Laars MGH3500, MGH1600, MGH2000, MGH4000, MGV1600 Installation And Operation Instructions Manual

...

Installation and Operation Instructions Document 1422

WARNING

AVERTISSEMENT

Installation and Operation Instructions for

HTD

MODULATING AND CONDENSING

20:1 Turndown. Laars Linc

Boiler

with VARI-PRIME

Model MGH1600 1,600 MBTU/h

Model MGH2000 1,999 MBTU/h

Model MGH2500 2,499 MBTU/h

Model MGH3000 3,000 MBTU/h

Model MGH3500 3,500 MBTU/h

Model MGH4000 4,000 MBTU/h

Water Heater

______________

Model MGV1600 1,600 MBTU/h

Model MGV2000 1,999 MBTU/h

Model MGV2500 2,499 MBTU/h

Model MGV3000 3,000 MBTU/h

Model MGV3500 3,500 MBTU/h

Model MGV4000 4,000 MBTU/h

FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,

qualied in hot water boiler and heater installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in ue gases which could cause serious injury, property damage, or

death. Improper installation and/or operation will void the warranty.

If the information in this manual is not

followedexactly,areorexplosionmayresult

causing property damage, personal injury or

loss of life.

Do not store or use gasoline or other

ammable vapors and liquids in the vicinity of

this or any other unit. WHAT TO DO IF YOU SMELL GAS

• Do not try to light any unit.

• Do not touch any electrical switch; do not

use any phone in your building.

• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's instructions.

• If you cannot reach your gas supplier, call

the re department.

Installation and service must be performed by

a qualied installer, service agency, or gas supplier.

Assurez-vous de bien suivres les instructions

données dans cette notice pour réduire au

minimum le risque d’incendie ou d’explosion

ou pour éviter tout dommage matériel, toute

blessure ou la mort.

Ne pas entreposer ni utiliser d’essence ni d’autres

vapeurs ou liquides inammables dans le voisinage

de cet appareil ou de tout autre appareil.

QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer d’appareils.

• Ne touchez à aucun interrupteur. Ne pas vous servir des

téléphones dansle bâtiment où vous êtes.

• Appelez immédiatement votre fournisseur de gaz depuis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le fournisseur de gaz, appelez le service des incendies.

L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualié ou par le

fournisseur de gaz.

H2397100-

T ABLE OF CONTENTS

LAARS Heating Systems

SECTION 1 General Information

1.A Introduction...........................................1

1.B Model Identication .............................1

1.C Warranty ...............................................1

1.D Safety Notes .........................................2

1.E Unit Overview .......................................4

1.F Gas Train Components ........................5

1.G Venting Dimensions & Sizing ...............6

1.H Dimensions...........................................6

1.I Unpacking and the Install Kit ................8

1.J Locating the Unit ..................................8

1.K Clearances ...........................................9

SECTION 2 Venting and Combustion Air

2.A General Venting Information...............10

2.B Vent and Air Pipe Material ..................10

2.B.1 Venting Reqs Unique to Canada ........10

2.B.1.a Flue Gas Sampling Port - ...................10

2.B.1.b Exhaust Vent Terminal - ..................... 11

2.C Vent and Air Pipe Sizing .....................12

2.C.1 Category lV Vent Sizes.......................13

2.C.2 Category II Vent Sizes ........................13

2.C.3 Common Venting ................................13

2.C.4 Common V ent Test ............................. 14

2.C.5 Combustion Air ...................................15

2.C.5.a Combustion Air From Room ...............15

2.C.5.b Ducted Combustion Air....................... 16

2.D Locating the Vent

and Combustion Air Terminals ............16

2.D.1 Side-wall V ent Terminal ...................... 16

2.D.2 Side-wall Combustion Air Terminal .....18

2.D.3 Vertical Vent Terminal .........................18

2.D.4 Vertical Combustion Air Terminal ........18

2.E Outdoor Installation ............................19

2.F Installations in the

Commonwealth of Massachusetts .....19

SECTION 3 Gas supply and Piping

3.A Gas Supply and Piping .......................20

3.B Gas Pipe Sizing ..................................21

SECTION 4 Water Flow & Headloss Data ..

4.A General Water Flow Information ........22

4.B Boiler Water Flow & Headloss Data ...22

4.C Water Heater Water Flow

and Headloss Data .............................23

SECTION 5 Piping

5.A Boiler Water Piping .............................24

5.A.1 Boiler Water Connections ...................24

5.A.2 Cold Water Make-Up ..........................24

5.A.3 Freeze Protection ...............................24

5.A.4 Suggested Boiler Piping Schematics .25

5.B Water Heaters ....................................29

5.B.1 Water Quality ......................................29

5.B.2 Heater Water Connections .................29

5.B.3 Cold Water Make-Up ..........................29

5.B.4 Freeze Protection ...............................30

5.B.5 Suggested Piping Schematics............30

SECTION 6 Condensate Drain Trap .......32

6.A Condensate Trap Instructions ............33

SECTION 7 Electrical Connections

7.A Installation Warnings ..........................34

7.B Main Power Connections ...................35

7.C Main Power Data ................................ 36

7.D Control Panel Layout .......................... 36

7.E Field Connections...............................36

7.E.1 Power .................................................36

7.E.2 Dry Contacts .......................................36

7.E.3 Temperature Sensors ......................... 38

7.E.4 Heat Demands ...................................39

7.E.5 Analog In and Analog Out ..................39

7.E.6 Dry Contacts. Run & Alarm ................39

7.E.7 RS 485, Cascade ...............................40

7.E.8 RS485 BMS........................................40

7.F Modbus to BACnet Memory Map .......41

7.G Wiring Diagrams .................................44

7.H High Voltage Wiring Diagrams ...........48

7.I Ladder Diagrams ................................55

SECTION 8 Control Operation

8.A The Home Screen ............................. 62

8.A.1 Home Screen Active Icons .................62

8.A.2 Keypad Operations.............................63

8.B Login to Lock / Unlock the Display . 64

8.C Quick Start ...................................... 65

8.C.1 Quick Start CH (Central Heat) ............65

8.C.2.a Quick Start CH1 (Central Heat, One) .66

8.C.2.b Quick Start CH2 (Central Heat, Two) .66

8.C.2 Quick Start DHW (Dom Hot Water) .... 66

8.C.3 Outdoor Reset ...................................67

8.C.4 Warm Weather Shut Down ................ 67

HTD

Section 8 (continued)

8.C.5 Anti-Short Cycle ................................68

8.C.6 Time & Date ...................................... 68

8.D Conguration ..............................69

8.D.1 CH (Central Heat) ...............................70

8.D.1.a CH1 (Central Heat, One) ....................70

8.D.1.a.3 PID Parameters ................................ 71

8.D.1.b CH2 (Central Heat, Two) ....................71

8.D.2 DHW (Domestic Hot Water) .............. 71

8.D.3 Outdoor Reset ...................................72

8.D.4 Cascade (Lead / Lag) ..................73-77

8.D.4.a Cascade CH (Central Heat) ..............78

8.D.4.a.1 Cascade CH Lead Settings ................ 79

8.D.4.a.1.A Cascade Base / Drop Load.............80

8.D.4.b Cascade DHW (Dom Hot Water) ....... 80

8.D.4.c Cascade Rotation ..............................81

8.D.4.c.1 Cascade Rotation Setup ...................81

8.D.4.d Cascade Redundancy ........................82

8.D.5 Hybrid .................................................82

8.D.6 Pumps ................................................83

8.D.6.a DHW Recirculation .............................84

8.D.6.b VARI-PRIME .......................................84

8.D.7 Manual Firing Rate ............................85

8.D.8 Temp Limits ....................................... 85

8.D.8.a Delta T Parameters ............................86

8.D.8.b Flue Limitation Parameters ................86

8.D.8.c Outlet Limitation Parameters ..............86

8.D.9 External .............................................87

8.D.9.a External – Remote Set Point ..............88

8.D.9.b External Firing Rate............................89

8.D.10 Time & Date ......................................89

8.D.11 Miscellaneous Features ..................90

8.D.11.a Demand Priority ................................91

8.D.11.b Anti-Short Cycle .................................91

8.D.11.c Warm Weather ...................................92

8.D.11.d COM Port, BMS .................................93

8.D.11.e Temperature Conversion ...................94

8.D.11.f Anti-Frost ...........................................94

8.D.11.g Trim (O2 Trim Enable / Disable) .......95

8.D.12 Login ..................................................95

8.E Service Screens ..........................96

8.E.1 Burner.................................................96

8.E.2 Digital I/O ( Input / Output ) ...............97

8.E.3 Analog I/O ..........................................98

8.E.4 Screen Settings Timeout ....................99

8.E.5 History ................................................99

8.E.6 Restart Touchscreen & Recalibrate ....99

8.E.7 Factory Reset ...................................100

8.E.8 HMI Model OEM only. .....................100

8.E.9 BIC Model OEM only .......................100

8.E.10 Both Model. OEM only. ...................100

8.E.11 About About the Firmware version. 100

8.E.12 O2 (Trim Set Point) ..........................100

8.E.13 LMV ..................................................100

8.F Messages and USB ........................ 101

8.F.1 Messages ......................................... 101

8.F.2 USB Functionality .............................101

8.G Active Demands .............................102

SECTION 9 Parameter Tables ...............103

SECTION 10 Initial startup Instructions

10.A Filling the Boiler System ................... 109

10.B Initial Operation ................................ 110

10.B.1 Initial Burner Operation .................... 110

10.B.2 Combustion Setup Procedure

Hi Fire, Low Fire ................................111

10.C Shutting Down the Unit..................... 113

10.D Restarting the Unit............................ 113

10.E Controllers ........................................ 113

10.F Transmitters .....................................114

SECTION 11 Maintenance

11.A System Maintenance ....................... 115

11.B Maintenance Notes .......................... 115

11.B.1 Burner............................................... 115

1 1.B.2 Gas Train Components .................... 115

11.B.3 Controller .......................................... 116

11.B.4 Spark Ignition Electrodes ................. 116

11.B.5 Flame Sensor ................................... 116

11.B.6 Blower Model 1600........................... 116

11.B.7 Blower Model 2000-4000 ................. 116

1 1.B.8 Heat Exchanger Tubes ..................... 117

11.B.9 Gas Pressure Switches .................... 117

1 1.B.10 Pressure Transmitters ......................118

11.B.11 Oxygen Sensor................................. 118

11.B.12 High Temperature Limits (optional) .. 118

SECTION 12 Troubleshooting

12.A Lockouts and Errors ........................ 119

12.B LMV Errors ....................................... 121

SECTION 13 Replacement Parts

13.A General Information.......................... 126

13.B Component Illustrations, Parts Lists,

and Part Numbers ...................126 - 140

LAARS Heating Systems

HTD

Auto & manual

F- 150psi PRV

G- Flange kit & 30psi PRV

H- Flange kit & 50psi PRV

Model Nomenclature

Series

Size / MBH

Construction

Fuel

Usage

B- 220/240V, single ph (1600-2000)

Electrical System

Revision

Additional Options

D- 480V, three ph (2000-4000)

C- 208V, three ph (2000-4000)

SECTION 1 General Information

Page 1

1.A Introduction

This manual includes information which will help you to install, operate, and maintain the Laars Heating Systems MagnaTherm HTD. Please read this manual completely before proceeding with the installation. If you have any questions regarding this equipment, please contact Laars Heating Systems, or your local Laars representative. Experience has shown that most operating problems are caused by improper installation.

Rating Plate

1.B ModelIdentication

1.C Warranty

LAARS Heating Systems MagnaTherm HTD boilers and volume water heaters are covered by a limited warranty. The owner should complete the warranty registration at

http://www.LAARS.com

ALL WARRANTY CLAIMS must be made by an authorized LAARS Heating Systems representative. Claims must include the serial number and model (this information can be found on the rating plate). All claims must also include the installation date and name of the installer. Shipping costs are not included in the warranty coverage.

Primary information regarding your unit can be found on the Rating Plate on the outside face of the right-side panel.

1 2 3 4 5 6 7 8 9 10 11 12 13 M G 3

M G 1 6 0 0

MagnaTherm

X- std MGH, 75psi PRV, H-Stamp N- MGV w/ H-St amp, 30psi PRV W- std MGV, 125ps i P RV, HLW-Stamp P- MGV w/ H-Stamp, 50psi PRV X- None H- Gateway LONworks A- 30psi PRV R- MGV w/ H-Stamp, 60psi PRV A- Gateway, BACnet IP* & alarm bell

B- 50psi PRV S- MGV w/ H-Stamp, 75psi PRV B- Gateway, LONworks J- Gateway LONworks C- 60psi PRV T- MGV w/ H-Stamp, 125psi PRV C- Alarm bell & high limits D- MGV 75psi PRV U- MGV w/ H-Stamp, 150psi PRV DE- MGH 125psi PRV 2- Fl ange kit, MGV w/ H-Stamp, 30psi PRV high limits & alarm bell

J- Flange kit & 60psi PRV 6- Flange kit, MGV w/ H-Stamp, 125psi PRV & high limits *BACnet Gateway is K- Flange kit & 75psi PRV 7- Flange kit, MGV w/ H-Stamp, 150psi PRV G- Gateway BACnet IP* used for BA Cnet IP L- Flange kit & 125psi PRV & alarm bell and Modbus TCP/ IP M- Flange kit & 150psi PRV & high limits

H - Hydronic

V - Volume W ater

2 0 0 0 2 5 0 0 3 0 0 0 3 5 0 0 4 0 0 0

Waterway Options

3- Flange kit, MGV w/ H-Stamp, 50psi PRV E- Gateway BACnet IP* & high limits 4- Flange kit, MGV w/ H-Stamp, 60psi PRV & alarm bell L- Alarm & high limits 5- Flange kit, MGV w/ H-Stamp, 75psi PRV F- Gateway BACnet I P*

N- Nat

G- Standard

H- CSD-1

A- 120V, single ph (1600-2000) F- 208V, single ph (1600-2000)

E- 600V, three ph (2000-4000)

3- Third

K- Gateway LONworks

Page 2

WARNING

Carbon Monoxide Hazard

Improper adjustment of the burners may lead to poor combustion quality , increasing the amount of carbon monoxide produced. Excessive carbon monoxide levels may lead to personal injury or death.

WARNING

This unit must be installed in accordance with the procedures detailed in this manual, or the manufacturers warranty will be voided. The installation must conform to the requirements of the local jurisdiction having authority , and, in the United States, to the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA54. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Gas Installation Code, and/or local codes. Where required by the authority having jurisdiction, the installation of these units must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1. Any modi cations to the boiler, its gas controls, or wiring may void the warranty. If  eld conditions require modi cations, consult the factory representative before initiating such modi cations.

WARNING

• 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 the unit.

• Feel water before bathing or showering.

• If this unit 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 125°F (52°C).

WARNING

The inlet gas pressure to the unit must not

exceed 13” W.C. (3.2kPa).

WARNING

Fire or Explosion Hazard

Improper con guration can cause fuel buildup and

explosion. Improper user operation may result in property loss, severe physical injury, or death.

Any changes to safety-related con guration

parameters must only be done by experienced and/or licensed burner/boiler operators and mechanics.

If any odor of gas is detected, or if the gas burner does not appear to be functioning in a normal manner, close

the main gas shuto󰀨 valve. Do not shut o󰀨 the power

switch. Contact your heating contractor, gas company, or factory representative.

NOTE: This unit is protected against hydronic over-pressurization. A pressure relief valve is included with each unit.

WARNING

Indicates an imminently hazardous situation which, if not avoided, can or will result in death or serious injury and can or will result in catastrophic property damage.

CAUTION

Indicates a potentially hazardous situation which, if not avoided, may result in moderate injury and/or property damage.

NOTE:

Indicates instructions that are important to that topic but not related to personal injury or property damage.

Safety Notes are used thoughout this manual to bring attention to the presence of hazards with various risk

levels and to o󰀨 er important information concering the life of this product. There are 3 basic types.

WARNING

CANCER AND REPRODUCTIVE HARM.

WWW.P65WARNINGS.CA.GOV.

AS REQUIRED BY THE STATE OF

CALIFORNIA PROPOSITION 65.

LAARS Heating Systems

1.D Safety Notes

HTD

WARNING

Electrical Shock Hazard

Electrical shock can cause severe injury , death or property damage. Disconnect the power supply before beginning installation or changing the wiring to prevent electrical shock or damage to the equipment. It may be

necessary to turn o󰀨 more than one power supply

to disconnect. All electrical wiring is to be done in accordance with

local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70 - latest Edition, or 2) CSA STD. C22.1 “Canadian Electrical Code

- Part 1.” This appliance must be electrically grounded in accordance with these codes.

WARNING

The Repair Parts list designates parts that contain

refractory ceramic  bers (RCF). RCF has been classi ed

as a possible human carcinogen. When exposed to

temperatures above 180ºF, such as during direct  ame

contact, RCF changes into crystalline silica, a known carcinogen. When disturbed as a result of servicing or repair, these substances become airborne and, if inhaled, may be hazardous to your health.

Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH) approved respirator.

2. Long sleeved, loose  tting clothing.

3. Gloves.

4. Eye Protection.

NOTE: All installations must be made in accordance with

1) American National Standard Z223.1/NFPA54-Latest Edition “National Fuel Gas Code” or

2) CSA B149.1 “Natural Gas and Propane Installation Code” or in Canada reference the B149.1 latest edition and with the requirement of the local utility or other authorities having jurisdiction. Such applicable requirements take precedence over the general instructions contained herein. All electrical wiring is to be done in accordance with the local codes, or in the absence of local codes, with: 1) The National Electrical Code ANSI/NFPA No. 70-latest Edition, or

2) CSA STD. C22.1 “Canadian Electrical Code - Part 1”. This appliance must be electrically grounded in accordance with these codes.

Page 3

The supply voltage to this unit must not be disengaged, except for service or isolation, or unless otherwise instructed by procedures outlined in this manual. To signal a call for heat, use the

CAUTION

correct terminals as instructed in the Electrical Connections, Field Wiring 7.E on page 36 of this manual.

Page 4

1.E Unit Overview

LAARS Heating Systems

Pressure Transmitters

Blower

Spark Generator

On all models, the Control Panel hinges forward for easy access to wiring and to the heat exchanger.

Control Panel

Heat Exchanger

Field Electrical Connections

Shown with front doors and side panels removed.

Power Pack

Gas Supply Valve

Air Intake and Filter

Main Power

Connections

Drain

Water Outlet

Water Inlet

Vent

Condensate

Trap

O2 Sensor

HTD

1.F Gas Train Components

The Gas Train for all sizes has the same layout. These two views of the gas train show the linear path of the gas around the front of the unit to the Air Mixing Valve and then into the blower.

Pilot Gas Valve

Manual Gas Valve

Page 5

Gas Inlet

Manual Gas Valve

High Gas Pressure

Switch

(Press to Re-Set)

Pressure Regulator

& Shut-o󰀨

Air / Fuel Mixer

Gas Inlet

Gas Valve

Gas Solenoid

Low Gas Pressure Switch (Press to Re-Set)

Low Gas Pressure

Switch

(Press to Re-Set)

Air Damper

Fuel Damper

High Gas Pressure

Switch

(Press to Re-Set)

Page 6

29.3 (75) 79.8 (

) 38.0 (96) 57.5 (

) 49.8 (

)

29.3 (75) 79.8 (203 ) 38.0 (96) 57.5 (147) 49.8 (126 )

30.8 (78) 87.0 (221 ) 41.5 (105) 60.5 (154) 60.8 (154 )

34.5 (88) 97.5 (

) 52.0 (

) 70.0 (

) 60.8 (

)

34.5 (88) 97.5 (

) 52.0 (

) 70.0 (

) 60.8 (

)

60.8 (

) 2.6 (

) 8.4 (21) 67.4 (

30.4 (77) 16.0 (

)

60.8 (154) 2.6 (7) 8.4 (21) 67.4 (171) 30.4 (77 ) 16.0 (41)

71.0 (180) 4.0 (10) 9.8 (25) 76.4 (194 ) 34.5 (88) 17.7 (45)

71.0 (180) 4.0 (10) 9.8 (25) 76.8 (195 ) 34.5 (88) 17.7 (45)

81.3 (

) 7.0 (18) 8.3 (21) 86.4 (

) 40.0 (

) 21.6 (55)

81.3 (207) 7.0 (18) 8.3 (21) 86.4 (219 ) 40.0 (102) 21.6 (55)

23.0 (58) 10.2 (26) 14.0 (36) 13.0 (33) 6.3 (16)

27.2 (69) 11.8 (30) 18.3 (46) 14.8 (38) 6.0 (15)

27.2 (

) 11.8 (30) 18.3 (46) 14.8 (

) 6.0 (15)

30.7 (78) 13.0 (33) 16.0 (41) 17.4 (44) 6.7 (17)

Category II Vent

1.G Venting Dimensions & Sizing

LAARS Heating Systems

Model

2000 8 20 8 20 100 30.5 8 20 100 30.5 14 36 2500

3000 10 25 10 25 100 30.5 10 25 100 30.5 18 46 3500

4000 12 30 12 30 100 30.5 12 30 100 30.5 22 56

*A vent increaser at the boiler outl et i s required **Equivalent Feet: To calculate maximum equivalent length, measure the linear feet of the pipe

***Category II: Category II pipe size m ay vary. Draf t must remain between -0.01 and -0.001" w.c.. Notes:

1. Installations in t he U.S. require exhaust vent pipe that is CPVC complying with ANS I/ASTM D1785 F441, stainless steel c omplying with UL1735, or polypropylene complying with ULC S636.

2. Installations in Canada require exhaust vent pi pe t hat is certified to ULC S636.

3. Intake (air) pipe must be PVC or CPVC that complies with ANSI/AS T M D1785 F441, ABS that complies with ANSI/ASTM D1527, stainless steel, or galvanized material.

Vent / Air

Connector Size

inches cm inches cm ft** m inches cm ft** m inches cm

6 15

and add 5 feet (1.5m) for each elbow used.

Air Pipe Size

6 15

8 20 100 30.5

10 25 100 30.5

Maximum

Ducted Air Pipe

Length

100 30.51600

Category IV

Vent Pipe Size

6 15 50 15.2 14 36

8* 20* 100 30.5 14 36

8 20 50 15.2 18 46

10* 25* 100 30.5 18 46

10 25 50 15.2 22 56

12* 30* 100 30.5 22 56

Maximum

Category IV

Vent Pipe

Length

Typical

Pipe Size***

1.H Dimensions

Model A B C D E

1600

203

147

126

2000 2500 3000 3500 4000

248 248

133 133

178 178

154 154

inches (cm)

Model G H J K N P

1600

154

171)

2000 2500 3000 3500

207

219

102

4000

inches (cm)

Model Q R S T U

1600 2000 2500 3000

3500 4000

inches (cm)

HTD

VIEW

REAR VIEW

REAR

‘Knock-

down’ Height

Vent

2” Gas ALL Sizes

Air Inlet

Pressure

Relief Valve

Water

Outlet

Water

Inlet

Electrical

Boxes

FRONT

VIEW

SIDE

VIEW

FRONT

VIEW

SIDE

VIEW

‘Knock-

down’ Height

Condensate Trap 1” Drain Hose on ALL Sizes

Contact Factory

Op�onal

Flanges,

Vent

2” Gas ALL Sizes

Gas

Valve

Touchscreen

Display

Air Inlet

Pressure

Relief Valve

Water

Outlet

Water

Inlet

Electrical

Boxes

*Vent

Diameter

*Air Inlet

Diameter

Height

Connection

Page 7

Model

1600

2000

2500

3000

3500

4000

* Collar dimension only. Refer to section 1.G for vent and air pi pe sizes.

**Knock-down Height is the height of the boiler after

the blower and gastrain have been removed. This is a design feature to make installations easier. See https://www.laars.com/videos

Figure 1. Dimensions

Collar

6 (15) 6 (15 ) 60.8 (154 )

8 (20) 8 (20 ) 60.8 (154 )

Collar

'Knockdown'

8 (20) 8 (20 ) 70.1 (180 )

10 (25) 10 (25 ) 70.1 (180 )

10 (25) 10 (25 ) 80.8 (205 )

12 (30) 12 (30 ) 80.8 (205 )

Water

3" groove lock

(opt. flange)

3" groove lock

(opt. flange)

3" groove lock

4" groove lock

(opt. flange)

Page 8

LAARS Heating Systems

1.I Unpacking and the Install Kit

This unit is shipped in a single crate. Carefully disassemble the crate and inspect the unit for any damage during shipping. Included in the crate and yet outside of the unit is the ‘Installation Kit’ box.

Inspect the contents of the the Installation Kit box, making sure that all parts are included and not damaged.

1. Gromet, Nylon.

2. Box containing Outdoor Sensor

3. Box containing System Sensor

4. Tank Sensor

5. Spring Clip (used to hold tank sensor in sensor well)

6. Condensate Trap Assembly (some assembly required). Instructions are included with the kit or can be found in SECTION 6 on page 32 of this Installation Manual.

7. Installation Instructions for Sensors.

NOTE: A condensate neutralizer is NOT included.

1.J Locating the Unit

This unit may be installed indoors or outdoors. If installing outdoors in a location that may experience freezing temperatures, precautions must be taken to prevent water in the heat exchanger and condensate inside and outside of the boiler from freezing. Damage due to freezing water or condensate is not covered by the warranty .

Choose a location for the unit which allows clearances on all sides for maintenance and inspection. See Table

2. Always install the unit on a rm, level surface. It is

recommended that the unit is installed on a raised 4” pad so that there is elevation for a condensate neutralizer kit (not included with unit).

The unit should not be located in an area where leakage of any connections will result in damage to the area

adjacent to the unit, or to lower oors of the structure.

When this type of location is not available, install a suitable drain pan, adequately drained, under the unit.

This unit is design-certied by CSA-International for installation on combustible ooring; in basements;

in utility rooms or alcoves. Boilers must never be installed on carpeting. The location for the unit should

be chosen with regard to the vent pipe lengths and external plumbing.

The unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.).

When vented vertically , the unit must be located as close as practical to the vertical section of the vent. If the vent terminal and/or combustion air terminal terminate through a wall, and there is potential for snow accumulation in the local area, both terminals should be installed at an appropriate level above grade or the maximum expected snow line.

The dimensions and requirements that are shown in Table 1 must be met when choosing the location for the unit.

Ensure the location takes into account the maximum allowable vent length shown in SECTION 2 of this manual.

Figure 2. Installation Kit

NOTE : The unit shall be installed such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, control replacement, etc.).

1.K Clearances

3500/4000

2500/3000

1600/2000

Suggested Top Service Clearance by Model

inches cm

24 61 inches cm inches cm inches cm 24 61 12 30 15 38 24 61

8 20 8 20

Suggested

Service

Clearance

3500/4000

2500/3000

1600/2000

Suggested Top Service Clearance by Model

inches cm inches cm inches cm

12 30 15 38 24 61

3500/4000

2500/3000

1600/2000

Suggested Top Service Clearance by Model

Clearance to

Combustibles

inches cm Front 18 46 Back 11 28 Left 4 10 Right 4 10 Top 1 2.5

Table 1. Clearances

HTD

Suggested

Service

Clearance

inches cm

24 61 24 61

8 20 8 20

See Table 2

Page 9

See Table 2 for Suggested Top Service

Clearances

inches cm inches cm inches cm

12 30 15 38 24 61

Table 2. Suggested Top Service Clearances

24”

8”

24”

Figure 3. Suggested Service Clearances

Page 10

WARNING

SECTION 2 Venting and Combustion Air

LAARS Heating Systems

2.A General Venting Information

Selection of improper vent materials for installations that are installed in closets, or will be operated in high ambient temperature levels, may lead to property damage, personal injury, or death.

Failure to use the appropriate vent material, installation techniques, or glues and sealants could lead to vent failure causing property damage, personal injury or death.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in non-metallic venting systems is prohibited and that covering non-

metallic vent pipe and ttings with thermal insulation is

prohibited.

All venting must be installed according to this manual and any other applicable local codes, including but not limited to, ANSI Z223.1/NFPA 54, CSA B149.1, CSAB149.2 and ULC S636. Failure to follow this manual and applicable codes may lead to property damage, severe injury, or death.

2.B Vent and Air Pipe Material

This unit requires a special venting system. Refer to venting supplier’s instructions for complete parts list and method of installation. The manufacturers and product lines listed in Table 3 and Table 4 have been tested and authorized to safely operate with this equipment. Suppliers of stainless steel and polypropylene venting that are not listed on these tables are not permitted for use with this appliance.

Do not mix venting suppliers and models in venting systems. Failure to comply could result in personal injury, property damage, or death.

Installations must comply with applicable national, state and local codes.

2.B.1 Venting Requirements Unique to Canada

These high e󰀩ciency boilers and water heaters are

Vent Category II and IV units. Per the requirements of CAN/CSA-B149.1, only BH vent systems can be connected to these units and such vent systems, either

ULC S636 certied stainless steel or other ULC S636 certied BH vent (eg. plastics) must be installed per the vent manufacturer’s certied installation instructions.

It is the responsibility of the appropriately licensed

technician installing this unit to use ULC S636 certied

vent material consistent with the requirements as described in the Venting and Combustion Air section.

If the system temperatures are unknown at the time of installation, class IIC or higher venting material is recommended.

This unit is certied to vent as a Category II (negative

pressure condensing) or Category IV (positive pressure condensing) appliance. It may be installed with vent materials meeting the standards listed in Table 5. The vent can terminate through the roof, or through an outside wall.

All installations must be done following the vent supplier’s recommended installation techniques. If these are not available, refer to the Manufacturer recommendations for the material used.

Class I venting systems are suitable for gas-red units producing ue gas temperature of more than 135°C, but

not more than 245°C.

Class II venting systems are suitable for gas-red units producing ue gas temperatures of 135°C or less.

Class II venting systems are further classied into four

temperature ratings as follows: A Up to and including 65°C / 149°F B Up to and including 90°C / 194°F C Up to and including 110°C / 230°F and D Up to and including 135°C / 275°F

2.B.1.a Flue Gas Sampling Port -

It is also the responsibility of the installer to ensure that

a ue gas sampling port is installed in the vent system. This ue gas sampling port must be installed near the ue connection of the unit: within 2 feet of the ue connection. There is no ue gas sampling port internal

to the unit, so one must be installed in the vent system

HTD

Figure 4. Test Port

external to the unit. A ue gas sampling port available as a component of the ULC S636 certied vent system

is preferred. However, if one is not available with the

certied vent system, manufacturer suggests using

Manufacturer Model Numbers (abbreviated)

Page 11

a tee with the branch connection sized to allow for

insertion of a ue gas analyzer probe. The branch

connection must be resealable with a cap or other means to ensure the vent system remains sealed. (See Figure 4)

Consideration must be given to the placement and

orientation of the ue gas sampling port to ensure that condensate is free to ow back into the unit and not

collect anywhere in the vent system - including in the

ue gas sampling port.

2.B.1.b Exhaust Vent Terminal -

An exhaust vent terminal must be installed. If an

exhaust vent terminal is not available with the certied

vent system, the manufacturer suggests the use of a

coupler tting from the certied vent system into which

the vent terminal screen can be installed. Be sure to install and terminate both vent and combustion air pipes per the instructions in this section.

Table 3. Allowable Single Wall Stainless Steel Vent Suppliers and Part Numbers

Manufacturer Model Numbers (abbreviated)

Table 4. Allowable Polypropylene Vent Manufacturers / Trade Names

Page 12

(Place in section 3.1)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Screen for horizontal galvanized air pipe D2012104 D2012101 D2012101 D2012102 D2012103 D2012103

Screen for horizontal PVC air pipe CA012004 CA012001 CA012001 CA012002 CA012003 CA012003

Screen for horizontal polypropylene air pipe CA012204 CA012201 CA012201 CA012202 CA012203 CA012203

Screen for vertical galvanized air pipe D2012204 D2012201 D2012201 D2012202 D2012203 D2012203

Screen for vertical PVC air pipe CA012404 CA012401 CA012401 CA012402 CA012403 CA012403

Screen for vertical polypropylene air pipe CA012604 CA012601 CA012601 CA012602 CA012603 CA012603

Table 3a - Ducted Air Accessories

(Place in section 3.2)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Horizontal vent terminal for stainless steel D2012004 D2012001 D2012001 D2012002 D2012003 D2012003

Screen for horizontal CPVC vent CA012104 CA012101 CA012101 CA012102 CA012103 CA012103

Screen for vertical stainless steel vent D2012304 D2012301 D2012301 D2012302 D2012303 D2012303

Screen for vertical CPVC vent CA012504 CA012501 CA012501 CA012502 CA012503 CA012503

(Place in section 3.1)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Screen for horizontal galvanized air pipe D2012104 D2012101 D2012101 D2012102 D2012103 D2012103

Screen for horizontal PVC air pipe CA012004 CA012001 CA012001 CA012002 CA012003 CA012003

Screen for horizontal polypropylene air pipe CA012204 CA012201 CA012201 CA012202 CA012203 CA012203

Screen for vertical galvanized air pipe D2012204 D2012201 D2012201 D2012202 D2012203 D2012203

Screen for vertical PVC air pipe CA012404 CA012401 CA012401 CA012402 CA012403 CA012403

Screen for vertical polypropylene air pipe CA012604 CA012601 CA012601 CA012602 CA012603 CA012603

Material United States Canada

Stainless steel UL 1738

CPVC, sch 40 ANSI/ASTM F441 Polypropylene ULC S636 Class 2C

Installation Standards

Table 5. Required Exhaust Vent Material

Table 6. Exhaust Vent Accessories

Material United States Canada

ABS ANSI/ASTM D1527

PVC, sch. 40 ANSI/ASTM D1785 or D2665

CPVC, sch. 40 ANSI/ASTM F441

Single wall galv. steel 26 gauge

Polypropylene ULC S636 Class 2C

Table 7. Required Combustion Air Pipe Material

LAARS Heating Systems

Venting must be ULC S636 certied for use as venting

material. The venting material class must be chosen based upon the intended application of the unit and

must be installed according to the maximum ue gas

temperature and the vent manufacturer’s instructions.

The air pipe material must be chosen based upon the intended application of the boiler or water heater and must be installed according to the vent manufacturer’s installation instructions.

Table 8. Ducted Air Accessories

2.C Vent and Air Pipe Sizing

This unit is certied to vent as a Category II or Category

IV appliance. Because Category II vent is non-positive, the vent size may not be the same as the positive pressure Category IV vent, even when the unit is the same size. Be sure to follow the instructions in this manual, based on the type of venting in your installation.

The venting must be correct to allow the condensate to run back to the unit to drain. Route the vent pipe to the heater as directly as possible. Seal all joints. Provide adequate hangers as required in the venting system manufacturer’s Installation Instructions, or at least every 4 feet.

The unit must not support the weight of the vent pipe.

The maximum equivalent pipe length allowed is 100 feet (30m). Each elbow is considered to be 5 feet

(1.5m). The manufacturer o󰀨ers accessory kits to use

with horizontal and vertical exhaust vent systems, as shown in Table 6

NOTE: For Category II and IV boilers, the horizontal runs must be sloping upwards not less than 1/4 inch per foot (21 mm/m) from the boiler to the vent terminal, so as to prevent accumulation of condensate and, where necessary , have the means provided for drainage of condensate.

A TTENTION: Pour la catégorie II & IV, les chaudières ont horizontal en pente vers le haut au moins 1/4 de pouce par pied (21 mm/m) à partir de la chaudière

pour l’évent borne; être installé de façon à éviter l’accumulation de condensats; et, le cas échéant, ont

des moyens prévus pour l’évacuation des condensats.

HTD

Category II Vent

WARNING

Page 13

2.C.1 Category lV Vent Sizes

Positive pressure vent systems may be either horizontally or vertically vented. The vent pipe used must be suitable for positive pressure, per the requirements shown in Section 2.B. Table 9 shows the pipe size and allowable maximum equivalent feet of piping allowed for both air and vent in a Category lV system.

The forced draft combustion air blower in the unit has

su󰀩cient power to vent properly when the guidelines in

Table 9 are followed.

The venting must be installed with appropriate

condensate traps and using only specic

manufacturers, models and materials outlined in this manual. Draft must always remain between -0.1” and

-0.001” at all ring rates. If pressures outside of this

range are measured, consult professional venting engineer for recommendations, such as double-acting barometric dampers to avoid reduced performance or hazardous conditions.

2.C.2 Category II Vent Sizes

Non-positive pressure vent systems are generally vertically-terminated. Table 9 gives guidelines for vent and air pipe sizes, but the draft must be measured to ensure that it remains between -0.1”w.c. and -0.001”w.c.

at all ring rates.

2.C.3 Common Venting

This unit can be common vented, however, the common venting must be a professionally designed and approved system. See Document 1396.pdf Application Guide for Common Venting (commercial condensing, available online. See Back Cover for website.) Category II and IV units are never permitted to share a vent with any Category 1 units.

Maximum

Category IV

Vent Pipe

Length

Typical

Pipe Size***

Model

Vent / Air

Connector Size

Air Pipe Size

Maximum

Ducted Air Pipe

Length

Category IV

Vent Pipe Size

inches cm inches cm ft** m inches cm ft** m inches cm

6 15

100 30.51600

6 15 50 15.2 14 36

8* 20* 100 30.5 14 36

2000 8 20 8 20 100 30.5 8 20 100 30.5 14 36 2500

8 20 100 30.5

8 20 50 15.2 18 46

10* 25* 100 30.5 18 46

3000 10 25 10 25 100 30.5 10 25 100 30.5 18 46 3500

10 25 100 30.5

10 25 50 15.2 22 56

12* 30* 100 30.5 22 56

4000 12 30 12 30 100 30.5 12 30 100 30.5 22 56

*A vent increaser at the boil er out l et is required **Equivalent Feet: To calcul ate maximum equivalent length, m easure the linear feet of the pipe

and add 5 feet (1.5m) for each el bow used. ***Category II: Category II pi pe s i ze may vary. Draft must remain between -0.01 and -0.001" w.c . . Notes:

1. Installations i n the U.S. require exhaust vent pipe that is CPVC complying with ANSI/ASTM D1785 F441, stainless st eel complying with UL1735, or polypropylene complying with ULC S636.

2. Installations i n Canada requi re exhaust vent pi pe that is certified to ULC S636.

3. Intake (air) pipe must be PVC or CPVC that complies with A NS I/ASTM D1785 F441, ABS that com pl i es with ANSI/ASTM D1527, st ai nl ess steel, or galvanized material.

Table 9. Vent/Air Pipe Diameters

Page 14

2.C.4 Common Vent Test

LAARS Heating Systems

NOTE: This section does not describe a method for common venting this unit. It describes what must be done when an unit is removed from a common vent system. This category IV unit requires special vent systems and fans for common vent. Contact the factory or your factory representative if you have questions about common venting this category IV unit.

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the units remaining connected to it.

At the time of removal of an existing boiler, the following steps shall be followed with each unit remaining connected to the common venting system placed in operation, while the other units remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or

restriction, leakage, corrosion or other deciencies which

could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the units remaining connected to the common venting system are located and other spaces of the building. Turn on any clothes dryers and any unit 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 replace dampers.

4. Place in operation the unit being inspected. Follow the startup instructions. Adjust thermostat so unit will operate continuously.

5. Test for spillage at the draft hood relief opening after ve minutes of main burner operation. Use the ame of a

match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each unit remaining connected to the common venting system properly vents when tested as outlined above, return the doors, windows,

exhaust fans, replace dampers and any other gas burning

unit to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, National Gas and Propane Installation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Appendix F in the National Fuel Gas Code, ANSI Z223.1 NFPA 54 and/or CAN/CSA B149.1, National Gas and Propane Installation Code.

Au moment du retrait d’une chaudiére existante, les

mesures suivantes doivent être prises pour chaque

appareil toujurs raccordé au systéme d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas:

Au moment de la sortie d’une chaudière existante,

la procédure suivante doit être suivie avec chaque

appareil reste connecté au système de ventilation communs placés dans l’exploitation, tandis que les autres appareils reste connecté au système de ventilation communs ne sont pas en fonctionnement.

1. Sceller toutes les ouvertures non utilisées du système d’évacuation.

2. Inspecter de facon visuelle le système d’évacuation

pour déterminer la grosseur et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les

fenêtres du bâtiment et toutes les portes entre l’espace où

les appareils toujours raccordés au système d’évacuation

sont installés et les autres espaces du bâtiment.

Mettre en march les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinière et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

4. Mettre l’appareil inspecté en marche. Suivre les instructions

d’allumage. Régler le thermostat de facon que l’appareil fonctionne de facon continue.

5. Faire fonctionner le brûleur principal pendant 5 min ensuite,

déterminer si le coup-tirage déborde à l’ouverture de

décharge. Utiliser la amme d’une allumette ou d’ une

chandelle ou la fumée d’ une cigarette, d’un cigare ou d’une pipe.

6. Une fois qu’il a été détermineé, selon la méthode indiquée

ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de facon adéquate.

Remettre les portes et les fenêtres, les vientilateurs,

les registre de cheminées et les appareils au gaz àleur position originale.

7, Tout mauvais fonctionnement du système d’évacuation

commun devrait être corrigé de facon que l’installation soit

conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/CSA-B149.1. Si la

grosseur d’une section du système d’évacuation doit être modié pour respecter les valeurs minimales des tableaux

pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFP A 54 et (ou) aux codes d’installation CAN/CSA-B149.1.

HTD

Page 15

2.C.5 Combustion Air

Boilers and water heaters must have provisions for combustion and ventilation air in accordance with the applicable requirements for Combustion Air Supply and

Ventilation in the National Fuel Gas Code, ANSI Z223 1;

or in Canada, the Natural Gas and Propane Installation Code, CSA B149.1. All applicable provisions of local building codes must also be adhered to.

This unit can take combustion air from the space in which it is installed, or the combustion air can be ducted directly to the unit. Combustion and Ventilation air must be provided in either case.

2.C.5.a Combustion Air From Room

In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with Method 1 or 2. (See the following descriptions.) Where ducts are used, they shall be of the same cross-sectional area as the free area of the openings to which they connect.

Method 1: Two permanent openings, one commencing within 12” (30 cm) of the top and one commencing within 12” (30 cm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors. When directly communicating with the outdoors, or when communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 square inch per 4000 Btu/hr (550 square mm/kW) of total input rating of all equipment in the enclosure. When communicating to the outdoors through horizontal ducts, each opening shall have a minimum free area of not less than 1 square inch per 2000 Btu/hr (1100 square mm/kW) of total input rating of all equipment in the enclosure.

Method 2: One permanent opening, commencing within 12” (300 mm) of the top of the enclosure, shall be permitted. The opening shall directly communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that directly communicate with the outdoors and shall have a minimum free area of 1 square inch per 3000 Btu/hr (734 square mm/kW) of the total input rating of all equipment located in the enclosure. This opening must not be less than the sum of the areas of all vent

connectors in the conned space.

Other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above.

In Canada, consult local building and safety codes or, in absence of such requirements, follow CAN/CSA B149.

Page 16

LAARS Heating Systems

2.C.5.b Ducted Combustion Air

The combustion air can be taken through the wall, or

through the roof. The manufacturer o󰀨ers accessories

to use with ducted air systems, as shown in Table 8. See Table 7 to select the appropriate diameter air pipe.

When taken from the roof, a eld-supplied rain cap or

an elbow arrangement must be used to prevent entry of rain water. (See Figure 7).

Use ABS, PVC, CPVC, polypropylene, stainless steel, or galvanized pipe for the combustion air intake (See Table 7). The intake must be sized per Table 9. Route the intake to the boiler as directly as possible. Seal all joints. Provide adequate hangers. The unit must not support the weight of the combustion air intake pipe. The maximum equivalent pipe length allowed is 100 feet (30 m). Each elbow is considered to be 5 feet (1.5m)

When using polypropylene or stainless steel materials

in horizontal duct congurations, a single elbow must

be installed on the end of the air inlet to act as an outdoor terminal. In vertical duct applications, two elbows must be installed on the end of the inlet to act as a vent terminal. When elbows are use as terminals, appropriate screens must be installed to prevent blockage. The elbow(s) required for termination are not included in the kits shown in Table 8

The connection for the intake air pipe is on the back panel.

In addition to air needed for combustion, air shall also be supplied for ventilation, including air required for comfort and proper working conditions for personnel. Refer to the applicable codes.

2.D Locating the Vent and Combustion Air

Terminals

2.D.1 Side-wall Vent Terminal

The appropriate side-wall vent terminal must be used. The terminal must be located in accordance with ANSI Z223.1/NFPA 54 and applicable local codes. In Canada, the installation must be in accordance with CSA B149.1 or .2 and local applicable codes.

Consider the following when installing the terminal:

1. Figure 6 on page 18 shows the requirements for

mechanical vent terminal clearances for the U.S. and Canada.

2. Vent terminals for condensing units or units with

condensing vents are not permitted to terminate above a public walkway, or over an area where condensate or vapor could create a nuisance or hazard.

3. Locate the vent terminal so that vent gases cannot

be drawn into air conditioning system inlets.

4. Locate the vent terminal so that vent gases cannot

enter the building through doors, windows, gravity inlets or other openings. Whenever possible, avoid locations under windows or near doors.

5. Locate the vent terminal so that it cannot be

blocked by snow. The installer may determine that a vent terminal must be higher than the minimum shown in codes, depending upon local conditions.

6. Locate the terminal so the vent exhaust does not

settle on building surfaces or other nearby objects. Vent exhaust bi-products may damage surfaces or objects.

7. If the boiler or water heater uses ducted

combustion air from an intake terminal located on the same wall, see See Figure 6 on page 18 for proper spacing and orientation.

HTD

Page 17

*When vent terminal is less than 10 feet (3 m) horizontally from a forced air inlet, the terminal must be at least 3 feet (0.9 m) above the air inlet. (US only)

U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm)

deck, or balcony See note 6 See note 6 B= Clearance to window or door that may be Direct vent only: 12 inches (30 cm); 36 inches (91 cm)

opened Other than Direct vent: 4 ft (1.2m) below or to

side of opening; 1 ft (30 cm) above opening

C= Clearance to permanently closed window See note 4 See note 5 D= Vertical clearance to ventilated so󰀩t located

above the terminal within a horizontal See note 4 See note 5 distance of 2 feet (61 cm) from the center line of the terminal

E= Clearance to unventilated so󰀩t See note 4 See note 5 F= Clearance to outside corner See note 4 See note 5 G= Clearance to inside corner See note 4 See note 5 H= Clearance to each side of center line 3 feet (91 cm) within a height 15 feet

extended above meter/regulator assembly See note 4 above the meter/regulator assembly

I= Clearance to service regulator vent outlet See note 4 3 feet (91 cm) J= Clearance to non-mechanical air supply Direct vent only: 36” (91cm)

inlet to building or the combustion air inlet Other than Direct vent: 4 ft (1.2m) below 36 inches (91 cm) to any other unit or to side of opening; 1 ft (30 cm) above opening

K= Clearance to a mechanical air supply inlet 3 feet (91 cm) above if within 10 feet (3 m) 6 feet (1.83 m)

horizontally

L= Clearance above paved sidewalk or paved Vent termination not allowed in this location 7 ft (2.1 m) driveway located on public property for category IV units. See note 5

M= Clearance under veranda, porch, deck, See note 4 12 inches (30 cm)

or balcony See note 5

Notes:

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

2. In accordance with the current CAN/CSA-B149 Installation Codes.

3. Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath the oor.

4. For clearances not specied in ANSI Z223.1 / NFPA 54, clearance is in accordance with local installation codes and the

requirements of the gas supplier.

5. For clearances not specied in CAN/CSA-B149, clearance is in accordance with local installation codes and the requirements of the gas supplier.

6. IMPORTANT: All terminals must be placed so that they remain a minimum 12” above expected snow line. Local codes may have

more specic requirements, and must be consulted.

Figure 5. Combustion Air and Vent Through Side-wall.

Page 18

LAARS Heating Systems

Multiple Vents

2” Min. (Typ)

Multiple Air Intakes

12”

2” Min. (Typ)

INLET

Above expected snow line

84”

213

12”

Terminals must be placed such that they are a Minimum of 12” above the

expected snow line. Local codes may have more specic requirements

and must be consulted. Refer to the NFP A 54 National Fuel Gas Code

Figure 6. Sidewall Vent and Air Terminals

2.D.2 Side-wall Combustion Air Terminal

Consider the following when installing the terminal.

1. Do not locate the air inlet terminal near a source

of corrosive chemical fumes (e.g., cleaning uid,

chlorine compounds, etc.).

2. Locate the terminal so that it will not be subject to damage by accident or vandalism. It must be at least 7 feet ( 2.1 m) above a public walkway.

3. Locate the combustion air terminal so that it cannot be blocked by snow. The National Fuel Gas Code requires that it be at least 12 inches (30 cm) above grade, but the installer may determine it should be higher, depending upon local conditions.

4. If the unit is side-wall vented to the same wall, use Figure 6 to determine the proper mounting locations.

5. Multiple vent kits should be installed such that the horizontal distance between outlet group and inlet group is 84” (213 cm). (See Figure 6)

6. The vent outlet must be at least 12” above the top of the air inlet, and must be at least 84” (213 cm) horizontally from the air inlet. (See Figure 6).

OUTLET

36”

and your local codes for all required clearances for venting.

2.D.4 Vertical Combustion Air Terminal

When combustion air is taken from the roof, a eld-

supplied rain cap or an elbow arrangement must be used to prevent entry of rain water. The opening on the end of the terminal must be at least 12” (30 cm) above the point at which it penetrates the roof, and high enough above the roof line to prevent blockage from snow. When the vent terminates on the roof, the combustion air must terminate at least 12” (30 cm) below the vent terminal.

Window

2.D.3 Vertical Vent Terminal

When the unit is vented through the roof, the vent must extend at least 3 feet (0.9 m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6 m) higher than any portion of a building within a horizontal distance of 10 feet (3.0 m), and high enough above the roof line to prevent blockage from snow. The vent

terminal o󰀨ered with the unit can be used in both vertical

and horizontal applications. When the combustion air is taken from the roof, the combustion air must terminate at least 12” (30 cm) below the vent terminal.

*In Canada, refer to CAN/CSA B149.1

Figure 7. Combustion Air and Vent Through Roof

HTD

WARNING

(Place in section 3.1)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Screen for horizontal galvanized air pipe D2012104 D2012101 D2012101 D2012102 D2012103 D2012103

Screen for horizontal PVC air pipe CA012004 CA012001 CA012001 CA012002 CA012003 CA012003

Screen for horizontal polypropylene air pipe CA012204 CA012201 CA012201 CA012202 CA012203 CA012203

Screen for vertical galvanized air pipe D2012204 D2012201 D2012201 D2012202 D2012203 D2012203

Screen for vertical PVC air pipe CA012404 CA012401 CA012401 CA012402 CA012403 CA012403

Screen for vertical polypropylene air pipe CA012604 CA012601 CA012601 CA012602 CA012603 CA012603

Table 3a - Ducted Air Accessories

(Place in section 3.2)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Horizontal vent terminal for stainless steel D2012004 D2012001 D2012001 D2012002 D2012003 D2012003

Screen for horizontal CPVC vent CA012104 CA012101 CA012101 CA012102 CA012103 CA012103

Screen for vertical stainless steel vent D2012304 D2012301 D2012301 D2012302 D2012303 D2012303

Screen for vertical CPVC vent CA012504 CA012501 CA012501 CA012502 CA012503 CA012503

Table 3* - Vent Accessories

(Place in section 3.5)

Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000

Air intake screen for unit placed outdoors CA0011904 CA011901 CA011901 CA011902 CA0011903 CA0011903

Vent terminal for unit placed outdoors CA011804 CA011801 CA011801 CA011802 CA011803 CA011803

Table 10. Air & Vent Accessories for units placed outdoors

2.E Outdoor Installation

This unit can only be installed outdoors in areas that will will never experience freezing temperatures. Precautions must be taken to prevent water in the heat exchanger and condensate inside and outside of the boiler from freezing. Damage due to freezing water or condensate is not covered by the warranty .

For proper operation in outdoor installations, the boiler must be equipped with the inlet air and exhaust terminal kits listed in Table 10. Additional instructions are supplied with the terminal kits.

If installing outdoors in a location that may experience freezing temperatures, provisions must be made to protect the unit from freeze damage. Manufacturer does not warranty damage caused by freezing temperatures.

2.F Installations in the Commonwealth of

Massachusetts

In Massachusetts the following items are required if the side-wall exhaust vent termination is less than seven

(7) feet above nished grade in the area of the venting,

including but not limited to decks and porches. (From Massachusetts Rules and regulations 248 CMR 5.08.)

1. Installation of Carbon Monoxide Detectors

At the time of installation of the side-wall vented

gas fueled unit, the installing plumber or gastter

shall observe that a hard wired carbon monoxide detector with an alarm battery back-up is installed on

the oor level where the gas unit is to be installed. In addition, the installing plumber or gastter shall

observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side-wall horizontally vented gas fueled equipment. It shall be the responsibility of the property

owner to secure the services of qualied licensed

professionals for installation of hard wired carbon monoxide detectors.

a. In the event that the side-wall horizontally vented

gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide with alarm and battery back-up may be installed on the next

adjacent oor level.

b. In the event that the requirements of the subdivision

cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements, provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm be installed.

2. Approved Carbon Monoxide Detectors Each carbon monoxide detector shall comply with

NFP A 720 and be ANSI/UL 2034 listed and IAS

certied.

3. Signage

A metal or plastic identication plate shall be

permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating unit or equipment. The sign shall read, in print no less than one-half (1/2) inch in size: “GAS VENT DIRECTLY BELOW , KEEP CLEAR OF ALL OBSTRUCTIONS.”

4. Inspection The state or local gas inspector of the side-wall

horizontally vented gas fueled unit shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1-4.

Page 19

Page 20

WARNING

SECTION 3 Gas supply and Piping

3.A Gas Supply and Piping

All Installations must conform to the National Fuel Gas Code ANSI Z223.1/NFPA54, and/or local codes. In Canada, the installation must conform to the latest edition of CSA B149.1 Natural Gas and Propane Gas Installation Code, and/or local codes. Gas piping should

be supported by suitable hangers or oor stands, not the

unit.

Review the following instructions before proceeding with the installation.

1. Verify that the unit is tted for the proper type of gas by

checking the rating plate.

NOTE: This unit is equipped to operate at elevations up to 2000 feet (610m). However, the unit will function

properly without the use of high altitude modication at

elevations up to 10,000 feet (3050 m). For elevations above 2000 ft (600 m), the input gas rating shall be reduced at a rate of 4 percent for each 1000 ft (300 m) above sea level. This must be considered before selecting the equipment size.

2. The gas pressure settings must match fuel type as

shown in Table 11.

3. Table 12 and Table 13 on page 21 o󰀨er some gas

pipe sizing information. Refer to the applicable gas code for more detailed sizing information.

4. Run gas supply line in accordance with all applicable

codes.

5. Locate and install manual shuto󰀨 valves in accordance

with state and local requirements.

6. A sediment trap must be provided upstream of the gas

controls.

7. All threaded joints should be coated with piping

compound resistant to action of liquied petroleum gas.

8. The unit and its individual shuto󰀨 valve must be

disconnected from the gas supply piping during any pressure testing of that system at test pressures in excess of 1/2 PSIG (3.45kpa).

9. The unit must be isolated from the gas supply system

by closing its individual manual shuto󰀨 valve during any

pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.45kpa).

10. The unit and its gas connection must be leak tested

before placing it in operation.

1 1. Purge all air from gas lines

o󰀨ers some gas

LAARS Heating Systems

Natural Gas LP (propane)

Min 4.0 IN - W.C. 8.0 IN - W.C. Max 10.5 IN - W.C. 13.0 IN - W.C.

Table 11. Gas Pressure

Do not use open ame to check for leaks. An open ame could lead to explosion, which could result in

property damage, serious injury or death.

If an inline high gas pressure regulator is used, it must be of the lockup type and located a minimum of 10 feet from the unit. Failure to do so may result in

insu󰀩cient gas volume supplied to the unit.

NOTE: This unit and all other gas units sharing the

gas supply line must be ring at maximum capacity

to properly measure the inlet supply pressure. The pressure can be measured at the supply pressure port on the gas valve. Low gas pressure could be an indication of an undersized gas meter, undersized gas supply lines and/or an obstructed gas supply line. The units may be equipped with low and high pressure gas switches that are integrally vent limited. These types of devices do not require venting to atmosphere.

NOTE: After placing the boiler in operation, the

ignition system safety shuto󰀨 device must be tested.

See 10.A on page 109

HTD

Nominal: 1½ 2 2½ 3 4 Actual ID: 1.61 2.067 2.469 3.068 4.026

Length (ft)

10 3,520 6,790 10,800 19,100 39,000 20 2,420 4,660 7,430 13,100 26,800 30 1,940 3,750 5,970 10,600 21,500 40 1,660 3,210 5,110 9,030 18,400 50 1,480 2,840 4,530 8,000 16,300 60 1,340 2,570 4,100 7,250 14,800

80 1,230 2,370 3,770 6,670 13,600 100 1,140 2,200 3,510 6,210 124,700 125 1,070 2,070 3,290 5,820 11,900

150 1,010 1,950 3,110 5,500 11,200 175 899 1,730 2,760 4,880 9,950 200 814 1,570 2,500 4,420 9,010 250 749 1,440 2,300 4,060 8,290 300 697 1,340 2,140 3,780 7,710 350 618 1,190 1,900 3,350 6,840 400 560 1,080 1,720 3,040 6,190

Notes:

1. Inlet pressure - 11.0 in w.c.

Capacity in Cubic Feet of Gas per Hour

Pipe Size (in.)

Natural Gas

Undiluted Propane

Pipe Size (in.)

Capacity in Cubic Feet of Gas per Hour

Nominal: 2 2½ 3 4 5 Nominal: 1½ 2 2½ 3 4 Actual ID: 2.067 2.469 3.068 4.026 5.047 Actual ID: 1.61 2.067 2.469 3.068 4.026 Length (ft) Length (ft)

10 4,020 6,400 11,300 23,100 41,800 10 3,520 6,790 10,800 19,100 39,000 20 2,760 4,400 7,780 15,900 28,700 20 2,420 4,660 7,430 13,100 26,800 30 2,220 3,530 6,250 12,700 23,000 30 1,940 3,750 5,970 10,600 21,500 40 1,900 3,020 5,350 10,900 19,700 40 1,660 3,210 5,110 9,030 18,400 50 1,680 2,680 4,740 9,660 17,500 50 1,480 2,840 4,530 8,000 16,300 60 1,520 2,430 4,290 8,760 15,800 60 1,340 2,570 4,100 7,250 14,800 70 1,400 2,230 3,950 8,050 14,600 80 1,230 2,370 3,770 6,670 13,600 80 1,30

0 2,080 3,670 7,490 13,600 100 1,140 2,200 3,510 6,210 124,700

90 1,220 1,950 3,450 7,030 12,700 125 1,070 2,070 3,290 5,820 11,900 100 1,160 1,840 3,260 6,640 12,000 150 1,010 1,950 3,110 5,500 11,200 125 1,020 1,630 2,890 5,890 10,600 175 899 1,730 2,760 4,880 9,950 150 928 1,480 2,610 5,330 9,650 200 814 1,570 2,500 4,420 9,010 175 854 1,360 2,410 4,910 8,880 250 749 1,440 2,300 4,060 8,290 200 794 1,270 2,240 4,560 8,260 300 697 1,340 2,140 3,780 7,710 150 704 1,120 1,980 4,050 7,320 350 618 1,190 1,900 3,350 6,840 300 638 1,020 1,800 3,670 6,630 400 560 1,080 1,720 3,040 6,190 350 587 935 1,650 3,370 6,100 Notes: 400 54

6 870 1,540 3,140 5,680 1. Inlet pressure - 11.0 in w.c.

Notes: 2. Pressure drop - 0.5 in w.c.

3. Specific gravity - 1.50

4. Schedule 40 metallic pipe

5. Intended use - Pipe sizing between single

4. Schedule 40 metallic pipe or second-stage (low pressure)

Capacity in Cubic Feet of Gas per Hour

Pipe Size (in.)

Natural Gas

Undiluted Propane

Pipe Size (in.)

Capacity in Cubic Feet of Gas per Hour

Undiluted Propane

Pipe Size (in.)

Capacity in Cubic Feet of Gas per Hour

regulator and appliance.

Undiluted Propane

Pipe Size (in.)

Capacity in Cubic Feet of Gas per Hour

3.B Gas Pipe Sizing

The following are gas line sizing examples from the National Fuel Gas Code. Size your gas lines properly,

based on your installation and all applicable codes.

SCH 40 METAL PIPE CAPACITY FOR 0.60 SPECIFIC GRAVITY

NATURAL GAS

NOMINAL PIPE SIZE @ 0.30” W.C. PRESSURE DROP

Nominal: 2 2½ 3 4 5 Actual ID: 2.067 2.469 3.068 4.026 5.047

Length (ft)

10 4,020 6,400 11,300 23,100 41,800 20 2,760 4,400 7,780 15,900 28,700 30 2,220 3,530 6,250 12,700 23,000 40 1,900 3,020 5,350 10,900 19,700 50 1,680 2,680 4,740 9,660 17,500 60 1,520 2,430 4,290 8,760 15,800 70 1,400 2,230 3,950 8,050 14,600

80 1,300 2,080 3,670 7,490 13,600

90 1,220 1,950 3,450 7,030 12,700 100 1,160 1,840 3,260 6,640 12,000 125 1,020 1,630 2,890 5,890 10,600 150 928 1,480 2,610 5,330 9,650 175 854 1,360 2,410 4,910 8,880 200 794 1,270 2,240 4,560 8,260 150 704 1,120 1,980 4,050 7,320 300 638 1,020 1,800 3,670 6,630 350 587 935 1,650 3,370 6,100 400 546 870 1,540 3,140 5,680

Table 12. Pipe Capacity for Natural Gas

1. Inlet pressure - Less than 2 psi

2. Pressure drop - 0.5 in w.c.

3. Specific gravity - 0.60

Page 21

SCH 40 METAL PIPE CAPACITY FOR 1.50 SPECIFIC GRAVITY

NOMINAL PIPE SIZE @ 11” W.C. INLET AND 0. 5” W.C. PRESSURE DROP

Nominal: 1½ 2 2½ 3 4 Actual ID: 1.61 2.067 2.469 3.068 4.026

Length (ft)

80 1,230 2,370 3,770 6,670 13,600 100 1,140 2,200 3,510 6,210 124,700 125 1,070 2,070 3,290 5,820 11,900 150 1,010 1,950 3,110 5,500 11,200 175 899 1,730 2,760 4,880 9,950 200 814 1,570 2,500 4,420 9,010 250 749 1,440 2,300 4,060 8,290 300 697 1,340 2,140 3,780 7,710 350 618 1,190 1,900 3,350 6,840 400 560 1,080 1,720 3,040 6,190

Table 13. Pipe Capacity for Propane

UNDILUTED PROPANE

Page 22

SECTION 4 Water Flow and Headloss Data

4.A. General Water Flow Information

MagnaTherm units are water-tube type units that require water flow for operation. Boilers are generally used in closed systems, so Laars bases the water flow data on temperature rise (difference between boiler inlet and outlet temperature.) Water heaters are used in open systems, with new water constantly being introduced to the system. This brings a constant supply of new minerals into the system, as well. Minerals can cause scale to form on the inside surfaces of water heater systems (heaters, tanks, pipes, valves, and other components). Laars uses the water-tube design to its advantage by basing the water flow data on water hardness, to assist in

minimizing mineral buildup in the heater's waterways.

4.B. Boiler Water Flow and Headloss Data

The water flow and headloss data shown in Table 15 is based on full input of the boiler. The boiler has a 20:1 turndown, meaning it modulates from 5% to 100% of full input. Table 16 shows the water flow required at the the boiler's minimum input, and this is the minimum water flow allowed through the boiler. Running in this condition is very rare, and if the system requires this minimum water flow, the water flow switch may need to be adjusted or replaced. Contact the factory if you have such a system.

25°F

30°F

35°F

40°F

1600

122

19.4

100

14.0

10.0

8.0

2000

150

30.0

128

24.5

109

17.1

13.6

2500

190

34.0

158

24.6

136

17.6

119

13.6

3000

226

47.0

190

34.2

164

25.8

142

18.9

3500

266

41.0

222

31.6

190

23.6

166

18.6

4000

300

48.0

255

38.2

218

28.5

190

22.5

1600

462

5.9

379

4.3

329

3.0

288

2.4

2000

568

9.1

485

7.5

413

5.2

360

4.1

2500

719

10.4

598

7.5

515

5.4

451

4.1

3000

856

14.3

719

10.4

621

7.9

538

5.8

3500

1007

12.5

840

9.6

719

7.2

628

5.7

4000

1136

14.6

965

11.6

825

8.7

719

6.9

SECTION 4 Water Flow and Headloss Data

4.A. General Water Flow Information

minimizing mineral buildup in the heater's waterways.

4.B. Boiler Water Flow and Headloss Data

Model

25°F

30°F

35°F

40°F

Water

Flow

(gpm)

Headloss

* (ft)

Water

Flow

(gpm)

Headloss

* (ft)

Water

Flow

(gpm)

Headloss

* (ft)

Water

Flow

(gpm)

Headloss

* (ft)

1600

122

19.4

100

14.0

10.0

8.0

2000

150

30.0

128

24.5

109

17.1

13.6

2500

190

34.0

158

24.6

136

17.6

119

13.6

3000

226

47.0

190

34.2

164

25.8

142

18.9

3500

266

41.0

222

31.6

190

23.6

166

18.6

4000

300

48.0

255

38.2

218

28.5

190

22.5

*Headloss is for boiler only (no piping)

Model

14°F 17°F 19°F 22°F

Water

Flow (l/m)

Headloss

* (m)

Water

Flow (l/m)

Headloss

* (m)

Water

Flow (l/m)

Headloss

* (m)

Water

Flow (l/m)

Headloss

* (m)

1600

462

5.9

379

4.3

329

3.0

288

2.4

2000

568

9.1

485

7.5

413

5.2

360

4.1

2500

719

10.4

598

7.5

515

5.4

451

4.1

3000

856

14.3

719

10.4

621

7.9

538

5.8

3500

1007

12.5

840

9.6

719

7.2

628

5.7

4000

1136

14.6

965

11.6

825

8.7

719

6.9

*Headloss is for boiler only (no piping)

Table 15. Boiler Water Flow and Headloss

Model

Water Flow

1600

2000

2500

3000

3500

4000

SECTION 4 Water Flow and Headloss Data

LAARS Heating Systems

4.A General Water Flow Information

This appliance is a water-tube design that requires

water ow for operation. Boilers are generally used in closed systems, so Laars bases the water ow data on temperature rise (di󰀨erence between boiler inlet and

outlet temperature.) Water heaters are used in open systems, with new water constantly being introduced to the system. This brings a constant supply of new minerals into the system, as well. Minerals can cause scale to form on the inside surfaces of water heater systems (heaters, tanks, pipes, valves, and other components). Laars uses the water-tube design to

its advantage by basing the water ow data on water

hardness, to assist in minimizing mineral buildup in the heater’s waterways.

Model

*Headloss is for boiler only (no piping)

Model

Water

Flow

(gpm)

Water

Flow (l/m)

Headloss

* (ft)

14°F 17°F 19°F 22°F

Headloss

* (m)

Water

Flow

(gpm)

Water

Flow (l/m)

*Headloss is for boiler only (no piping)

Headloss

* (ft)

Headloss

* (m)

4.B Boiler Water Flow & Headloss Data

The water ow and headloss data shown in Table 14 is

based on full input of the boiler. The boiler has a 20:1 turndown, meaning it modulates from 5% to 100% of

full input. Table 15 shows the water ow required at

the the boiler’s minimum input, and this is the minimum

water ow allowed through the boiler. Running in this

condition is very rare, and if the system requires this

minimum water ow, the water ow switch may need

to be adjusted or replaced. Contact the factory if you have such a system.

Water

Flow

(gpm)

Headloss

* (ft)

Water

Flow

(gpm)

Headloss

* (ft)

Water

Flow (l/m)

Headloss

* (m)

Water

Flow (l/m)

Headloss

* (m)

Table 14. Boiler Water Flow and Headloss

(gpm)

(l/m)

Table 15. Minimum Allowable Water Flow Rates

HTD

Table 16. Minimum Boiler Water Flow

4.C. Water Heater Water Flow and Headloss Data

Water flow and headloss for water heaters is based on the water's hardness, to help minimize scale (mineral) buildup inside the heater's water tubes.

Table 17 shows water flow and headloss based on the hardness of the system's water. Temperature rise is shown for information and testing/troubleshooting purposes.

1600

152

31.0

177

41.0

2000

152

33.0

177

43.9

2500

190

33.7

220

46.0

3000

190

36.0

220

46.0

3500

222

30.6

266

40.6

4000

224

30.0

266

41.2

1600

575

9.4

670

12.5

2000

575

10.1

670

13.4

2500

719

10.3

833

14.0

3000

719

11.0

833

14.0

3500

840

9.3

1007

12.4

4000

848

9.1

1007

12.6

4.C Water Heater Water Flow and Headloss Data

Water ow and headloss for water heaters is based on

the water’s hardness, to help minimize scale (mineral) buildup inside the heater’s water tubes. Table 16

shows water ow and headloss based on the hardness

of the system’s water. Temperature rise is shown for information and testing/troubleshooting purposes.

1-10 Grains Per Gallon Hardness 11-15 Grains Per Gallon Hardness

Model

Flow Rate

(gpm)

Headloss*

(ft)

Temp Rise

(°F)

Flow Rate

(gpm)

Headloss*

(ft)

Page 23

Temp Rise

(°F)

*Headloss is for heater only (no piping)

1-10 Grains Per Gallon Hardness 11-15 Grains Per Gallon Hardness

Model

Flow Rate

(l/m)

Headloss*

(m)

*Headloss is for heater only (no piping)

Table 16. Water Heater Water Flow and Headloss Data

Temp Rise

(°C)

Flow Rate

(l/m)

Headloss*

(m)

Temp Rise

(°C)

Page 24

WARNING

SECTION 5 Piping

5.A Boiler Water Piping

LAARS Heating Systems

5.A.1 Boiler Water Connections

NOTE: This unit must be installed in a closed

pressure system with a minimum of 12 psi (82.7 kPa)

static pressure at the boiler.

The water piping should be supported by suitable

hangers or oor stands. Do not support the piping with

this unit. The hangers used should allow for expansion and contraction of pipe. Rigid hangers may transmit noise through the system resulting from the piping sliding in the hangers. We recommend that padding be used when rigid hangers are installed. Maintain 1” (2.5 cm) clearance to combustibles for all hot water pipes.

Suggested piping diagrams are shown in Figure 8 through Figure 11. These diagrams are meant only as guides. Components required by local codes must be properly installed.

Thisunit’se󰀩ciencyishigherwithlowerreturn

water temperatures. Therefore, to get the best low return temperature with multiple boilers, pipe as shown in Figure 10 and Figure 11 on page 28.

Pipe the discharge of the relief valve (full size) to a drain or in a manner to prevent injury in the event of pressure relief. Install an air purger, air vent, expansion tank,

hydronic ow check valve in the system supply loop,

and any other devices required by local codes. The

minimum ll pressure must be 12 psig (82.7 kPa). Install shuto󰀨 valves where required by code.

5.A.2 Cold Water Make-Up

5.A.3 Freeze Protection

If installed indoors, and there is an event such as a power outage, interruption of gas supply, failure of system components, activation of safety devices, etc.,

this may prevent a boiler from ring. Any time a boiler is subjected to freezing conditions, and the boiler

isnotabletore,and/orthewaterisnotableto

circulate, there is a risk of freezing in the boiler or in the pipes in the system. When water freezes,

it expands. This may result in bursting of pipes, or damage to the boiler, and this could result in leaking or ooding conditions.

Do not use automotive antifreeze. To help prevent freezing, The manufacturer recommends the use of inhibited glycol concentrations between 20% and 35% glycol. Typically, this concentration will serve as burst protection for temperatures down to approximately

-5°F (-20°C). If temperatures are expected to be lower than -5°F (-20°C), glycol concentrations up to 50% can be used. When concentrations greater than 35%

areused,waterowratesmustbeincreasedto

maintain the desired temperature rise through the boiler.

1. Connect the cold water supply to the inlet

connection of an automatic ll valve.

2. Install a suitable back ow preventer between the automatic ll valve and the cold water supply.

3. Install shut o󰀨 valves where required.

In some installations, a hot water heating boiler is connected to heating coils located in an air handling unit where the coils may be exposed to refrigerated air circulation. In these cases, the boiler piping system must

be equipped with ow control valves or other automatic

means to prevent gravity circulation of the boiler water during the cooling cycle.

A boiler installed above radiation level, or as required by the authority having jurisdiction, must be provided with a

low water cuto󰀨 device either as a part of the boiler or at

the time of boiler installation.

Glycol must not be used in domestic hot water

applications. Refer to 5.B.4 on page 30 for

instructions on freeze protection for units (domestic

hot water).

Di󰀨erent glycol products may provide varying degrees of

protection. Glycol products must be maintained properly

in a heating system, or they may become ine󰀨ective. Consult the glycol specications, or the glycol manufacturer, for information about specic products,

maintenance of solutions, and set up according to your particular conditions.

The following manufacturers o󰀨er glycols, inhibitors,

and anti foamants that are suitable for use in the unit. Please refer to the manufacturers instructions for proper selection and application.

• Sentinel Performance Solutions Group

HTD

• Hercules Chemical Company

• Dow Chemical Company

The boiler control o󰀨ers some assistance with freeze

protection, as long as the boiler is energized, and able

to re.

1. If the outlet sensor detects less than 45°F, the

control energizes the boiler pump.

2. If the outlet sensor detects less than 35°F, the

control will re at low rate.

3. Once in freeze protect mode, the boiler will remain in

that state until the outlet sensor detects greater than 50°F.

Space heating zone circuits

Page 25

5.A.4 Suggested Boiler Piping Schematics

This boiler is a high e󰀩ciency appliance. Boiler e󰀩ciency can be maximized by using piping and distribution congurations that return the lowest

temperature possible to the boiler, while still meeting the needs of the system.

Figure 8 on page 25 through Figure 11 on page 28

show suggested piping congurations for boilers. These

diagrams are only meant as guides. All components or piping required by local code must be installed.

Low temp. radiant zone

Space heating zone circuit

Air vent

4 pipe dia. max.

System pump

Water feed controls

4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max.

Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met.

Figure 8. Boiler Piping — Single Boiler, Multiple Temperature Zones

Zoning with circulators

Page 26

Note This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met.

LAARS Heating Systems

Air vent

Expansion tank

4 pipe dia. max.

4 pipe Dia. Max

Low temp. radiant zone

Water feed controls

Indirect DHW tank

Low temp. radiant zone

Anti-scald mixing valve

Domestic hot water out

Cold water

Figure 9. Boiler Piping — Single Boiler with Low Temperature Zones and Indirect DHW Tank Indirect

tank directly o󰀨 of boiler

+ 114 hidden pages

Laars MGH3500, MGH1600, MGH2000, MGH4000, MGV1600 Installation And Operation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

T ABLE OF CONTENTS

SECTION 1 General Information

1.A Introduction

1.C Warranty

1.D Safety Notes

1.E Unit Overview

1.F Gas Train Components

1.G Venting Dimensions & Sizing

1.H Dimensions

1.I Unpacking and the Install Kit

1.J Locating the Unit

1.K Clearances

SECTION 2 Venting and Combustion Air

2.A General Venting Information

2.B Vent and Air Pipe Material

2.B.1 Venting Requirements Unique to Canada

2.C Vent and Air Pipe Sizing

2.C.1 Category lV Vent Sizes

2.C.2 Category II Vent Sizes

2.C.3 Common Venting

2.C.4 Common Vent Test

2.C.5 Combustion Air

2.C.5.a Combustion Air From Room

2.C.5.b Ducted Combustion Air

2.D.2 Side-wall Combustion Air Terminal

2.D.4 Vertical Combustion Air Terminal

2.D.3 Vertical Vent Terminal

2.E Outdoor Installation

SECTION 3 Gas supply and Piping

3.A Gas Supply and Piping

3.B Gas Pipe Sizing

SECTION 4 Water Flow and Headloss Data

4.A General Water Flow Information

4.B Boiler Water Flow & Headloss Data

4.C Water Heater Water Flow and Headloss Data

SECTION 5 Piping

5.A Boiler Water Piping

5.A.1 Boiler Water Connections

5.A.2 Cold Water Make-Up

5.A.3 Freeze Protection

5.A.4 Suggested Boiler Piping Schematics