LAARS Mighty Therm LO-NOx PW User Manual

Installation and Operation Instructions Document 2140A
Installation and Operation Instructions for
Mighty Therm Lo-NOx
Hydronic Boilers and Volume Water Heaters Models PH and PW Sizes 500-1825
These instructions are to be stored in the pocket provided on the boiler.
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler installation and maintenance. Improper installation and/or operation could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or death. Improper installation and/or operation will void the warranty.
W ARNING
If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use any phone in your building.
• Immediately call your gas supplier from a nearby phone. Follow the gas supplier's instructions.
• If you cannot reach your gas supplier, call the fire department.
Installation and service must be performed by a qualified installer, service agency, or gas supplier.
H0256700A
Page 2
LAARS HEATING SYSTEMS
TABLE OF CONTENTS
SECTION 1. General Information
1.1 Introduction................................................... 3
1.2 Heater Identification...................................... 3
1.3 General Flow Requirement........................... 3
SECTION 2. Installation
2.1 Heater Placement......................................... 4
2.2 Installation of Indoor Heaters ........................ 4
2.2.1 Combustion Air Supply..................................4
2.2.1.a Conventional Ventilation ...............................4
2.2.1.b Forced-Air V entilation ................................... 5
2.2.2 Venting..........................................................5
2.2.3 Removal of Existing Heater .......................... 6
2.3 Installation of Outdoor Heaters ..................... 6
2.4 Gas Supply and Piping ................................. 6
2.5 Electrical Wiring............................................7
SECTION 3. Water Piping Instruction
3.1 General Piping Practice ................................ 8
3.2 Heating Boiler (PH Model) ............................ 8
3.2.1 Variable Water Flow System......................... 8
3.2.2 System Pressure Requirements ...................8
3.2.3 Hot/Chilled Water Systems...........................8
3.2.4 Combined Sp ace Heating/Potable
Water Heating Systems................................ 9
3.2.5 Piping System Requirements...................... 10
3.2.6 Filling the System ....................................... 10
3.3 Water Heater (PW Model) .......................... 10
3.3.1 Water Chemistry.........................................10
3.3.2 Piping System Requirements...................... 11
3.3.3 Water Expansion ........................................ 11
3.3.4 Pump Requirements................................... 11
3.3.5 Water Pressure........................................... 13
3.3.6 Tank Installation..........................................14
3.3.7 Two-Temperature........................................ 14
SECTION 4. Operating Instructions
4.1 Controls - General ...................................... 15
4.1.1 Electronic Ignition Control ...........................15
4.1.2 Hot Surface Igniter......................................15
4.1.3 Combustion Air Pressure Switch.................15
4.1.4 Operating Controls...................................... 15
4.1.5 High Limit Control ....................................... 15
4.1.6 Flow Switch ................................................ 16
4.1.7 Low Water Cut Off...................................... 16
4.2 S tart-Up Requirement s ............................... 16
4.3 Normal Operating Sequence ...................... 17
4.4 Hi-Limit Checkout ....................................... 17
4.5 Start-Up Procedure..................................... 17
4.5.1 Lighting Instructions.................................... 18
4.5.2 To Turn Off Gas to Appliance...................... 18
4.6 Setting the Temperature Controls ............... 18
4.6.1 Hydronic Boilers.......................................... 18
4.6.2 Water Heaters ............................................ 18
SECTION 5. Maintenance
5.1 General Instructions.................................... 18
5.2 Combustion Air Blower ............................... 19
5.3 Heat Exchanger.......................................... 19
5.3.1 External Cleaning of Heat Exchanger .........19
5.3.2 Internal Cleaning of Heat Exchanger .......... 20
5.4 Gas and Electric Controls ........................... 20
5.5 Burner Removal and Cleaning.................... 20
SECTION 6. Troubleshooting
6.1 Sequence of Operation............................... 20
6.2 Electrical Components................................21
6.2.1 General Troubleshooting ............................ 21
6.2.2 Electrical Troubleshooting...........................21
6.3 Mechanical Components ............................ 23
6.3.1 Pressure Relief Valves Leaking
Intermittently or S teadily..............................23
6.3.2 Heater is Pounding, Knocking or
Emitting Steam from Relief Valves..............23
6.3.3 Soot in Flueways or in Tubes, or Noxious
Fumes Indicative of Bad Combustion ......... 23
6.3.4 Water Dripping in Firebox ........................... 23
SECTION 7. Parts Descriptions and Order Numbers
7.1 Jack and Combustion Chamber
Components ............................................... 25
7.2 Water System ............................................. 25
7.3 Electrical Components................................26
7.4 Gas Train....................................................26
7.5 Burner Tray.................................................26
7.6 Outdoor Jacket ...........................................33
Mighty Therm Lo-NOx
Page 3
SECTION 1. General Information
1.1 Introduction
This manual provides information for the installation and operation of Laars gas-fired hydronic boilers and water heaters. It is strongly recommended that all application and installation procedures be reviewed completely before proceeding with the installation. Consult the Laars factory, or local factory representative with any problems or questions regarding this equipment. Experience has shown that most problems are caused by improper installation, not system design.
Some accessory items are shipped in separate packages. Verify receipt of all items listed on the package slip. Inspect everything for possible damage upon delivery, and inform the carrier of any shortages or impairments. Any such claims should be filed with the carrier. The carrier, not the shipper, is responsible for shortages and damage to the shipment whether visible or concealed.
IMPORTANT WARNING
The Laars heaters must be installed in accordance with the procedures outlined in this manual. The warranty does not apply to boilers not installed or operated in accordance with these procedures. Consult local building and safety codes
before proceeding with work. The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code; ANSI Z223.1, National Electrical Code ANSI/NFPA 70 and/ or in Canada CAN 1 -13149 requirements.
When required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers safety codes for controls and safety devices for automatically fired boilers No. CSD-1, and in Canada CGA 3.3. Any modification to the boiler, its gas controls, gas orifices, wiring or draft diverter may void the Laars warranty. If field conditions require such modifications, consult factory.
1.2 Heater Identification
Consult rating plate on the boiler. The following example simplifies the boiler identification.
1 2 3456
PH 1200 I N 21 K
(1) Basic heater model (see descriptions below). (2) Input rate x 1000 BTU/h. (3) Indoor (I) or Outdoor (E) installation. (4) Gas type: Natural (N). (5) Ignition system: (21) Hot surface (proved igniter)
ignition system.
(6) Firing modes:
On/Off (C) 2-stage (K)
Figure 1. Boiler Configuration.
Model PH hydronic heating boilers come with integrally mount pumps. Pumps are sized for pressure drop through the heat exchanger only.
Model PW water heaters for use with separate storage tank come with integrally mount pumps. Pumps are sized for pressure drop through the heat exchanger plus 30 feet (9.1m) of pipes and normal fitting.
Laars heaters are available in two configurations: an indoor version and an outdoor version. Both are available from the factory (see Figure 1).
1.3 General Water Flow Requirement
For proper operation, all low volume hot water heaters must have continuous flow through the heat exchanger when firing. The system pump must be capable of developing sufficient pressure to overcome the resistance of the heater plus the entire circulating system at the designed flow rate.
Page 4
LAARS HEATING SYSTEMS
SECTION 2. Installation
2.1 Heater Placement
The heater must be placed to provide specific clearances on all sides for maintenance and inspections. There must also be minimum distances maintained from combustible surfaces. These clearances also apply to noncombustible materials because the heater requires air circulation for proper operation.
The heater should be mounted on a level surface. An integral base for an installation on combustible flooring is provided as standard equipment on all models.
Do not install a heater on carpeting.
Under the national Fuel Gas Code, ANSI Z223.1, it is permissible to place the heater on floors other than noncombustible when the installation complies with the American Insurance Code. Figures 2, 3, and 4 show common installation on combustible flooring.
Clearance Indoor Outdoor
from in. mm in. mm
Top 30 762 unobstructed
Water Conn. side 12* 305 24 610
Pump side 6* 152 24 610
Front Alcove* unobstructed Rear 8 203 24 610
Vent pipe** 6 152 - - -
Hot water pipes per code per code
* Water connection and pump side clearances of 24" (610mm)
and front clearances of 48" (1219mm) will allow easier service access.
** One inch using type B vent (refer to Manufacturer's Instructions).
Table 1. Minimum Heater Clearances From
Adjacent Surfaces.
2.2 Installation of Indoor Heaters
Locate the heater to provide adequate clearance for inspection and service on all sides. See Table 1.
Install indoor heaters on a waterproof floor with an adequate floor drain and a 6" (152mm) minimum curb on all four sides to protect the building if heater repairs are required. The manufacturer will not be
held liable for any water damage in connection with this heater.
2.2.1 Combustion Air Supply
The heater location must provide sufficient air supply for proper combustion and ventilation of the surrounding area as outlined in the latest edition of ANSI standard Z223.1, and any local codes that may be applicable. Inadequate combustion air supply may result in incomplete combustion, sooting of the heat exchanger, and unsafe operation of the boiler.
2.2.1.a Conventional Ventilation
In the United States, the most common requirements specify that the space shall communicate with the outdoors in accordance with method 1 or 2, which follow. 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 inches (300 mm) of the top and one commencing within 12 inches (300 mm) 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
Figure 2. Typical Heater Installation on Concrete Slab.
Figure 3. Typical Heater Installation on Roof Using
Raised Platform (wood).
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/h (550 square mm/kW) of the 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/h (1100 square mm/Kw) of the total input rating of all equipment in the enclosure.
Mighty Therm Lo-NOx
Figure 4. Typical Heater Installation on Concrete Slab.
Heater Each Opening*
Size square inches square cm
500 125 807 715 179 1155
999 250 1613 1010 253 1632 1200 300 1936 1430 358 2310 1825 457 2950
* Net Free Area. Check with louver manufacturers for net free area of louvers.
Correct for screen resistance to the net free area if a screen is installed. Check all local codes applicable to combustion air.
Area indicated is for and one at the ceiling, so the total net free area could be double the figures indicated. For special conditions refer to the latest edition of ANSI Z223.1.
Consult factory if openings do not communicate directly through the walls with the outdoors.
Table 2. Minimum Recommended Air Supply to Heater,
one of two openings: one at floor level
Per Method 1.
See Table 2 for recommended opening sizes pertaining to Method 1.
Method 2: One permanent opening, commencing
within 12 inches (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/h (700 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 confined space.
Other methods of introducing combustion and ventilation air are acceptable, provided they conform to the requirements in the applicable codes.
In Canada, consult local building and safety codes or, in absence of such requirements, follow CAN/CGA B149.
An improperly ventilated equipment room can get excessively hot and cause accelerated deterioration of controls and electrical components.
In Canada, Table 2 does not apply. Consult local building codes or, in the absence of such requirements, follow CGA requirements and/or CAN/CGA B-149 standard.
Page 5
2.2.1.b Forced-Air Ventilation
In the United States: any equipment which exhausts air from the heater room can deplete the combustion air supply or reverse the natural draft action of the venting system. This could cause flue products to accumulate in the heater room. Additional air must be supplied to compensate for such exhaust. The information in Table 2 is not applicable in installations where exhaust fans or blowers of any type are used. Such installations must be designed by qualified engineers.
In Canada: follow Canadian standard, CAN/ CGA B-149 or local codes.
If a blower or fan is used to supply air to the heater room, the installer should make sure it does not create drafts which could cause nuisance shutdowns. If a blower is necessary to provide adequate combustion air to the heater, a suitable switch or interlock must be wired into the heater control circuit to prevent the heater from firing unless the blower is operating.
The heater must be completely isolated and protected from any source of corrosive chemical fumes such as trichlorethylene, perchloroethylene, chlorine, etc.
2.2.2 Venting
IMPORTANT NOTE: Mighty Therm LO-NOx units are not fan-assisted. They are natural draft appliances. The fans on the Mighty Therm LO-NOx units are for combustion assistance only. Venting systems must be sized as natural draft, atmospheric vent, and not as fan-assisted vent systems.
1. Laars heaters have built-in draft diverters for
natural draft operation and must not be
connected to any portion of a mechanical draft
system under positive pressure. The flue outlet
must be connected to a clear, unobstructed vent
of adequate capacity ending above the highest
point of the building with an approved vent cap.
The venting system should be installed
according to Category 1, Natural Draft per the
latest edition of ANSI Z223.1 and/or, in Canada,
CAN/CGA B-149 and any local codes having
jurisdiction.
2. Do not weld or fasten the vent pipe to the boiler
drafthood. The weight of the stack must not rest
on the heater.
The drafthood and heater top must be easily removable for normal heater service and inspection. IMPORTANT NOTE: Do not use sheet metal screws at the snap lock joints of Type B gas vents.
3. Avoid using long horizontal runs of the vent pipe, and too many 90° elbows, reductions or restrictions. Horizontal runs should have at least a 1/4" (6mm) rise per foot in the direction of flow. A vent connector should be supported for the design and weight of the material used to maintain clearances and prevent physical damage and separation of joints.
Page 6
LAARS HEATING SYSTEMS
4. Avoid terminating heater vents near air conditioning or air supply fans. The fans can pick up exhausted flue products from the heater and return them inside the building creating a possible health hazard. A minimum of 4 feet (1.2m) horizontal distance must be maintained from electrical meters, gas meters, and relief equipment.
5. Always use double-wall or insulated vent pipe (Type B or equivalent). In cold weather, uninsulated outside vents can chill the rising flue products blocking the natural draft action of the venting systems. This can create a health hazard by spilling flue products in the heater room.
6. Avoid oversized vent piping or extremely long runs of pipe which may cause excessive cooling and condensation. Rule of Thumb: the total length of the vent, including the connector and any offset, should not exceed 15 feet (4.6m) for every inch (25mm) of vent diameter. Longer total lengths shown in venting tables are based on maximum capacity, not condensation factors.
7. When the installation of a draft fan is necessary in connecting a venting system to a Laars heater, the installation should be engineered by competent personnel following good engineering practices. The draft fan supplier should be consulted for correct size. The installation should be in accordance with the latest edition of ANSI Z223.1 and/or, in Canada, CAN/CGA B­149 and any local codes having jurisdiction. When a draft fan is installed, a suitable draft switch must be wired into the boiler control circuit at terminal designated "Field Interlock" to prevent firing of the boiler unless a positive draft has been established.
2.2.3 Removal of Existing Heater
At the time of removal of an existing heater, the
following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch and determine that there is no blockage or restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows, as well as all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.
5. Test for spillage at the draft hood relief opening (if the appliance is equipped with a drafthood), after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return door, windows, exhaust fans, fireplace dampers and any other gas-burning appliances to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1. When 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 G in the National Fuel Gas Code, ANSI Z223.1.
In Canada, at the time the boiler is removed from
common venting system, the common venting system should be resized so the installation conforms to CAN/ CGA B149.1 or .2.
2.3 Installation of Outdoor Heaters
(Not available in Canada)
1. Locate the heater to provide the clearances as listed in Table 1, “Minimum Heater Clearances.”
2. Do not place the heater in an enclosure or wall recess. Avoid locations where wind deflection off structures might cause downdraft. When such wind conditions are possible, place the heater at least 3 feet (0.9m) from the structures.
3. Never install the heater under any kind of roof overhang. Do not place the heater below or adjacent to any doors, windows, louvers, grills, etc., which connect in any way with an inhabited area of a building. This includes other structures such as garages or utility rooms (see Figure 5).
4. Although the Laars models are CSA designed certified for outdoor installations, such installations are not recommended in areas where the danger of freezing exists unless proper precautions are taken for freeze protection.
Outdoor installations are not recommended in areas where the danger of snow blockage exists.
Mighty Therm Lo-NOx
Figure 5. Incorrect Outdoor Installation.
The heater should be located a safe distance from Propane gas storage and filling equipment. Consult local codes and fire protection authorities for advice on specific installation restrictions.
2.4 Gas Supply and Piping
Review the following instructions before
proceeding with the installation.
1. Verify that the heater is fitted for the proper type
of gas by checking the rating plate. Laars heaters
are normally equipped to operate below a
2000 foot (609.6m) altitude. Heaters equipped to
operate at higher altitudes have appropriate
stickers or tags attached, also printed
information on rating plate.
2. Use the figures in Table 3 to provide adequate
gas piping from the gas meter to the heater.
Distance from Gas Meter or Last Stage Regulator
Size 0-100' 100-200' 200-300'
500 1½" 2" 2" 715 2" 2" 2½"
999 2" 2½" 3" 1010 2" 2½" 3" 1200 2½" 3" 3" 1430 2½" 3" 3"
1825 2½" 3" 3½"
NOTE: These figures are for Natural Gas (.65 Sp. Gr.), and are based on 1/2" water column pressure drop. Check supply pressure with a manometer, and local code requirements for variations. An average number of tees and elbows have been taken into account.
Table 3. Gas Piping Sizes.
3. A sediment trap (drip leg) must be provided ahead of the gas controls (see Figure 6). A manual gas shutoff valve must also be provided for service convenience and safety. A cap must be provided for cleaning purposes. Check the local codes.
Page 7
Figure 6. Sediment Trap Installation.
4. The heater 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 1/2 psig. The heater must be isolated from the gas supply piping system by closing its individual manual gas shutoff valve during any pressure testing of the piping system at test pressures equal to or less than 1/2 psig.
5. Provide gas supply pressure to the heater as follows:
Natural
Gas Max. (inches water column) 10 Min. (inches water column) 6.5
NOTE: the heater and all other gas appliances sharing the boiler gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure. Low gas pressure could be an indication of an undersized gas meter and /or obstructed gas supply line.
6. The correct burner manifold gas pressure is stamped on the rating plate. The regulator is preset at the factory and normally requires no further adjustment.
7. The gas manifold and control assembly is factory tested and conforms to the safe lighting and other performance criteria specified in the latest editions of ANSI Z21.13 and CGA 3.3 Low Pressure Boiler Standard.
8. Before operating the heater, test the complete gas supply system and all connections for leaks using a soap solution. Do not use raw flame.
Caution
Since some leak test solutions (including soap and water) may cause corrosion or stress cracking, the piping must be rinsed with water after testing, unless it has been determined that the leak test solution is noncorrosive.
Page 8
2.5 Electrical Wiring
WARNING
The heater must be electrically grounded in accordance with the most recent edition of the National Electrical Code, ANSI/NFPA 70. In Canada, all electrical wiring to the boiler should be in accordance with the latest edition of CSA C22.1 Canadian Electrical Code, Part 1. Do not rely on the gas or water piping to ground the metal parts of the boiler. Plastic pipe or dielectric unions often isolate the heater electrically. Service and maintenance personnel who work on or around the heater may be standing on wet floors and could be electrocuted by an ungrounded heater.
Wiring diagrams are included in the information
packet provided with each unit.
1. All Laars heaters need 115V 60Hz supply voltage unless specifically ordered otherwise. Check heater wiring and pump for correct voltage, frequency and phase. Consult the National Electrical Code or the Canadian Electrical Code regarding branch circuit requirements for equipment with these motors.
2. The heater should be wired exactly as shown in the wiring diagram.
3. All field installed electrical safety devices and all field installed controllers (valve end switches, draft switches, relays, timers) can be connected to the heater control to the terminals shown in the wiring diagram designated “Field Interlock.”
4. Where the heater is installed with a draft fan refer to the fan manufacturer's wiring diagram. The draft switch should be wired across the field interlock terminals in the heater control panel.
SECTION 3. Water Piping Instruction
3.1 General Piping Practice
1. Be sure to provide valves at the inlet and outlet of the heater so it can be readily isolated for service. A butterfly, ball type or similar type of valve is recommended.
2. The pressure relief valve installed in the tapped opening provided in the outlet header (see Figure
7), must be piped, but not fastened, to a drain or floor sink. The drain pipe must be the same size as the valve outlet and must pitch downward from the valve. Pay special attention to relief valve settings in installations where the heater is located on the ground floor of a tall building, or where the operating temperature of the heater is
LAARS HEATING SYSTEMS
Figure 7. Pressure Relief Valve Location.
above 210°F (99°C). In both instances, the static pressure of the system is elevated and could cause the relief valve to leak and bring considerable raw water into the system.
3. Where no special setting of the relief valve is ordered, the factory will furnish a 75 psi setting for heating boilers (PH models), and 125 psi for water heaters (PW models).
4. The pressure relief valve lever must be tripped at least once a year to insure that waterways are clean. When manually operating lever, water will discharge through the drain line. Precautions must be taken to avoid contact with hot water and water damage.
3.2 Heating Boiler (PH Model)
3.2.1 Variable Water Flow System
Heating systems using zone valves, zone pumps
or 3-way valves can experience reduced water flow through the boiler. This can result in an excessive water temperature rise and unstable boiler operation. If the system water flow is variable, the boiler's temperature sensor must be installed in the outlet water. Laars recommends primary-secondary pumping for all variable flow systems (see Figure 9). Primary­secondary pumping is mandatory for variable flow systems. The boiler pump in a primary-secondary system maintains constant flow through the boiler even though the system flow is variable. In a primary­secondary system the pressure drop of the boiler is not added to the system.
3.2.2 System Pressure Requirements
The boilers are designed to operate on closed,
pressurized systems. Maintain a minimum of 12 psi (81.8 kPa) on the system where boiler supply water temperature is 200°F (93°C) or less. If higher temperatures are required, the minimum system
Mighty Therm Lo-NOx
Page 9
pressure should be at least 15 psi (102.2 kPa) above the water vapor pressure corresponding to the elevated water temperature.
Heating boilers are not suitable for open systems unless the supply water temperatures are kept below 180°F (82°C), and a minimum of 5 psi (34.1 kPa) static head is maintained at the boiler.
3.2.3 Hot/Chilled Water Systems
When a boiler is connected to an air conditioning system where the same water is used for heating and cooling, you must prevent chilled water from entering the boiler When changing such a system from cooling to heating, allow the chilled water to circulate through the building, after the chiller has been turned off, for a period long enough for the water to warm up to at least 105°F (41°C) before the water flows into the boiler. It is equally important to prevent hot water from entering the chiller. The system shown in Figure 8 is suggested to make sure the system water is neither too hot nor too cold when a changeover takes place. When a boiler is connected to heating coils located in air handling units (where they may be exposed to refrigerated air circulation), install a flow control valve or other automatic means to prevent gravity circulation of chilled water through the boiler. Chilled water in the boiler will create condensate on the boiler tubes. Boilers installed in violation of the
foregoing may void the warranty.
3.2.4 Combined Space Heating/Potable Water Heating Systems
When using the Laars boiler as a source of heat for a combined space heating/potable water heating system, be sure to follow the instructions of the space heating system.
Suggested Wiring Diagram For
Tempering System Water at
Changeover From Heating To Cooling
DPDT Manual or Automatic Change-Over Switch DPDT - Set at Change-Over Temperature
115/24V Transformer
From Chiller
3-Way Valve No. 1 Change-Over (Heating and Cooling)
Valve Motors 2-Pos 3-Wire - 24V
From Boiler
3-Way Valve No. 2 To By-Pass Both Heater and Chiller
Clock Timer Auto-Resetting Set at 15 Minute SPDT
To Boiler and Chiller
By-Pass
From System
To System
WARNING: This drawing shows suggested piping configuration and valving. Check with local codes and ordinances for additional requirements.
12"
Max.
LEGEND:
Thermometer Temperature
Sensor Globe Valve Check V alve Pressure Reducing Valve
w/Fast Fill Bypass
Purge Valve
Expansion T ank with Air Scoop and Auto Air Vent
3-Wa y Valve Valve Pump
12"
Max.
Figure 8. Boiler-Chiller Installation.
Boiler Circulation
Pump
Cold Water
Make-Up
System Pump
12"
12"
Max.
Boiler circuit piping must be equal to or larger than boiler water connection size.
Boiler circulation pump sized for flow through boiler.
Dotted devices indicate alternate locations.
Max.
Figure 9. Primary-Secondary Plumbing.
Page 10
LAARS HEATING SYSTEMS
Do not use water piping, fittings, valves, pumps, and any other components which are not compatible with potable water.
Do not connect the heater, which will be used to supply potable water, to any heating system or components previously used with a nonpotable water heating system.
Do not add boiler treatment or any chemicals to the heating system piping, since the piping contains water for potable use.
Do not use solder containing lead in the potable water lines.
Some jurisdictions may require a backflow preventer in the cold water line. In such cases, pressure relief valve may discharge water due to expansion. An expansion tank approved for potable water will eliminate this condition. Follow the manufacturer's instructions for installation of the expansion tank.
3.2.5 Piping System Requirements
1. Provide a boiler installed above radiation level
with a low water cutoff device either as part of
the boiler or at the time of boiler installation.
2. Install manual and/or automatic bleeding devices
at high points in the system to eliminate air.
Install a correctly sized expansion or
compression tank with suitable air charger and
tank drainer, as appropriate.
3. Support the weight of all water and gas piping by
suitable hangers or floor stands.
4. Check piping diagrams with local applicable
plumbing, heating and building safety codes.
3.2.6 Filling The System
1. Ensure the system is fully connected. Close all
bleeding devices and open make-up water valve.
Allow system to fill slowly.
2. If make-up water pump is employed, adjust
pressure switch on pumping system to provide a
minimum of 12 psi (81.8 kPa) at the highest
point in the heating loop.
3. If a water pressure regulator is provided on the
make-up water line, adjust the pressure regulator
to provide at least 12 psi (81.8 kPa) at the
highest point in the heating loop.
4. Open bleeding devices on all radiation units at
the high points in the piping throughout the
system, unless automatic air bleeders are
provided at such points.
5. Run system circulating pump and boiler pump
for a minimum of 30 minutes with the boiler gas
shut off.
6. Open all strainers in the circulating system,
check flow switch operation, and check for
debris.
7. Recheck all air bleeders as described in Step 4
above.
8. Check liquid level in expansion tank. With the system full of water and under normal operating pressure, the level of water in the expansion tank should not exceed 1/4 of the total, with the balance filled with air.
9. Start up boiler according to procedure described in Section 4. Operate the entire system, including the pump, boiler, and radiation units for one (1) hour.
10. Recheck the water level in the expansion tank. If the water level exceeds 1/4 of the volume of the expansion tank, open the tank drainer and drain to that level.
11. Shut down the entire system and vent all radiation units and high points in the system piping as described in Step 4 above.
12. Close make-up water valve and check strainer in pressure reducing valve for sediment or debris from the make-up water line. Reopen make-up water valve.
13. Check gauge for correct water pressure and also check water level in system. If the height indicated above the boiler insures that water is at the highest point in the circulating loop, then the system is ready for operation.
14. Within three (3) days of start-up, recheck all air bleeders and expansion tank as described in Steps 4 and 8 above.
3.3 Water Heater (PW Model)
3.3.1 Water Chemistry
Laars equipment is designed for use in a wide
variety of water conditions. The water velocity maintained in the heat exchanger tubes is kept high enough to prevent scaling from hard water and low enough to avoid corrosion from soft water. Ninety­five percent of the urban areas in the country have water that is compatible with this equipment, but in some areas a water supply will contain a large quantity of scaling chemicals or the water may be extremely soft and corrosive. In rare situations the water will contain both scaling chemicals and corrosive chemicals such as calcium or sodium chloride. These conditions may be the result of a nearby well or pumping station and the particular condition may not be characteristic of the entire city water system.
If an installer observes damage from these
conditions to any water handling equipment in the area, a factory representative should be contacted immediately for assistance in minimizing maintenance costs. If erosion is present, the pump impeller can be replaced to reduce water velocity. If scaling conditions are bad, tube cleaning maintenance schedules can be established to prevent tube burn-out and cracking. Neglecting the problem could mean serious damage to the heater and water system.
Scaling can be recognized as a layer deposited
Mighty Therm Lo-NOx
Page 11
on the inner walls of the tube which reduces the inner diameter of the tube. Scale can be any color or texture; smooth or rough, granular or amorphous. Signs of erosion are generally pitting, cavitation, ridges and “islands” on the inner walls of the tubes. Since this condition results from extremely soft water sources, or as a result of a water softening program, the internal copper surfaces will be extremely shiny. Other chemicals, such as chlorine or chlorides in the water, will cause dark surfaces of erosion.
In areas where the water supply is extremely corrosive, it is advisable to order the heater with cupro-nickel tubes in the exchanger.
Damage From Scaling, Corrosion, or Erosion is Not Covered by the Warranty.
3.3.2 Piping System Requirements
1. Check piping diagrams with local applicable
plumbing, heating and building safety codes.
2. All two-temperature systems using temperature
valves must have forced recirculation in the low
temperature building loop.
3. A check valve installed at the hot water inlet to
the tempering valve will prevent cold water from
being drawn in reverse through the tempering
valve into the hot water.
4. When installing a tempering valve, place at
bottom of antithermosyphon loop at least 24"
high to prevent excessive hot water from
entering mixed water supply. Bring the cold
water supply up from the floor to the valve (see
Figure 10).
The following suggestions may solve the
problem:
1. Replace the installed water pressure reducing valve with a suitable valve having a back flow port. These valves have a back flow port which allows water to flow backwards when the pressure in the system exceeds the pressure in the mains.
2. Install a check valve around the pressure reducing valve to permit reverse flow. This will allow the expanded water to back flow into the mains (see Figure 11).
Figure 11. Check Valve/Pressure Reducing Valve Installation.
3. Install an auxiliary small relief valve set at 25 psi less than the main relief valve. The valve must be piped to a drain and may require occasional cleaning. It will bleed off the expanded water and protect the main pressure relief valve from becoming fouled.
4. Install a properly sized expansion tank.
Figure 10. Tempering Valve Installation.
3.3.3 Water Expansion
When cold water is heated the water expands. If no water is being used during the heat-up period the expanded water will normally back up into the city mains.
A water pressure reducing valve installed in the incoming cold water line may act as a check valve and prevent the expanded water from moving backward. This will cause pressure to rise in the heater, which will be relieved by the pressure relief valve.
If the relief valve pops frequently a mineral deposit may build up on the valve seat, causing it to leak.
3.3.4 Pump Requirements
1. The factory provided pump on PW heaters are
sized to provide proper circulation through the heater and heater-to-tank circulation loop (see Figures 12, 13 and 14). If the heater-to-tank circulation loop does not contain more than 6 elbows and 30 feet of pipe, use pipe fittings in the loop no smaller than the following:
Model Pipe Size
500 through 715 2"
999 through 1825 2-1/2"
If the heater-to-tank circulating loop contains more than 6 elbows and 30 feet of pipe, use pipe or fittings in the loop no smaller than the following:
Model Pipe Size
500 through 715 2-1/2"
999 through 1825 3"
Loading...
+ 25 hidden pages