INSTALLATION AND SERVICE MANUAL

EB-EW-I-S-09

INSTALLATION AND SERVICE MANUAL

HOT WATER HEATING BOILERS

Domestic Water Heaters

150,000 - 300,000 Btu/hr MODELS

IMPORTANT:

This is a gas appliance and should be installed by a licensed electrician and/or certified gas supplier.

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

WARRANTY

WARNING

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Refer to this manual for assistance or additional information, consult a qualified installer, service agency or the gas supplier. This appliance contains material that has been identified as carcinogenic, or possibly carcinogenic to humans.

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

Factory warranty (shipped with appliance) does not apply to appliances improperly installed or improperly operated.

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

CHECKING EQUIPMENT

Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the appliance which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on packing slip with those actually received. In case there is damage or a shortage, immediately notify carrier.

1. Excessive water hardness causing a lime build-up in the copper tube is not the fault of the equipment and is not covered under the manufacturer's warranty (see Water

Treatment and Water Chemistry).

2. Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer's warranty (see Boiler Flow Rates and Temperature Rise for flow requirements).

DO NOT Use this appliance if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

WARNING

SPECIAL INSTRUCTIONS

TO OWNER

Note: Retain this manual for future reference.

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

This manual supplies information for the installation, operation and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an installation.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbors phone. Follow the 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 the gas supplier.

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CONTENTS

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Combustion/Ventilation Air Requirements . . . . . . . . . .4

Venting - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Conventional Venting . . . . . . . . . . . . . . . . . . . . . . . . . . .8

E+Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Direct Vent Sidewall . . . . . . . . . . . . . . . . . . . . . . . . . .14

Direct Vent Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Outdoor Installation . . . . . . . . . . . . . . . . . . . . . . . . . .22

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Gas Pressure & Piping . . . . . . . . . . . . . . . . . . . . . . . . .24

Manifold Pressure Adjustment . . . . . . . . . . . . . . . . . . .26

Supply Pressure Measurement . . . . . . . . . . . . . . . . . . .28

Water Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . .30

Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . .30

Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . .32

Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . .34

Hot Surface Ignition Control . . . . . . . . . . . . . . . . . . . .35

Operation & Diagnostic Lights . . . . . . . . . . . . . . . . . .35

Ignition & Control Timings . . . . . . . . . . . . . . . . . . . . .35

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

Flame Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Combustion Air Adjustments . . . . . . . . . . . . . . . . . . . .37

Burner Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Heat Exchanger Inspection . . . . . . . . . . . . . . . . . . . . .39

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Gas Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Heating Boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Typical Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Pump Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Pressure Drop Curve . . . . . . . . . . . . . . . . . . . . . . . . . .41

Boiler Pump Operation . . . . . . . . . . . . . . . . . . . . . . . .41

Bypass Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .41

Low Temperature Systems . . . . . . . . . . . . . . . . . . . . . .42

Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Temperature Rise Chart . . . . . . . . . . . . . . . . . . . . . . . .43

Placing Boiler in Operation . . . . . . . . . . . . . . . . . . . . .44

Boiler Temperature Control . . . . . . . . . . . . . . . . . . . . .45

Remote Thermostat Connection . . . . . . . . . . . . . . . . . .45

Domestic Water Heater . . . . . . . . . . . . . . . . . . . . . . .46

Water Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . .46

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

Piping Requirements . . . . . . . . . . . . . . . . . . . . . . . . . .47

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Thermostat Adjustment . . . . . . . . . . . . . . . . . . . . . . . .48

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . .54

Revision Notes . . . . . . . . . . . . . . . . . . . . . . .Back Cover

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USER WARNING

The information contained in this manual is in tend ed for use by qualified professional in stall ers, service technicians or gas suppliers. Con sult your local expert for proper installation or service procedures.

IMPORTANT

Consult and follow local Building and Fire

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

IMPORTANT

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

WARNING

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

WARNING

To minimize the possibility of serious personal injury, fire or damage to your appliance, never violate the following safety rules.

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

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

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

CODES

The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.

In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas

Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation

Code. Where required by the authority having jurisdiction, the installation must conform to American Society of

Mechanical Engineers Safety Code for Controls and Safety

Devices for Automatically Fired Boilers, ASME CSD-1.

All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code, Section IV. Where required by the authority having jurisdiction in Canada, the installation must comply with the CSA International

CAN/CGA-B149 .1 and/or B149.2 Installation Code and/or local codes.

Construction

This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided, as specified in the ANSI standards for gas-fired appliances,

ANSI Z21.13 and ANSI Z21.10.3.

INSTALLATION PROCEDURE

LOCATION OF UNIT

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

FIG. 1 Typical (Front View) Cabinet Construction

2.

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

3.

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

4.

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

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5.

The appliance must be installed on a level floor. A combustible wood floor may be used without additional bases or special floor buildup. Maintain required clearances from combustible surfaces.

6.

The appliance must not be installed on carpet or other combustible material other than wood flooring.

7.

Outdoor models require the installation of an optional outdoor kit. Instructions for mounting the parts in the kit are included in the venting section of this manual.

Outdoor models MUST NOT be installed directly on the ground. The outdoor appliance must be installed on a concrete, brick, block or wood flooring. Outdoor models have additional special location and clearance requirements. These are specifically addressed in the venting section under Outdoor Installation. A windproof/rainproof cabinet protects the appliance from the weather.

COMBUSTION AND VENTILATION AIR

REQUIREMENTS FOR

CONVENTIONALLY VENTED

APPLIANCES

Provisions for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and

Ventilation, of the latest edition of the National Fuel Gas

Code, ANSI Z223.1, in Canada, the latest edition of CGA

Standard B149 Installation Code for Gas Burning

Appliances and Equipment, or applicable provisions of the local building codes.

CLEARANCES FROM COMBUSTIBLE

CONSTRUCTION

The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting.

FIG. 3 Installation Clearances Drawing

FIG. 4 Combustion Air Direct from Outside

Clearances from Combustible Construction:

Right Side - 1" (25.4 mm)

Rear - 1" (25.4 mm)

Left Side - 6" (15 cm) (24" (61 cm) suggested for service)

Front - 3" (76.2 mm) (24" (61 cm) suggested for service)

Top - 3" (76.2 mm)

Flue - 1" (25.4mm)

All appliances have been approved for closet installation .

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

1. If air is taken directly from outside the building with no duct, provide two permanent openings: a.

b.

Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5cm

per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.

Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input

(5.5cm

2 per kW). This opening must be located within

12" (30 cm) of the bottom of the enclosure.

2

4

FIG. 5 Combustion Air through Ducts

FIG. 7 Combustion Air from Outside - Single Opening

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr

(11cm 2 per kW).

4. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7cm 2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure.

5. See venting section for combustion air requirements on

E+Venting and direct vent applications.

TABLE - A

MINIMUM RECOMMENDED

COMBUSTION AIR SUPPLY TO

MECHANICAL ROOM

FIG. 6 Air from an Interior Space

3. If air is taken from another interior space, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/hr (22cm 2 per kW) of input, but not less than 100 square inches (645 cm 2 ).

Boiler

Input

Outside Air*

2 Openings

150,000 38 in 2

Outside Air*

1 Opening

50 in 2

Inside Air

2 Openings

150 in 2

199,999 50 in

2

67 in

2

200 in

2

250,000 63 in 2 83 in 2

250 in 2

300,000 75 in

2

100 in

2

300 in

2

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each opening must have twice (2 times) the free area required for each Outside Air

Openings. The above requirements are for the appliance only, additional gas fired appliances in the mechanical room will require an increase in the net free area to supply adequate combustion air for all appliances. Combustion air requirements are based on the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada refer to CSA

International CAN/CGA B149.1 or B149.2 Installation Code.

Check all local code requirements for combustion air.

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All dimensions based on net free area in square inches.

Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%.

Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within

12" (30 cm) of the floor of the mechanical room. Each opening must have net free area as specified in Table A.

Single openings shall commence within 12" (30 cm) of the ceiling.

Conventionally vented applications where outside air is used must have adequate combustion and ventilation air supplied to the mechanical room in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA B149

Installation Code for Gas Burning Appliances and

Equipment, or applicable provisions of the local building codes.

CAUTION

The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code, ANSI

Z223.1, in Canada, the latest edition of CAN/CGA B149

Installation Code for Gas Burning Appliances and

Equipment.

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

The combustion air supply must be completely free of any chemical fumes which may be corrosive to the appliance.

Common chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as

Freon, trichlorethylene, perchlorethylene, chlorine, etc.

These chemicals, when burned form acids which quickly attack the heat exchanger finned tubes, tube headers, flue collectors, and the vent system. The result is improper combustion and a non-warrantable, premature appliance failure.

Vent connection is made directly to the top of the appliance.

No additional draft diverter is required. The connection from the appliance vent to the stack must be made as direct as possible.

The negative draft in conventional vent installations must be within the range of a negative 0.02 to 0.05 inches water to ensure proper operation. All draft readings are made while appliance is in stable operation (approximately 2 to 5 minutes).

Locate units as close as possible to chimney or gas vent.

EXHAUST FANS: Any fan or equipment which exhausts air from the mechanical room may deplete the combustion air supply and/or cause a down draft in the venting system.

Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected. If a fan is used to supply combustion air to the boiler room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the appliance.

See the vent material requirements for each of the specific venting options. Conventional venting systems use Type

"B" double wall vent material. Direct vent systems have specific vent kits and material requirements noted for each application.

Any vent materials not provided or specified must be listed by a nationally recognized test agency for use as vent material.

E+Vent and Direct Vent venting systems have specific requirements for combustion air ducts from the outside which are directly connected to the appliance. See the requirements for this combustion air duct in the venting section for each specialized vent system.

Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions. Horizontal portions of the venting system shall be supported to prevent sagging.

Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm per meter) from the appliance to the vent terminal. Follow manufacturers instructions.

VENTING

General

Vent installations for connection to gas vents or chimneys must be in accordance with Part 7, "Venting of Equipment," of the latest edition of the National Fuel Gas Code, ANSI

Z223.1, in Canada, the latest edition of CAN/CGA B149

Installation Code for Gas Burning Appliances and

Equipment or applicable provisions of the local building codes.

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The weight of the venting system must not rest on the appliance. Adequate support of the venting system must be provided in compliance with local codes and other applicable codes. All connections should be secured with rustproof sheet metal screws.

Barometric Damper Location

Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance.

The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the appliance’s flue outlet. The barometric damper MUST NOT be installed in a bull head tee installed on the appliance’s flue outlet. The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to appliance’s flue outlet. This location ensures that any positive velocity pressure from the appliance’s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products. Adjust weights on damper to ensure that draft is maintained within the specified range.

FIG. 8 Vent Termination from a Peaked roof 10' or less from Ridge

FIG. 10 Vent Termination from a Flat Roof 10' or less from Parapet Wall

FIG. 9 Vent Termination from a Peaked roof more than 10' from Ridge

FIG. 11 Vent Termination from a Flat Roof more than

10' from Parapet Wall

The vertical vent terminal should exhaust outside the building at least 2 feet (61 cm) above the highest point of the roof within a 10 foot (3.05 m) radius of the termination.

A vertical termination less than 10 feet (3.05 m) from a parapet wall must be a minimum of 2 feet (61 cm) higher than the parapet wall.

The vertical termination must be a minimum of 3 feet

(91 cm) above the point of exit.

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The vent cap should have a minimum clearance of 4 feet

(1.22 m) horizontally from and in no case above or below,

unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

Do not terminate the vent in a window well, stairwell, alcove, courtyard or other recessed area. The vent cannot

terminate below grade.

Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney.

All appliances are shipped from the factory equipped for conventional negative draft venting.

All other optional vent systems require the installation of specific vent kits and venting materials. The following is a detailed explanation of the installation requirements for each venting system, components used and part numbers of vent kits for each model.

E+Conventional Venting

To avoid a blocked flue condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

Flue gases will form a white plume in winter. Plume could obstruct window view.

Flue gas condensate can freeze on exterior surfaces or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Flue gas condensate can cause discoloration of exterior building surfaces. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

IMPORTANT:

Examine the venting system at least once a year.

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

FIG. 12 Conventional Venting Installation

A CONVENTIONAL NEGATIVE DRAFT

VENTING SYSTEM

VENT SYSTEM OPTIONS

This appliance has five venting options. They are:

1. Conventional Negative Draft Venting

Conventional negative draft venting with vertical termination.

2. E+ with a Vertical Conventional Vent

E+Vent with a vertical conventional vent for flue products and a combustion air pipe from either the sidewall or roof top.

Follow all requirements in the General Venting section for venting flue products to the outdoors, obtaining adequate combustion and ventilation air and general installation instructions. All conventionally vented appliances must have combustion and ventilation air supplied to the mechanical room in accordance with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA B149 Installation Code for Gas

Burning Appliances and Equipment, or applicable provisions of the local building codes.

3. Direct Venting with Sidewall Terminations

Direct vent with sidewall terminations for flue products and combustion air.

4. Direct Venting with Vertical Terminations

Direct vent with vertical through-roof terminations for flue products and combustion air.

5. Outdoor Installation

Outdoor installation consists of the installation of a special vent cap / top assembly, gas valve cover, deflectors, and a weatherproof junction box.

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A bell increaser is installed directly on the appliance vent outlet. The bell increases the vent size by 1 inch (25.4 mm) in diameter. The bell increaser MUST be installed on the appliance vent outlet for all conventional negative draft vent systems. Vent connection is made directly to the bell increaser on top of the appliance. No additional draft diverter or barometric damper is required on single appliance installations with a dedicated stack and a negative draft within the specified range of a negative 0.02 to 0.05

inches water. Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have a barometric damper installed to regulate draft within the proper range. If the draft in a dedicated stack for a single

appliance installation exceeds the specified draft, a barometric damper must be installed to control draft.

A vertical termination less than 10 feet (3.05 m) from a parapet wall must be a minimum of 2 feet (61 cm) higher than the parapet wall.

The vent pipe sizes are:

CONVENTIONAL VENT FLUE SIZE

Input Btu/hr

TABLE - B

150,000

199,999

The vent cap should have a minimum clearance of 4 feet

(1.22 m) horizontally from and in no case above or below, unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief

Flue Size*

equipment.

5"

MASONRY CHIMNEY INSTALLATIONS

(Conventional Venting Only)

5"

250,000 6"

300,000 6"

*Vent size with 1" bell increaser installed for conventional negative draft venting

On a conventionally vented, negative draft appliance, the connection from the vent to the stack or vent termination outside the building MUST be made with listed Type "B" double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter. Use the

National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks. The Type

"B" vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer’s listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes.

A masonry chimney must be properly sized for the installation of a high efficiency gas fired appliance.

Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry chimneys, with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft. This will result in condensing of flue products, damage the masonry flue/tile, insufficient draft and possible spillage of flue products into an occupied living space. Carefully inspect all chimney systems before installation. If there is any doubt about the sizing or condition of a masonry chimney, it must be relined with a properly sized and approved chimney liner system.

Inspection of a Masonry Chimney

Locate appliances as close as possible to chimney or gas vent.

Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm per meter) from the appliance to the vent terminal. Follow manufacturers instructions.

Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure. Connection to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury.

Any vent materials not provided or specified must be listed by a nationally recognized test agency for use as vent material.

A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products. A clay tile lined chimney must be structurally sound, straight and free of misaligned tile, gaps between liner sections, missing sections of liner or any signs of condensate drainage at the breaching or clean out. If there is any doubt about the condition of a masonry chimney, it must be relined. An unlined masonry chimney must not be used to vent flue products from this high efficiency appliance.

An unlined chimney must be relined with an approved chimney liner system when a new appliance is being attached to it. Metallic liner systems (Type "B" double-wall or flexible or rigid metallic liners) are recommended.

Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney.

The vent terminal should be vertical and exhaust outside the building at least 2 feet (61 cm) above the highest point of the roof within a 10 foot (3.05 m) radius of the termination.

The vertical termination must be a minimum of 3 feet

(91 cm) above the point of exit.

Common venting systems may be too large when an existing appliance is removed. At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to the common venting system are not in operation.

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1. Seal any unused opening 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 and other unsafe condition.

A CONVENTIONAL VERTICAL

NEGATIVE DRAFT VENTING SYSTEM

WITH COMBUSTION AIR PROVIDED

FROM A SIDEWALL OR ROOF TOP

INLET CAP

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.

Close fire place 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 draft hood/relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

Follow all requirements in the General Venting section and

Conventional Negative Draft Venting for venting flue products to the outdoors and general installation instructions.

This vent system uses two pipes, one vertical pipe with a roof top termination for the flue products and one pipe for combustion air. The combustion air pipe may terminate horizontally with a sidewall air inlet or vertically with a roof top air inlet. A bell increaser is installed directly on the vent outlet. This bell increases the vent size by 1" (25.4

mm) in diameter. The bell increaser MUST be installed on the vent outlet for all conventional negative draft vent systems. Vent connection is made directly to the bell increaser on top of the appliance. No additional draft diverter or barometric damper is required on single appliance installations with a dedicated stack and a negative draft maintained between 0.02 to 0.05 inches water. The flue may be combined with the vent from any other negative draft, Category I appliances. Multiple appliance installations common vented with other negative draft appliances require that each appliance must have a barometric damper installed to regulate draft within the proper range. The common vent and connectors from multiple appliances must be sized per the requirements of the venting tables for type "B" double wall vents in the latest edition of the National Fuel Gas Code, ANSI Z223.1.

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to there previous conditions of use.

7. Any improper operation of the common venting

The sidewall or vertical roof top E+Vent combustion air system should be corrected so that the installation conforms to the latest edition of the requirements. The air inlet pipe connects directly to the

National Fuel Gas Code, ANSI Z223.1, in appliance to supply combustion air. In most installations,

Canada, the latest edition of CAN/CGA the combustion air inlet pipe will be a dedicated system

Standard B149 Installation Code for Gas with one air inlet pipe per appliance. Multiple air inlets

Burning Appliances and Equipment. When may be combined if the guidelines in "Combined Air Inlet resizing any portion of the common venting

Points" are followed. The air inlet pipe will be connected system, the common venting system should be to a combustion air inlet cap as specified in this section. resized to approach the minimum size as determined using the appropriate tables in

Appendix G in the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada, the

Combustion air supplied from outdoors must be free of contaminants (see Combustion and Ventilation Air Section). latest edition of CAN/CGA Standard B149

Installation Code for Gas Burning Appliances and Equipment.

10

Vertical Roof Top Air Inlet

The air inlet cap for the vertical roof top air inlet is assembled from components purchased locally. The air inlet cap consist of two 90° ells installed at the point of termination for the air inlet pipe. The first 90° ell is installed on the roof top at the highest vertical point of the air inlet pipe and turned horizontal, the second 90° ell is installed on the horizontal outlet of the first ell and turned down. A 90° ell and a 90° street ell may be used to make this assembly. If a straight piece of pipe is used between the two ells, it should not exceed 6" (51 mm) in length. The termination ell on the air inlet must be located a minimum of 12" (30 cm) above the roof or above normal levels of snow accumulation.

FIG. 13 E+Vent with Sidewall Air

Sidewall Air Inlet

The sidewall air inlet cap is supplied in the E+Sidewall Vent

Kit which should be ordered from the manufacturer. This sidewall cap will supply combustion air for a single appliance only.

Locate appliances as close as possible to sidewall where the combustion air supply system will be installed.

To prevent recirculation of flue products from an adjacent vent cap into the combustion air inlet, follow all applicable clearance requirements in the latest edition of the National

Fuel Gas Code and instructions in this manual.

The combustion air inlet cap must be installed at least one foot (30 cm) above ground level and above normal snow levels.

FIG. 15 Air Inlet Cap for Roof Top Termination

The point of termination for the combustion air inlet cap

MUST be at least 2 feet (61 cm) below the point of flue gas termination (vent cap) if it is located within 10' (3.05 m) of the flue outlet. Use care to ensure that the 90° ell assembly is properly installed on the air inlet pipe.

FIG. 14 E+Vent with Roof Top Air

The combustion air inlet cap must not be installed closer than

10 feet (3.05 m) from an inside corner of an L-shaped structure.

The combustion air inlet cap must be installed at least one foot

(30 cm) above the roof top and above normal snow levels.

11

Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury, death or property damage

Combined Air Inlet Points

The air inlet pipes from multiple appliances can be combined to a single common connection if the common air inlet pipe has a cross sectional area equal to or larger than the total area of all air inlet pipes connected to the common air inlet pipe. [Example: two 5" air inlet pipes (19.6 in 2 each) have a total area of 39.2 in 2 require a 8"(50.3 in 2 area area) common air inlet pipe.] The air inlet point for multiple appliance air inlets must be provided with an exterior opening which has a free area equal to or greater than the total area of all air inlet pipes connected to the common air inlet. This exterior opening for combustion air must connect directly to the outdoors. The total length of the combined air inlet pipe must not exceed a maximum of 50

(15.25 m) equivalent feet. You must deduct the restriction in area provided by any screens, grills or louvers installed in the common air inlet point. These are common on the sidewall air inlet openings. Screens, grills or louvers installed in the common air inlet can reduce the free area of the opening from 25% to 75% based on the materials used.

NOTE:

The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Length of Air Inlet Pipe

The total equivalent length of the sidewall or vertical roof top E+Vent combustion air inlet pipe must not exceed a maximum of 50 (15.24 m) equivalent feet in length.

Subtract 5 feet (1.52 m) for each elbow in the air intake system. Do not exceed limits for the combustion air inlet piping lengths.

Sealing of Type "B" double wall vent material or galvanized vent pipe material used for air inlet pipe on a sidewall or vertical roof top E+Vent Combustion Air

Supply System

Air Inlet Pipe Materials

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from those specified in this section.

1. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL

Standard 723 or 181A-P or a high quality UL

Listed silicon sealant such as those manufactured by Dow Corning or General Electric.

Select air inlet pipe material from the following specified materials:

2. Do not install seams of vent pipe on the bottom of horizontal runs.

PVC or CPVC (4", 5"or 6" I.D.)*

Dryer Vent (not recommended for roof top air inlet)

3. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe.

Galvanized steel vent pipe with joints and seams sealed as specified below.

4. Ensure that the air inlet pipes are properly supported.

Type "B" double wall vent with joints and seams sealed as specified below.

* Plastic pipe requires an adapter (not provided) to transition between the air inlet and cap.

WARNING

Using other vent or air intake materials, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer's instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.

The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used.

The PVC, CPVC, or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent should use a screw type clamp to seal the vent to the appliance and air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

When a sidewall or vertical roof top E+Vent combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

12

WARNING

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

**Minimum diameter, installer may increase diameter one pipe size for ease of installation if needed. A 6" diameter air inlet cap may be ordered as Sidewall E+Vent Kit

SVK3022.

The sidewall air inlet cap supplied in the Sidewall E+Vent

Kit is used to supply combustion air to a single appliance.

The roof top vent cap for flue products should be a standard commercial cap purchased locally. The use of a sidewall air inlet cap other than the manufacturers recommended cap for single appliance installations or use of a common air inlet cap for multiple appliances with insufficient free area and/or protection from wind and weather may result in operational problems with the appliance or potentially hazardous spillage of flue products which can cause personal injury, death or property damage.

Venting of Flue Products

FIG. 16 Sidewall Air Inlet Cap

Vent Kits

The sidewall E+Vent Kit must be ordered from the manufacturer for single appliance installations with sidewall air inlet. The part number for each kit is listed by appliance size. Each kit includes a sidewall combustion air inlet cap to supply air to a single appliance and instructions for proper installation. The flue pipe, roof top vent cap and air inlet pipes are purchased locally. The air inlet cap for a vertical roof top termination is fabricated from materials purchased locally. The air inlet cap for the combined air supply from multiple appliances must be purchased locally.

On a conventionally vented, negative draft appliance, the connection from the vent to the stack or vent termination outside the building MUST be made with listed Type "B" double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter. The bell increaser, factory installed on the flue outlet, MUST be used. Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks. The type "B" vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturers listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes. The vertical flue of an

E+Vent must maintain a negative draft within the specified range.

An appliance installed in an application such as a restaurant or industrial installation where exhaust fans, air handlers or other mechanical equipment are creating an excessive negative pressure in the mechanical room may require that

TABLE - C

the appliance be installed with an optional direct vent system. Local codes which require the installation of a

SIDEWALL VENT KITS

Input

Conventional

Vent Flue

Btu/hr

Size*

150,000 5”

Air Inlet

Pipe**

4” certified direct vent system must use one of the ANSI tested direct vent systems. The direct vent system uses a sealed

Sidewall E+

AL29-4C stainless steel vent material and a sealed

Vent Kit

combustion air inlet pipe. See E+Vertical Direct Vent

System or E+Sidewall Direct Vent System installation

SVK3020 requirements in this manual.

199,999

250,000

300,000

5”

6”

6”

4”

5”

5”

SVK3020

SVK3021

SVK3021

The connection from the vent to the vent termination outside the building MUST be made with type "B" double wall vent materials and must be direct as possible with no reduction in diameter. The vent accessories, such as

*Vent size with 1" increaser installed for conventional negative draft venting.

13

firestop spacers, thimbles, caps, etc., MUST be from the same vent material and installed in accordance with the manufacturers listing. The vent connection through the roof must provide correct spacing to combustible surfaces.

Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm per meter) from the appliance to the vent terminal. Follow manufacturers instructions.

The vent cap shall terminate at least 3 feet (91 cm) above any forced air inlet within 10 feet (3.05 m).

The vent shall terminate at least 4 feet (1.22 m) below, 4 feet (1.22 m) horizontally from or 1 foot (30 cm) above any door, window or gravity air inlet to the building.

Do not terminate the vent in a window well, stairwell, alcove, courtyard other recessed area. The vent can not terminate below grade.

Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

CAUTION

An appliance which is shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit. Proper freeze protection must be provided, see

Freeze Protection.

The vent cap should have a minimum clearance of 4 feet

(1.22 m) horizontally from and in no case above or below, unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

FIG. 17 E+Vent Sidewall Direct Vent System

The E+Sidewall Direct Vent System

Locate units as close as possible to chimney or gas vent.

Vent connectors serving appliances vented by natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure. Connection to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury.

A DIRECT VENT SYSTEM WITH

SIDEWALL TERMINATIONS

Follow all requirements in the General Venting section for venting flue products to the outdoors and general installation instructions. All direct vent appliances must have combustion air supplied directly to the appliance with a separate air pipe.

The Vent terminal should be vertical and exhaust outside the building at least 2 feet (61 cm) above the highest point of the roof within a 10 foot (3.05 m) radius of the termination.

The vertical termination must be a minimum of 3 feet

(91 cm) above the point of exit in the rooftop.

A vertical termination less than 10 feet (3.05 m) from a parapet wall must be a minimum of 2 feet (61 cm) higher than the parapet wall.

The vent cap should have a minimum clearance of 4 feet

(1.22 m) horizontally from and in no case above or below, unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

14

The bell increaser, installed on the appliance vent outlet, must be removed. The bell increaser is NOT USED with the direct vent system. Vent connection is made directly to the top of the appliance. No additional bell increaser, draft diverter or barometric damper is required. The direct vent system uses a two pipe system, one pipe for the flue products and one pipe for the combustion air supply. The sidewall vented flue MUST be a dedicated stack. The flue can NOT be combined with any other appliance vent or common vent from multiple appliances. The vent on a direct vent system may have a positive pressure in the flue which requires all vent joints and seams to be sealed gastight. The sidewall direct vent system has specific vent material and installation requirements. The flue from a direct vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system. Choose acceptable vent materials from those listed on page 15.

Sidewall Air Inlet for Direct Vent

The combustion air inlet pipe must also be a dedicated system with one air inlet pipe per appliance. The air inlet pipes from multiple appliances can NOT be combined to a single common connection. The air inlet pipe connects directly to the appliance to supply combustion air. The air inlet pipe must be sealed. Choose acceptable combustion air pipe materials from those specified in this section.

The sidewall vent cap and sidewall air inlet cap supplied in the Sidewall Direct Vent Kit MUST be used to vent the flue products to the outdoors and supply combustion air. Use of a vent cap and/or air inlet cap other than the manufacturers recommended caps may result in operational problems with the appliance or potentially hazardous spillage of flue products which can cause personal injury, death or property damage.

Flue Pipe Materials

Select venting material from the following specified vent materials:

Heat-Fab Saf-T CI Vent with AL29-4C stainless steel

(Call 800-772-0739 for nearest distributor)

Z-Flex Z-Vent with AL29-4C stainless steel

(Call 1-800-654-5600 for nearest distributor)

Protech Systems Inc. Fas-N-Seal Vent with

AL29-4C stainless steel (Call 1-800-766-3473 for nearest distributor)

Flex-L International, Inc. Star-34 Vent with

AL29-4C stainless steel

(Call 1-800-561-1980 for nearest distributor)

FIG. 18 Sidewall Direct Vent Caps

Sidewall Direct Vent Kits

Metal-Fab Corr/Guard Vent with AL29-4C stainless steel

(Call 1-800-835-2830 for nearest distributor) or other listed AL29-4C vent systems suitable for positive pressure

The sidewall direct vent kit must be ordered from the appliance manufacturer. The part number for each kit is listed by appliance size. Each kit includes a sidewall vent cap for flue products, a firestop, a combustion air inlet cap and instructions for proper installation. The flue pipe and air inlet pipes are purchased locally.

Air Inlet Pipe Materials

Select air inlet pipe material from the following specified materials:

PVC or CPVC (4", 5"or 6" I.D.)*

TABLE - D

SIDEWALL DIRECT VENT KITS

Dryer Vent

Galvanized steel vent pipe with joints and seams sealed as specified below.

Input

Btu/hr

Direct Vent

Flue Size*

150,000 4"

Air Inlet

Pipe*

4"

Sidewall E+

Vent Kit

HDK3013

199,999

250,000

300,000

4"

5"

5"

4"

5"

5"

HDK3013

HDK3014

HDK3014

*Minimum diameter, installer may increase diameter one pipe size for ease of installation if needed.

Type "B" double wall vent with joints and seams sealed as specified below.

* Plastic pipe requires an adapter (not provided) to transition between the air inlet and cap.

15

NOTE:

The use of double wall vent material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Sealing of vent material for use with the Sidewall Direct

Vent system

The vent materials, Heat-Fab Saf-T CI Vent, Z-Flex Z-Vent,

Protech Systems Fas-N-Seal Vent, Flex-L Star-34 Vent,

Metal-Fab Corr/Guard Vent or listed AL29-4C vent system suitable for positive pressure, must be installed and sealed per the vent manufacturers installation instructions.

WARNING

Using other vent or air intake materials, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer's instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the appliance.

Length of Flue Pipe and Air Inlet Pipe

The total equivalent length of the direct vent flue pipe or the air inlet pipe must not exceed a maximum of 50 (15.24 m) equivalent feet in length for each pipe. Subtract 5 feet

(1.52 m) for each elbow in the vent pipe or air intake system. Do not exceed limits for piping lengths.

Sealing of Type "B" double wall vent material or galvanized vent pipe material used for air inlet pipe on a Direct Vent System

FIG. 19 Drain Tee Installation

Drain Tee Installation

1. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL

Standard 723 or 181A-P or a high quality UL

Listed silicon sealant such as those manufactured by Dow Corning or General Electric.

2. Do not install seams of vent pipe on the bottom of horizontal runs.

3. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe.

4. Ensure that the air inlet pipes are properly supported.

A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee must be installed as the first fitting after the horizontal ell on the top of the appliance. See the typical vent installation drawings. Plastic drain tubing, sized per the vent manufacturers instructions, shall be provided as a drain line from the tee. The drain tubing must have a trap provided by a 3" (76 mm) diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the condensate drain line with the nylon wire ties. The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system. Refer to the condensate drain installation instructions as supplied by the manufacturer of the vent material. See "Freeze Protection" for more information.

The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used.

The PVC, CPVC, or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent should use a screw type clamp to seal the vent to the appliance and air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

When a direct vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent manufacturers instructions. The air inlet pipe must also be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

16

DANGER

Failure to properly seal all vent joints and seams may result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death.

The vent for a direct vent system shall NOT terminate above public walkways.

The vent shall not be installed closer than 10 feet (3.05 m) from an inside corner of an L-shaped structure.

The connection from the vent to the vent termination outside the building MUST be made with one of the specified vent materials and must be direct as possible with no reduction in diameter. The vent accessories not otherwise provided, such as firestop spacers, thimbles, caps, etc., MUST be from the same vent material manufacturer and installed in accordance with the manufacturers listing. The vent connection through the sidewall must provide correct spacing to combustible surfaces. The vent pipe connection to the sidewall vent cap

MUST have a gas-tight seal to prevent the leakage of flue products.

Do not terminate the vent in a window well, stairwell, alcove, courtyard, or other recessed area. The vent can not terminate below grade.

Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

The vent cap should have a minimum clearance of 4 feet

(1.22 m) horizontally from and in no case above or below, unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

Combustion Air Inlet

Combustion air supply pipes can NOT be combined into a single pipe for multiple appliance installations.

Combustion air supplied from outdoors must be free of contaminants (See Combustion and Ventilation Air). To prevent recirculation of flue products into the combustion air inlet, follow all instructions in this section.

To help prevent recirculation of flue products:

The combustion air inlet cap MUST NOT be installed above the flue outlet cap.

FIG. 20 Sidewall Vent Locations

Venting of Flue Products

The combustion air inlet cap must be installed horizontally or below the flue outlet and MUST maintain a minimum 3 foot (91 cm) radius clearance from the flue outlet cap.

Locate appliances as close as possible to the sidewall where the vent for flue products will be installed.

The combustion air inlet cap and vent cap for flue outlet

MUST be located on the same sidewall and in the same pressure zone.

Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm per meter) from the appliance to the vent terminal. Follow manufacturers instructions.

The combustion air inlet cap must not be installed closer than 10 feet (3.05 m) from an inside corner of a L-shaped structure.

The vent cap shall terminate at least 3 feet (91 cm) above any forced air inlet within 10 feet (3.05 m).

The vent shall terminate at least 4 feet (1.22 m) below, 4 feet (1.22 m) horizontally from or 1 foot (30 cm) above any door, window or gravity air inlet to the building.

The combustion air inlet cap must be installed at least 1 foot

(30 cm) above ground level and above normal snow levels.

The vent system shall terminate at least 1 foot (30 cm) above grade and above normal snow levels.

17

Multiple Sidewall Direct Vent Installations

FIG. 22 Vertical Direct Vent Installation

The E+Vertical Direct Vent System FIG. 21 Installation of Multiple Direct Vent Caps

The combustion air inlet caps for multiple appliance installations must maintain the minimum 3 foot (91 cm) radius clearance below or horizontally from the closest flue outlet. Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the 3 foot (91 cm) radius minimum clearance between air inlet and flue outlet must be maintained. All clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple appliance installations.

A DIRECT VENT SYSTEM WITH

VERTICAL THROUGH-ROOF

TERMINATIONS

Follow all requirements in the General Venting section for venting flue products to the outdoors and general installation instructions. All direct vent appliances must have combustion air supplied directly to the appliance with a separate air pipe.

CAUTION

Appliances which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit. Proper freeze protection must be provided, see

Freeze Protection.

The bell increaser, installed on the vent outlet, must be removed. The bell increaser is NOT USED with the direct vent system. Vent connection is made directly to the top of the appliance. No additional bell increaser, draft diverter or barometric damper is required. The direct vent system uses a two pipe system, one pipe for the flue products and one pipe for the combustion air supply. The vertical throughroof vented flue MUST be a dedicated stack. The flue can

NOT be combined with any other appliance vent or common vent from multiple appliances. The vent on a direct vent system may have a positive pressure in the flue which requires all vent joints and seams to be sealed gastight. The direct vent vertical through-roof venting system has specific vent material and installation requirements.

The flue from a direct vent system must have a condensate drain with provisions to properly collect and dispose of any condensate that may occur in the venting system. Choose acceptable vent materials from those listed below.

The combustion air inlet pipe must also be a dedicated system with one air inlet pipe per appliance. The air inlet pipes from multiple appliances can NOT be combined to a single common connection. The air inlet pipe connects directly to the appliance to supply combustion air.

18

The air inlet pipe must be sealed. Choose acceptable combustion air pipe materials from those specified in this section.

The direct vent vertical through-roof vent system DOES

NOT require the purchase of a special vent kit from the manufacturer. The specified flue pipe, vertical through-roof flue outlet cap, air inlet pipe and components to assemble the through-roof combustion air inlet cap are purchased locally.

Input

Btu/hr

TABLE - E

DIRECT VENT FLUE

AND AIR PIPE SIZES

150,000

199,999

250,000

300,000

Direct Vent

Flue Size *

Air Inlet

Pipe*

4"

4"

5"

5"

*Minimum diameter, installer may increase diameter one pipe size for ease of installation if needed.

4"

4"

5"

5" installed on the horizontal outlet of the first ell and turned down. A 90° ell and a 90° street ell may be used to make this assembly. If a straight piece of pipe is used between the two ells, it should not exceed 6" (51 mm) in length. The termination ell on the air inlet must be located a minimum of 12" (30 cm) above the roof or above normal levels of snow accumulation. The point of termination for the air inlet must be 24" (61 cm) lower than the point of flue gas termination if it is located within 10' (3.05 m) of the flue outlet. Use care to ensure that the 90° ell assembly is properly installed on the air inlet pipe. Incorrect installation and/or location of the air inlet cap can allow the discharge of flue products to be drawn into the combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury, death or property damage

A vertical vent cap as specified by the vent material manufacturer MUST be used to vent the flue products to the outdoors. The vent cap for the flue products is purchased locally. The point of discharge for the flue products in a vertical direct vent system must terminate a minimum of 24" (61 cm) above the point where the air inlet is located if the air inlet is within a 10' (3.05 m) radius of the flue discharge. Incorrect installation and/or location of the vent cap for flue products can allow the discharge of flue products to be drawn into the combustion process on the heater. This can result in incomplete combustion and potentially hazardous levels of carbon monoxide in the flue products. This will cause operational problems with the heater and possible spillage of flue products which can cause personal injury, death or property damage

Flue Pipe Materials

Select venting material from the following specified vent materials:

Heat-Fab Saf-T CI Vent with AL29-4C stainless steel

(Call 1-800-772-0739 for nearest distributor)

Z-Flex Z-Vent with AL29-4C stainless steel

(Call 1-800-654-5600 for nearest distributor)

FIG. 23 Air Inlet Cap for Vertical Direct Vent System

Roof Top Air Inlet Cap for Vertical Direct Vent

Protech Systems Inc. Fas-N-Seal Vent with

AL29-4C stainless steel

(Call 1-800-766-3473 for nearest distributor)

Flex-L International, Inc. Star-34 Vent with

AL29-4C stainless steel

(Call 1-800-561-1980 for nearest distributor)

The air inlet cap for the vertical through-roof direct vent system is assembled from components purchased locally.

The air inlet cap consist of two 90° ells installed at the point of termination for the air inlet pipe. The first 90° ell is installed on the roof top at the highest vertical point of the air inlet pipe and turned horizontal, the second 90° ell is

19

Metal-Fab Corr/Guard Vent with AL29-4C stainless steel (Call 1-800-835-2830 for nearest distributor) or other listed AL29-4C vent systems suitable for positive pressure

Air Inlet Pipe Materials

Select air inlet pipe material from the following specified materials:

PVC or CPVC (4", 5"or 6" I.D.)*

Dryer Vent

Galvanized steel vent pipe with joints and seams sealed as specified below.

The PVC or CPVC air inlet pipe should be cleaned and sealed with the pipe manufacturers recommended solvents and standard commercial pipe cement for the material used.

The PVC, CPVC, or Dryer Vent air inlet pipe should use a silicone sealant to ensure a proper seal at the boiler connection. Dryer vent should use a screw type clamp to seal the vent to the boiler and the assembly of 90° ells which make up the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

Type "B" double wall vent with joints and seams sealed as specified below.

Sealing of vent material for use with the Vertical Direct

Vent System

* Plastic pipe requires an adapter (not provided) to transition between the air inlet and cap.

The vent materials, Heat-Fab Saf-T CI Vent, Z-Flex Z-Vent,

Protech Systems Fas-N-Seal Vent, Flex-L Star-34,

Metal-Fab Corr/Guard Vent or listed AL29-4C vent system suitable for positive pressure, must be installed and sealed per the vent manufacturers installation instructions.

WARNING

Using other vent or air intake materials, failure to properly seal all seams and joints or failure to follow vent pipe manufacturer's instructions can result in personal injury, death or property damage. Mixing of venting materials will void the warranty and certification of the boiler.

Length of Flue Pipe and Air Inlet Pipe

The total equivalent length of the direct vent flue pipe or the air inlet pipe must not exceed a maximum of 50 (15.24 m) equivalent feet in length for each pipe. Subtract 5 feet

(1.52 m) for each elbow in the vent pipe or air intake system. Do not exceed limits for piping lengths.

Sealing of Type "B" double wall vent material or galvanized vent pipe material used for air inlet pipe on a Direct Vent System

FIG. 24 Drain Tee Installation

2. Do not install seams of vent pipe on the bottom of horizontal runs.

3. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply aluminum foil duct tape or silicone sealant to all screws or rivets installed in the vent pipe.

4. Ensure that the vent pipe and air inlet pipes are properly supported.

Drain Tee Installation

1. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL

Standard 723 or 181A-P or a high quality UL

Listed silicon sealant such as those manufactured by Dow Corning or General Electric.

20

A drain tee must be installed in the vent pipe to collect and dispose of any condensate that may occur in the vent system. The drain tee must be installed as the first fitting after the horizontal ell on the top of the appliance. See the typical vent installation drawings. Plastic drain tubing, sized per the vent manufacturers instructions, shall be provided as a drain line from the tee. The drain tubing must have a trap provided by a 3" (76 mm) diameter circular trap loop in the drain tubing. Prime the trap loop by pouring a small quantity of water into the drain hose before assembly to the vent. Secure the trap loop in position with nylon wire ties. Use caution not to collapse or restrict the condensate drain line with the nylon wire ties. The condensate drain must be routed to a suitable drain for disposal of condensate that may occur in the direct vent system. Refer to the condensate drain installation instructions as supplied by the

manufacturer of the vent material. See "Freeze Protection" for more information.

When a direct vent system is disconnected for any reason, the flue must be reassembled and resealed according to the vent manufacturers instructions. The air inlet pipe must also be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

The vertical through-roof vent cap should have a minimum clearance of 4 feet (1.22 m) horizontally from and in no case above or below, unless a 4 foot (1.22 m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

Combustion Air Inlet

Combustion air supply pipes can NOT be combined into a single pipe for multiple appliance installations.

DANGER

Failure to properly seal all vent joints and seams may result in flue gas spillage and carbon monoxide emissions causing severe personal injury or death.

Combustion air supplied from outdoors must be free of contaminants (See Combustion and Ventilation Air). To prevent recirculation of flue products into the combustion air inlet, follow all instructions in this section.

The connection from the vent to the vent termination outside the building MUST be made with one of the specified vent materials and must be direct as possible with no reduction in diameter. The vent accessories, such as firestop spacers, thimbles, caps, etc., MUST be from the same vent material manufacturer and installed in accordance with the manufacturers listing. The vent connection through the roof top must provide correct spacing to combustible surfaces. The vent pipe connection to the roof top vent cap MUST have a gas-tight seal to prevent the leakage of flue products.

The combustion air inlet cap MUST be at least 2 feet

(61 cm) below the vertical through-roof flue outlet cap, if within 10 feet (3.05 m).

The combustion air inlet cap and vent cap for the flue outlet

MUST be located on the same roof top surface and in the same pressure zone.

The combustion air inlet cap must not be installed closer than 10 feet (3.05 m) from an inside corner of a L-shaped structure.

Venting of Flue Products

The combustion air inlet cap must be installed at least one foot (30 cm) above the roof top and above normal snow levels.

Locate appliances as close as possible to the vertical through-roof vent for flue products.

Horizontal runs must slope upwards not less than 1/4 inch per foot (21 mm per meter) from the appliance to the vent terminal. Follow manufacturers instructions.

The vertical through-roof vent cap shall terminate at least 3 feet (91 cm) above any forced air inlet within 10 feet

(3.05 m).

The vertical through-roof vent shall terminate at least 4 feet

(1.22 m) below, 4 feet (1.22 m) horizontally from or 1 foot

(30 cm) above any door, window or gravity air inlet to the building.

The vent terminal shall not be installed closer than 10 feet

(3.05 m) from an inside corner of an L-shaped structure.

Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

FIG. 25 Multiple Vertical Direct Vent Installations

21

Multiple Vertical Direct Vent Installations

The combustion air inlet caps for multiple appliance installations must maintain the minimum 2 foot (61 cm) clearance below the closest vertical flue outlet if within 10 feet (3.05 m). Multiple flue outlet caps may be installed side by side and multiple air inlet caps may be installed side by side but the air inlet must always be at least 2 feet (61 cm) below the closest flue outlet if the outlet is within

10 feet (3.05 m). All clearance and installation requirements in this section and the applicable portions of the general venting section must be maintained on multiple appliance installations.

 CAUTION

Boilers which are shut down or will not operate may experience freezing due to convective air flow in the air inlet pipe connected to the unit.

Proper freeze protection must be provided, see

Freeze Protection.

The Outdoor Vent System

junction box mounts directly to the left side panel of the appliance and provides a weatherproof enclosure for the

120 VAC service and pump connections.

NOTE

If the appliance is equipped with an optional indoor flow switch, the flow switch must be changed to the outdoor version listed in the parts list (RPL7030).

Combustion air supply must be free of contaminants (see

Combustion and Ventilation Air, page 4). To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section.

 WARNING

Outdoor models MUST be installed outdoors and

MUST use the vent cap supplied by the manufacturer. Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors. All covers, doors, and jacket panels must be properly installed to ensure proper operation and prevent hazardous condition.

 CAUTION

Appliances which are shut down or will not operate may experience freezing due to convective air flow in the outdoor vent cap installed on the appliance. In cold climates, continuous pump operation or pump delay is recommended to help prevent freezing of water on outdoor systems.

Proper freeze protection must be provided. See

Freeze Protection.

FIG. 26 Outdoor Installation Illustration

OUTDOOR INSTALLATION

Appliances can be installed outdoors when equipped with the optional outdoor kit. The outdoor kit includes the outdoor vent cap / top assembly, gas valve cover, deflectors, and a weatherproof junction box.

Outdoor Vent/Air Inlet Location

Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain a minimum clearance of 3" (76 mm) from the rear of the outdoor vent cap to combustible surfaces and a minimum clearance of 1" (25 mm) from the back of the unit. To avoid a blocked air inlet or blocked flue condition, keep the air inlet, flue outlet and drain slot clear of snow, ice, leaves, debris, etc.

The bell increaser installed on the appliance vent outlet must be removed. The bell increaser is NOT USED with the outdoor vent cap. The outdoor vent cap /top assembly mounts directly to the top of the appliance and covers the flue outlet. The combustion air is provided through the slotted openings in the jacket. The deflectors cover the slotted openings. The appliance is self venting and requires no additional vent piping.

Do not locate appliance so that high winds can deflect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion or damage to controls. Locate appliance at least 3 feet (0.91m) from any wall or vertical surface to prevent adverse wind conditions from affecting performance.

The gas valve cover mounts directly to the left side panel of the appliance and covers the gas valve and gas valve wiring connector.

Multiple appliance outdoor installations require 48"

(1.22m) clearance between each vent cap.

The standard junction box that is installed on the left side panel of the appliance must be removed. The weatherproof

22

The outdoor cap must be located 4 feet (1.22m) below and

4 feet (1.22m) horizontally from any window, door, walkway, or gravity air intake.

The combustion air inlet of the outdoor cap must be located at least 1 foot (0.30m) above grade and above normal snow levels.

Locate appliance at least 10 feet (3.05m) away from any forced air inlet.

Locate appliance at least 3 feet (0.91m) outside any overhang.

Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs or other plants to obstruct the proper operation of the outdoor vent system.

Do not install in locations where rain from building runoff drains will spill onto the appliance.

Flue gas condensate can freeze on exterior walls or on the vent cap. Frozen condensate on the vent cap can result in a blocked flue condition. Some discoloration to exterior building or appliance surfaces can be expected. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

 CAUTION

Appliances which are shut down or will not operate may experience freezing due to convective air flow down the vent cap installed on the appliance. Proper freeze protection must be provided. See

Freeze Protection.

GAS SUPPLY

Verify appliance is supplied with type gas specified on rating plate. This appliance is orificed for operation up to

2000 feet altitude. The appliance will be derated 4% per

1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation. Field conversions for operation at high altitude must be performed by factory authorized personnel only. The appliance will be marked to indicate suitability for high altitude operation.

INLET GAS PRESSURE: Measured at the inlet pressure tap located upstream of the combination gas valve.

TABLE - G

INLET GAS PRESSURE

Min. (Inches-Water Column)

Nat. Gas LPG

13" w.c.

4.0" w.c.

8" w.c.

FIG. 27 Outdoor Kit Installed on Appliance

The Outdoor Kit

The required outdoor kit part numbers are listed by appliance size. The venting kit must be furnished by the manufacturer in accordance with CSA International and

ANSI requirements. Each kit includes the outdoor vent cap / top assembly, gas valve cover assembly, deflectors, and weatherproof junction box assembly.

TABLE-F

Outdoor Kits

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

MANIFOLD PRESSURE: Measured at the pressure tap on the downstream side of the combination gas valve. The gas regulator on the appliance’s combination gas valve(s) is adjustable to supply proper manifold pressure for normal operation. If adjustment of regulator pressure is required, see Manifold Adjustment Procedure. Do not increase

regulator pressure beyond specified pressure setting.

TABLE - H

NET MANIFOLD PRESSURE

Input

Btu/hr

Outdoor Kit with

Outdoor Kit without

Pump Cover Pump Cover

150,000 ODK3062 ODK3069

199,999 ODK3063

250,000 ODK3067

300,000 ODK3068

ODK3070

ODK3071

ODK3072

Btu/hr Input

150,000 - 300,000

Btu/hr Input

150,000 - 300,000

Nat. Gas Regulator

Setting

1.8" w.c.

LP Gas Regulator

Setting

4.6" w.c.

23

TABLE - I

MULTIPLE APPLIANCE INSTALLATIONS GAS PIPING SIZE CHART

Maximum Capacity of Pipe in Thousands of Btu/hr per hour for gas pressures of 14 Inches Water Column (0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on NAT GAS, 1025 Btu/hr per Cubic Foot of Gas and 0.60

Specific Gravity)

GAS PRESSURE TEST

1. The appliance must be disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

2. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

outside the building. The appliance will not operate properly if the reference hose is removed or a vent to atmosphere is installed.

7.Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes.

8.Inlet gas connections to the gas valve is 3/4" NPT for the

150,000 through 300,000 Btu/hr models.

3. The appliance and its gas connection must be leak-tested before placing it in operation.

GAS CONNECTION

1.Safe operation of appliance requires properly sized gas supply piping. See data below.

TABLE - J

SINGLE APPLIANCE INSTALLATIONS

SUGGESTED GAS PIPE SIZE

Btu/hr

Input

DISTANCE FROM METER

2.Gas pipe size may be larger than heater connection.

3.Installation of a union is suggested for ease of service.

4.Install a manual main gas shutoff valve, outside of the appliance gas connection and before the gas valve, when local codes require.

5.A trap (drip leg) MUST be provided in the inlet of the gas connection to the appliance.

6.The combination gas valve has an integral vent limiting device and does not require venting to atmosphere,

24

0 -

50'

51' -

100'

101' -

200'

150,000 1"

1"

199,999 1" 1"

201' -

300'

301' -

500'

250,000

300,000

1" 1 1/4" 1 1/2"

1 1/4" 1 1/2" 1 1/2" 1 1/2" 2"

For each elbow or tee, add equivalent straight pipe to total length from table below.

90

°

TABLE - K

FITTINGS TO EQUIVALENT

STRAIGHT PIPE

Diameter Pipe (inches)

3/4"

1" 1 1/4" 1 1/2" 2" 3" 4" 5"

4. Install a sediment trap in the supply line to the gas control.

5. Thread pipe the proper amount for insertion into gas valve. Effective length of standard 3/4" NPT thread is

9/16", overall length of thread is 3/4". DO NOT

THREAD PIPE TOO FAR. Valve distortion or malfunction may result if the pipe is inserted too deeply.

6. Apply a moderate amount of good quality pipe compound (DO NOT use Teflon tape) to pipe only, leaving two end threads bare.

Equivalent length of Straight Pipe (feet)

2' 2 1/2' 3 1/2' 4' 5' 10' 14'

20'

GAS PIPING

FIG. 28 Gas Piping to Heater

All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gases. All piping must comply with local codes and ordinances. Tubing installations must comply with approved standards and practices.

FIG. 29 Wrench to Support Gas Valve for Piping

Connection

7. Remove seal over control inlet.

8. Connect pipe to control inlet. Use wrench to square ends of the control.

9. For LP gas, consult your LP gas supplier for expert installation.

10. Ensure that all air is properly bled from the gas line before starting the ignition sequence. Start-up without properly bleeding air from the gas line may require multiple reset functions of the ignition control module to achieve proper ignition.

Install Piping to Control

1. The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient capacity. Verify pipe size with your gas supplier.

2. Use new, properly threaded black iron pipe free from chips. If tubing is used, make sure the ends are square, deburred and clean. All tubing bends must be smooth and without deformation. Avoid flexible gas connections.

3. Run pipe or tubing to the control. If tubing is used, obtain a tube to pipe coupling to connect the tubing to the control.

25

MANOMETER

2

3

4

0

1

1

4

3

2

GAS VALVE

4. Turn the power switch to the “ON” position.

5. Set the thermostat to call for heat. The fan will start.

6. While the combustion air fan is running for the prepurge cycle and the pressure in the front chamber stabilizes, record the pressure in the front chamber.

This pressure will be used to calculate the net manifold pressure.

7. Turn the power switch to the “OFF” position.

8. Remove the manometer or magnahelic hose from the front chamber barb and reinstall the hose from the air pressure switch to the barb.

9. Turn all gas valve knobs and the manual gas cock to the

“OFF” position.

FIG. 30 Manometer Connection for Manifold Pressure

Adjustment

GAS MANIFOLD PRESSURE

ADJUSTMENT PROCEDURE

IMPORTANT:

The gas valve is referenced to the fan pressurized chamber by a hose connected from the vent of the gas valve regulator to the chamber pressure tap located on the left side of the jacket. Reference the drawings in this section for component location and connection points for pressure measurement.

The referenced chamber pressure must be subtracted from the manifold pressure to obtain actual net manifold pressure for normal operation. A manometer or magnahelic gauge legible in 0.1" increments up to 10" water column is required to check and adjust the manifold pressure. The regulator cover screw on the gas valve must be in place and tight for the appliance to operate properly.

FIG. 31 Manifold Gas Pressure Measurement

10. Remove the 1/8" hex plug, located on the “outlet” side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge (see Figure 31).

Minimum range of scale should be up to 5" w.c. for natural gas and 10" w.c. for propane gas.

1. Turn the power switch to the “OFF” position.

2. Remove the top front jacket panel.

3. Locate the air pressure switch located to the right of the combustion air fan. Trace the hose from the air pressure switch to the barb located in the top of the upper chamber. Remove the hose from this barb and connect the hose from the manometer or magnahelic to this barb to measure the air pressure in the front chamber.

11. A reference pressure hose is factory installed from the barbed connection on the gas valve regulator to the fan pressurized front chamber. All manifold pressure measurements made with the reference hose in place will be the sum of the net manifold pressure and the air pressure in the front chamber.

12. Turn the power switch to the “ON” position.

13. Turn all gas valve knobs to the “ON” position.

26

14. Set the thermostat to call for heat.

15. Before the valve opens, the manometer or magnahelic gauge will read a positive air pressure of 1.4" w.c. to

1.8" w.c. in the jacket as supplied by the combustion air fan in the prepurge cycle. There is no gas flow at this point. This air pressure reading is normal.

16. The gas valve will open at the end of the trial for ignition stage and remain open as the burners fire.

Observe the gas manifold pressure when valves open.

If insufficient gas pressure is supplied to the burners, the burners will not fire. Record the gas pressure indicated on the manometer or magnahelic. Subtract the air pressure in the front chamber (as recorded in

Step 6) from the gross manifold pressure observed at the end of trial for ignition and when the burners are firing. The gross manifold pressure will typically be within the range of 3.4" w.c. to 3.9" w.c. for Natural Gas and 6.1" w.c. to 6.7" w.c. for L.P. Gas at full fire. The difference in the gross manifold pressure and the front chamber pressure is the net manifold pressure setting of the gas valve’s regulator. Compare the net setting to the setting specified for the type of gas used. Adjust regulator as required. Set the thermostat to a setting lower than the appliance’s water temperature to turn the burners off. Allow appliance to run through the post purge sequence. Turn the power switch to the “OFF” position.

screw 1/4 turn in the desired rotation and cycle the burners on in the sequence listed below and record the observed chamber and regulator settings. Subtract to determine the net manifold pressure setting. Repeat as necessary to achieve the specified net manifold pressure setting.

19. Replace cover screw on the regulator and turn the power switch to the “ON” position. Set the thermostat to call for heat. Observe gas regulator pressure again at the burner “ON” stages. Repeat this sequence until the proper regulator setting has been obtained.

NOTE:

If the regulator cover screw is not in place and tight, the appliance will not function properly.

20. Turn the power switch to the “OFF” position.

21. Turn gas valves and manual gas cock knob to the

“OFF” position.

22. Remove the gas pressure fitting from the gas valve and replace with the 1/8" hex plug (that was previously removed) and tighten.

TABLE - L

NET MANIFOLD PRESSURE

Regulator Pressure Less

Front Chamber Pressure

23. Ensure that the chamber pressure reference hose is properly connected to the gas valve.

24. Turn the gas valve knobs to the “ON” position.

25. Turn the power switch to the “ON” position and replace the jacket panel. The appliance is now ready to operate.

Type of Gas

Natural Gas

Net Manifold Pressure Setting

1.8" w.c.

L.P. Gas 4.6" w.c.

If manifold pressure cannot be properly maintained, check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control.

NOTE:

The front chamber pressure must be subtracted from the gross regulator pressure to obtain actual net manifold pressure for normal operation. The front chamber pressure may vary based on elevation, stages of operation, vent length and model. For information on chamber pressure, see Combustion

Air Adjustment. Do not increase net manifold

pressure beyond the specified pressure setting.

17. If adjustment is necessary, remove the regulator cover screw on the gas valve.

18. Turn regulator adjustment screw clockwise to raise regulator gas pressure, counterclockwise to lower the regulator gas pressure. Turn regulator adjustment

27

TABLE - M

MINIMUM AND MAXIMUM GAS SUPPLY

PRESSURES

Min. (Inches-Water Column)

Nat. Gas LPG

13" w.c.

4.0" w.c.

8" w.c.

MANOMETER

2

3

4

0

1

7

8

5

6

8

7

6

5

4

3

2

1

GAS VAL V E

10. If gas pressure is out of range, contact gas utility, gas supplier, qualified installer or service agency to determine necessary steps to provide proper gas pressure to the control.

11. If gas supply pressure is within normal range, proceed to remove gas manometer and replace pressure tap fittings in the gas control.

FIG. 32 Manometer Connection for Gas Supply

Pressure Measurement

12. Turn the power switch and thermostat to "OFF" position.

13. Turn gas valve knob to "OFF" position.

CHECKING GAS SUPPLY PRESSURE

14. Shut off gas supply at the manual valve in the gas piping to the appliance. If fuel supply is LP gas, shut off gas supply at the tank.

1. Turn the power switch and thermostat to "OFF" position.

15. Remove the manometer and related fittings from "inlet" side of the gas valve, replace 1/8" hex plug in gas valve.

2. Turn gas valve knob to "OFF" position.

3. Shut off gas supply at the manual valve in the gas piping to the appliance. If fuel supply is LP gas, shut off gas supply at the tank.

16. Turn on gas supply at the manual valve, turn on LP gas at tank if required.

17. Turn the power switch to "ON" position.

4. Remove the 1/8" hex plug, located on "inlet" side of the gas valve and install a fitting suitable to connect to a manometer or magnahelic gauge. Range of scale should be 14" w.c. or greater to check inlet pressure.

18. Turn the gas valve knob to "ON" position.

19. Set the thermostat to call for heat.

IMPORTANT:

5. Turn on gas supply at the manual valve, turn on LP gas at tank if required.

6. Turn the power switch to "ON" position

7. Turn the gas valve knob to "ON" position

8. Set the thermostat to call for heat.

Upon completion of any testing on the gas system, leak test all gas connections with a soap solution while main burners are operating.

Immediately repair any leak found in the gas train or related components. Do Not operate an appliance with a leak in the gas train, valves or related piping.

9. Observe the gas supply pressure as the burners are firing. Ensure inlet pressure is within specified range.

Check burner performance by cycling the system while you observe burner response. Burners should ignite promptly.

Flame pattern should be stable, see "Maintenance-Normal

Flame Pattern." Turn system off and allow burners to cool,

28

then cycle burners again to ensure proper ignition and flame characteristics.

WATER CONNECTIONS

connecting flow switch wires to the terminals. This wiring connection installs the flow switch in the 24 VAC safety circuit for the ignition control. A flow switch installed in 1

1/4" pipe requires a minimum flow of 10 GPM to make the flow switch and start burner operation. A flow switch installed in 1 1/2" pipe requires a minimum flow of 13

GPM to make the flow switch and start burner operation.

A flow switch installed in 2" pipe requires a minimum flow of 19 GPM to make the flow switch and start burner operation. A water flow switch meets most code requirements for a low-water cut off device on boilers requiring forced circulation for operation.

FIG. 33 Connections to the Appliance

Inlet and Outlet Connections

For ease of service, install unions on inlet and outlet of the appliance. The connection to the appliance marked "Inlet" on the header should be used for return from the system.

The connection on the header marked "Outlet" is to be connected to the supply side of the system.

FIG. 34 Water Flow Switch

RELIEF VALVE

WATER FLOW SWITCH

(IF EQUIPPED)

LOW WATER CUTOFF

(IF EQUIPPED)

This appliance is supplied with a relief valve(s) sized in accordance with ASME Boiler and Pressure Vessel Code,

Section IV ("Heating Boilers"). The relief valve(s) is installed in the vertical position and mounted in the hot water outlet. No valve is to be placed between the relief valve, and the appliance. To prevent water damage, the discharge from the relief valve shall be piped to a suitable floor drain for disposal when relief occurs. No reducing couplings or other restrictions shall be installed in the discharge line. The discharge line shall allow complete drainage of the valve and line. Relief valves should be manually operated at least once a year.

CAUTION

A hot water supply boiler installed above radiation level must be provided with a low water cutoff device either as part of the appliance or at the time of installation.

An electronic or float type low water cut off is available as a factory supplied option on all appliances. Low water cutoffs should be inspected every six months, including flushing of float types.

COMBINATION GAS VALVE

Avoid contact with hot discharge water.

Each appliance has a combination gas valve to cycle the gas supply on and off to the burners. The combination valve consists of a gas regulator and two valve seats to meet the requirements for redundant gas valves. The valve has a gas control knob that must remain in the open position at all times when the appliance is in service. The gas control valve has pressure taps located on the inlet and discharge sides of the valve. Manifold pressure is adjusted using the regulator located on the valve.

A water flow switch is available as a factory supplied option on 150,000 through 300,000 Btu/hr heating boilers and water heaters. The flow switch should be wired across the X and B terminals on the appliance’s internal terminal strip. Remove the jumper between the terminals before

29

The manifold pressure is preset at the factory and adjustment is not usually required. If the manifold pressure is to be adjusted, follow the "Gas Manifold Pressure

Adjustment Procedure" for proper adjustment.

ALARM BELL

(IF EQUIPPED)

An alarm bell is available as a factory supplied option on

150,000 - 300,000 Btu/hr heating boilers and water heaters.

The alarm bell is shipped separately for remote mounting and is not weatherproof. If ordered on an outdoor unit, mount the alarm bell inside a building. Refer to the wiring diagram on page 53 of this manual for wiring connections.

Pump Wiring for a Heating Boiler

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

ELECTRICAL CONNECTIONS

This appliance is wired for 120 VAC service. The appliance, when installed, must be electrically grounded in accordance with the requirements of the authority having jurisdiction or in the absence of such requirements, with the latest edition of the National Electrical Code ANSI/NFPA

No. 70. When the appliance is installed in Canada, it must conform to the CAE C22.1, Canadian Electrical Code, Part

1 and/or local Electrical Codes.

1. All wiring between the appliance and field installed devices shall be made with type T wire [63°F (35°C) rise].

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

FIG. 35 Boiler Control Panel

3. The pump must run continuously when appliance is being fired (hot water supply boilers must use the optional pump delay or intermittent pump controller if the pump is to be cycled).

4. To avoid serious damage, DO NOT energize the appliance until the system is full of water. Serious damage may result.

5. Provide the appliance with proper overload protection.

6. Install wall thermostat on inside wall. DO NOT install thermostat in an area affected by drafts, sunlight, light fixtures, hot or cold water pipes or near a fireplace.

FIG. 36 Water Heater Control Panel

TEMPERATURE ADJUSTMENT

TABLE - N

AMP DRAW DATA

150,000 through 300,000 Btu/hr Models

Operating Temperature Control

NOTE:

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

Firing Control

F-9 (Single Stage)

M-9 (Two Stage)

Fan

1.15

1.15

Valve/

Maximum

Total Amps

Controls

@ 120 VAC

3.97

4.15

5.12

5.30

WARNING

Return water temperatures must not be less than

140°F. If lower return water temperatures are required, follow the instructions for

Low

Temperature Bypass Requirements or Three-Way

Valves, see pages 42 and 43.

30

Locating Temperature Control

Remove the control panel door on the front of the appliance in order to locate and access the temperature control.

Temperature Control Settings

There are three setting knobs on the temperature control unless your appliance is specified as a boiler only with an outdoor air reset option. If your appliance is a boiler only with an outdoor air reset option, there are additional controls for this option. They are explained under Outdoor

Air Reset Option, page 32.

NOTE:

Anytime that OJ1 is the only jumper cut, a new overlay is required under the Set Point knob on the temperature controller because the scale has changed to a maximum of 190°F.

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

The three setting knobs on the temperature control are for

Set point, Differential, and High-Fire Offset (see Figure

37).

Set Point

The Set Point knob specifies the target water temperature in degrees, Fahrenheit. After the water temperature reaches the set point, the temperature control shuts off the burners.

Differential

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

FIG. 37 Temperature Control

Maximum Set Point Determination

The maximum set point for the control is factory set.

Boilers can be set to 240°F max., water heaters are set to

190°F max., and specialty state and local codes to 200°F.

These maximum set points are established by cutting the

OJ1 and OJ2 jumpers located on the right side of the temperature controller. The maximum set point is determined as shown below in TABLE-O.

TABLE O

Maximum Set point Determination

OJ1

Connected

Cut

Connected

Cut

OJ2

Connected

Connected

Cut

Cut

Max.

Set Point

240°F

190°F

200°F

160°F

High-Fire Offset

The temperature control operates a two-stage firing system.

The two stages are High-Fire and Low-Fire. High-Fire operates all burners while Low-Fire operates approximately one-half of the burners.

The High-Fire knob specifies the number of degrees below set point that the High-Fire stage shuts down. At that point, the appliance will continue to operate at the Low-Fire stage until the set point is reached.

The High-Fire offset knob has settings between 0 F and

20 F. If set at 0 F, the High-Fire offset is disabled and the appliance will operate at the High-Fire stage until the set point is reached and the temperature control shuts the appliance off.

No matter what the High-Fire offset knob is set to, the appliance will light at Low Fire and operate for approximately 10 to 120 seconds before the High-Fire stage actuates.

Boiler Application

Standard boiler appliances are shipped with one sensor, the inlet water temperature sensor. An optional sensor can be purchased and installed for use as a remote system sensor.

Boilers with the outdoor air reset option also have an outside air temperature sensor.

Water Heater Application

Water heater appliances are shipped with two sensors; the inlet water temperature sensor and the multi-purpose temperature sensor to be used as a tank sensor.

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Temperature Control Sensors

This is a two-stage temperature control that controls the burner ignition, pump, and alarm functions. This temperature controller can measure up to three different sensor inputs, depending upon how the appliance is set up.

They are as follows:

1. Inlet Water Temperature Sensor

2. Multi-Purpose Temperature Sensor

3. Outside Air Temperature Sensor

Inlet Water Temperature Sensor

This sensor measures the inlet water temperature coming into the appliance.

Multi-Purpose Temperature Sensor

Depending upon how your appliance is set up, this sensor can be used as a system sensor in a boiler system or a tank sensor for water heater applications. Connect this sensor to the two blue wires in the upper left-hand corner of the control panel.

Outdoor Air Temperature Sensor

The outside air temperature sensor will only be used for boiler systems. The outside air sensor is optional. This sensor allows you to tie boiler operation to the outdoor air temperature. As outside temperatures drop, the control will increase the temperature setting of the boiler. As outdoor temperatures rise, the control will decrease the temperature to the selected set point of the boiler. You can set the control to shut the boiler off when a desired outdoor air temperature level is reached.

You must purchase the sensor from the appliance manufacturer. The sensor comes with a housing that helps protect the sensor from the elements. Mount the air sensor housing under the eve of the roof. Make sure the housing is out of direct sunlight. This will ensure that the sensor will accurately read the true outdoor temperature. Connect the outdoor air temperature sensor to the terminal block on the outdoor air reset board. For more information on mounting the sensor, see Remote Mounting of Sensors, this page.

Placement of Sensors

Inlet Temperature Sensor

The inlet water temperature sensor is placed into the inlet bulbwell on the boiler. This sensor is installed by the factory in new appliances. Make sure to insert the sensor all the way into the bulbwell, leaving no air pocket between the front surface of the sensor and the back of the bulbwell. Air pockets are thermally non-conductive and will cause sensors to read inaccurately.

System Sensor

The system sensor is used for boiler applications. This sensor will control the boiler operation based upon the water temperature within the building loop.

Tank Sensor

The tank sensor is used in water heating applications. Place the sensor in a water storage tank to measure water temperature. For more information on mounting the sensor, see Remote Mounting of Sensors this page.

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Remote Mounting of Sensors

You must mount the outside air temperature sensor outside the building. To mount remote sensors, follow the guidelines listed on this page. Take care to correctly wire sensors to the appliance. Erratic temperature readings can be caused by poor wiring practices. Twist the wires between the appliance and the remote sensor. Turn wires at least three or four turns per linear foot of wiring. This provides protection against some types of electrical interferences.

1. Do not route temperature sensor wiring with building power wiring.

2. Do not locate temperature sensor wiring next to control contactors.

3. Do not locate temperature sensor wiring near electric motors.

4. Do not locate temperature sensor wiring near welding equipment.

5. Make sure good mechanical connections are made to the sensor, any interconnecting wiring and the controller.

6. Do not mount sensor with leadwire end pointing up in an area where condensation can occur.

7. Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists. Shielded cable is recommended on all cable runs of more than 25 feet in length. cable at the sensor end.

required.

NOTE:

Ground the cable shield at the connection to the boiler temperature control only. Do not ground the shielded

To maintain temperature accuracy, sensor wires should be 18 AWG two conductor (18/2). Use shielded wire if

OUTDOOR AIR RESET OPTION

Outdoor Air Reset Option

For boilers ordered with the Outdoor Air Reset option, there is an additional control (FIG. 38). There are three setting knobs for Shutdown, Outdoor Air Max., and Ratio. There is also a switch to turn the outdoor air shutdown feature On or

Off. An O.A. Sensor is also included.

CN1

50

55

60

45

VR3

40 70

SHUTDOWN

55

50 60

65

45

65

VR1

40 70

O.A. MAX.

O.A. SENSOR

ON

ENABLE

SW1

DISABLE

O.A. SHUTDOWN

0.8

0.9

1.0

1.1

1.2

0.7

1.3

0.6

1.4

VR2

0.5

RATIO

1.5

W1

10

11

12

W3

W2

FIG. 38 Optional Outdoor Air Reset Control

FIG. 39 Outdoor Air Control Example Chart

Shutdown

The Shutdown knob specifies the outdoor air lockout temperature at which the control would prevent the appliance from operating.

Outdoor Air Max (O.A. Max)

The O.A. Max knob allows a reset up to the maximum outdoor air temperature specified by this knob setting.

When the outdoor air temperature is above the specified setting, the unit will not function in the O.A. Reset Mode, but will continue to run at the selected set point temperature.

Note that the set point knob will now indicate the

“minimum” boiler temperature. Target temperature is determined by the ratio and outdoor air temperature below the O.A. Max setting.

Ratio

The Ratio knob allows control over the reset ratio to be used during Outdoor Air Reset. The allowable ratios are as low as 0.5:1 or as high as 1.5:1.

Outdoor Air Shutdown Enable/Disable Switch

The Outdoor Air Shutdown Enable/Disable switch turns the outdoor air shutdown feature On and Off. Disabling the

Outdoor Air Shutdown feature allows the appliance to operate regardless of the outdoor air temperature. This is needed for indirect domestic hot water systems for example.

ADDITIONAL TEMPERATURE

CONTROLS

High Water Temperature Limit Control

The appliance is equipped with a fixed setting, auto-reset high water temperature limit control. The heating boiler temperature limit control has a fixed limit setting of 240°F

(115°C); the water heater temperature limit control has a fixed limit setting of 200°F (93°C). If water temperature exceeds the set point, the limit will break the control circuit and shut down the appliance. The limit control will only be reset after the water temperature has cooled below the set point of the limit. The high water temperature limit control is mounted in the outlet side of the front header.

Selecting the 0.5:1 ratio will increase the set point 0.5°F for every 1.0°F drop in outdoor air temperature up to the maximum set point temperature.

Manual Reset High Water Temperature Limit Control

(Standard on Water Heaters and Optional on Boilers)

Selecting the 1.5:1 ratio will increase the set point 1.5°F for every 1.0°F drop in outdoor air temperature up to the maximum set point temperature.

See Figure 39 for an outdoor air reset chart example.

The appliance may be optionally equipped with a fixed setting, manual reset high water temperature limit control.

This manual reset temperature limit control has a fixed limit setting of 230°F (110°C). If water temperature exceeds this set point, the limit will break the control circuit and shut down the appliance. The limit control can only be reset after the water temperature has cooled below the set point of the limit. Reset of the limit control is accomplished by pushing the Red Reset Button located on the control.

33

NOTE:

The limit control will not reset until the water temperature has dropped below the set point of the high limit.

LIGHTING INSTRUCTIONS

FOR YOUR SAFETY,

READ BEFORE OPERATING

WARNING

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

3. Remove the upper front access panel

4. Turn the power switch on the inside of the cabinet to

"OFF" position.

5. Set the thermostat to the lowest setting.

6. This appliance is equipped with an ignition device which automatically lights the burners. DO NOT try to light the burners by hand.

7. Turn the gas control knob on the gas valve clockwise to the "OFF" position.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a neighbors phone.

• Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call the fire department.

FIG. 40 Combination Gas Valve

8. Wait five (5) minutes to clear out any gas. If you smell gas, STOP! Follow the instructions in the safety information "What To Do If You Smell Gas". If you don't smell gas, go on to the next step.

1. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

Do not try to light the burner by hand.

9. Turn the gas control knob on the gas valve counterclockwise to the "ON" position.

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

10. Set the thermostat to the desired setting.

11. Turn the power switch on the inside of the cabinet to the

“ON” position.

3. Use only your hand to turn the gas control lever. Never use tools. If the lever will not turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

12. Replace control access panel.

13. Turn on all electrical power to the appliance.

4. Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

14. If the appliance will not operate, follow the instructions

"To Turn Off Gas To Appliance" and call your service technician or gas supplier.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Turn off all electrical power to the appliance.

TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance if service is to be performed.

34

2. Turn the gas control knob on the gas valve clockwise to the "OFF" position. Do not force.

WARNING

Should overheating occur or the gas fail to shut off, turn off the manual gas control valve to the appliance.

The unit has a lighted ON/OFF power switch on the outer cabinet (left side) and five (5) LED indicators on the electronic ignition control module to monitor the units operation.

TABLE - P

IGNITION MODULE

INDICATING LIGHTS

IGNITION SYSTEM CHECKOUT

1. Turn off gas supply to appliance.

2. Turn thermostat to highest setting.

3. Turn electric power on.

4. The ignition module will lock out and the

LED will blink.

5. Readjust thermostat to normal setting.

6. Turn on gas supply.

7. Turn power off then on again to reset ignition module.

8. If ignition system fails to operate properly, repair work must be performed by a qualified serviceman or installer.

HOT SURFACE IGNITION SYSTEM

The hot surface ignition module is not repairable. Any modification or repairs will invalidate the warranty and may create hazardous conditions that result in property damage, personal injury, fire, explosion and/or toxic gases.

A faulty ignition module must be replaced with a new unit.

The hot surface igniter is also the flame sensor.

OPERATION AND

DIAGNOSTIC LIGHTS

Indicating Light Function

Power on Switch - On - 120 VAC supplied to unit

Power LED

Purge LED

Ignitor LED

Valve LED

dule

operation.

Flame LED

- On - Module is powered from 24

VAC system and operating properly

- Blinks continuously if voltage is too high on transformer secondary

- Off - Module is not powered

- Off - Combustion air fan is not powered OR air flow is not proven

- On - When unit is in prepurge or interpurge

- Blinks continuously when there is a pressure switch fault

- Off - Igniter is off

- On - When hot surface ignitor is on

- Off - Gas valve is closed

- On - Control signaling gas valve is on

- Blinks continuously when control is in LOCKOUT because it failed ignition

- Off - Flame is not present

- On - Control signaling flame is present

- Blinks continuously when L1 and neutral are reversed

IGNITION AND CONTROL TIMINGS

Prepurge (Combustion Air Fan Only) - 15 Seconds

Time to Prove Pressure Switch (Airflow) - 5 Minutes

Maximum

NOTE:

Pressure switch must open within 45 seconds of call for heat or control will lockout.

Igniter Warm-up Time - 20 Seconds

Trial For Ignition - 6 Seconds

35

Postpurge (Combustion Air Fan Only) - 30 Seconds

Pump Delay Timing - 30 Seconds after burner shutdown

(on units equipped with an optional, factory supplied pump delay or intermittent pump control system).

FREEZE PROTECTION FOR A HEATING

BOILER SYSTEM

(If Required)

FREEZE PROTECTION

1. Use only properly diluted inhibited glycol antifreeze designed for hydronic systems. Inhibited propylene

glycol is recommended for systems where incidental contact with drinking water is possible.

1. For water heaters, and boilers with the pump delay option, if either the inlet sensor or the optional multipurpose temperature sensor reads below 40°F, the pump relay will turn ON. When the temperature rises above

50°F the pump relay will turn OFF.

CAUTION

DO NOT use undiluted or automotive type antifreeze.

2. Location - Heating boilers and water heaters must be located in a room having a temperature safely above freezing [32°F(0°C].

2. A solution of 50% antifreeze will provide maximum protection of approximately -30°F.

3. Caution - A room where the appliance is installed and operating under a negative pressure may experience a downdraft in the flue of an appliance which is not firing.

The cold outside air pulled down the flue may freeze a heat exchanger. This condition must be corrected to provide adequate freeze protection.

3. Follow the instructions from the antifreeze manufacturer. Quantity of antifreeze required based on total system volume including expansion tank volume.

4. Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Follow the manufacturer’s instructions. DO NOT use undiluted or automotive type antifreeze.

4. Glycol is denser than water and changes the viscosity of the system. The addition of glycol will decrease heat transfer and increase frictional loss in the boiler and related piping. A larger pump with more capacity may be required to maintain desired flow rates in a glycol system.

5. A snow screen should be installed to prevent snow and ice accumulation around the appliance venting system in cold climates.

5. Local codes may require a back flow preventer or actual disconnect from city water supply when antifreeze is added to the system.

WATER TREATMENT

6. Shut-down and Draining - If for any reason, the appliance is to be shut off, the following precautionary measures must be taken: a.

Shut off gas supply.

In hard water areas, water treatment should be used to reduce the introduction of minerals to the system. Minerals in the water can collect in the heat exchanger tubes and cause noise on operation. Excessive build up of minerals in the heat exchanger can cause a non-warrantable failure.

b.

Shut off water supply.

c.

Shut off electrical supply.

MAINTENANCE

d.

Drain the appliance completely. Remove one threaded plug or bulb well from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger. Blow all water out of the heat exchanger.

e.

Drain pump and piping.

Listed below are items that must be checked to ensure safe reliable operations. Verify proper operation after servicing.

CAUTION

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

36

1. Examine the venting system at least once a year. Check more often in first year to determine inspection interval.

Check all joints and pipe connections for tightness, corrosion or deterioration. Clean screens in the venting air intake system as required. Have the entire system, including the venting system, periodically inspected by a qualified service agency.

2. Using the view port, located below the water connections, visually check main burner flames at each start up after long shutdown periods or at least every six months. shutter is factory pre-set and should not need adjustment in most cases. If adjustment is required, the fan air shutter may be manually adjusted to a dimension specified for each model. Follow the steps below to adjust the fan air shutter if the appliance does not function properly or a continuous low air condition is observed:

WARNING

This area is hot and direct contact could result in burns.

FIG. 43 Combustion Air Shutter Adjustment

FIG. 42 Burner Flame Patterns

a. Normal Flame: A normal flame is blue, with slight yellow tips, with a well defined inner cone and no flame lifting.

b. Yellow Tip: Yellow tip can be caused by blockage or partial obstruction of air flow to the burner(s).

c. Yellow Flames: Yellow flames can be caused by blockage of primary air flow to the burner(s) or excessive gas input. This condition MUST be corrected immediately.

d. Lifting Flames: Lifting flames can be caused by over firing the burner(s) or excessive primary air.

If improper flame is observed, examine the venting system, ensure proper gas supply and adjust the combustion air.

3. Combustion Air Shutter Adjustment: This appliance uses a fan assisted combustion process. The fan air

37

A. Check for proper installation and draft in venting system. Correct as required.

B. Remove upper front access door.

C. Turn the power switch to the "OFF" position.

D. Turn the gas valve knob to the "OFF" position

E. Use a ruler to measure the distance from the base of the fan to the end of the air shutter. Compare this distance to the specified "A" dimension for the appliance.

300,000

AIR SHUTTER

ADJUSTMENT OPENING

Btu/hr Input

TABLE - Q

150,000

199,999

250,000

“A” Dimension Opening

1-1/16"

1-3/16"

1-5/8"

1-5/8"

F.

If adjustment is necessary, follow these steps. If no adjustment is necessary, go to step "I".

a.

Loosen two combustion air blower mounting nuts and slide the air shutter to the specified "A" dimension. See chart.

b. Tighten the combustion air fan mounting nuts.

c. If the differential pressure cannot be obtained, shut the appliance down and inspect the vent system (both air and flue gas passageways) for obstructions or leaks.

d. Tighten combustion air blower mounting nuts.

L.

Turn the power switch to "OFF" position.

c.

Proceed to step "N" to check appliance for proper operation.

M.

Remove gauge and tee connections, ensuring connections are made at the pressure switch correctly; the chamber pressure to the connection and the burner venturi pressure to the connection.

G. If the appliance does not function properly after manually setting the air shutter, use a magnahelic or slope gauge to set the air shutter based on differential air pressure.

N.

Turn the gas valve knob to "ON" position.

O.

Turn the power switch to "ON" position.

H. Install a tee in each of the hoses connecting the chamber pressure and burner venturi pressure to the pressure switch. Install a connecting hose from the branch of each tee to a manometer, magnahelic or slope gauge, legible in 0.1" increments up to 3" w.c.

Connect chamber pressure to the positive pressure side of the gauge and burner venturi pressure to the negative side of the gauge.

P.

Replace upper front access door.

Q.

When the main burner lights, observe the burner flame through observation port. Flames should be light blue in color with slight yellow tips; flames should be settled on burner head with no lifting.

R.

The appliance is now ready to operate.

I. Turn the power switch to "ON" position. Combustion air fan should start. Leave the gas valve "OFF".

BURNER REMOVAL

AND CLEANING

J. With the combustion air fan running, the gauge will read a system differential pressure. The proper differential pressure should be in the following range, depending upon length of pipe used:

WARNING

TABLE - R

DIFFERENTIAL AIR PRESSURE

Btu/hr Input Differential Pressure

The combustion chamber lining in this appliance contains ceramic fiber materials. Ceramic fibers can transform into cristobalite (crystalline silica) when exposed to temperatures above 2192°F (1200°C) dependent upon the length of exposure time.*

150,000

199,999

250,000

300,000

1.4 - 1.8" w.c.

The International Agency for Research on Cancer

(I.A.R.C.) has concluded, "Crystalline silica inhaled in

1.4 - 1.8" w.c. the form of quartz or cristobalite from occupational sources is carcinogenic to humans."**

1.5 - 1.9" w.c.

1.5 - 1.9" w.c.

Testing has confirmed that the ceramic fibers in this application do not reach 2192°F (1200°C).

K.

If adjustment is necessary, follow these steps. If no adjustment is necessary, go to step "L". a. Loosen two combustion air blower mounting nuts, to allow the air shutter to slide. See Figure 43.

*Reference Dyson, D., Butler, M., Hughes, R., Fisher,

R., and Hicks, G. The Devitrification of Aluminosilicate Ceramic Fiber Materials - The Kinetics of the

Formation of Different Crystalline Phases, Ann.

Occup. Hyg. Vol. 41, No. 55, 1997.

**Reference I.A.R.C. Monograph 68, June 1997.

b. If differential pressure needs increasing, pull the air shutter out with thumb and finger gradually and evenly. Push in the air shutter to decrease differential pressure.

38

NOTE:

HEAT EXCHANGER CLEANING

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guides.

5. Check the heat exchanger surface for sooting. If present, heat exchanger must be cleaned and problem corrected. Proceed as follows.

REMOVAL OF COMBUSTION CHAMBER LINING

OR BASE PANELS:

• Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95)

(http://www.cdc.gov/niosh/hompage.html).

• Lightly mist with water (only those areas being handled) the combustion chamber lining or base insulation to prevent airborne fibers.

• Remove combustion chamber lining or base insulation from the boiler and place it in a plastic bag for disposal.

• Wash potentially contaminated clothes separately from other clothing. Rinse clothes thoroughly.

• NIOSH stated First Aid:

Eye: Irrigate immediately.

Breathing: Fresh air.

a.

Remove manifold/orifice assembly as described in steps “a” through “e” in “Burner Removal”.

b.

hose from burner tap.

c.

Disconnect wiring from hot surface igniter and

Remove inner combustion chamber door mounting screws, tilt slightly and slide door assembly out toward front of appliance. Use caution to prevent damage to refractory, hot surface igniter, hose and wiring.

d.

Check "V" baffles on top of heat exchanger.

Remove and clean if necessary.

e.

Remove soot from heat exchanger with a stiff bristle brush. Use a vacuum to remove loose soot from surfaces and inner chamber.

4. Flue Gas Passageways Cleaning Procedures: Any sign of soot at burners indicates a need for cleaning. The following cleaning procedure must only be performed by a qualified serviceman or installer. Proper service is required to maintain safe operation. Properly installed and adjusted appliances seldom need flue cleaning.

f.

Carefully reinstall combustion chamber door, jacket panels, dividers, burners, manifolds wires and hoses. Use new gasket material for proper air seal.

g.

Reassemble and test for gas leaks.

h.

Cycle appliance and check for proper operation.

All gaskets on disassembled components must be replaced with new gaskets on reassembly. Gasket kits are available from your distributor.

a.

b.

c.

d.

Turn off main power to appliance.

Turn off main manual gas shutoff to appliance.

Remove the front outer jacket panels.

Remove gas valve from the manifold.

An appliance installed in a dust or dirt contaminated atmosphere will require cleaning of the burners on a 3 to 6 month schedule or more often, based on severity of contamination. Contaminants can be drawn in with the combustion air. Non-combustible particulate matter such as dust, dirt, concrete dust or dry wall dust can block burner ports and cause non-warrantable failure Use extreme care when operating an appliance for temporary heat during new construction. The burners and fan will probably require a thorough cleaning before the appliance is placed in service.

e.

Remove screws from manifold mounting

6. Combustion Air Fan: The combustion air fan should be brackets. Pull manifold(s)/ orifice assembly away from checked every 6 months. Clean as required when burners. Remove hose from burner tap.

installed in a dust or dirt contaminated location.

f.

Remove mounting screws from each burner and slide burner out toward front of appliance. Use caution to prevent damage to burner gaskets, refractory, hot surface igniter or wiring.

7. Water Circulating Pump: Inspect pump every 6 months and oil as necessary. Use SAE 30 non-detergent oil or lubricant specified by pump manufacturer.

g.

Remove soot from burners with a stiff bristle brush. Damaged burners or burner gaskets must be replaced.

8. Keep appliance area clear and free from combustible materials, gasoline and other flammable vapors and liquids.

9. Check frequently to be sure the flow of combustion and ventilation air to the boiler is not obstructed.

39

GAS TRAIN AND CONTROLS

CAUTION

A leak in a boiler "system" will cause the

"system" to intake fresh water constantly, which will cause the tubes to accumulate a lime/scale build up. This will cause a

NON-WARRANTABLE FAILURE.

WATER CONNECTIONS

HEATING BOILERS ONLY

This boiler is shipped from the factory with 2" NPT inlet and outlet connections on the 150,000 through 300,000

Btu/hr models. If required, field installed reducing bushings may be used to decrease the inlet and outlet water connections to 1-1/2" NPT on the 150,000 and 199,999

Btu/hr models only. Low boiler flow can result in noise on burner operation.

CIRCULATOR PUMP REQUIREMENTS

FIG. 44 Gas Train Drawings

PIPING OF THE BOILER SYSTEM

The drawings in this section show typical heating boiler piping installations. Before beginning the installation, consult local codes for specific plumbing requirements.

The installation should provide unions and valves at the inlet and outlet of the boiler so it can be isolated for service.

An air separation device must be supplied in the installation piping to eliminate trapped air in the system. Locate a system air vent at the highest point in the system. The system must also have a properly sized expansion tank installed. Typically, an air-charged diaphragm-type compression tank is used. The expansion tank must be installed close to the boiler and on the suction side of the system pump to ensure proper operation. Caution: this

boiler system should not be operated at less than 12

PSIG. Hot water piping must be supported by suitable hangers or floor stands, NOT by the boiler. Copper pipe systems will be subject to considerable expansion and contraction. Rigid pipe hangers could allow the pipe to slide in the hanger resulting in noise transmitted into the system. Padding is recommended on rigid hangers installed with a copper system. The boiler pressure relief valve must be piped to suitable floor drain. See the relief valve section in the Installation and Service Manual.

This is a low mass, high efficiency hot water boiler which must have adequate flow for quiet, efficient operation.

Pump selection is critical to achieve proper operation. A pump should be selected to achieve proper system design water temperature rise. A heat exchanger head-loss chart

(Table Q) is provided to assist in proper pump selection.

Also provided is a System Temperature Rise Chart

(Table S). This table provides GPM and boiler head-loss at various temperature rises for each boiler based on Btu/hr input. Temperature rise is the difference in boiler inlet temperature and boiler outlet temperature while the boiler is firing. Example: The boiler inlet temperature is

160°F (71°C) and the boiler outlet temperature is 180°F

(82°C), this means that there is a 20°F (11°C) temperature rise across the boiler.

40

TABLE - S

PRESSURE DROP CURVE FOR

150,000 THROUGH 300,000 BTU/HR MODEL

CIRCULATOR PUMP SPECIFICATIONS BOILER BYPASS REQUIREMENTS

1. Maximum operating pressure for pump must exceed system operating pressure.

2. Maximum water temperature should not exceed nameplate rating.

3. Cast iron circulators may be used for closed loop systems.

4. An expansion tank must be installed near the boiler and on the suction side of the pump.

CIRCULATOR PUMP OPERATION

(Heating Boilers Only)

A factory wired pump control relay is supplied in the control panel of each heating boiler. External wire leads are provided to supply 120 VAC power to the pump, allowing the control relay to cycle the pump. Caution: The external

power leads for pump operation may be "Hot" when the

main power switch on the boiler is "ON." The field installed boiler pump using these wire leads must not exceed 1 HP at 120VAC. As shipped from the factory, this control relay is set to cycle the boiler pump on each call for heat with an external room thermostat installed across terminals R1 and W1 on the internal terminal strip. For continuous pump operation, connect the pump to the 120V supply.

PUMP INSTALLATION AND MAINTENANCE: For installation and maintenance information on the circulator pump, refer to pump manufacturers instructions included in the instruction package.

41

FIG. 45 Boiler with Bypass Installed

The installer must ensure that the boiler is supplied with adequate flow without excessive temperature rise. It is recommended that this boiler be installed with a bypass in the piping, a properly sized circulator and piping system.

The bypass will help to ensure that the boiler can be supplied with adequate water flow. A typical bypass with a valve is shown in Figure 45. If the boiler temperature rise exceeds 40°F (22°C), it is an indication that the boiler may not be receiving adequate flow and adjustment of the bypass is required. If a high temperature rise is experienced, check the pump for proper operation and check the system

piping for any obstruction. A larger pump may be necessary. The installation of the recommended system bypass as shown in Figure 45 allows an increased flow through the boiler. If there is any doubt that the pump may not provide adequate flow, bypass piping should be provided at the time the boiler is installed. The bypass should be fully sized with a balancing valve to allow for proper adjustment. The balancing valve allows the flow through the bypass to be adjusted based on the individual system requirements. A bypass is recommended on all multiple zone systems in addition to a properly sized circulator and system piping.

CAUTION

At no time should the system pressure be less than 12 PSIG.

FIG. 47 Boiler with Low Temperature Bypass Piping

LOW TEMPERATURE

BYPASS REQUIREMENTS

FIG. 46 Boiler with Primary/Secondary Piping

Boilers used with multiple zone systems are recommended to be installed with a primary/secondary piping system as shown in Figure 46. This type of system uses a dedicated pump to supply flow to the boiler only. This pump is sized based on desired boiler flow rate, boiler head loss and head loss in the secondary system piping. A primary/secondary piping system may be installed on smaller input boilers but generally a properly sized system pump with a bypass will provide adequate flow.

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

These conditions indicate the need to open the bypass adjustment valve and/or installation of a larger circulator pump. System noise may also indicate an oversized boiler.

42

A boiler operated with an inlet temperature of less than

140°F (60°C) must have a bypass to prevent problems with condensation. A bypass as shown in Figure 47 must be piped into the system at the time of installation. This piping is like a primary/secondary boiler installation with a bypass in the secondary boiler piping. Inlet water temperatures below 140°F (60°C) can excessively cool the products of combustion resulting in condensation on the heat exchanger and in the flue. Condensation can cause operational problems, bad combustion, sooting, flue gas spillage and reduced service life of the vent system and related components. The bypass allows part of the boiler discharge water to be mixed with the cooler boiler return water to increase the boiler inlet temperature above 140°F (60°C).

This should prevent the products of combustion from condensing in most installations. The bypass should be fully sized with a balancing valve to allow for proper adjustment. A valve must also be provided on the boiler discharge, after the bypass. Closing this discharge valve forces water through the bypass. Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open. A small amount of the higher temperature boiler discharge water is mixed with the system water to maintain the desired lower system temperature. A remote low temperature range operator is recommended to control the boiler operation based on the lower system temperature. This remote operator should be wired across the R1 and W1 terminals (see Room

Thermostat Connection and Terminal Strip instructions).

BOILER FLOW RATES

CAUTION

The maximum flow rate through the 150,000 through 300,000 Btu/hr boilers must not exceed

60 GPM.

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

FIG. 48 Boiler with 3-Way Valve Piping

THREE WAY VALVES

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

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

Figure 48. Based on boiler sizing and system flow requirements, this piping may still result in boiler short cycling.

The basic guide for minimum flow in this boiler is based on a 40°F (22°C) temperature rise in most installations. Lower flow and a higher temperature rise is acceptable if the boiler system is specifically designed for the characteristics of a higher temperature rise. A system not specifically designed for a higher temperature rise may experience overheating of the boiler water. This can cause short burner on cycles, system noise and in extreme cases, a knocking flash to steam. These conditions can lead to operational problems and non-warrantable failures of the boiler. High temperature rise systems must be designed by a qualified engineer.

TABLE - U

MINIMUM REQUIRED FLOW

Model

150,000 Btu/hr

199,999 Btu/hr

250,000 Btu/hr

300,000 Btu/hr

Flow

6 GPM

8 GPM

10 GPM

12 GPM

10°F

TABLE - T

SYSTEM TEMPERATURE RISE CHART

Based on Boiler Output in Btu/hr

15°F 20°F 25°F Btu/hr 30°F 40°F

Input Output GPM Ft/hd GPM Ft/hd

GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd

300,000 252,000

25.2 0.9

50.5

1.4 22.4

1.7 28.0

2.6

33.6

1.6

12.6

0.4

25.2

43

1.1

20.2

0.3

8.4

0.2 0.2

0.7

16.8

0.6

12.6

0.5

TEMPERATURE/PRESSURE GAUGE

no air bubbles visible in the water stream before closing the drain valve.

This boiler is equipped with a dial type temperature/ pressure gauge. This gauge is factory installed in the outlet side of the heat exchanger. The gauge has one scale to read system pressure and a separate scale to read water temperature in °F. The temperature/pressure gauge can be used to determine temperature rise by first recording the temperature of the boiler water with the boiler off. Record the temperature of the boiler water as the boiler fires and the discharge temperature stabilizes. Subtract the boiler water temperature with the boiler off from the stable outlet water temperature with the boiler firing. This temperature difference is the temperature rise.

b. Repeat this procedure for each circuit.

5. Open all valves after all circuits have been purged.

Make sure there are no system leaks.

NOTE:

Do not use petroleum based stop leak products.

All system leaks must be repaired. The constant addition of make-up water can cause damage to the boiler heat exchanger due to scale accumulation. Scale reduces flow and heat transfer, causing overheating of the heat exchanger.

TYPICAL HEATING BOILER

INSTALLATIONS

General Plumbing Rules

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

1. Check all local codes.

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

2. For serviceability of boiler, always install unions.

8. Recheck all air vents as described in step 4 above.

3. Always pipe pressure relief valve to an open drain.

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

9. Inspect the liquid level in the expansion tank. The system must be full and under normal operating pressure to ensure proper water level in the expansion tank. Ensure that diaphragm type expansion tanks are properly charged and not water logged.

5. Expansion tank must be installed near the boiler and on the suction side of the pump.

6. Support all water piping.

PLACING THE BOILER

IN OPERATION

Filling the System: All air must be purged from the system for proper operation. An air scoop and air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve.

10. Start the boiler according to the "Start-Up Instructions" in the Installation and Service Manual. Operate the system, including the pump, boiler and radiation units, for one hour.

11. Recheck the water level in the expansion tank. If it exceeds half the tank volume, open the tank to reduce the water level. Recheck pressure charge on diaphragm type tanks.

12. Shut down the entire system and vent all radiation units and high points in the system.

1. Close all drain cocks and air vents.

2. Open the makeup water valve and slowly fill the system.

13. Close the water makeup valve and check the strainer and pressure reducing valve for sediment or debris.

Reopen the water makeup valve.

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

14. Verify system pressure with the boiler pressure gauge before beginning regular operation.

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

15. Within three days of startup, recheck and bleed all air vents and the expansion tank using these instructions.

a. Open one circuit drain valve and let the water drain for at least five minutes. Ensure that there are

44

INSTALLATION WITH A CHILLED

WATER SYSTEM

temperature set point is based on your system’s requirements. Turn the con trol set point dial to the desired operating water tem per a ture. Observe the boiler discharge tem per a ture after each set point adjustment to ensure prop er operation.

ROOM THERMOSTAT OR REMOTE

THERMOSTAT CONNECTION TO

TERMINAL BOARD

A room thermostat or remote temperature control may be connected to the boiler. The room thermostat should be installed on an inside wall, away from the influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sun rays or fireplaces. Follow the manufacturers instructions supplied with the thermostat for proper installation and adjustment. The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection.

FIG. 49 Installation with a Chilled Water System

Pipe refrigeration systems in parallel. Install duct coil downstream at cooling coil. Where the hot water heating boiler is connected to a heating coil located in the air handling units which may be exposed to refrigeration air circulation, the boiler piping system must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle. The coil must be vented at the high point and hot water from the boiler must enter the coil at this point. Due to the fast heating capacity of the boiler, it is not necessary to provide a ductstat to delay circulator operation. Also, omit thermostat flow checks as the boiler is cold when heating thermostat is satisfied. This provides greater economy over maintaining standby heat (see Figure 49).

BOILER OPERATING

TEMPERATURE CONTROL

FIG. 50 Terminal Strip

The operating temperature control is located in the control sensing element for the operator is placed in a bulb well installed in the inlet side of the heat exchanger. Carefully observe the dis charge water temperature on the initial boiler on cycles. The location of the temperature sensor will

Remove the jumper between the R1 and W1 terminals on the terminal strip. Refer to the chart in this section to determine maximum allowable length and wire gauge recommended to connect the switching contacts of the room thermostat to the R1 and W1 terminals on the terminal strip. Connection to the terminal strip will allow the room thermostat to make and break the 24 VAC boiler control circuit turning the boiler on and off based on the room ambient temperature requirements. Set the boiler operating temperature control as described above. tem per a ture from the boiler. This sens ing element location allows a boiler operating with a low to moderate flow rate to sustain longer burner on cycles, preventing short boiler

“ON” cycles based on high discharge water tem per a tures.

For example, a boiler operating with a 180°F dis charge and a 20°F temperature rise would require approximately a

160°F to 165°F set point with the temperature sensor installed on the inlet side of the heat exchanger. The exact

45

WIRE GAUGE REQUIREMENTS FOR

TERMINAL STRIP CONNECTION

Wire Gauge

12 GA

14 GA

16 GA

18 GA

TABLE - V

Maximum Allowable

Length

100 ft

75 ft

50 ft

30 ft

DOMESTIC WATER HEATER

WATER VELOCITY CONTROL

IMPORTANT:

To ensure proper velocity through the heat exchanger, it is necessary to regulate the temperature rise across the heat exchanger from inlet to outlet. This must be done on initial installation and periodically rechecked. With the correct temperature rise across the heat exchanger, you may be assured of the proper velocity in the tubes. This will yield long life and economical operation from your water heater.

Excessive lime build-up in the tube is a result of too little velocity in the tubes. Excessive pitting or erosion in the tube is caused by too much velocity through the tubes. Care should be taken to measure temperature rise and maintain a velocity as follows:

This section applies only to those units used to supply domestic hot water, usually in conjunction with a storage tank. The use of a properly sized pump and the control of water velocity, as explained below, are important for correct operation of your water heater.

This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes and instructions in the general installation and service sections apply to these instructions. Water heaters are designed for installation with a storage tank. The use of a properly sized pump and the control of water velocity, as explained below, is important for correct operation of your water heater.

NOTE:

These water heaters are provided from the manufacturer with a single power supply to the unit for operation of both the standard circulating pump and controls.

All circulating pumps shipped with these units equipped with the Pump Delay Systems are all bronze pumps to ensure that no water discoloration can occur in an extended off cycle of the pump.

1. With the pump running and the hot water supply boiler off, the inlet and outlet thermometers should read the same temperatures. If they do not, an adjustment must be made to your final calculation.

2. Turn the water heater on and allow time for the temperature to stabilize. Record the difference between the inlet and outlet temperatures. This difference will be the "temperature rise."

3. Compare the temperature rise on the heater with the required temperature rise in Table W. Should adjustment be needed, proceed as follows:

If the temperature rise is too high, the water velocity is too low. Check the following:

1. Check for restrictions in the outlet of the water heater.

2. Be sure all valves are open between the water heater and the tank.

3. Check the pump to be sure it is running properly and that the pump motor is running in the proper direction.

4. Be sure the circulation pipes between the water heater and storage tank are not less than 2" diameter for a single appliance 150,000 through

300,000 Btu/hr installation.

5. Common manifold piping for multiple appliance installations will require larger minimum pipe sizes to ensure proper flow. See Table X.

If the temperature rise is too low, the water velocity is too high. Adjust as follows:

1. Slowly throttle the valve on the outlet side of the water heater until the temperature rise is steady at the required temperature rise as noted in Table W.

46

2. Sustained high water velocity and low temperature rise may result in pitting or erosion of the copper tubes in the heat exchanger. This is a non-warrantable failure.

Temperature rise must be properly adjusted to achieve the specified flow rate.

TABLE - X

COMMON WATER MANIFOLD SIZE FOR

MULTIPLE WATER HEATER

INSTALLATIONS

Pipe sizing chart provides minimum pipe size for common manifold piping to ensure adequate flow.

TABLE - W

WATER HEATER

TEMPERATURE RISE

150,000 THROUGH 300,000 BTU/HR MODELS

Btu/hr Input Temperature Rise °F

Number of

Appliances

Common Manifold

Size (Min)

150,000

199,999

250,000

300,000

4.6

6.2

7.7

9.3

WATER CHEMISTRY

4

5

6

1

2

3

4"

5"

5"

2"

3"

3 1/2"

The required temperature rise and the standard pump sizing are based on the heating of potable water with a hardness of

5 to 25 grains per gallon and a total dissolved solids not exceeding 350 PPM. Consult the manufacturer when heating potable water exceeding these specifications.

Heating of high hardness and/or high total dissolved solids water will require a larger circulating pump, an optional cupro-nickel heat exchanger and a revised temperature rise specification based on the water chemistry of the water to be heated. Water with a hardness of less than 5 grains per gallon will usually have a low pH which can be aggressive and corrosive causing non-warrantable damage to the heater, pump and associated piping. Corrosion due to water chemistry generally shows up first in the hot water system because heated water increases the rate of corrosive chemical reactions.

COLD WATER SUPPLY

PUMP OPERATION

1. The water heater must be connected to a properly sized pump that circulates water between the heater and storage tank.

2. Pump is sized to heater input and water hardness. Care should be taken to size pump correctly. See "Water

Chemistry."

3. The water heater is equipped with a factory supplied pump delay system.

4. Lubricate pump to manufacturers recommendations.

Pump damage due to inadequate lubrication is non-warrantable.

MIXING

VALVE

THERMOMETER

BUILDING HOT

WATER SUPPLY

VERTICAL TANK INSTALLATION

LOCK-TEMP

STORAGE TANK

EXPANSION TANK IF REQUIRED

DOMESTIC WATER HEATER

SUPPLY BOILER

RELIEF VALVE

5. Standard 150,000 through 300,000 Btu/hr water heaters are furnished with a 1/4 HP, 120 VAC, 5.8 Amp circulating pump. The circulating pump must be mounted on the units inlet water connection. The pump is sized based on installation of the storage tank and heater in close proximity. If the number of fittings and straight pipe exceeds the quantities shown in this section, a larger pump will be required.

DRAIN

The standard pump selection is based on the following pipe and fittings from the appliance to the storage tank:

BUILDING

RETURN

FIG. 51 Typical Water Heater Piping with Storage Tank

47

6 - 90° elbows 2 - ball valves

2 - unions 1 - cold water tee

Not more than 45 feet of straight pipe.

THERMOSTAT ADJUSTMENT

(Domestic Hot Water Use)

For every elbow and tee in excess of those shown above,

DEDUCT 5 FEET from maximum allowable straight pipe in heater to tank circulating loop.

TABLE - Y

MINIMUM PUMP PERFORMANCE

Based on heating potable water with a hardness of 5 to 25 grains per gallon and total dissolved solids not exceeding

350 PPM. See "Water Chemistry".

This appliance has an adjustable thermostat to control water temperature. See temperature adjustment procedure in general section of the manual. The thermostat is factory pre-set at approximately 125°F (52°C). Households with small children or invalids may require 120°F (49°C) or lower temperature setting to reduce risk of scald injury.

Some states may require a lower temperature setting.

Check with your gas supplier for local requirements governing the temperature setting. Remember, no water heating system will provide exact temperature at all times.

Allow a few days of operation at this setting to determine the correct temperature setting consistent with your needs.

Btu/hr Input

150,000 - 300,000

GPM

55

HEAT EXCHANGER

Ft. Hd.

10

NOTE:

(1) This water heater, when set at the lower temperature setting, is not capable of producing hot water of sufficient temperature for sanitizing purposes. (2) Higher stored water temperature increases the ability of the water heater to supply desired quantities of hot water, however remember.

This is a highly sophisticated heat exchanger, designed to carry water in such a way that it generates a scouring action which keeps all interior surfaces free from build-up of impurities. The straight-line, two pass design of the tubes sends water into the headers at a properly rated velocity.

The configuration of the headers, in turn, creates a high degree of turbulence which is sufficient to keep all contaminants in suspension. This "scouring action" provides greater cost savings for owners. Tubes are always able to transfer heat at peak efficiency. Every surface within this water containing section is of a non-ferrous material, providing clear, clean, rust-free hot water.

Straight copper tubes-finned on the outside for maximum heat transfer-coated cast iron one piece cored headers make up an entirely rust-proof appliance. On all models, header inspection plugs can be removed for field inspection and cleaning of copper tubes. The entire heat exchanger may be easily removed from the appliance.

CAUTION

Hotter water increases the risk of scald injury.

Incorrect piping of the cold water supply to the system may result in excessive low temperature operation causing condensate formation on the heat exchanger and operational problems. The cold water supply piping must be installed in the discharge piping from the heater to the storage tank. This allows the cold water to be tempered in the storage tank before entering the heater. See typical installation drawings provided with the appliance for correct piping. Higher water temperatures reduce condensate formation.

CAUTION

Setting the temperature selector to higher settings provides hotter water, which increases the risk of scald injury.

THERMOSTAT SETTINGS

1. The thermostat is adjusted to a low test setting when shipped from the factory.

2. Set the thermostat to the lowest settings which will satisfy hot water demands and prevent risk of scald injury.

48

This water heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install an ASSE approved mixing valve in the water system.

This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.

• Water temperature over 125°F (52°C)

can cause severe burns instantly or

death from scalds.

• Children, disabled and elderly are

at highest risk of being scalded.

• See instruction manual before

setting temperature at heating

appliance.

• Feel water before bathing or showering.

• If this appliance is used to produce

water that could scald if too hot,

such as domestic hot water use,

adjust the outlet control (limit) or use

temperature limiting valves to obtain

a maximum water temperature of

The following chart (Table Z) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

TABLE - Z

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F

130°F

135°F

140°F

145°F

150°F

155°F

1 1/2 to 2 minutes

About 30 seconds

About 10 seconds

Less than 5 seconds

Less than 3 seconds

About 1 1/2 seconds

About 1 second

WARNING

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

THERMAL EXPANSION

A relief valve which discharges periodically may be due to thermal expansion in a closed system. A water heater installed in a closed system, such as one with a backflow preventer or check valve installed in the cold water supply, shall be provided with means to control expansion. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug or cap the relief valve

discharge!

CATHODIC PROTECTION

Hydrogen gas can be produced in a hot water system that has not been used for a long period of time (generally two weeks or more). Hydrogen gas is extremely flammable.

To prevent the possibility of injury under these conditions, we recommend the hot water faucet be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system. If hydrogen is present, there will be an unusual sound such as air escaping through the pipe as the hot water begins to flow. There should be no smoking or open flames near the faucet at the time it is open.

OPTIONAL RELIEF VALVE

The water heater is normally supplied with a temperature and pressure relief valve(s) sized in accordance with applicable codes. Appliances may be supplied with an optional pressure only relief valve(s). When a water heater equipped with this optional relief valve is piped to a separate storage vessel, the storage vessel must have a properly installed temperature and pressure relief valve which complies with local codes.

49

LADDER DIAGRAM - WATER HEATER

150,000 - 300,000 BTU/HR

TO 120 VAC POWER SUPPLY

POWER SWITCH

OFF ON

A

L1

(HOT)

PUMP

DELAY

L2

*

PUMP

IGN MOD P5

IGN MOD P6

COMBUSTION

AIR BLOWER

IGNITER

120 VAC

TRANSFORMER

24 VAC

6

LWCO

2

*

LWCO

R1 W1

MRHL

THERMOSTAT

CN 7

CN 8

24VDC

PUMP

DELAY

CN 1-4 CN 1-3

R2

W2

*

HFGV

LIMIT

SWITCH

*

FLOW

SWITCH

LOW

AIR

X B

P 3-7

P 3-2

P 3-3

IGNITION

MODULE

P 3-1

P 3-8

P 3-6

P 3-5

*

RELAY

(ALARM)

GAS

VALVE

C

NO

NC

TDR

C

NO

NC

*

ALARM

CONTACTS

*

ALARM BELL

**

LOUVER

CONTACTS

50

WIRING DIAGRAM - WATER HEATER

150,000 - 300,000 BTU/HR

3-NO 4-N

7-C 6-NO 5-N

ALARM CON

FLOW SWITC

*

*

2 1 C

51

J1

PROBE

ON-OFF SW

LADDER DIAGRAM - BOILER

150,000 - 300,000 BTU/HR

TO 120 VAC POWER SUPPLY

L1

(HOT)

L2

POWER SWITCH

OFF ON

A

*

PUMP

DELAY

24V

PUMP

RELAY

*

PUMP

IGN MOD P5

IGN MOD P6

6

LWCO

2

*

LWCO

A

R1

W1

MRHL

THERMOSTAT

CN 7

CN 8

CN 1-1 CN 1-2

CN 1-4 CN 1-3

R2

24VDC

PUMP

DELAY

W2

*

HFGV

24VAC

PUMP

RELAY

LIMIT

SWITCH

*

FLOW

SWITCH

LOW

AIR

X B

P 3-7

P 3-2

P 3-3

IGNITION

MODULE

P 3-1

P 3-8

P 3-6

P 3-5

*

RELAY

(ALARM)

COMBUSTION

AIR BLOWER

IGNITER

120 VAC

TRANSFORMER

24 VAC

GAS

VALVE

C

NO

NC

TDR

C

NO

NC

*

ALARM

CONTACTS

*

ALARM BELL

**

LOUVER

CONTACTS

52

WIRING DIAGRAM - BOILER

150,000 - 300,000 BTU/HR

3-NO 4-N

7-C 6-NO 5-N

ALARM CO

FLOW SWITC

N O

*

2 1 C

53

J1

PROBE

TROUBLESHOOTING CHART

STEP

1

WITH 120 VAC POWER TO

APPLIANCE, TURN ON POWER

SWITCH, SWITCH LIGHTS UP?

NO 120 VAC POWER TO UNIT?

YES

NO

CHECK 120 VAC POWER SUPPLY.

YES

CHECK WIRING TO SWITCH?

YES

NO CHECK WIRING CONNECTIONS.

STEP

2

IGNITION CONTROL MODULE?

YES

STEP

3

SET THERMOSTAT BELOW

WATER TEMPERATURE.

STEP

8

IGNITION MODULE IGNITER "LED"

LIGHTS UP & PURGE "LED" TURNS OFF?

NO

REPLACE MODULE.

STEP

4

YES

SET THERMOSTAT TO CALL

FOR HEAT.

YES

NOTE: THIS CHART IS FOR

CONTINUOUS PUMPS ONLY.

SEE INSTALLATION INSTRUCTIONS

FOR INTERMITTENT PUMP AND

PUMP DELAY OPTIONS FOR

PUMP OPERATION.

NOTE: MUST OPEN WITHIN

45 SEC. AFTER CALL FOR

HEAT AND CLOSE WITHIN

5 MIN. AFTER CAB STARTS

OR MODULE LOCKS OUT.

STEP

5

COMBUSTION AIR BLOWER

(CAB) STARTS?

NO AIR PROVING SWITCH OPEN?

NO REPLACE SWITCH.

YES

CHECK FOR 120 VAC

AT CAB?

NO CHECK WIRING CONNECTIONS.

YES

STEP

6

AIR PROVING SWITCH

CLOSES?

YES

STEP

7

IGNITION MODULE PURGE

"LED" LIGHTS UP?

NO

NO

YES

REPLACE CAB.

AIR SHUTTER ADJUSTMENT

CORRECT? SEE INSTRUCTIONS.

NO

YES

ADJUST AIR SHUTTER TO

PROPER SET POINTS; CHECK

FOR AIR LEAKS FROM BURNER

COMPARTMENT / PRESSURE HOSE.

REPLACE SWITCH.

"LED" BURNED OUT BUT CONTROL

FUNCTIONS. REPLACE AT A

CONVENIENT TIME.

YES

"LED" BURNED OUT BUT CONTROL

FUNCTIONS. REPLACE AT A

CONVENIENT TIME.

YES

NO

CHECK 120 VAC THRU SWITCH?

120 VAC MODULE?

NO

NO

REPLACE SWITCH.

CHECK WIRING CONNECTIONS.

YES

54

TROUBLESHOOTING CHART (CONTINUED)

STEP

9

IGNITER / SENSOR WARMS UP

AND GLOWS RED.

NO

120 VAC AT IGNITER/SENSOR?

NO CHECK WIRING CONNECTIONS.

YES

NO

YES

STEP

10

IGNITION MODULE VALVE

"LED" LIGHTS UP?

NO

REPLACE IGNITER/SENSOR.

"LED" BURNED OUT BUT CONTROL

FUNCTIONS. REPLACE AT A

CONVENIENT TIME.

REPLACE MODULE.

YES

STEP

11

IGNITER "LED" TURNS OFF

& VALVE "LED" STAYS ON?

NO

24 VAC TO GAS VALVE?

YES

NO

CHECK WIRING CONNECTIONS.

GAS VALVE OPEN?

YES

NO

REPLACE GAS VALVE.

CHASSIS GROUND & WIRING CONNECTIONS TO IGNITER?

YES

NO

CHECK WIRING CONNECTIONS.

YES

IGNITER/SENSOR MOUNT PROPERLY?

YES

NO CHECK MOUNTING.

STEP

12

GAS SUPPLY PRESSURE TO GAS VALVE CORRECT?

MAIN BURNER RUNS UNTIL

CALL FOR HEAT ENDS AND

VALVE "LED" TURNS OFF?

YES

MANIFOLD PRESSURE CORRECT?

YES

NO YES

NO

NO

SET GAS SUPPLY PRESSURE.

SEE INSTRUCTIONS.

SET MANIFOLD PRESSURE.

SEE INSTRUCTIONS.

STEP

13

SET THERMOSTAT ABOVE

WATER TEMPERATURE?

REPLACE IGNITER.

CONTINUITY OF CHASSIS

GROUND CONNECTIONS?

NO

TIGHTEN OR REPLACE GROUND.

YES

YES

STEP

14

THERMOSTAT OPENS?

YES

NO

IGNITER/SENSOR MOUNTED PROPERLY?

YES

NO

STEP

15

STEP

16

GAS VALVE CLOSES?

REPLACE IGNITER.

YES

NO GAS VALVE CLOSES WHEN ONE LEAD IS REMOVED?

CAB STOPS AFTER 30 SEC. POST PURGE?

YES

CORRECT MOUNTING.

REPLACE THERMOSTAT.

REPLACE GAS VALVE.

STEP

17

SYSTEM OK?

NO

REPEAT PROCEDURE UNTIL

SYSTEM OPERATES NORMALLY.

55

Revision 6 (EB-EW-i&s-06) reflects changes made to the O.A. section.

Revision 7 - (EB-EW-I&s-07) reflects changes made to

LBLs on Pages 50-53.

Revision 8 - (ECO #C02870) reflects changes made to the scald section, pages 47 - 49 and the addition of a mixing valve to the piping diagram (FIG. 51, pg. 47).

Revision 9 - (ECO #C03126) reflects changes made to

Table Q (Air Shutter Adjustment Opening) on page 37.

EB-EW-I-S-09

CP-5M-2/09

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