COSMOGAS BMS 10/20, BTS 15/29, BMS 15/29, BTS 10/20 Instruction Manual

INSTRUCTION MANUAL
For installation, use and
maintenance for the
MODELS:
BMS & BTS
Direct V ent
Space / Water Heater
For Heating and Domestic Hot Water
These instructions MUST be read prior to installation and
left near the appliance when the installation is completed.
Text complies with minimum size requirements.
U.S.A.
62403262R04 -06/02
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SAFETY INSTRUCTIONS
WARNING: If the information in this manual is not followed exactly , a fire or explosion may result causing property damage, personal injury or death.
— Do not store or use gasoline or other
flammable vapors and liquids in the vicinity of this or any other appliance.
— WHAT TO DO IF YOU SMELL GAS
Do not try to light any appliance.
Do not touch any electrical switch; do not use any phone in your building.
Immediately call your gas supplier from a neighbor’s 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.
FOR YOUR SAFETY
Do not store or use gasoline or other flammable, combustible, or corrosive vapors and liquids in the vicinity of this or any other appliance.
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These instructions must be read prior to installation. If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death.
Hazards and Your Safety - Hot Water Can Scald!
Water temperature over 125°F 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 water heater! Feel water before bathing or showering. Temperature limiting valves are available, see manual.
If there is a smell of gas:
-Turn the gas cock off - Air the room - Do not try to light any appliances - Do not use any phone in your building - Do not touch any electrical switch - Extinguish any flames - Call immediately a licensed authorized technician or your local gas company - Follow the gas supplier’s instructions - If you cannot reach your gas supplier, call the fire department.
If there is a smell of combustion products:
-Turn the unit off - Air the room - Call a licensed authorized technician.
Installation, alterations
Licensed authorized personnel must carry out the installation, calibration or alteration of the gas apparatus. Flue gas ducts must not be modified in any way. Any replaced part or packaging parts should never be left within reach of children.
Explosive products or easily inflammable products
Do not keep, use or store explosive materials or easily inflammable materials such as Gasoline, Adhesives, Solvents, Paint Thinner, Butane, Liquefied Propane, paper, etc., near the heater.
Maintenance
The user, according to the heater’s operating instructions, has to keep the installation in good condition and guarantee the reliable, safe operation of the heater. At least once a year the user must call in a licensed authorized technician for routine maintenance, before using it for central heating.
Servicing Manual
When the installation and commissioning of the system has been completed, the installer should instruct the homeowner to save the installation manual near the heater so that service technicians may refer to it in the future. Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. V
ERIFY PROPER OPERATION AFTER SERVICING.
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.
SAFETY INSTRUCTIONS
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GENERAL INFORMATION
This instruction manual refers to two types of heaters, the BMS and the BTS.
BMS - this appliance is a wall mounted, direct vent space/water heater BTS - this appliance is a self standing floor model, direct vent space/water heater
Each type of heater can be of two different input power rating; a 10/20 or 15/29;
10/20 has an input power rating of 87,000 Btu/hr (26 kW) 15/29 has an input power rating of 107,000 Btu/hr (31.6 kW)
BMS 10/20
or
BMS 15/29
or
BTS 10/20
or
BTS 15/29
When referring to this instruction manual, be sure of which type of heater you are working with. This can be verified by referring to the data plate marked “Space water heater model” . This data plate is located on the bottom side of the BMS, or on the inside of the front door (internal side) of the BTS.
Also verify the type of gas for which the heater is set. A label in the front of your heater states “NA TURAL GAS”, for heaters set to natural gas, or “LP GAS” for heaters set to LP gas.
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GENERAL INFORMA TION ...................................................................................................... 4
T ABLE OF CONTENTS .......................................................................................................... 5
GENERAL LA YOUT of the main components of model BMS ............................................... 7
GENERAL LA YOUT of the main components of model BTS................................................ 9
A INST ALLA TION INSTRUCTIONS ..................................................................................... 11
1 Operating and adjusting the output to the radiation system ...................................... 11
2 Location ..................................................................................................................... 11
3 Installation ................................................................................................................. 11
3.1 Installation template ........................................................................................ 12
3.1.1 Clearances for installation ............................................................................ 12
3.2 Safety Relief V alve ........................................................................................... 13
3.3 Heating supply and Return .............................................................................. 1 3
3.3.1 Installation of two heaters............................................................................. 13
3.3.2 Installation of three or more heaters ............................................................ 1 3
3.3.3 Radiant heating installation .......................................................................... 13
3.3.4 Used of glycol................................................................................................ 1 3
3.4 Domestic Hot and Cold water ......................................................................... 1 4
3.5 Water Hardness............................................................................................... 14
3.6 Gas Supply ....................................................................................................... 14
3.6 Gas Supply (cont.)............................................................................................ 15
3.7 Room Thermostat Connection ........................................................................ 15
3.8 Electrical Supply Connection ........................................................................... 1 5
4 VENTING SYSTEMS .................................................................................................. 17
4.1 Concentric Flue (Coaxial) ................................................................................ 17
4.2 Split Flue .......................................................................................................... 1 9
4.3 Chimney Venting .............................................................................................. 1 9
4.4 Venting Locations - Outside Walls (Direct Venting) ......................................... 19
4.5 Kit for air intake/flue discharge ........................................................................ 1 9
4.7 Water Connections for Model BMS .................................................................. 32
4.8 Water Connections for Model BTS................................................................... 33
5 REGULA TING THE DOMESTIC HOT W A TER ............................................................ 40
6 BURNER ................................................................................................................... 40
6.1 Changing the Gas Type ................................................................................... 4 0
6.2 Adjusting Gas Flow and Pressure to the Burner............................................. 4 0
7 WIRING DIAGRAMS................................................................................................... 41
B OPERA TING AND MAINTENANCE INSTRUCTIONS for BMS ........................................... 44
9 BMS model; INSTRUCTION FOR USE ...................................................................... 44
9.1 Start-Up Instructions ........................................................................................ 4 4
9.2 Checks Prior to Ignition.................................................................................... 4 4
9.3 Ignition Procedure............................................................................................ 4 4
9.4 Summer-Winter Mode...................................................................................... 4 5
9.5 Adjusting Central Heating................................................................................ 4 5
9.6 Manual Reset High-Limit Thermostat ............................................................. 45
9.7 Resetting the Ignition Module .......................................................................... 4 5
9.8 Heating Circulator Pump ................................................................................. 4 5
9.9 Low water cut-off device................................................................................... 45
T ABLE OF CONTENTS
6
9.10 Shut-Down Procedure ................................................................................... 45
9.11 Maintenance ................................................................................................... 45
9.12 Draining water from the heater ...................................................................... 4 5
C OPERA TING AND MAINTENANCE INSTRUCTIONS for BTS ............................................ 46
10 - BTS model - INSTRUCTIONS FOR USE ............................................................... 46
10.1 Start-Up Instructions ...................................................................................... 4 6
10.2 Checks Prior to Ignition.................................................................................. 4 6
10.3 Ignition Procedure .......................................................................................... 4 6
10.4 Summer-Winter Mode .................................................................................... 4 7
10.5 Adjusting Central Heating .............................................................................. 47
10.6 Manual Reset High-Limit Thermostat ........................................................... 47
10.7 Resetting the Ignition Module ........................................................................ 4 7
10.8 Heating Circulator Pump ............................................................................... 47
10.9 Low water cut-off device................................................................................. 47
10.10 Shut-Down Procedure ................................................................................. 47
10.11 Maintenance ................................................................................................. 47
10.12 Draining water from the heater.................................................................... 4 7
D TROUBLESHOOTING ...................................................................................................... 48
11 Troubleshooting Sequence of Operation to Light the Burner................................... 48
12 Troubleshooting Sequence of Operation for a Call for Heat .................................... 49
E IMPORT ANT INFORMATION FOR THE CUSTOMER ......................................................... 51
F SP ARE PARTS ................................................................................................................ 52
G TECHNICAL FEA TURES .................................................................................................. 53
NOTES................................................................................................................................ 55
T ABLE OF CONTENTS
7
GENERAL LA YOUT of the main components of model BMS
Figure 1 - BMS Front view
Coaxial discharge
Split discharge
A = Flue discharge B = Air intake
8
GENERAL LA YOUT of the main components of model BMS
Figure 2 - BMS Side and top views
1 Central heating supply 2 Central heating return 3 Gas inlet 4 Domestic hot water outlet 5 Cold water inlet 6 Flue gas discharge fan 7 Automatic air vent 8 Thermostat bulb pocket
9 Gas valve service switch 10 Instrument panel 11 Temperature-pressure gauge 12 Failure lamp indicator 13 Ignition and detection electrodes 14 Burner 15 Gas manifold 16 Exchanger shell clamps 17 Gas valve 18 High limit thermostat 19 Power and circulator pump switches 20 Domestic hot water priority
thermostat
21 Central heating regulation knob 22 Heater temperature control 23 Electrical control board 24 Ignition module 25 Electrical plastic cover 26 Electrical junction box 27 Expansion tank 28 Pressure switch 29 Domestic water heat exchanger 30 Heat exchanger 31 Turbulator 32 Support bracket 33 Central heating regulation valve 34 Circulator pump 35 Transformer
36 Low water cut-off
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GENERAL LA YOUT of the main components of model BTS
Figure 3 - BTS Front view
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GENERAL LA YOUT of the main components of model BTS
1 Central heating supply 2 Central heating return 3 Gas inlet 4 Domestic hot water outlet 5 Cold water inlet 6 Flue gas discharge fan 7 Automatic air vent 8 Thermostat bulb pocket
9- ­10 Instrument panel 11 Temperature-pressure gauge 12 Failure lamp indicator 13 Ignition and detection electrodes 14 Burner 15 Gas manifold 16 - ­17 Gas valve 18 High limit thermostat 19 Power and circulator pump switches
20 Domestic hot water priority
thermostat
21 Central heating regulation knob 22 Heater temperature control 23 Electrical control board 24 Ignition module 25 - ­26 Electrical junction box 27 Expansion tank 28 Pressure switch 29 - ­30 - ­31 - ­32 - ­33 Central heating regulation valve 34 Circulator pump 35 Transformer 36 Low water cut-off
A Flue discharge B Air intake
Figure 4 - BTS side view
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A INSTALLATION INSTRUCTIONS
1 Operating and adjusting the output to the radiation system
The COSMOGAS heater can be installed in any domestic or light commercial building where the maximum BTU/H required is not greater than 88,800 BTU/H. The unit has a internal mixing valve (heating side only) that can be adjusted to regulate the supply water temperature delivered to the heating system. The heating system will not receive any water unless the water temperature inside of the heater is at a minimum of 140°F. The heater built-in domestic hot water priority thermostat will cease the power to the circulator until the temperature is greater than 140°F.
2 Location
This space/water heater unit is not intended for outdoor installation. Choose a location centralized to the piping system along with consideration to the vent pipe length. Additionally, you will need to place the space/water heater so that the controls, drain, inlet/outlet, and gas valve are easily accessed. Also, care must be exercised when choosing the location of this appliance, where leakage from the safety relief valves, leakage from related piping, or connections, will not result in damage to the surrounding areas, or to the lower floor of the building. No valve is to be placed between the safety relief valves and the heater. The discharge from the temperature and pressure relief valve must be conducted to a suitable place for disposal. No reducing coupling or other restriction shall be installed in the discharge line. The discharge line should allow complete drainage of both valve and line.
3 Installation
The installation must conform to local codes and ordinances or, in the absence of local codes, the
National Fuel Gas Code ANSI Z 223.1/NFPA 54
- 1984. When installed the appliance must be
electrically grounded in accordance with the
National Electrical Code, ANSI/NFPA No.70 -
1987.
For Canada, the installation should conform to CGA B149.1 INST ALLA TION CODES and/or local installation codes. The gas supply piping system should be tested before the heater is connected. The heater, (complete with all its parts: external jacket, intake and discharge flue pipes, etc.), must be installed leaving a distance of at least 10 cm,
(4”), from sidewalls and ceiling. Installation of the BTS combi directly on combustible flooring such as carpeting shall be installed on a metal or wood panel extending behind the full width and depth of the appliance by at least 3”, (76.2 mm), in any direction or, if the appliance is installed in an alcove or closet, the entire floor shall be covered by the panel.
Figure 5 - Installation template, Only for model BMS
Figure 4A
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3.1 Installation template
ONL Y model BMS is provided with an installation template to facilitate proper installation alignments (See figure 5 below).
3.1.1 Clearances for installation
The figures 5A and 5B show the proper distances to keep from any obstacle pertaining to the support bracket (2) or to the wall.
The procedure for installing the BMS is as follow:
1) - Take the support bracket (2) and choose a position with proper clearances, as per Figures 5A & 5B. A minimum clearance of 40” (1000mm) is required from the front of the heater.
WARNING: Please take caution when choosing a mounting surface for the heater. The weight of the heater with water is approximately 165 lbs. Make certain that the wall can support such weight.
2) Screw the bracket to the wall. The screws MUST screwed in correspondence of the 16" vertical studs (see figures 4A and 5A)
3) Place the template onto the support bracket and make all rough-in holes for the piping to the heater. The hole for the coaxial flue vent kit discharge may also be cut at this time.
4) Install the heater on the support bracket and secure all of the connections.
Figure 5A - Clearances for model BMS
Figure 5B - Clearances for model BTS
A INST ALLA TION INSTRUCTIONS
13
A INSTALLATION INSTRUCTIONS
3.2 Safety Relief Valve
An ASME approved safety relief valve, (set at 30 psi), must be installed in a vertical
position on the outlet side of the central heating system, and as close as possible to the heater. There must be no valves between the safety relief valve and the heater. Manually operate the safety relief valve at least once a year to ensure proper operation. Precaution must be taken prior to operating the safety relief valve, to avoid contact with hot water coming out of the safety relief valve and to prevent water damege. If the safety relief valve discharges periodically, this may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the safety relief valve.
3.3 Heating supply and Return
The central heating supply and return pipes are marked with different colored caps, (supply red and return blue). If there are any heating elements above heater level, it is advisable to install a check valve on the supply pipe to prevent “natural circulation” phenomena from occurring. If the heater is to be connected to an existing system it is advisable to wash out and remove any deposits from inside the existing pipes, and install a filter at the lowest point to trap any additional impurities when it is running. This equipment is designed for use in a closed loop system. Installation schematics are found in figures 23 to 28. WARNING !!! All the schematics in figures 23 to 28 are only samplesl. Safety apparatus, pipe diameters, and auxiliary accessories, must be verified by a qualified personnel only and in accordance with the national and/or local codes.
3.3.1 Installation of two heaters
Iinstalling two heaters in parallel. Follow the schema in the figure 23
3.3.2 Installation of three or more heaters
Installing three or more heaters in parallel. Follow the schema in the figure 24
3.3.3 Radiant heating installation
When the heater is used in conjuction with radiant heating, it is imperative that the tubing contains an oxygen diffusion barrier. If you are unsure whether or not the tubing has a barrier, a heat exchanger must be used to protect the heater from oxygen corrosion (See figure 25). This situation will also occur if the heater is used on an open-loop system where new, cold-fill water is introduced into the system. The oxygen will remove itself from solution and react chemically with the ferrous components (i.e. steel), causing them to rust and corrode. THIS TYPE OF
FAILURE IS NOT COVERED BY THE WARRANTY!
3.3.4 Used of glycol
If glycol is used with the heater, the glycol must be recognized as safe or approved by the United States Food and Drug Administration for food contact as listed in Code of Federal Regulations, title 21, part 182 of the Food Additive Regulations. Any additives introduced into the heating system must be recognized as safe by the United States Food and Drug Administration. If a
non-approved additive is used, it can cause serious health problems or possibly death.The pressure of the heating system
side of the heater must be fitted with devices (automatic water feed/pressure reducing valve not to exceed 30 psi) arranged to function automatically in order to maintain the pressure of the heating side at a level below that of the potable water leaving the heat exchanger.
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3.4 Domestic Hot and Cold water
The domestic hot water flow restrictor must be installed on the cold water inlet, (Refer to figure 25, 26, 27 and 28). For servicing purposes, install a shut-off valve upstream from the cold water inlet. The heater’s thermostat can be regulated to provide domestic hot water between 100°F and 180°F. Water temperature over 125°F can cause severe burns instantly. Since it is required that the heater water temperature reach above 140°F in order for the heating system side of the unit to operate, it is
imperative that a mixing valve be installed external of the heater to further regulate the temperature of the domestic hot water (See figures 23, 25, 26, 27 and 28). Failure to install a domestic side mixing valve will result in severe burns!
Piping and components connected to the water heater for space heating shall be suitable for use with potable water, and shall not be connected to any heating system or components previously used with a non­potable water heating appliance. The domestic hot water circuit needs an
ASME approved pressure relief valve, set at 150 psi, installed as close as possible to the heater. There must be no valves between the relief valve and the heater . The relief valve discharge pipe must not be restricted or plugged.
3.5 Water Hardness
In hard water areas (above 150 p.p.m), it is recommended that a suitable water treatment device (softener with filters) be installed. Excessive buildup of minerals in the heat exchanger can cause a non­warranty failure. Water hardness can be determined by using the standard test or by checking with your local water authority. Toxic chemicals, such as used for heater treatment, should not be introduced into the potable water used for space heating.
3.6 Gas Supply
Before making any gas connections, verify that the heater is being supplied with same gas type as indicated on the rating plate. The rating plate is located on the front of the BMS, and is located on the front door of the BTS. This heater has orifices which will operate at an altitude of up to 2,000 feet. For installations in higher elevations, down­rate the heater by 10%. Install a manual gas cock outside of the heater. Refer to Figures 1 and 3, item 3, for the gas inlet location of the heater. Gas piping to the heater must be sufficient to guarantee a supply of gas to meet maximum requirements. See Table 1 for max. and min. values of gas pressure (Back of manual).
All piping must comply with local codes and ordinances or with the National Fuel Gas Code, (ANSI Z223.1 NFPA No. 54), whichever applies. The appliance and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of ½ psig, (3.5 kPa). The appliance must be isolated from the gas supply piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than ½ psig, (3.5 kPa).
A INST ALLA TION INSTRUCTIONS
15
A INSTALLATION INSTRUCTIONS
Length of Gas Pipe Capacity of Gas Pipe Size in MBTUH
1/2" 3/4" 1" 1 1/4"
10'
132 278 520 1050
20'
92 190 350 730
30'
73 152 285 590
40'
63 130 245 500
50'
115 215 440
75'
93 175 360
100'
79 150 305
150'
64 120 250
Additional length to be added for
1.3' 1.7' 2.2' 2.7'
each bend or tee
3.6 Gas Supply (cont.)
A Electrical supply
connection
B Room thermostat
connection
Figure 6 - Connecting the room thermostat and electrical supply
3.7 Room Thermostat Connection
This is installed by removing the electrical junction box cover indicated in fig.6, (see fig.1 and 3, item
26), and connecting the two wires of the room thermostat, or zone valve control thermostat, to the low voltage terminals, (figure 6, item B). NOTE:
first remove factory installed jumper from terminals. The room thermostat must always
be located in a point of the house where the temperature is not subject to sudden changes.
3.8 Electrical Supply Connection
The heater must be connected to a 115V 60Hz, single phase electrical supply fused to 15 amps, Grounding is required as well as the installation of a main emergency switch immediately upstream from the heater. An electrical junction box (see figures 1 and 3, item 26) is provided for connections for both the line voltage of 1 15V 60 Hz (See figure 6 item A) , and the room thermostat at low voltage of 24Vac (See figure 6 item B). The cable wire of the line voltage must be insered into the heater, through the p ass­cable positioned in the side of the idraulic connections (see figure 6A and 6B).
16
A INST ALLA TION INSTRUCTIONS
Figure 6A - Installation of the electrical supply cable on the model BMS
a) Remove or loosen screw (2) b) Pop- out the passage tunnel for the supply cable. Pass the supply cable through the passage (1) c) Connect the supply cable to the junction box d) Tighten screw (2); e) Re-insert the passage tunnel into its position (4). f) Feed wire to junction box and connect as shown in Figure 6.
Figure 6B - Installation of the electrical supply cable on the model BTS
a) Remove or loosen screw (2) b) Pop- out the passage tunnel for the supply cable. Pass the supply cable through the passage (1) c) Connect the supply cable to the junction box d) Tighten screw (2); e) Re-insert the passage tunnel into its position (4). f) Feed wire to junction box and connect as shown in Figure 6.
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A INSTALLATION INSTRUCTIONS
4 VENTING SYSTEMS
This heater can be fitted with either a concentric or split type venting system. Particular attention must be taken when installing the vent pipes that go through the wall to the outside. It must always be possible to carry out routine maintenance operations of the flue. The vent pipe must be installed in such a way that it can be removed, if needed, in the future. Hence, a suitable sheath should be prepared in which to insert the vent pipe. Both venting systems are suitable for venting through a wall 1” to 24” thick. The connection of the vent air intake system to the heater can turn 360°, which means in all directions, making installation extremely easy. To turn it just loosen the securing screws on the base of the vent elbow where it attaches to the heater, turn to desired position, then tighten the screws without forcing them. You must place the terminal in an open area, and follow the following guidelines:
Make certain that exhaust gas does not re-circulate back into the intake pipe.
Never vent into a walkway or patio area, or an alley , or otherwise public area less than 7ft from the ground level. This is to prevent anyone from walking into the vent;
Never vent over or under a window or over a doorway;
Never install a heat saver or similar product to capture waste heat from exhaust;
Always have vent 1ft above ground level, away from shrubs and bushes.
Follow local gas codes in your region or refer to National Fuel Gas Code, or Can
B149.1 INST ALLATION CODES.
Always have vent at least 3ft from an inside corner of outside walls.
Maintain at least 4ft clearance to electric, gas meters and exhaust fans.
Always place screens in all openings in intake and exhaust to prevent foreign matter from entering the heater.
The vent terminals, (concentric, split type exhaust), must be a minimum of 1ft above the ground level.
If split type vent will be venting into a chimney, make certain that no other
appliances are vented into it. This power­vented heater must not share a chimney . Vent exhaust terminal should be inserted into, but not beyond, inner wall of chimney. Do not vent into transient pipe. Warranty will be void.
CAUTION! - Take all precautionary measures to allow the angle of the flue to run down slightly to the outside, NEVER rising. Anticipate for all horizontal pipes, an inclination of 1/4” per foot toward the discharge. If a vertical pipe follows a horizontal one, place a condensation discharge fitting in the lowest part of the vertical pipe. A condensation discharge pipefitting must also be used for vertical discharge pipe installations directly from the heater with a pipe whose length is more than 10”. During normal operating conditions, the heater will have exhaust gases exiting from the flue pipe. The smoke will be heavier on some days than on others. This is due to the outdoor weather conditions (the temperature, humidity, etc.), and is extremely common.
4.1 Concentric Flue (Coaxial)
The (Coaxial) concentric vent, (air inlet and flue outlet), system consists of 2 pipes: the outer one for fresh air intake, the inner pipe for flue exhaust discharge. With optional pipe, it is possible to increase the overall length up to 15ft (4.5 m). There are also 90° concentric elbows available, if they are installed, there will be a loss of draught equal to that caused by 3ft, (1 m), of straight pipe. Connections between the various parts must be secured by using self-tapping screws, (see fig.9). The vents stainless steel end terminal must always come completely out of the outer pipe. If for any reason the intake grid is blocked, the heater will not receive enough air for combustion and the burner would fail to ignite.
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