
Diverts hot water from the boiler into various areas
(zones) of a building.
M
INI
-T
HERM
JV
Mini-Therm JVH
Description
Gas System
1 Pilots
Pilot Assembly (Nat.), Hot Surface
Pilot Assembly (LP), Hot Surface
2 Burner with Pilot Bracket
3 Main Burner
4 Main Gas Valves
Gas Valve, Hot Surface, (Nat.) SV9600H
Gas Valve, Hot Surface, (LP) SV9500H
5 Gas Orifices
(0-2000 FT.) Nat., Orifices
(2001-5000 FT.) Nat., Orifices
(5001-8000 FT.) Nat., Orifices
(8001-10,000 FT.) Nat., Orifices
(0-5000 FT.) LP, Orifices
(5001-8000 FT.) LP, Orifices
(8001-10,000 FT.) LP, Orifices
6 Gas Manifold
Electrical System
7 Controller, Tekra
8 Transformerll5/24V(50VA)
9 Switch, Air Pressure (0-5000 FT.)
Switch, Air Pressure (5001-10000 FT.)
10 Blower/Motor, Induced Draft
11 Switch, Roll-out Safety
12 Switch, Limit
13 Ignition Control
Wire Harness (not shown)
Fuse, 5-Pack, 4-Amp (not shown)
Temp Sensor (not shown)
Outdoor Sensor (not shown)
Water System
14 Heat Exchanger
15 Gauge, Temperature/Pressure
16 Gauge, Temperature
17 Valve, Pressure Relief 30 PSI
18A Well, Immersion, 1/2" NPT
18B Well, Immersion, 3/4" NPT
19 Valve, Drain 1/2' NPT
Jacket and Fire Box Components
20 Base Weldment
21 Front Panel a c k e t 2 2 J
23 Cover, top rear
24 Cover, top front
25 Access Panel, heat exchanger plug
26 Cover, piping jacket top
27 Flue Collector Weldment
28 Burner Tray Weldment
29 Control Box Weldment
30 Control Box Cover
31 Burner Cover
32 Tile Cover
33 Heat Exchanger Baffle
34 Front Refractory
35 Rear Refractory
36 Orifice Plates
Orifice Plate, Nat. (0-5000 FT.)
Orifice Plate, Nat. (5001-10,000 FT.)
Orifice Plate, LP (0-5000 FT.)
Orifice Plate, LP (5001-10,000 FT.)
37 Flue Outlet
38 Bracket, pressure switch
JVH-50
RE2344300
E2074400
E2074501
E2074504
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
R0402007
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400701
11028301
1 1 0 2 7 9 0 1
11028501
11028401
10535900
11047601
20403901
20403001
20608500
11045901
20403304
10469504
10485307
T2007704
T2007804
20404605
20404605
20404606
20404604
D2004201
11028200
RW2001800
RW2001900
L0056500
L0052500
R0384700
R0384800
L0032200
L0050700
L0032600
L0050300
L0032900
L0032800
L0032700
L0052601
JVH-75
R0402008
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400702
11028301
1 1 0 2 7 9 0 1
11028502
11028402
10535901
11047602
20403902
20403002
20608500
11045901
20403305
10469505
10485305
T2007705
T2007805
20404607
20404606
20404608
20404606
D2004201
11028200
JVH-100
RW2001800
RW2001900
L0056500
L0052500
R0384700
R0384800
L0032200
L0050700
L0032600
L0050300
L0032900
L0032800
L0032700
L0052602
RW2001800
RW2001900
L0056500
L0052500
R0384700
R0384800
L0032200
L0050700
L0032600
L0050300
L0032900
L0032800
L0032700
L0052603
RW2001800
RW2001900
L0056500
L0052500
R0384700
R0384800
L0032200
L0050700
L0032600
L0050300
L0032900
L0032800
L0032700
L0052604
RE2344300
E2074400
E2074501
E2074504
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
RE2344300
E2074400
E2074501
E2074504
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
RE2344300
E2074400
E2074502
E2074505
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
R0402009
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400703
11028303
1 1 0 2 7 9 0 3
11028503
11028403
10535900
11047601
20403903
20403003
20608500
11045901
20403306
10469506
10485306
T2007706
T2007806
20404609
20404608
20404610
20404612
D2004201
11028200
Size
JVH-125
R0402010
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400704
11028303
1 1 0 2 7 9 0 3
11028504
11028404
10535901
11047602
20403904
20403004
20608500
11045901
20403304
10469504
10485307
T2007704
T2007804
20404605
20404605
20404606
20404604
D2004201
11028200
JVH-160
R0402011
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400705
11028306
1 1 0 2 7 9 0 5
11028505
11028405
10535901
11047602
20403905
20403005
20608500
11045901
20403305
10469505
10485305
T2007705
T2007805
20404607
20404606
20404608
20404606
D2004201
11028200
JVH-225
RW2001800
RW2001900
L0056500
L0052500
R0384700
R0384800
L0050700
L0032600
L0050300
L0050300
L0032900
L0032800
L0032800
L0052605
RW2001800
RW2001900
L0056500
L0052500
RV2001900
R0384800
L0050700
L0032600
L0050300
L0050300
L0032900
L0032800
L0032800
L0052606
RE2344300
E2074400
E2074502
E2074505
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
RE2344300
E2074400
E2074503
E2074506
R2069600
E2103200
R0061300
E2102800
E2347500
RE0084401
E2347600
E2347400
R0402012
A2000400
2400-392
R0061400
E0025902
E2345700
70-270
20400706
11028306
1 1 0 2 7 9 0 6
11028506
11028406
10535901
11047602
20403906
20403006
20608500
11045901
20403306
10469506
10485306
T2007706
T2007806
20404609
20404608
20404610
20404612
D2004201
11028200
Mini-Therm JVi
Page 38
Page 31
LAARS Heating Systems
24
23
26
25
21
22
13
8
7
12
16
30
29
15
37
11
4
31
36
10
33
18B
(left side)
38
18A
(right side)
5
6
32
34
2
28
3
1
Figure 19A. JVH Parts Identification.
20
ITEMS14, 39
AND INSULATION
NOT SHOWN
19
17
14
27
9
25
32
35
M
INI
-T
HERM
JV
10C Parts List JVS
Mini-Therm JVS
Description JVS-50
Gas System
1 Pilots
Pilot Assembly (Nat.)
Pilot Assembly (LP)
2 Main Gas Valves
Gas Valve, Natural
Gas Valve, LP
3 Gas Manifold
3 Burner, Main
4 Burner W/Pilot Bracket
Burner/Air Shutter (LP) (not shown) L0055900
Gas Orifices (not shown)
Gas Orifice (Nat.)
Gas Orifice (LP)
R0061600
W0039600
R0385100
V0077500
L0052601
L0052500
L0056500
L0032200
L0032900
Electrical System
5 Controller
6 Transformer 115/24V (40VA)
7 Ignition Control
8 Limit Switch
9 Blocked Vent Safety Switch
10 Roll-out Safety Switch
Wiring Harness (not shown)
Hi-Tension Lead (not shown)
Fuse, 5-Pack, 4-Amp (not shown)
Temp Sensor (not shown)
Outdoor Sensor (not shown)
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449514
RE0084401
E2347600
E2347400
Water System
11 Heat Exchanger, Rev 1
11 Heat Exchanger, Rev 2
(after 2012)
12 Pressure Relief Valve, 30PSI
13A Well, Immersion, 1/2" NPT
13B Well, Immersion, 3/4" NPT
14 Drain Valve 1/2" NPT (not shown)
R0402001
R11061001
R0061400
E0025902
E2345700
70-216
Temp/Pressure Gauge (not shown) R0060600
Jacket and Fire Box Components
15 Draft Diverter
16 Rear Panel
17 Jacket
18 Top
19 Cover, Piping, Top
20 Flue Collector
21 Access Panel HX, (L&R)
22 Base, Control Box
23 Cover, Control Box
24 Burner Cover
25 Heat Exchanger Baffle
26 Tile Cover
27 Refractory, Front
28 Refractory, Rear
29 Base Assembly
11020101
11020201
11020301
11020401
11047603
20034901
10535900
20608500
11045901
10500601
10485301
10469501
T0022001
T0021701
10467101
Non-Combustible Base Kit (optional) 10466701
Vent Damper Components
Vent Damper Assembly (not shown) E2071501
Vent Damper Harness (not shown) E0099100
JVS-75
R0061600
W0039600
R0385100
V0077500
L0052602
L0052500
L0056500
L0055900
L0032200
L0032900
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449514
RE0084401
E2347600
E2347400
R0402002
R11061002
R0061400
E0025902
E2345700
70-216
R0060600
11020102
11020201
11020301
11020401
11047604
20034902
10535900
20608500
11045901
10500601
10485308
10469502
T0022002
T0021702
10467102
10466701
E2071502
E0099100
JVS-100
Size
JVS-125 JVS-160 JVS-225
R0061600
W0039600
R0407700
V0079100
L0052603
L0052500
L0056500
L0055900
L0032200
L0032900
R0061600
W0039600
R0407700
V0079100
L0052604
L0052500
L0056500
L0055900
L0032200
L0032900
R0061600
W0039600
R0407700
V0079100
L0052603
L0052500
L0056500
L0055900
L0032200
L0032900
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449514
RE0084401
E2347600
E2347400
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449514
RE0084401
E2347600
E2347400
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449515
RE0084401
E2347600
E2347400
R0061600
W0039600
R0407700
V0079100
L0052604
L0052500
L0056500
L0055900
L0032200
L0032900
RE2344300
R0021300
E2102800
R0061300
R2061100
E2103200
E2347700
10449516
RE0084401
E2347600
E2347400
R0402003
R11061007
R0061400
E0025902
E2345700
70-216
R0060600
11020103
11020203
11020303
11020403
11047603
20034903
10535900
11045700
11045800
10500602
10485309
10469503
T0022003
T0021703
10467103
10466702
E2071502
E0099100
R0402004
R11061008
R0061400
E0025902
E2345700
70-216
R0060600
11020104
11020203
11020303
11020404
11047604
20034904
10535900
11045700
11045800
10500602
10485311
10469504
T0022004
T0021704
10467104
10466702
E2071503
E0099101
R0402005
R11061009
R0061400
E0025902
E2345700
70-216
R0060600
11020105
11020205
11020305
11020405
11047604
20034905
10535900
11045700
11045800
10494105
10485310
10469505
T0022605
T0021705
10467105
10466703
E2071503
E0099101
R0402006
R11061010
R0061400
E0025902
E2345700
70-216
R0060600
11020106
11020206
11020306
11020406
11047606
20034906
10535900
11045700
11045800
10494106
10485306
10469506
T0022606
T0021706
10467106
10466704
E2071504
E0099101
Mini-Therm JVS
LAARS Heating Systems
19
18
9
15
24
5
22
23
8
7
17
20
6
13B
(on left side)
13A
26
2
12
25
11
21
16
26
28
All Manuals (Install &
Operate, Start Up, and
Service Manuals) can be downloaded at
3
1
14
27 29
4
Figure 19B. JVS Parts Identification.
www.laars.com
For LAARS Product and Service VIDEOS h t t p s : / / w w w. y o u t u b e .
com/user/LaarsHeating
Customer Service and Product Support:
800.900.9276 • Fax 800.559.1583
Headquarters:
20 Industrial Way, Rochester, NH, USA 03867 • 603. 335. 6300 • Fax 603. 335. 3355
9 Brigden Gate, Halton Hills, Ontario, Canada L7G 0A3 • 905.203.0600 • Fax 905.636.0666
www.Laars.com
Litho in U.S.A. © Laars Heating Systems 1807 Document 1254D
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