Lochinvar 45, 000 - 260, 000 Btu-hr User Manual

Installation & Service Manual

Models: 45,000 - 260,000 Btu/hr

This manual supplies information for the installation,
operation, and servicing of the appliance. It is strongly
recommended that this manual be reviewed completely
before proceeding with an installation. Perform steps in
the order given. Failure to comply could result in severe
personal injury, death, or substantial property damage.

 WARNING:

Save this manual for future reference.

SBR-I-S Rev A

2

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.

Contents

HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2

PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3-4

RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

THE SOLUTION --HOW IT WORKS . . . . . . . . . . . . . . . . . . . 6-8

1. DETERMINE BOILER LOCATION

Location of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . 10-12

2. VENTING

A Conventional Negative Draft Venting System . . . . . . . 13-14

Vertical Vent Termination Clearances . . . . . . . . . . . . . . . 15

Masonry Chimney Installation . . . . . . . . . . . . . . . . . . . . . 16

Inspection of a Masonry Chimney . . . . . . . . . . . . . . . 16

Automatic Vent Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3. GAS CONNECTIONS

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Manifold Pressure Adjustment Procedure . . . . . . . . 20

Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . 21

Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 22

4. WATER CONNECTIONS

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Water Flow Switch (if equipped) . . . . . . . . . . . . . . . . . . . 23

Low Water Cutoff (if equipped) . . . . . . . . . . . . . . . . . . . . 24

Typical Heating Boiler Installations . . . . . . . . . . . . . . . . . 24-25

Piping of the Boiler System . . . . . . . . . . . . . . . . . . . . . . . 25

Performance Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . . . . 27-28

Low Temperature Bypass Requirements . . . . . . . . . . . . . 28

Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Primary / Secondary Piping . . . . . . . . . . . . . . . . . . . . 29-31

Full System Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33

5. ELECTRICAL CONNECTIONS

Boiler Operating Temperature Control . . . . . . . . . . . . . . . 34

Room Thermostat or Remote Thermostat Connection . . 34

Auxiliary Device Connection to Terminal Strip . . . . . . . . . 34

Pump Wiring for a Heating Boiler . . . . . . . . . . . . . . . . . . 35

Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 35

Temperature Control Settings . . . . . . . . . . . . . . . . . . . . . 35

Maximum Set Point Determination . . . . . . . . . . . . . . . . . 36

Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . . . 38

Additional Temperature Controls . . . . . . . . . . . . . . . . . . . 38

Blocked Vent and Flame Roll-Out / Flame Interlock Switch . 39

6. STARTUP

Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Lighting Instructions for Spark Ignition Pilot Models (M9) . . . . 40

Safety Shutoff Test for Spark Ignition Pilot System . . . . . . 41

Intermittent Pilot Spark Ignition System (M9) . . . . . . . . . . . . 42

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

7. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 43-48

8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 49

9. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3

Installation & Service Manual

Please read before proceeding

NOTICE

This is a gas appliance and should be
installed by a licensed electrician and/or
certified gas supplier. Service must be
performed by a qualified service installer,
service agency or the gas supplier.

 WARNING

If the information in these instructions is
not followed exactly, a fire or explosion may
result causing property damage, personal
injury, or death.

This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present, unless the
installation is such to eliminate the probable
ignition of gasoline or flammable vapors.

What to do if you smell gas –

• Do not try to light any appliance.

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

• Immediately call your gas supplier from a
near by phone. Follow the gas supplier’s
instructions.

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

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

Warranty –

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

Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.

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

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

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

Checking equipment –

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

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

 WARNING

Improper installation, adjustment,
alteration, service or maintenance can result
in severe personal injury, death, or
substantial property damage. Refer to this
manual for assistance or additional
information, consult a qualified installer,
service agency or the gas supplier.

 Owner warning –

NOTE: Retain this manual for future reference.

The information contained in this manual is intended for use by
qualified professional installers, service technicians, or gas
suppliers. Consult your local expert for proper installation or

service procedures.

IMPORTANT

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

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

 WARNING

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

4

Installation & Service Manual

Please read before proceeding

 WARNING

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

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

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

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

Codes –

The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These regulations shall be carefully
followed in all cases. Authorities having jurisdiction shall be
consulted before installations are made. In the absence of such
requirements, the installation shall conform to the latest edition
of the National Fuel Gas Code, ANSI Z223.1. Where required by
the authority having jurisdiction, the installation must conform
to American Society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired Boilers,
ASME CSD-1. All boilers conform to the latest edition of the
ASME Boiler and Pressure Vessel Code, Section IV. Where
required by the authority having jurisdiction, the installation
must comply with the Canadian Association Code, CAN/CGA­B149.1 and/or B149.2 and/or local codes.

This appliance meets the safe lighting performance criteria with
the gas manifold and control assembly provided as specified in
the ANSI standards for gas-fired appliances, ANSI Z21.13 and
ANSI Z21.10.3.

5

Ratings

Notes:

1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.

2. Net I=B=R ratings are based on net installed radiation of
sufficient quantity for the requirements of the building and
nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.

3. Use only the vent materials and methods specified in the
Installation and Service Manual.

4. The Solution is orificed for operation up to 2000 feet
altitude. The ap pli ance will be derated 4% per 1000 feet
above 2000 feet el e va tion. Consult the factory for
installations above 2000 feet elevation.

5. Ratings have been confirmed by the Hydronics Institute,
Section of AHRI.

Maximum allowed working pressure is located on the rating plate.

NOTICE

Installation & Service Manual

Solution Boiler

I=B=R Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

Input
MBH

(Note 4)

Min Max

Gross

Output

MBH

(Note 1,5)

Net

I=B=R

Ratings

Water,

MBH

(Note 1,5)

CBN045 23 45 37 32

CBN075 38 75 62 54

CBN090 45 90 75 65

CBN135 68 135 112 97

CBN180 90 180 149 130

CBN215 108 215 178 155

CBN260 130 260 216 188

Other Specifications

Boiler Water

Content
Gallons

Water

Connections

Gas

Connections

Vent

Size

(Note 3)

0.87 1 1/2" 1/2" 4"

0.91 1 1/2" 1/2" 5"

0.91 1 1/2" 1/2" 5"

0.95 1 1/2" 1/2" 6"

0.99 1 1/2" 3/4" 7"

1.02 1 1/2" 3/4" 7"

1.06 2" 3/4" 8"

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

UP TO 2000 FT.

The Solution - How it works...

1. Control panel cover

The control panel cover provides access to the thermostat, ignition
module, and transformer.

2. Burner (not shown)

The burner is a cylindrical stainless steel tube used to regulate
burner flame.

3. Drain port

Location from which the heat exchanger can be drained.

4. Flue outlet

The flue outlet allows the connection of the vent pipe to the unit.

5. Gas connection

The gas pipe connection on this appliance is 1/2", or 3/4" NPT. To
deliver the correct amount of gas volume to the appliance it may
be necessary to have a larger gas line reduced at the appliance.
Please reference the National Fuel Gas Code charts for more
details.

6. Gas valve

The gas valve allows the proper amount of gas to pass into the
burner for combustion.

7. Heat exchanger

The heat exchanger allows system water to flow through specially
designed tubes for maximum heat transfer. The glass lined
headers and copper finned tubing are encased in a jacket that
contains the combustion process.

8. High limit sensor

Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting, it will break
the control circuit, shutting the appliance down.

9. Ignition module

The ignition module responds to a call for heat signal to provide
burner operation.

10. Junction box

The junction box contains the connection points for the line
voltage power and all pumps.

11. Performance loop

A pumped bypass provides constant flow through the heat
exchanger when the building system flow is reduced.

12. Performance Loop Pump

The pump ensures adequate flow to operate the unit.

13. Pilot (not shown)

The pilot is a spark ignition device used to light a pilot flame which
in turn is used to light the main burners.

14. Pump relay

The pump relay energizes the pump on a call for heat.

15. Relief valve

The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded.

16. Sight Glass

The sight glass provides a view of the burner surface, burner flame,
and the pilot flame.

17. Temperature and pressure gauge

The temperature and pressure gauge monitors the outlet
temperature of the appliance as well as the system water
pressure.

18. Temperature sensor

This sensor monitors inlet water temperature. If selected as the
controlling sensor, the appliance will maintain the setpoint at this
sensor.

19. Terminal strip

The boiler is equipped with a terminal strip on the left side of the
unit to allow easy connection to contact points.

20. Top panel

Removable panel to gain access to the internal components.

21. Thermostat

The thermostat monitors the water temperature via a temperature
sensor and will initiate a call for heat when the water temperature
drops below the setpoint plus the differential on the thermostat.

22. Transformer

The transformer reduces 120 VAC supply voltage to 24 VAC for the
control circuit.

23. Water inlet (system return)

The water inlet is a 1 1/2" pipe connection that receives water
from the system and delivers it to the heat exchanger.

24. Water outlet (system supply)

The water outlet is a 1 1/2" pipe connection that supplies
water to the system with connections for a flow switch, a relief
valve, and a temperature and pressure gauge.

25. Gas manifold pipe

Delivers gas from the gas valve to the main burners through a
number of orifices.

Installation & Service Manual

6

Models 45,000 - 90,000 Btu/hr Front View

Models 45,000 - 90,000 Left Side (inside unit)

Models 45,000 - 90,000 Right Side (inside unit)

Models 45,000 - 90,000 Rear View

The Solution - How it works... (continued)

Installation & Service Manual

7

10

17

15

8

3

5

4

20

1

19

23

11

14

16

25

22

21

7

18

9

12

6

24

8

Installation & Service Manual

The Solution - How it works...

Models 135,000 - 260,000 Btu/hr Left Side (inside unit)

Models 135,000 - 260,000 Btu/hr Right Side (inside unit)

Models 135,000 - 260,000 Btu/hr Rear View

Models 135,000 - 260,000 Btu/hr Front View

3

3

7

18

12

24

6

10

17

15

8

3

5

4

1

19

20

11

23

14

21

25

22

9

Installation & Service Manual

1 Determine boiler location

NOTICE

Clearances from combustible construction
are noted on the appliance rating plate.

Location of unit

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

2. The appliance must be installed indoors where it is
protected from exposure to wind, rain and weather.

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

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

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

6. All units have been approved for alcove installation (an
ALCOVE is a closet enclosure without a front door).

7. The appliance must not be installed on carpet.

8. All units have been approved for use on combustible
surfaces.

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

Figure 1-1_Alcove Installation - Models 45,000 ­180,000 Btu/hr

Figure 1-2_Alcove Installation - Models 215,000 ­260,000 Btu/hr

9

Recommended Service Clearances:

Left - 24”
Front - 24”

14"
TOP

6 " RIGHT

6 " REAR

18 "
FRONT

18 "
LEFT

Recommended Service Clearances:

Left - 24”
Front - 24”

29"
TOP

6 " RIGHT

6 " REAR

18 "
FRONT

18 "
LEFT

Installation & Service Manual

10

Figure 1-3_Combustion Air Direct from Outside

Combustion and ventilation air
requirements for conventionally vented
appliances

Provisions for combustion and ventilation air must be in
accordance with, Air for Combustion and Ventilation, of the
latest edition of the National Fuel Gas Code, ANSI Z223.1, in
Canada, the latest edition of CGA Standard B149 Installation
Code for Gas Burning Appliances and Equipment, or
applicable provisions of the local building codes.

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

1. If air is taken directly from outside the building
with no duct, provide two permanent openings (see
FIG. 1-3):

(a) Combustion air opening, with a minimum free

area of one square inch per 4000 Btu/hr input
(5.5 cm

2

per kW). This opening must be

located within 12" (30 cm) of the floor.

(b) Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu/hr input
(5.5 cm

2

per kW). This opening must be

located within 12" (30 cm) of the ceiling.

Figure 1-4_Combustion Air Through Ducts

2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the room where
the appliance is installed, each of the two openings should
be sized based on a minimum free area of one square inch
per 2000 Btu/hr (11cm

2

per kW) (see FIG. 1-4).

Figure 1-5_Combustion Air from Interior Space

3. If air is taken from another interior space that is adequately

ventilated, each of the two openings specified above should
have a net free area of one square inch for each 1000 Btu/hr
(22cm

2

per kW) of input, but not less than 100 square

inches (645cm2) (see FIG. 1-5).

1 Determine boiler location

4. If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the
opening must be sized based on a minimum free area of
one square inch per 3000 Btu/hr (7 cm

2

per kW). This
opening must be located within 12" (30 cm) of the top of
the enclosure (see FIG. 1-6).

Figure 1-6_Combustion Air from Outside Single Opening

Combustion air require ments are based on the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada refer
to National Standard CAN B149.1. Check all local code
re quire ments for combustion air.

All dimensions are based on net free area in square inch es.
Metal louvers or screens reduce the free area of a combustion
air opening a minimum of approximately 25%. Check with
louver manufacturers for exact net free area of louvers. Where
two openings are pro vid ed, one must be within 12" (30 cm) of
the ceiling and one must be within 12" (30 cm) of the floor of
the room where the appliance is installed. Each opening must
have a net free area as specified in Table 1B (on page 12).
Single openings shall be located with in 12" (30 cm) of the
ceiling.

 CAUTION

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

The combustion air supply must be completely free of any
flammable vapors that may ignite or chemical fumes which may
be corrosive to the appliance. Common corrosive chemical
fumes which must be avoided are fluorocarbons and other
halogenated compounds, most commonly present as
refrigerants or solvents, such as freon, tricholorethylene,
perchlorethylene, chlorine, etc. These chemicals, when burned,
form acids which quickly attack the heat exchanger finned tubes,
headers, flue collectors, and the vent system. The result is
improper combustion and a non-warrantable, premature
appliance failure.

The result is improper combustion and a non-warrantable,
premature appliance failure.

EXHAUST FANS: Any fan or equipment which exhausts air
from the equipment room may deplete the combustion air
supply and/or cause a downdraft in the venting system. Spillage
of flue products from the venting system into an occupied living
space can cause a very hazardous condition that must be
immediately corrected. If a fan is used to supply combustion air
to the equipment room, the installer must make sure that it does
not cause drafts which could lead to nuisance operational
problems with the appliance.

Installation & Service Manual

11

1 Determine boiler location (continued)

Installation & Service Manual

12

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

Input

Btu/hr

*Outside Air from

2 Openings Directly from

Outdoors

*Outside Air from
1 Opening Directly
from Outdoors, in

2

*Outside Air from

2 Ducts Delivered from

Outdoors

**Inside Air from

2 Ducts Delivered from

Interior Space

To p

Opening, in

2

Bottom

Opening, in

2

To p

Opening, in

2

Bottom

Opening, in

2

To p

Opening, in

2

Bottom

Opening, in

2

45,000

12

(78 cm2)

12

(78 cm2)

15

(97 cm2)

23

(149 cm2)

23

(149 cm2)

100

(646 cm2)

100

(646 cm2)

75,000

19

(123 cm2)

19

(123 cm2)

25

(162 cm2)

38

(246 cm2)

38

(246 cm2)

100

(646 cm2)

100

(646 cm2)

90,000

23

(148 cm2)

23

(148 cm2)

30

(194 cm2)

45

(291 cm2)

45

(291 cm2)

100

(646 cm2)

100

(646 cm2)

135,000

34

(220 cm2)

34

(220 cm2)

45

(291 cm2)

68

(439 cm2)

68

(439 cm2)

135

(871 cm2)

135

(871 cm2)

180,000

45

(291 cm

2

)

45

(291 cm

2

)

60

(388 cm

2

)

90

(581 cm

2

)

90

(581 cm

2

)

180

(1,162 cm

2

)

180

(1,162 cm

2

)

215,000

54

(349 cm2)

54

(349 cm2)

72

(465 cm2)

108

(697 cm2)

108

(697 cm2)

215

(1,388 cm2)

215

(1,388 cm2)

260,000

65

(420 cm2)

65

(420 cm2)

87

(562 cm2)

130

(839 cm2)

130

(839 cm2)

260

(1,678 cm2)

260

(1,678 cm2)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a
duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings.
The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in
the net free area to supply adequate combustion air for all appliances.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.
For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet
per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

The distance of the vent terminal from adjacent
build ings, windows that open and building open ings MUST
comply with the latest edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition of CGA Standard
B149 In stal la tion Code for Gas Burn ing Appliances and Equip ­ment.

Vent connection is made directly to the top of the
ap pli ance. This appliance is designed with a built-in draft
diverter. No additional external draft hood is re quired. The
connection from the appliance vent to the common vent or
chimney must be made as direct as possible.

Vent installations for connection to gas vents or
chimneys must be in accordance with “Vent ing of
Equipment,” of the latest edition of the Na tion al Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edi tion of CGA
Standard B149 Installation Code for Gas Burning Appliances
and Equipment or applicable pro vi sions of the local building
codes.

Adequate combustion and ventilation air must be
sup plied to the room where the appliance is installed in
accordance with the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada, the latest edition of CGA
Stan dard B149 Installation Code for Gas Burning Ap pli anc es
and Equipment, or applicable pro vi sions of the local building
codes.

1 Determine boiler location

Installation & Service Manual

13

2 Venting

A Conventional Negative Draft
Venting System

The negative draft in a conventional vent in stal la tion must be
within the range of a negative 0.02 to 0.05 inches water
column to ensure proper operation. All draft read ings are
made while the appliance is in stable op er a tion
(approximately 2 to 5 minutes).

Multiple appliance installations with combined vent ing or
common venting with other negative draft ap pli anc es require
that each appliance must have draft with in the proper range.
If the draft mea sured above the appliance’s built-in draft
diverter ex ceeds the specified range in a dedicated chimney
for a single appliance installation or in combined venting with
other negative draft appliances, a baro met ric damper must be

in stalled to control draft.

Figure 2-1_Conventional Negative Draft Vertical Venting

TABLE - 2A

VENT PIPE SIZES

Input Btu/hr Flue Size

45,000 4"

75,000 5"

90,000 5"

135,000 6"

180,000 7"

215,000 7"

260,000 8"

On a conventionally vented, negative draft ap pli ance, the
connection from the vent to the chimney or vent termination
on the outside of the building MUST be made with listed Type
“B” double wall (or equivalent) vent connectors and must be
direct as possible with no reduction in diameter. Use the
National Fuel Gas Code venting tables for dou ble wall vent to
properly size all vent connectors and stacks. The Type “B” vent
and accessories, such as firestop spacers, thim bles, caps, etc.,
MUST be installed in accordance with the manufacturer’s
list ing. The vent connector and firestop must provide correct
spacing to combustible surfaces and seal to the vent connector
on the upper and lower sides of each floor or ceiling through
which the vent connector passes.

Any vent materials used must be listed by a na tion al ly
recognized test agency for use as vent ma te ri al.

Locate appliance as close as possible to a chimney or gas vent.

Avoid long horizontal runs of the vent pipe, 90° el bows,
reductions and restrictions. Horizontal por tions of the
venting system shall be supported to prevent sagging.
Horizontal runs must slope up wards not less than 1/4 inch
per foot (21 mm/m) from the appliance to the vent terminal.
Follow manufacturer’s instructions.

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

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

Vent connectors serving appliances vented by nat u ral draft
shall not be connected to any portion of a
me chan i cal draft system operating under positive
pres sure. Connection to a positive pressure chim ney may
cause flue products to be discharged into the living space
causing serious health injury.

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

(a) Seal any unused opening in the common venting

system.

(b) Visually inspect the venting system for proper size

and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion and other
deficiencies which could cause an unsafe condition.

(c) Insofar as is practical, close all building doors and

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

(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.

(e) Test for spillage at the draft hood/relief opening after 5

minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar or
pipe.

(f) After it has been determined that each appliance

remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
other gas burning ap pli anc es to their previous
conditions of use.

(g) Any improper operation of the common venting

system should be corrected so that the installation
conforms to the latest edition of the Na tion al Fuel Gas
Code, ANSI Z223.1. In Canada, the latest edition of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment. When resizing any por ­tion of the common venting system, the common
venting system should be resized to ap proach the min ­i mum size as determined using the appropriate tables
in Part 11 in the latest edition of the National Fuel Gas
Code, ANSI Z223.1. In Canada, the latest edition of
CGA Stan dard B149 Installation Code for Gas Burning
Appliances and Equipment.

Installation & Service Manual

2 Venting

14

Vertical Vent Termination Clearances

Figure 2-2_Vent Termination from Peaked Roof 10' or
Less from Ridge

Figure 2-4_Vent Termination from Flat Roof 10' or Less
from Parapet Wall

Figure 2-3_Vent Termination from Peaked Roof More
than 10' from Ridge

Figure 2-5_Vent Termination from Flat Roof More Than
10' from Parapet Wall

The vent terminal should be vertical and exhaust outside the
building at least 2 feet (0.61m) above the high est point of the
roof within a 10 foot (3.05m) radius of the termination. The
vertical termination must be a minimum of 3 feet (0.91m)
above the point of exit.

A vertical terminal less than 10 feet (3.05m) from a parapet
wall must be a minimum of 2 feet (0.61m) higher than the
parapet wall.

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

The venting system shall terminate at least 3 feet (0.9m) above
any forced air inlet within 10 feet (3.05m).

The venting system shall terminate at least 4 feet (1.2m)
below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above
any door, window or gravity air inlet into any building.

Do not terminate the vent in a window well, stair well, alcove,
courtyard or other recessed area. The vent can not terminate
below grade. The bot tom of the vent terminal shall be located
at least 12 inches (30cm) above grade.

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

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

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

NOTICE

Examine the venting system at least once a
year. Check all joints and vent pipe
con nec tions for tightness. Also check for
corrosion or de te ri o ra tion. Immediately
correct any problems ob served in the
venting system.

2' MIN

10' OR LESS

3' MIN

CHIMNEY

RIDGE

Installation & Service Manual

15

2 Venting (continued)

10' OR LESS

10' OR LESS

MORE THAN 10'

10'

2' MIN

RIDGE

CHIMNEY

3' MIN

2' MIN

CHIMMEY

WALL OR
PARAPET

2' MIN

3' MIN

CHIMMEY

10' OR MORE

3'

NOTE:
NO HEIGHT ABOVE
PARAPET REQUIRED
WHEN DISTANCE
FROM WALLS OR
PARAPETS IS MORE
THAN 10'.

WALL OR
PARAPET

CHIMNEY

Installation & Service Manual

16

Masonry Chimney Installation

A masonry chimney must be properly sized for the
installation of a gas fired appliance. Venting of an appliance
into a cold or oversized masonry chimney can result in
op er a tion al and safety problems. Exterior masonry
chim neys, with one or more sides exposed to cold out door
tem per a tures, are more likely to have venting problems. The
temperature of the flue gases from an appliance may not be
able to suf fi cient ly heat the ma son ry structure of the chim ney
to generate proper draft. This will result in condensing of flue
gases, damage the masonry flue/tile, insufficient draft and
possible spill age of flue gases into an occupied living space.
Care ful ly in spect all chimney systems before installation. If
there is any doubt about the sizing or condition of a masonry
chimney, it must be relined with a prop er ly sized and
approved chimney liner system.

Inspection of a Masonry Chimney

A masonry chimney must be carefully inspected to determine
its suitability for the venting of flue gas es. A clay tile lined
chimney must be structurally sound, straight and free of
misaligned tile, gaps between liner sections, missing sections
of liner or any signs of con den sate drainage at the breaching
or clean out. If there is any doubt about the condition of a
masonry chimney, it must be relined. An unlined masonry
chimney must not be used to vent flue gases from this appliance.
An unlined chimney must be relined with an approved
chimney liner system when a new appliance is be ing attached to
it. Metallic liner systems (Type “B” double wall or flexible or
rigid metallic liners) are recommended. Consult with local
code officials to determine code requirements or the
advisability of using or relining a masonry chimney.

Sidewall Venting - Negative Draft

Figure 2-6_Unit with Fan Assisted Venting

The in duced draft fan MUST also be equipped with a prov ing
switch, properly interlocked into the ap pli ance’s con trol circuit
to prove fan operation before the main burn ers are allowed to
fire. A vertical or sidewall vent termination for an induced draft
fan MUST be in stalled per the recommendations of the fan
manufacturer and provide proper clearances from any
combustion or ventilation openings, win dows, doors or other
open ings into the building. All induced draft fan in stal la tions
must comply with local code requirements.

Fan Assisted Venting

A Power Venter Kit is available on Models 45,000 - 135,000
Btu/hr only (see Table 2B).

TABLE - 2B

VENT MATERIALS

Kit

Number

Input

Btu/hr

Material

KIT3103

45,000 PVC Rated (CPVC Optional)

75,000 PVC Rated (CPVC Optional)

KIT3104

90,000 CPVC Rated

135,000 CPVC Rated

Minimum Vent Length = 12 Equivalent Feet*

(ALL UNITS)

Maximum Vent Length = 25 Equivalent Feet*

(ALL UNITS)

* Equivalent Feet: 90° Elbow = 5 Feet

45° Elbow = 3 Feet

2 Venting

This appliance is NOT approved for sidewall venting with
the negative draft venting system as shipped from the
factory. An induced draft fan MUST be used if the
installation requires that the flue gases be vented out a
sidewall unless a power venter is used, see Fan Assisted
Venting. A properly sized and in stalled induced draft fan
may also be used to vent the flue gases ver ti cal ly if required
by jobsite re stric tions. The induced draft fan must be listed
by a nationally recognized test agency, be properly sized and
installed per the rec om men da tions of the in duced draft fan
manufacturer and meet local code requirements. Use care to
ensure that the me chan i cal ly supplied draft does not exceed
the range of a negative 0.02 to 0.05 inches water column to
ensure proper operation. If draft exceeds the spec i fied range,
the fan must be adjusted or the installation of a baro met ric
damper in the flue may be required to prop er ly control draft.
An induced draft fan MUST be interlocked into the
appliance’s control circuit to start when the appliance calls
for heat.

Installation & Service Manual

17

The vent damper is a useful tool for saving energy when
installed inside the living space where air can cir cu late freely
around the appliance. The vent damper will not save as much,
if any, energy if it is installed in locations such as:

- Unheated garage

- Attic

- Crawlspace

- Mechanical room that is vented outdoors

For installation and maintenance on the vent damper, refer to
the instructions supplied with the vent damper.

Residential heating boilers with inputs of less than
300,000 Btu/hr must have the vent damper prop er ly installed
and the vent damper wire harness plugged into the ter mi nal
block on the side of the control panel to allow the boiler to
function. Larger input heating boilers will have a jumper plug
installed in the ter mi nal block to allow operation without a
damper. Remove the jumper plug from the terminal block to
connect an optional vent damper wire harness. The jumper
plug MUST be in place if an optional vent damper is not used
on larger input heating boilers.

 CAUTION

Do not install the vent damper within 6"
(152 mm) of combustible materials.

Install the vent damper to service only the single ap pli ance for
which it is intended. If improperly installed, a hazardous
condition such as an ex plo sion or carbon monoxide poisoning
could result.

The damper position indicator must be in a visible lo ca tion
with access for service following in stal la tion. The damper
must be in an open position when appliance main burners are
operating.

The part number for the automatic vent damper required on
this heating boiler is printed on the rating plate. Vent damper
regulations are design certified per the latest edition of ANSI
Z21.66.

VENT DAMPER

Figure 2-7_Vent Damper and Vent Damper Terminal
Block

 WARNING

The vent damper must be installed directly
on the flue outlet located on the top of the
draft hood (see FIG. 2-7). Do not alter the
wire har ness sup plied with the vent damper.
Follow the instructions supplied with the
vent damper.

 CAUTION

An appliance which is shut down or will not
operate may experience freezing due to
con vec tive air flow down the flue pipe
connected to the unit. Proper freeze
protection must be pro vid ed, see Freeze
Pro tec tion.

Automatic Vent Damper

This heating boiler is design certified for use with the
automatic vent damper (FIG. 15) part number printed on the
boiler’s rating plate. A vent damper must be installed on all
residential heating boilers with inputs of less than 300,000
Btu/hr to comply with minimum efficiency requirements. A
vent damper is factory supplied with residential heating
boilers with inputs of 45,000 thru 260,000 Btu/hr.

2 Venting (continued)

18

3 Gas connections

Installation & Service Manual

Gas Supply

Verify that the appliance is supplied with the type gas
spec i fied on the rating plate. This appliance is orificed for
operation up to 2000 feet altitude. The ap pli ance will be
derated 4% per 1000 feet above 2000 feet el e va tion. Consult
the factory for installations above 2000 feet elevation. Field
conversions for operation at high altitude must be performed
by certified per son nel only. The appliance will be marked to
indicate suitability for high al ti tude operation.

GAS SUPPLY PRESSURE: Measured at the inlet pres sure tap
located upstream of the combination gas valve(s) see
FIG. 3-5, page 22.

TABLE - 3A

GAS SUPPLY PRESSURE

Max. (Inches Water Column)

Natural Gas LP Gas

14 14

Min. (Inches Water Column) 4.5 11

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

MANIFOLD PRESSURE: Measured at the pres sure tap on
the downstream side of the com bi na tion gas valve(s) (see
FIG. 3-5, page 22). The gas regulator settings for single stage
and two stage operation are factory set to supply proper
manifold pressure for normal operation. To check manifold
pressure, see Manifold Ad just ment Procedure. Do not increase
manifold pressure beyond spec i fied pressure settings shown
below in Table 3B.

TABLE - 3B

MANIFOLD PRESSURE

Input Gas

Btu/hr

Single and
Two-Stage

Two Stage

Full or High Fire

Settings

Low Fire Settings

Natural

Gas

LP Gas

Natural

Gas

LP Gas

45,000 3.5" 10" 0.9" 2.5"

75,000 2.4" 7" 0.9" 2.5"

90,000 - 180,000 3.5" 10" 0.9" 2.5"

215,000 - 260,000 3.5" 10" 0.9" 2.5"

Gas Pressure Test

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

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

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

Gas Connection

1. Safe operation of the appliance requires properly sized gas
supply piping. See data in Table 3C.

2. Gas pipe size may be larger than appliance gas connection.

3. Installation of a union is suggested for ease of service, see
FIG. 3-1 on page 19.

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

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

FIG. 3-1 on page 19.

6. The combination gas valve has an integral vent lim it ing
device and does not require venting to atmosphere,
outside the building.

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

TABLE - 3C

FITTINGS TO EQUIVALENT STRAIGHT PIPE

Diameter Pipe (inches)

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

Equivalent Length of Straight Pipe (feet)

2 2 3 4 5 10 14 20

TABLE - 3D

GAS CONNECTIONS

Btu/hr

INPUT

Pipe Size

45,000 - 135,000 1/2"

180,000 - 260,000 3/4"

3 Gas connections (continued)

19

Installation & Service Manual

TABLE - 3E

GAS PIPING SIZE CHART

Nominal
Iron Pipe

Size

Inches

Length of Pipe in Straight Feet

Maximum
Capacity of Pipe
in Thousands of

Btu/hr per hour

for gas pressures

of 13.5 Inches

Water Column

(0.5 PSIG) or less

and a pressure

drop of 0.5 Inch

Water Column

(Based on NAT

GAS, 1025

Btu/hr per Cubic

Foot of Gas and

0.60 Specific
Gravity)

10 20 30 40 50 60 70 80 90 100 125 150 175 200

3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74

1 697 477 384 328 292 267 246 226 210 200 179 164 149 138

1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287

1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441

2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820

2 1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300

3 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340

4 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720

Gas Piping

Figure 3-1_Gas Line Connection

All gas connections must be made with pipe joint
com pound resistant to the action of liquefied pe tro leum and
natural gas. All piping must comply with local codes. Tubing
installations must com ply with ap proved standards and
practices. Reference FIG. 3-1 for a typical installation.

Install Piping to Control

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

2. Use new, properly threaded black iron pipe free from chips.
If tubing is used, make sure the ends are cut squared,
deburred and clean. All tubing bends must be smooth and
without deformation. Avoid flexible gas connections.
Internal diameter of flexible lines may not provide proper
volume of gas.

3. Run pipe or tubing to the gas valve or manifold inlet. If
tubing is used, obtain a tube to pipe coupling to connect
the tubing to the gas valve or man i fold inlet.

4. DO NOT OVER TIGHTEN. Over tightening may result in
damage to the gas valves. Valve distortion or malfunction
may result if the pipe is inserted too deeply into the gas
valve.

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

6. Remove seal over gas valve or manifold inlet.

7. Connect pipe to gas valve or manifold inlet. Use wrench to
square ends of the gas valve (FIG. 3-2).

GAS VALVE

GAS SHUTOFF VALVE

TRAP
(DRIP LEG)

Installation & Service Manual

20

APPLY WRENCH FROM TOP OR BOTTOM

OF GAS CONTROL TO EITHER SHADED AREA

APPLY WRENCH

TO FLANGE ONLY

WHEN FLANGE IS

NOT USED

WHEN FLANGE

IS USED

Figure 3-2_Wrench

8. For L.P. gas, consult your L.P. gas supplier for expert
installation.

IMPORTANT

Upon completion of any piping
con nec tions to the gas system, leak test all
gas con nec tions with a soap solution
while system is un der pressure.
Immediately repair any leaks found in the
gas train or related components. Do Not
op er ate an appliance with a leak in the gas
train, valves or related piping.

Gas Manifold Pressure Adjustment
Procedure

3.5"

MANOMETER

GAS VALVE

PRESSURE REGULATOR ADJUSTMENT
(UNDER CAP SCREW)

OUTLET
PRESSURE TAP

PILOT OUTLET

GAS CONTROL KNOB

RED RESET BUTTON

INLET
PRESSURE TAP

Figure 3-3_Manifold Pressure Adjustment

1. Turn the power “OFF” at the main dis con nect switch.

2. Turn gas valve control knob to “OFF” po si tion.

3. Remove the 1/8" hex plug located on the out let side of the
gas valve and install a fitting suitable to connect to a
manometer or magnahelic gauge. See FIG. 3-3. Minimum
range of scale should be up to 5" w.c. for Natural gas
mod els and 10" w.c. for L.P. gas models.

4. Remove the pressure regulator adjustment cap screw on
the gas valve. See FIG. 3-3 for location.

5. Turn the power “ON” at the main dis con nect switch.

6. Turn gas valve control knob to “ON” po si tion.

7. Set the thermostat(s) to call for heat.

8. Observe gas regulator pressure when all burn ers are firing.
See Table 3B, Manifold Pressure (page 18) for proper
regulator pressure settings.

9. If adjustment is necessary, turn regulator ad just ment screw
clockwise to raise regulator gas pres sure, counterclockwise
to lower gas pres sure, to proper setting. NOTE: Adjustment
fitting is plas tic and may require slightly greater turning
force than a metal fitting.

10. Turn the power “OFF” at the main dis con nect switch.

NOTICE

Do not increase regulator pres sure beyond
specified pressure setting.

11. Turn gas valve control knob to “OFF” position.

12. Remove fitting from the gas valve and re place the 1/8" hex
plug that was previously removed and tighten.

13. Turn the gas valve control knob to “ON” position.

14. Turn the power “ON” at the main dis con nect switch. The
appliance is now ready to op er ate.

If manifold pressure can not be properly adjusted, use the
procedure on page 21 to check gas supply pressure with a
manometer connected to the inlet pressure tap on the gas
control.

3 Gas connections

Installation & Service Manual

21

Checking Gas Supply Pressure

Figure 3-4_Gas Supply Pressure

1. Turn the power “OFF” at the main dis con nect
switch.

2. Turn gas valve control knob to the “OFF” position.

3. Shut off gas supply at the manual valve in the gas piping

to the appliance. If fuel supply is L.P. gas, shut off gas
supply at the tank.

4. Remove the 1/8" hex plug, located on the “inlet” side of

the gas valve and install a fitting suitable to connect to a
manometer or magnahelic gauge. Range of scale should
be 14" w.c. or greater to check inlet pressure. See
FIG.’s 3-3 and 3-4 for location.

5. Turn on gas supply at the manual valve, turn on L.P. gas

at tank if required.

6. Turn the power “ON” at the main dis con nect switch.

7. Follow the “Lighting Instructions” in Section 6 - Startup

to light the pilot . Turn gas valve control knob to the
“ON” position.

8. Set the thermostat(s) to call for heat.

9. Observe the gas supply pressure with all burn ers firing.
Ensure inlet pressure is within specified range. Check gas
supply pressure with all other gas fired appliances in
operation to en sure prop er gas volume during periods of
peak gas usage.

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

11. If the gas supply pressure is within the spec i fied range,
proceed with the following steps to return the appliance to
service.

12. Turn the power “OFF” at the main dis con nect switch.

13. Turn gas valve control knob to “OFF” position.

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

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

16. Turn on gas supply at the manual valve, turn on L.P. Gas at
tank if required.

17. Turn the power “ON” at the main dis con nect switch.

18. Turn the gas valve control knob to the “ON” position.
Spark ignition models will au to mat i cal ly light the pilot on
a call for heat.

19. Set the thermostat to call for heat. The appliance is now
ready to operate.

IMPORTANT

Upon completion of any testing on the gas
system, leak test all gas connections with a
soap solution while main burners are
operating. Im me di ate ly repair any leak
found in the gas train or re lat ed
components. Do Not operate an appliance
with a leak in the gas train, valves or related
piping.

Check burner performance by cycling the system while you
observe burner response. Burners should ignite promptly.
Flame pattern should be stable, see the “Main te nance Section ­Normal Flame Pattern”. Turn system off and allow burners to
cool, then cycle burners again to en sure proper ignition and
flame characteristics.

3 Gas connections (continued)

GAS SUPPLY PRESSURE

MANOMETER

GAS VALVE

Combination Gas Valves

A

Figure 3-5_M9 Gas Valve

Venting of Combination Gas Valves

The combination gas valve regulator used on all
mod els is equipped with an integral vent limiting
orifice. The vent limiter ensures that the volume of
gas emitted from the valve does not exceed the
maximum safe leak age rate allowed by agency
re quire ments. Com bi na tion gas valve/regulators
equipped with integral vent limiters are not
re quired to have vent or relief lines piped to the
outdoors. A dust cap is provided at the vent
termination point on the valve to prevent block age
of the vent limiter by foreign material. The
com bi na tion gas valve regulator with an integral
vent limiter complies with the safety code
requirements of CSD-1, CF-190(a) as shipped from
the manufacturer with out the in stal la tion of
additional vent lines.

Two Stage Burner Control System

The 45,000 thru 260,000 Btu/hr boilers (M9) are
equipped with a two stage burner control system.

Each unit has a combination gas valve to control the gas supply to the
burners. The com bi na tion valve con sists of a gas regulator and two valve
seats to meet the requirements for redundant gas valves. The valve has a
gas control knob that must remain in the open po si tion at all times when
the appliance is in service. Each gas valve has pres sure taps located on the
inlet and outlet sides. Manifold pressure is adjusted using the regulator
located on the valve. The manifold pres sure is pre set at the factory and
adjustment is not usu al ly re quired. If the manifold pressure is to be
ad just ed, follow the “Gas Manifold Pressure Ad just ment Pro ce dure”,
page 20 for proper adjustment.

3 Gas connections

22

Installation & Service Manual

PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)

INLET PRESSURE TAP

WIRING TERMINALS

S CONTROL KNOB

G

OUTLET
PRESSURE TAP

PILOT OUTLET

Relief Valve

Figure 4-1_Relief Valve

This appliance is supplied with a relief valve(s) sized in
accordance with ASME Boiler and Pressure Ves sel Code,
Section IV (“Heating Boilers”). The re lief valve(s) is mounted
directly into the heat ex chang er inside the header (see
FIG. 4-1). To pre vent water damage, the dis charge from the
relief valve shall be piped to a suit able floor drain for disposal
when relief occurs. No reducing couplings or other
restrictions shall be installed in the discharge line. The
discharge line shall allow complete drainage of the valve and
line. Relief valves should be manually operated at least once
a year.

 CAUTION

Avoid contact with hot discharge water.

Water Flow Switch (if equipped)

Figure 4-2_Water Flow Switch - Top Connections

A water flow switch is available as a factory sup plied option on
all heating boilers (see FIG. 4-2). The flow switch should be
wired between terminals X and B. Remove the jumper between
the X and B terminals on the terminal strip. This wiring
connection installs the flow switch in the 24 VAC safety cir cuit
to prove water flow before main burner ig ni tion. A flow switch
installed with the fac to ry sup plied minimum adjustment setting
requires a spe cif ic minimum flow to make the switch and start
burner operation. The flow rate required is a function of the
diameter of pipe and tee used for installation. Ensure that the
pump installed on the boiler will supply adequate flow to make
the flow switch con tacts and operate the boil er.

A water flow switch meets most code re quire ments for a low
water cut off device on boil ers requiring forced cir cu la tion for
operation.

4 Water connections

23

Installation & Service Manual

RELIEF VALVE

FLOW SWITCH

FLOW

Low Water Cutoff (if equipped)

A hot water boiler installed above radiation level must be
provided with a low water cutoff device either as part of the
unit or installed at the time the boiler is installed. An
electronic low water cutoff is available as a kit on all units.
Low water cutoffs should be in spect ed every six months,
including flushing of float types.

TABLE - 4A

MINIMUM REQUIRED FLOW

FOR HEATING BOILER

Input Btu/hr GPM Flow

45,000 1.9

75,000 3.1

90,000 3.7

135,000 5.6

180,000 7.4

215,000 8.9

260,000 10.7

NOTICE

Minimum flow is based on a 40°F
tem per a ture rise across the boiler.
Minimum flow may not prove a flow
switch installed in the boiler piping. Use
care when operating a boiler at or near
the min i mum recommended flow
because conditions unique to the
installation (system pressure, operation
of multiple zone valves, glycol,
variations in flow, etc.,) may result in
overheating of the boiler water caus ing
noise or nui sance operation of safety
limit con trols. Typical heat ing boiler
applications will op er ate with a 20°F to
30°F temperature rise across the boiler.

Typical Heating Boiler Installations

General Plumbing Rules

1. Check all local codes.

2. For serviceability of the boiler, always install unions.

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

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

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

6. Support all water piping.

Placing the Boiler in Operation

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

1. Close all drain cocks and air vents.

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

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

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

A. Open one circuit drain valve and let the water drain for

at least five minutes. Ensure that there are no air
bubbles visible in the wa ter stream before closing the
drain valve.

B. Repeat this procedure for each circuit.

5. Open all valves after all circuits have been purged. Make
sure there are no system leaks.

NOTICE

Do not use petroleum based stop leak
products. All system leaks must be
repaired. The constant addition of
make-up water can cause damage to the
boiler heat exchanger due to scale
accumulation. Scale reduces flow and
heat transfer, causing overheating of the
heat exchanger.

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

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

8. Recheck all air vents as described in step 4, General
Plumbing Rules.

4 Water connections

24

Installation & Service Manual

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

10. Start the boiler according to the Section 6 - “Start-Up
Instructions” in this manual. Operate the system,
including the pump, boiler and radiation units, for one
hour.

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

12. Shut down the entire system and vent all ra di a tion units
and high points in the system.

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

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

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

TABLE - 4B

SYSTEM TEMPERATURE RISE CHART

Based on Boiler Output in Btu/hr

Btu/hr

10°F T 20°F T 30°F T 40°F T

Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd

45,000 36,900 7.4 0.6 3.7 0.2 2.5 0.2 1.9 0.2

75,000 61,500 12.3 1.3 6.2 0.4 4.1 0.3 3.1 0.2

90,000 73,800 14.9 1.4 7.4 0.5 5.0 0.3 3.7 0.2

135,000 110,700 22.3 3.2 11.1 1.2 7.4 0.6 5.6 0.3

180,000 147,600 29.7 5.1 14.9 1.6 9.9 0.7 7.4 0.4

215,000 176,300 -- -- 17.0 1.3 11.8 0.8 8.9 0.4

260,000 213,200 -- -- 21.5 2.1 14.3 0.9 10.7 0.5

Piping of the Boiler System

The drawings in this section (see FIG’s 4-7 thru 4-11) show
typical heating boil er piping installations. Before beginning the
in stal la tion, consult local codes for specific plumb ing
re quire ments. The installation should provide unions and
valves at the inlet and outlet of the boil er so it can be isolated for
service. The boiler cir cu lat ing pump, air sep a ra tor, expansion
tank and oth er components required for proper installation
must be purchased locally. An air separation device must be
supplied in the in stal la tion piping to eliminate trapped air in the
system. Lo cate a system air vent at the highest point in the
sys tem. The system must also have a properly sized expansion
tank installed. Typically, an air charged di a phragm-type
expansion tank is used. The expansion tank must be installed
close to the boiler and on the suction side of the system pump to
ensure proper op er a tion.

 CAUTION

This boiler system should not be operated at
less than 12 PSIG.

4 Water connections (continued)

25

Installation & Service Manual

Hot water pip ing must be supported by suitable hangers or
floor stands, NOT by the boiler. Copper pipe systems will be
subject to considerable expansion and con trac tion. Rigid
pipe hangers could allow the pipe to slide in the hanger
resulting in noise transmitted into the system. Padding is
recommended on rigid hangers installed with a copper
system. The boiler pressure relief valve must be piped to a
suitable floor drain. See the relief valve section on page 23 of
this manual.

 CAUTION

A leak in a boiler system will cause the
system to intake fresh water constantly,
which will cause the tubes to accumulate
a lime/scale build up. This will cause a
NON-WARRANTABLE FAILURE.

Water Connections

Heating Boilers with inputs of 45,000 - 260,000 Btu/hr have
1 1/2" NPT inlet and outlet connections.

 CAUTION

Field installed reducing bushings may
de crease flow re sult ing in boiler noise or
flashing to steam.

Circulator Pump Requirements

This is a low mass, high efficiency hot water boil er which must
have adequate flow for quiet, efficient op er a tion. The boiler
circulating pump must be field supplied. The boiler circulator
pump must operate con tin u ous ly while the boiler is firing.
Pump selection is critical to achieve proper op er a tion. A
pump should be selected to achieve proper system design
water temperature rise. A heat ex chang er pressure drop chart
(Table 4C) is provided to assist in proper pump selection.
Also provided is a System Temperature Rise Chart (Table 4B
on page 25). This table provides GPM and boiler head-loss at
various temperature rises for each boiler based on Btu/hr
input. Temperature rise is the difference in boiler inlet
temperature and boiler outlet temperature while the boiler is
firing. Example: The boiler inlet tem per a ture is 160°F and the
boiler outlet temperature is 180°F, this means that there is a
20°F tem per a ture rise across the boiler.

TABLE - 4C

HEAT EXCHANGER PRESSURE DROP CHART

CB 315

CB 360

CB 399

CB 500

FT/HD

Gallons per Minute

0

5

10

15 20 25

30

35

7

6

5

4

3

2

1

0

4 Water connections

26

Installation & Service Manual

Circulator Pump Specifications

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

2. Maximum water temperature should not ex ceed
nameplate rating.

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

4. A properly sized expansion tank must be in stalled near
the boiler and located on the suction side of the pump.

PUMP INSTALLATION AND MAIN TE NANCE: The boiler
circulating pump must be purchased lo cal ly. For installation
and maintenance information on the circulator pump, refer to
the pump man u fac tur ers in struc tion package included with
the pump.

4 Water connections (continued)

27

Installation & Service Manual

Figure 4-3_Boiler Wiring - Circulation Pump to Junction Box

Circulator Pump Operation

Boilers are equipped with a relay for controlling the
circulation pump for the hot water loop. The relay turns ON
and OFF in response to the “W” input from the wall
thermostat or zone control.

The field installed boiler pump MUST NOT exceed 1 h.p.
For continuous pump operation, wire the system pump to
the 120V supply. The pump should be connected at the
junction box as shown in FIG. 4-3.

PERFORMANCE LOOP

These units are equipped with an integral performance loop,
which is designed to provide efficiency optimization by
maintaining a constant flow through the unit’s heat exchanger
loop when building system flow is reduced. The performance

loop assembly is standard equipment and is NOT to be used
as a system or boiler pump.

NOTICE

The performance loop is dedicated to
the unit and does not affect the
building’s system or primary/secondary
flow characteristics and will not
circulate the building.

It is acceptable to remove the performance loop as long as
the following requirements are met:

1. The boiler is piped to the system in primary/secondary
fashion.

2. The system setpoint is 140°F or higher.

3. The boiler circulating pump is sized for the appropriate
flow through the boiler.

4. The system sensor is installed in an acceptable location
for sensing the system supply temperature.

5. If water temperature is below 140°F a low temperature
bypass must be installed, (VAL30000 - 1 1/2" LTV Valve
Kit) and follow the piping diagram in FIG. 4-4.

NOTICE

If removal of the performance loop is
necessary, consult the manufacturer for
a Solution Without a Performance Loop
(KIT30068).

 WARNING

Failure to install the system sensor can
cause operation problems such as
nuisance high limit trips.

Primary/Secondary Boiler Piping

A pri ma ry/secondary pip ing system may also be in stalled to
ensure proper boiler flow rates. Primary/sec ond ary piping is
also ideal for systems using a mixture of propylene glycol and
water. A primary/secondary piping system uses a dedicated
pump to supply flow to the boiler only. This pump is sized
based on de sired boiler flow rate, boiler head loss and head loss
in the sec ond ary system piping only. The secondary pump, in ­stalled in the boiler piping, ensures a constant wa ter flow rate
to the boiler for proper operation. Boiler installation with a
primary/secondary piping sys tem can prevent noise problems
caused by low sys tem water flows. A primary/secondary piping
system is recommended on any boiler where low water flow
conditions may present an operational problem.

120V

SUPPLY

TO

UNIT

TO

CIRCULATION

PUMP

TO PERFORMANCE

LOOP PUMP (OPT.)

Full Flow Application

It is acceptable for the Solution boiler to be installed in a full
flow application, as long as the following requirements are
met:

1. The performance loop is in place and functional.

2. The system flow is not lower than the minimum boiler
flow.

3. The boiler setpoint is 140°F or higher.

4. If water temperature is below 140°F you must install a
low temperature bypass, VAL30000, and follow the piping
diagram shown in FIG. 4-7.

Boiler Flow Rates

 CAUTION

The maximum flow rate through the boil er
with a copper heat exchanger must not
ex ceed 30 GPM.

The heat exchanger is generally capable of op er at ing within the
flow rates of a residential heating system. Should the flow rate
exceed the maximum allowable flow rate through the boiler 30
GPM) an external bypass must be installed. The bypass should be
fully sized with a balancing valve to al low for proper ad just ment of
flow. Flow rate can be determined by measuring the temperature
rise through the boiler.

The basic guide for minimum flow in this boiler is based on a
40°F temperature rise in most in stal la tions. Low er flow and a
higher temperature rise is acceptable if the boiler system is
specifically de signed for the char ac ter is tics of a higher
tem per a ture rise. A system not specifically designed for a higher
temperature rise may experience over heat ing of the boiler water.
This can cause short burn er on cycles, system noise and in
ex treme cases, a knocking flash to steam. These
con di tions can lead to operational problems and
non-war rant able fail ures of the boiler. High temperature rise
systems must be designed by a qualified engineer.

Low Temperature Bypass Requirements

Inlet water temperatures below 140°F (60°C) can excessively
cool the prod ucts of combustion re sult ing in condensation on
the heat exchanger and in the flue. Condensation can cause
operational prob lems, bad combustion, sooting, flue gas spillage
and reduced service life of the vent system and related
components. The bypass allows part of the boiler discharge
water to be mixed with the cooler boiler return water to in crease
the boiler inlet temperature above 140°F (60°C). This should
prevent the prod ucts of com bus tion from condensing in most
in stal la tions. The bypass should be fully sized with a bal anc ing
valve to allow for proper adjustment. A valve must also be
provided on the boiler discharge, after the by pass. Closing this
discharge valve forces water through the bypass. Start boiler
adjustment with the bypass valve in the full open position and
the boiler discharge valve half open. A small amount of the
high er temperature boiler discharge water is mixed with the
system water to maintain the de sired lower system tem per a ture.

 WARNING

Varying the flow through a Solution boiler
can cause harmonic noises and high limit
trips if the flow is below the minimum
boiler flow rate found in Table 4A.

4 Water connections

28

Installation & Service Manual

 CAUTION

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

A boiler operated with an inlet temperature of less than 140°F
(60°C) must have a bypass to prevent problems with
condensation. A bypass as shown in FIG. 4-8 (see page 33)
must be piped into the system at the time of installation.

A primary/secondary piping system is ideal for sys tems filled
with a propylene glycol and water mix ture. A glycol and water
mixture is more dense than water only and may result in a
lower boiler flow rate. A lower boiler flow may cause noisy
operation or short cycling of the burners. A larger secondary
pump may be used on a primary/sec ond ary system to pro vide
an increased boiler flow rate. A glycol and water system may
require from 10 to 20% more flow to compensate for the
in creased density of the glycol and its effect on the heat
transfer process in the boiler. The exact in crease in flow that
may be required is based on the type and percentage of glycol
added to the boiler system. Consult the manufacturer of the
glycol for additional recommendations when using a gly col
and water fill for your boiler system.

The installer must ensure that the boiler has ad e quate flow
without excessive temperature rise. The tem per a ture rise on
a multiple zone system should be made when only the zone
with the longest length and/or high est head loss is open. Low
system flow can result in overheating of the boiler water
which can cause short burner on cycles, system noise and in
extreme cases, a knocking flash to steam. System noise may
also indicate an oversized boiler.

Primary/Secondary Boiler Piping

(continued)

Primary / Secondary Piping

Figure 4-4_Primary / Secondary Piping of a Single Boiler

4 Water connections (continued)

29

Installation & Service Manual

PRESSURE

MAKE UP WATER

TO

SYSTEM

BACKFLOW

PREVENTER

SYSTEM SUPPLY
SENSOR

SYSTEM
CIRCULATOR

BALL VALVE

(TYPICAL)

REDUCING VALVE

PRESSURE

GAUGE

AIR
SEPARATOR

NOT TO EXCEED APART

12"

FROM

SYSTEM

EXPANSION

TANK

DRAIN POINT

(TYPICAL)

UNION

(TYPICAL)

TEMPERATURE / PRESSURE

GAUGE

BOILER
CIRCULATOR

DRAIN

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

SOLUTION

BOILER

Figure 4-5_Single Boiler - Primary / Secondary with Low Temperature Bypass

Primary / Secondary Piping

4 Water connections

30

Installation & Service Manual

PRESSURE
REDUCING VALVE

PRESSURE

GAUGE

AIR
SEPARATOR

12"NOT TO EXCEED APART

PREVENTER

MAKE UP WATER

TO

SYSTEM

BACKFLOW

SYSTEM SUPPLY
SENSOR

SYSTEM
CIRCULATOR

FROM

SYSTEM

BALL VALVE

(TYPICAL)

EXPANSION

TANK

DRAIN POINT

(TYPICAL)

UNION

(TYPICAL)

TEMPERATURE / PRESSURE

GAUGE

LOW TEMPERATURE BYPASS

BOILER
CIRCULATOR

DRAIN

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

SOLUTION

BOILER

Primary / Secondary Piping

Figure 4-6_Multiple Boilers Zoned with Circulators

BOILER 1

(LEADER)

INDIRECT

DHW TANK

ANTI-SCALD

MIXING VALVE

COLD

WATER

IN

TEMPERATURE /

PRESSURE

GAUGE

AIR SEPARATOR

ZONE #1

ZONE #2

ZONE #3

ZONE #4

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

DRAIN POINT

(TYPICAL)

MAKE UP WATER

HOT

WATER

OUT

BOILER
CIRCULATOR

BACKFLOW

PREVENTER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

EXPANSION

TANK

ZONE #1

ZONE #2

ZONE #3

ZONE #4

ZONE CIRCULATORS

(TYPICAL)

FLOW CHECK

VALVE

SYSTEM SUPPLY

SENSOR

(WHEN USED)

RECIRCULATION

LOOP

AQUASTAT

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

MAY SUBSTITUTE LOW LOSS HEADER

NOT TO EXCEED 12" APART

BOILER 2

(LEADER 1)

4 Water connections (continued)

31

Installation & Service Manual

Figure 4-7_Single Boiler Full System Flow

Full System Flow

4 Water connections

32

Installation & Service Manual

PRESSURE
REDUCING VALVE

BACKFLOW

PREVENTER

MAKE UP WATER

SYSTEM SUPPLY
SENSOR

SYSTEM
CIRCULATOR

TO

SYSTEM

BALL VALVE

(TYPICAL)

PRESSURE

GAUGE

AIR
SEPARATOR

FROM

SYSTEM

EXPANSION

TANK

UNION

(TYPICAL)

TEMPERATURE / PRESSURE

GAUGE

DRAIN

PRESSURE

RELIEF VALVE

Y-STRAINER

(RECOMMENDED)

SOLUTION

BOILER

Installation & Service Manual

33

SOLUTION

BOILER

BACKFLOW

PREVENTER

PRESSURE
REDUCING VALVE

PRESSURE

GAUGE

TEMPERATURE / PRESSURE

GAUGE

AIR
SEPARATOR

EXPANSION

TANK

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE
RELIEF VALVE

MAKE UP WATER

FROM
SYSTEM

BOILER
CIRCULATOR

SYSTEM
CIRCULATOR

TO

SYSTEM

SYSTEM SUPPLY
SENSOR

DRAIN

Y-STRAINER

(RECOMMENDED)

3-WAY VALVE W/BYPASS PIPE

Figure 4-8_Single Boiler Full System Flow with Low Temperature Bypass

Full System Flow

4 Water connections (continued)

34

Installation & Service Manual

5 Electrical connections

This appliance is wired for 120 VAC service. The appliance,
when installed, must be electrically ground ed in accordance
with the requirements of the authority having jurisdiction or
in the absence of such re quire ments, with the latest edition of
the National Electrical Code ANSI/NFPA No. 70. When the
unit is in stalled in Canada, it must conform to the CSA C22.1,
Ca na di an Electrical Code, Part 1 and/or local Electrical
Codes.

1. All wiring between the appliance and field

in stalled devices shall be made with type T wire
[63° F(35° C) rise].

2. Line voltage wire exterior to the appliance must be

enclosed in approved conduit or approved metal clad
cable.

3. The pump must run continuously when the appliance is

being fired.

4. To avoid serious damage, DO NOT en er gize the

appliance until the system is full of water. Serious
damage may result.

5. Provide the unit with proper overload protection.

6. Install a wall thermostat on the inside wall. DO NOT

install the thermostat in an area affected by drafts,
sunlight, light fixtures, hot or cold water pipes or near a
fireplace. See “Room Thermostat or Remote Thermostat
Connection to Terminal Strip” (this page), for prop er
wiring con nec tion.

Boiler Operating Temperature Control

The operating temperature control is located in the control
panel, behind the control panel front ac cess door. The sensing
element for the operator is placed in a bulbwell installed in
the heat exchanger. Carefully observe the inlet water
temperature on the initial boiler on cycles. The exact
temperature set point is based on your system’s requirements.
Turn the con trol set point dial to the desired operating water
tem per a ture. Observe the boiler discharge tem per a ture after
each set point adjustment to ensure prop er operation.

Room Thermostat or Remote Thermostat
Connection to Terminal Strip

A room thermostat or remote temperature control may be
connected to the boiler. The room ther mo stat should be
installed on an inside wall, away from the influences of drafts,
hot or cold water pipes, lighting fixtures, televisions, sun rays
or fire plac es. Follow the manufacturers instructions supplied
with the ther mo stat for proper installation and ad just ment.
The boiler is equipped with a terminal strip on the left side of
the control panel to allow easy connection (FIG. 5-1).

Remove the jumper between the R and W terminals on the
terminal strip. Refer to the chart in this section (Table 5A) to
determine maximum allowable length and wire gauge
recommended to connect the switching con tacts of the room
thermostat to the R and W terminals on the terminal strip.
Connection to the terminal strip will allow the room thermostat
to make and break the 24VAC boiler control circuit turning the
boiler on and off based on the room ambient temperature
re quire ments. Set the boiler operating temperature control as
described in this section.

A

B

Figure 5-1_Terminal Strip Connections

Auxiliary Device Connection to Terminal
Strip

A terminal connection strip is provided for ease of connection
for Power Venting Systems, see FIG. 5-1, inset A.

A field supplied powered venter or powered louver/damper may
be connected to the Solution boiler via a terminal strip located
on the left side of the unit, see FIG. 5-1, inset B.

A 24 VAC relay can be powered from this location when a call for
heat has been established. A device proving switch can be
interlocked back to the appliance to ensure its operation before
the appliance is allowed to fire.

Reference the wiring diagram on page 50 of this manual.

TABLE - 5A

TERMINAL STRIP WIRING

Wire Gauge

Allowable Length

Maximum

12 GA 100 ft.

14 GA 75 ft.

16 GA 50 ft.

18 GA 30 ft.

35

Installation & Service Manual

5 Electrical connections (continued)

Pump Wiring for a Heating Boiler

The heating boiler circulating pump must be pur chased
locally. The max i mum load for the pump switched by the
internal pump relay must not exceed 1 HP. The current draw
for a field installed 120 VAC pump MUST be add ed to the
boiler’s current draw to de ter mine the minimum wire size for
120 volt service.

TABLE - 5B

AMP DRAW DATA

45,000 thru 260,000 Btu/hr Models

FIRING CONTROLS

MAXIMUM

TOTAL AMPS

@ 120 VAC

M9 with Performance Loop Pump 1.25

TEMPERATURE CONTROL

PUMP RELAY

MANUAL RESET HIGH LIMIT (IF EQUI PPED)

IGNITION MODULE

TRANSFORMER

Figure 5-2_Intermittent Pilot System M9 Control Panel

Temperature Adjustment

Operating Temperature Control

NOTICE

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

 WARNING

Return water temperatures must not be less
than 140°F. If lower return water
temperatures are required, follow the
instructions for Low Temperature Bypass
Requirements, see page 28.

Locating Temperature Control

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

Temperature Control Settings

Remove the control panel door on the front of the unit in unless
your unit is specified as a boiler only with an outdoor air reset
option. If your unit is a boiler only with an outdoor air reset
option, there are additional controls for this option. They are
explained under Outdoor Air Reset Option, page 38.

The three setting knobs on the temperature control are for Set
point, Differential, and High-Fire Offset (see FIG. 5-3).

Figure 5-3_Temperature Control

Maximum Set Point Determination

The maximum set point for the control is factory set. Boilers
can be set to 240°F max.

These maximum set points are established by cutting the OJ1
and OJ2 jumpers located on the right side of the temperature
controller. The maximum set point is determined as shown
below in Table 5C.

TABLE - 5C

MAXIMUM SET POINT DETERMINATION

OJ1 OJ2

MAX.

SET POINT

Connected Connected 240°F

Cut Connected 190°F

Connected Cut 200°F

Cut Cut 160°F

NOTICE

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

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

High-Fire Offset

The temperature control operates a two-stage firing system. The
two stages are High-Fire and Low-Fire. High-Fire operates all
burners at full rate while Low-Fire operates the burners at
approximately one-half rate.

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

The High-Fire Offset knob has settings between 0°F and 20°F. If
set at 0°F, the High-Fire Offset is disabled and the unit will
operate the High-Fire stage until the set point is reached and the
temperature control shuts the unit off.

If the High Fire Offset knob is set to 0 or 1, the delay will be
10 seconds; if set to 2 or above the delay will be 120 seconds.

Boiler Application

Standard boiler units are equipped with one inlet water
temperature sensor. A system sensor is also provided for use as
a remote system sensor. Boilers with the outdoor air reset
option also have an outside air temperature sensor.

Temperature Control Sensors

This is a two-stage temperature control that controls the burner
ignition and pump functions. This temperature controller can
measure up to three different sensor inputs, depending upon
how the unit is set up. They are as follows:

1. Inlet Water Temperature Sensor

2. System Sensor

3. Outside Air Temperature Sensor

Inlet Water Temperature Sensor

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

The inlet water temperature sensor is placed into the inlet
bulbwell on the boiler. This sensor is installed by the factory in
new units.

System Sensor

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

Set Point

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

Differential

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

Installation & Service Manual

5 Electrical connections

36

5 Electrical connections (continued)

37

Installation & Service Manual

Outdoor Air Temperature Sensor

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

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

Wiring of Remote Sensors

To wire remote sensors, follow the guidelines below. Take care
to correctly wire sensors to the unit. Erratic temperature
readings can be caused by poor wiring practices. Twist the
wires between the unit and the remote sensor. Turn wires at
least three or four turns per linear foot of wiring. This
provides protection against some types of electrical
interferences.

1. Do not route temperature sensor wiring with building

power wiring.

2. Do not locate temperature sensor wiring next to control

contactors.

3. Do not locate temperature sensor wiring near electric

motors.

4. Do not locate temperature sensor wiring near welding

equipment.

5. Make sure good mechanical connections are made to the

sensor, any interconnecting wiring and the controller.

6. Do not mount sensor with leadwire end pointing up in an

area where condensation can occur.

7. Use shielded wiring to connect the sensor to the control

when the possibility of an electrically noisy environment
exists. Shielded cable is recommended on all cable runs of
more than 25 feet in length.

NOTICE

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

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

Installation of Remote Sensors

1. Turn OFF the main electrical power and the main manual
gas shutoff to the appliance.

2. Remove the side access panel from the appliance to gain
access to the thermostat.

3. Locate the sensor in the kit. Determine the location of the
remote sensor and measure the amount of wire needed to
connect the sensor to the thermostat. See Wiring of the
Remote Sensors for guidelines.

4. Use twisted pair wire, minimum 18 gauge or larger. See
Table 5A, page 34 regarding distance versus wire gauge.
Ensure all wire insulation is trimmed to reveal at least 3/8"
of exposed wire.

5. Connect the measured wire to the sensor wire using wire
caps (see FIG. 5-4). Install .250 x .032 insulated female
quick connect terminals to the end of the wires. Feed the
wires through the access hole located on the back of the unit
and secure the connectors to the thermostat connections
(Sys/Tank) CN5 and CN6 located in the upper right-hand of
the thermostat.

6. Turn on the electrical power and the main manual gas
shutoff to the appliance.

7. Replace the side access panel.

8. Fire the appliance and resume operation.

Figure 5-4_Installation of Remote Sensors

ACCESS HOLE

CONNECT THE MEASURED
WIRE TO THE SENSOR WIRE

Installation & Service Manual

38

Outdoor Air Reset Option

For boilers ordered with the Outdoor Air Reset option, there
is an additional control (FIG. 5-5). There are three setting
knobs for Shutdown, Outdoor Air Max., and Ratio. There is
also a switch to turn the outdoor air shutdown feature On or
Off. An O.A. Sensor is also included.

R4R4

R6R6

R8R8

R16R16

R15R15

C7C7

C9C9 C10C10

VR2VR2

VR3VR3

OJ1OJ1

OJ2OJ2

D4D4

J4J4

CN1CN1

CN2CN2

CN9CN9

CN7CN7

CN8CN8

CN3CN3

CN4CN4

CN5CN5

CN6CN6

W1W1

TST2314TST2314

2020

1515

1010

55

(F-)0(F-)0

1515

1414

1313

1212

1111

10

99

88

77

66

55

OFFOFF

120120

240240

220220

200200

160160

140140

SETPOINTSETPOINT

DIFFERENTIALDIFFERENTIAL

HIGH-FIREHIGH-FIRE

OFFSETOFFSET

(c)2002 L.C.(c)2002 L.C.

SHUTDOWN

45

50

45

1.3

O.A. MAX.

70

40

VR1

65

RATIO

VR2

0.6

0.5

0.7

1.4

1.5

W1 W2

W3

60

50

7040

55

60

VR3

65

DISABLE

O.A. SHUTDOWN

1.0

0.9

0.8

1.2

1.1

O.A. SENSOR

ENABLE

ON

SW1

55

CN1

Shutdown

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

Outdoor Air Max (O.A. Max)

The O.A. Max knob allows a reset up to the maximum
outdoor air temperature specified by this knob setting. When
the outdoor air temperature is above the specified setting, the
unit will not function in the O.A. Reset Mode, but will
continue to run at the selected set point temperature.

Note that the set point knob will now indicate the “minimum”
boiler temperature. Target temperature is determined by the
ratio and outdoor air temperature below the O.A. Max
setting.

Ratio

The Ratio knob allows control over the reset ratio to be used
during Outdoor Air Reset. The allowable ratios are as low as

0.5:1 or as high as 1.5:1.

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

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

If the outdoor design and boiler design temperatures are known,
the Ratio setting can be calculated using the following formula:

Ratio = (boiler design temperature - operator set point)

(O.A. Max. setting - outdoor design temperature)

Note that the reset set point cannot exceed the maximum set
point of the boiler thermostat.

These settings are illustrated graphically in FIG. 5-6.

Figure 5-5_Optional Outdoor Air Reset Control

Figure 5-6_Outdoor Air Control Example Chart

Outdoor Air Shutdown Enable/Disable Switch

The Outdoor Air Shutdown Enable/Disable switch turns the
outdoor air shutdown feature On and Off. Disabling the
Outdoor Air Shutdown feature allows the unit to operate
regardless of the outdoor air temperature. This is needed for
indirect domestic hot water systems for example.

Additional Temperature Controls

High Water Temperature Limit Con trol

The appliance is supplied with a fixed setting, auto-reset high
water temperature limit control. The setting of this control
limits max i mum discharge water tem per a ture. If water
temperature exceeds the setting, the limit will break the con trol
circuit and shut down the appliance. The limit control will only
be reset after the water tem per a ture has cooled well below the
setting of the limit. The auto-reset high water temperature limit
control is mount ed in the outlet side of the front header.

5 Electrical connections

5 Electrical connections (continued)

39

Installation & Service Manual

Blocked Vent and Flame Roll-Out / Flame
Interlock Switch

Figure 5-7_Blocked Vent Switch Location

/

Figure 5-8_Flame Roll-Out / Flame Interlock Switch Location

All units are equipped with manual reset blocked vent and flame
roll-out / flame interlock switches. These temperature switches
are located in the controls compartment and in the relief
opening of the boiler’s built-in draft hood. Each switch has a
red reset button. In the event the system has actuated to shut off
the main burner gas supply, wait for the boiler to cool, then
press the red reset to return the boiler to operation. Op er a tion
of a blocked vent and/or flame roll-out / interlock switch usually
indicates a problem with the venting system, obstruction of the
heat ex chang er flue gas passageway and/or a combustion air
supply prob lem. The cause for operation of the blocked vent
and/or flame roll-out / interlock switch must be determined and
corrected. If the boiler cannot be restored to normal operation,
contact a qualified ser vice in stall er, service agency or the gas
supplier.

OUTER AIR
DEFLECTOR

UPPER FRONT
JACKET PANEL

BLOCKED VENT SWITCH
INVERTED TO SHOW RESET
UNDERNEATH

DRAFT HOOD

FRONT OF UNIT

DETAIL A

LOWER FRONT
JACKET PANEL

HEX FILLER BRACKET

FLAME ROLL-OUT SWITCH
INTERLOCK SWITCH

40

6 Start-up

Installation & Service Manual

Initial Start-up

Follow the Lighting Instructions on the label applied to the
appliance.

A. On boilers with the system pump delay option, the

operating temperature control will energize the
pump relay which energizes the pump on a call for
heat. The operating temperature control will de­energize the pump relay approximately 30 seconds
after the call for heat ends. If either the inlet sensor
or the optional multi-purpose temperature sensor
reads below 40°F, the pump relay will turn ON.
When the temperature rises above 50°F the pump
relay will turn OFF.

On boilers, the pump will operate whenever the “W”
terminal is energized.

B. Location - The appliance should be located within a

room having a temperature safely above freezing
[32°F(0°C)].

C. Shutdown and Draining - If, for any rea son,

the appliance is shut off, the following
pre cau tion ary measures must be taken:

1. Shut off gas supply,

2. Shut off water supply.

3. Shut off electrical supply.

4. Drain the heat exchanger completely. Re move one
3/8" NPT plug or bulbwell from the inlet side and
one from the outlet side of the front head er of the
heat exchanger.

5. Drain the pump. Remove the 3/4" plug in the
performance loop.

Pre-start Checklist

1. Inspect the burners to be sure they are prop er ly aligned.

2. Inspect the pilot gas line, thermocouple leads, ignition
leads and wire connections to the gas valve to be sure
none were damaged during shipment.

3. Check to ensure that gas connections have been made
properly and the gas line is purged of air.

4. Check to ensure that water connections are tight and the
appliance and piping system have been properly filled.

5. Ensure that discharge from the relief valve has been
piped to a floor drain.

6. Verify that properly sized combustion and
ven ti la tion air openings are provided and not obstructed
in any way.

7. Check carefully for gas leaks.

8. Read the appliance’s safety warnings, light ing instructions
and check out procedure carefully, be fore firing the system.

Lighting Instructions for Spark Ignition
Pilot Models

FOR YOUR SAFETY READ BEFORE

OPERATING

 WARNING

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

A. This appliance is equipped with an ignition device

which automatically lights the pilot. Do not try to light
the pilot by hand.

B. BEFORE OPERATING, smell around the appliance

area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle to the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

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

Immediately call your gas supplier from a near by
phone. Follow the gas supplier’s instructions.

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

C. Use only your hand to turn the gas control knob.

Never use tools. If the knob will not turn by hand,
don’t try to repair it, call a qualified ser vice technician.
Force or attempted repair may result in a fire or
explosion.

D. Do not use this appliance if any part has been under

water. Immediately call a qualified service technician
to inspect the appliance. The pos si ble damage to a
flooded appliance can be extensive and present
numerous safety hazards. Any appliance that has been
under water must be replaced.

6 Start-up (continued)

41

Installation & Service Manual

Operating Instructions

1. STOP! Read the safety information first.

2. Remove the control panel door.

3. Set the thermostat to the lowest setting (OFF).

4. Turn off all electrical power to the appliance.

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

6a. 45,000 - 135,000 Btu/hr models, rotate the gas control

knob on the gas valve clockwise to the “OFF” position.

6b. 180,000 - 260,000 Btu/hr models, rotate the gas control

knob on the gas valve clockwise to the line on the collar
around the knob. Depress the knob and continue
rotation to the “OFF” position.

7. Wait five (5) minutes to clear out any gas, then smell for
gas, including near the floor. If you smell gas, STOP!
Follow the steps in the “What To Do If You Smell Gas”
section in the safety information on page 40. If you do
not smell gas go on to the next step.

8a. 45,000 - 135,000 Btu/hr models, rotate the gas control

knob on the gas valve counterclockwise to the “ON”
position.

8b. 180,000 - 260,000 Btu/hr models, rotate the gas control

knob on the gas valve counterclockwise to the line on
the collar around the knob. Al low the knob to “pop” up,
and continue rotation to the “ON” position.

9. Turn on all electric power to the appliance.

10. Set the thermostat to the desired setting.

11. Re-install the control panel door.

12. If the appliance will not operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service
technician or gas supplier.

To Turn Off Gas to Appliance

1. Set the thermostat to the OFF position.

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

3a. 45,000 - 135,000 Btu/hr models, rotate the gas control

knob on the gas valve clockwise to the “OFF” position. Do
not force.

3b. 180,000 - 260,000 Btu/hr models, rotate the gas control

knob on the gas valve clockwise to the line on the collar
around the knob. Depress the knob and continue rotation
to the “OFF” position. Do not force.

 WARNING

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

Safety Shutoff Test for Spark
Ignition Pilot System

1. Turn “OFF” gas supply to the appliance.

2. Turn thermostat to highest setting.

3. Turn electric power “ON”.

4. Pump relay pulls in to start pump.

5. The ignition will begin sparking at the pilot.

6. The ignition module will lock out after the 90 second trial
for ignition period.

7. Immediately call a qualified serviceman or
in stall er to repair an ignition system that fails to
lock out and properly shut down burner operation.

8. After successful completion of the test, re ad just the
thermostat to normal setting.

9. Turn “ON” gas supply.

10. Turn power “OFF” then “ON” to reset ignition module.

11. If ignition system fails to operate properly, re pair work
must be performed by a qualified serviceman or installer.

Installation & Service Manual

42

Ignition and Control Timings

M9 Intermittent Spark Ignition Pilot Mod els

Pilot Trial for Ignition Period - 90 Seconds

Pilot Failure Response Time - 0.8 Seconds at less than 1.0 µA
flame current

Pump Delay Timing (Optional on Boilers) - 30 Seconds after
burner shut down

Freeze Protection

1. For boilers with the pump delay option, if either the inlet
sensor or the optional multi-purpose temperature
sensor reads below 40°F, the pump relay will turn ON.
When the temperature rises above 50°F the pump relay
will turn OFF.

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

3. Caution - A room where the appliance is installed and
operating under a negative pressure may experience a
downdraft in the flue of an appliance which is not firing.
The cold outside air pulled down the flue may freeze a
heat exchanger. This condition must be cor rect ed to
provide adequate freeze protection.

4. Freeze protection for a heating boiler or hot water supply
boiler using an indirect coil can be provided by using
hydronic system antifreeze. Follow the manufacturers
instructions. DO NOT use un di lut ed or automotive type
antifreeze.

5. A snow screen should be installed to pre vent snow and
ice accumulation around the appliance vent ing system in
cold climates.

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

(a) Shut off gas supply.

(b) Shut off water supply.

(c) Shut off electrical supply.

(d) Drain the unit completely. Remove one threaded

plug or bulbwell from the inlet side of the front
header and one from the outlet side of the front
header on the heat exchanger. Blow all wa ter out of
the heat exchanger.

(e) Drain pump and piping.

Freeze Protection for a Heating Boiler
System (if required)

1. Use only properly diluted inhibited glycol an ti freeze
designed for hydronic systems. Inhibited propylene glycol
is recommended for systems where incidental contact with
drinking water is possible.

 CAUTION

DO NOT use undiluted or automotive type
antifreeze.

2. A solution of 50% propylene glycol will pro vide maximum
protection of approximately -30°F.

3. Follow the instructions from the glycol an ti freeze
manufacturer. The quantity of glycol an ti freeze required is
based on total system volume including ex pan sion tank
volume.

4. Glycol is more dense than water and chang es the viscosity
of the system. The addition of glycol will decrease heat
transfer and in crease frictional loss in the heating boiler
and re lat ed piping. A larg er pump with more capacity may
be required to maintain desired flow rates in a glycol
system.

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

Water Treatment

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

Intermittent Pilot Spark Ignition
System

 WARNING

The ignition module is not repairable.
Any mod i fi ca tion or repairs will invalidate
the warranty and may create hazardous
conditions that result in prop er ty damage,
personal injury, fire, explosion and/or
toxic gases. A faulty ignition module must
be re placed with a new module.

6 Start-up

43

Installation & Service Manual

Maintenance and annual startup

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if
necessary;

• Check for leaks (water, gas, flue)

• Examine venting system

• Check system water pressure/system
piping/expansion tank

• Check control settings

• Check wiring and connections

• Flame inspection (stable, uniform)

• Check flue gas passageways

• Inspect and clean the burners

• Perform start-up checkout and
performance verification per Section 6 -
Start-up.

If combustion or performance
indicate need:

• Clean heat exchanger

• Remove and wash burners

ANNUAL START-UP

Owner maintenance

(see the User’s Information Manual for instructions)

Daily

• Check appliance area

• Check pressure/temperature
gauge

Monthly

• Check vent piping

• Check relief valve

Periodically

• Test low water cutoff (if used)

• Reset button (low water cutoff)

Every

6 months

• Check appliance piping (gas and

water) for leaks

• Operate relief valve

End

of season

months

• Shut appliance down (unless
boiler used for domestic hot
water)

Table 7A_Service and Maintenance Schedules

7 Maintenance

Follow the service and maintenance procedures given throughout this manual and in component literature
shipped with the appliance. Failure to perform the service and maintenance could result in damage to the
appliance or system. Failure to follow the directions in this manual and component literature could result in
severe personal injury, death, or substantial property damage.

The appliance should be inspected annually only by a qualified service technician. In addition, the
maintenance and care of the appliance designated in Table 7A and explained on the following pages must be
performed to assure maximum appliance efficiency and reliability. Failure to service and maintain the
appliance and system could result in equipment failure.

Electrical shock hazard – Turn off power to the appliance before any service operation on the appliance except
as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical
shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct
before proceeding.

Inspect appliance area

1. Verify that appliance area is free of any combustible
materials, gasoline and other flammable vapors and
liquids.

Inspect appliance interior

1. Remove the outer access panels and inspect the interior of
the appliance.

2. Vacuum any sediment from inside the appliance and
components. Remove any obstructions.

Eliminate all system or appliance leaks.
Continual fresh makeup water will reduce
appliance life. Minerals can build up in
sections, reducing heat transfer,
overheating heat exchanger, and causing
heat exchanger failure. Leaking water may
also cause severe property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems
found.

3. Check gas line using the procedure found in Section 3 -
Gas Connections.

Check all piping for leaks

 WARNING

 WARNING

 WARNING

 WARNING

 CAUTION

Label all wires prior to dis con nec tion when servicing controls. Wiring errors can cause improp er and
dangerous operation.

Listed below are items that must be checked to en sure safe
reliable operation. Verify proper op er a tion after servicing.

Flue vent system and air supply

1. Examine the venting system at least once a year. Check
more often in the first year to de ter mine in spec tion interval.
Check all joints and pipe connections for tightness,
corrosion or deterioration. Clean louvers and/or screens in
the combustion air intake system as required. Have the
entire system, including the venting system, periodically
inspected by a qualified service agency.

2. Check for gastight seal at every connection, seam of air
piping, and vent piping periodically inspected by a qualified
service agency.

Venting system must be sealed gastight to
prevent flue gas spillage and carbon
monoxide emissions, which will result in
severe personal injury or death.

 WARNING

Check water system

1. Verify all system components are correctly installed and
operational.

2. Check the cold fill pressure for the system. Verify it is
correct (must be a minimum of 12 PSI).

3. Watch the system pressure as the boiler heats up (during
testing) to ensure pressure does not rise too high. Excessive
pressure rise indicates expansion tank sizing or performance
problem.

4. Inspect automatic air vents and air separators. Remove air
vent caps and briefly press push valve to flush vent. Replace
caps. Make sure vents do not leak. Replace any leaking
vents.

7 Maintenance

Installation & Service Manual

44

7 Maintenance (continued)

45

Installation & Service Manual

Check Expansion Tank

1. Expansion tanks provide space for water to move in and
out as the heating system water expands due to
temperature increase or contracts as the water cools.
Tanks may be open, closed, diaphragm or bladder type.
See Section 4 - Water Connections for suggested best
location of expansion tanks and air eliminators.

Check Relief Valve

1. Inspect the relief valve and lift the lever to verify flow.

Before operating any relief valve, ensure that it is piped
with its discharge in a safe area to avoid severe scald
potential. Read Section 4 - Water Connections before
proceeding further.

Safety relief valves should be re-inspected
AT LEAST ONCE EVERY THREE
YEARS, by a licensed plumbing contractor
or authorized inspection agency, to ensure
that the product has not been affected by
corrosive water conditions and to ensure
that the valve and discharge line have not
been altered or tampered with illegally.
Certain naturally occurring conditions
may corrode the valve or its components
over time, rendering the valve inoperative.
Such conditions are not detectable unless
the valve and its components are
physically removed and inspected. This
inspection must only be conducted by a
plumbing contractor or authorized
inspection agency – not by the owner.
Failure to re-inspect the boiler relief valve
as directed could result in unsafe pressure
buildup, which can result in severe
personal injury, death, or substantial
property damage.

 WARNING

Following installation, the valve lever must
be operated AT LEAST ONCE A YEAR to
ensure that waterways are clear. Certain
naturally occurring mineral deposits may
adhere to the valve, rendering it inoperative.
When manually operating the lever, water
will discharge and precautions must be taken
to avoid contact with hot water and to avoid
water damage. Before operating lever, check
to see that a discharge line is connected to
this valve directing the flow of hot water
from the valve to a proper place of disposal.
Otherwise severe personal injury may result.
If no water flows, valve is inoperative. Shut
down the appliance until a new relief valve
has been installed.

2. After following the above warning directions, if the relief
valve weeps or will not seat properly, replace the relief valve.
Ensure that the reason for relief valve weeping is the valve
and not over-pressurization of the system due to expansion
tank waterlogging or undersizing.

 WARNING

46

Installation & Service Manual

Check All Wiring

1. Inspect all wiring, making sure wires are in good
condition and securely attached.

Check Control Settings

1. Adjust settings if necessary. See Section 5 - Electrical
Connections for adjustment procedures.

2. Check settings of external limit controls (if any) and
adjust if necessary.

Check Burner Flame

Visually check main burner flames at each start-up after long
shutdown periods or at least every six months. A burner
viewport is located on the burner mounting flange.

Perform Start-up and Checks

1. Start appliance and perform checks and tests specified in
Section 6 - Start-up.

2. Verify cold fill pressure is correct and that operating
pressure does not go too high.

The area around the burner viewport is
hot and direct contact could result in
burns.

 WARNING

NORMAL

A

YELLOW TIP

B

D

FLAME LIFT

C

YELLOW FLAME

 WARNING: The area around the burners is hot and direct contact could result in burns!

Figure 7-1_Flame Pattern Illustration

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

Ye l l o w T ip : Yellow tip can be caused by blockage or partial
obstruction of air flow to the burner(s).

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

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

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

Combustion Air

This ap pli ance uses an atmospheric combustion process.
Combustion air is provided to the burners by the gas injection
pressure into the venturi of the burn ers. The burners do not
have an adjustable air shutter. Ad e quate combustion air must be
supplied to the room where the appliance is installed to ensure
proper burner operation. Check frequently to be sure the flow
of com bus tion and ventilation air to the unit is not obstructed.
When the main burn ers light, observe the burn er flame. Flames
should be light blue in color with slight yellow tips; flames
should be settled on burner head with no lifting when supplied
with correct vol ume of combustion air.

Check Flue Gas Passageways

Any sign of soot around the outer jacket, at the burn ers or in the
areas between the fins on the cop per heat exchanger indicates a
need for cleaning. The following cleaning procedure must only
be per formed by a qualified serviceman or installer. Prop er
service is required to maintain safe operation. Properly installed
and ad just ed appliances sel dom need flue cleaning.

All gaskets on disassembled components
must be replaced with new gaskets on
re as sem bly. Gasket kits are available from
your distributor.

NOTICE

Heat Exchanger / Burner Access

 WARNING

The combustion chamber insulation in this
appliance contains ceramic fiber material.
Ceramic fibers can be converted to
cristobalite in very high temperature
applications. The International Agency for
Research on Cancer (IARC) has concluded,
“Crystalline Silica in the form of quartz or
cristobalite from occupational sources is
carcinogenic to humans (Group 1).” Normal
operating temperatures in this appliance are
below the level to convert ceramic fibers to
cristobalite. Abnormal operating conditions
would have to be created to convert the
ceramic fibers in this appliance to
cristobalite.

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

7 Maintenance

7 Maintenance (continued)

47

Installation & Service Manual

 Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of
respirator is based on the OSHA requirements for
cristobalite at the time this document was written.
Other types of respirators may be needed depending on
the jobsite conditions. Current NIOSH
recommendations can be found on the NIOSH website at
(http://www.cdc.gov/niosh/homepage.html). NIOSH
approved respirators, manufacturers and phone numbers
are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye
protection.

 Apply enough water to the combustion chamber lining to

prevent airborne dust.

 Remove combustion chamber lining from the appliance

and place it in a plastic bag for disposal.

 Wash potentially contaminated clothes separately from

other clothing. Rinse clothes thoroughly.

 NIOSH stated First Aid:

Eye: Irrigate immediately.
Breathing: Fresh air.

a. Turn “OFF” main power to the appliance.

b. Turn “OFF” external manual gas shutoff valve to

appliance.

c. Remove the control panel door.

d. Remove the outer air deflector (FIG. 7-2)

e. Disconnect gas valve wiring and remove gas manifold

assembly.

f. Remove ignition wire leading to the pilot assembly

from the ignition module.

g. Disconnect the wiring from the flame rollout/interlock

switch, see FIG. 5-8, page 39.

h. Remove the lower front jacket panel.

i. Remove the control panel mounting screws. When

removing the control panel, lay the control panel to
the side with the wiring intact, being careful not to
damage any of the wiring.

Remove the combustion chamber door. Use caution
to prevent damage to burn ers, refractory, pilot or
wiring.

Inspection and Cleaning

j. Check the heat exchanger surface for sooting. The

external surfaces of the copper tubes should be free of
any soot deposits. (A slight black smudge is normal
with some types of gases.) If abnormal soot deposits
are present, the heat exchanger must be cleaned and
the cause of the soot problem corrected. Proceed as
follows:

k. Remove soot from burners and bottom of the finned

tubes with a stiff bristle brush. Dirt may also be
removed from burner ports by rinsing the burner
thor ough ly with water. Drain and dry burners before
re-installing. Damaged burners must be re placed.

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

l. Remove gas manifold as described in steps a. thru e. in

“Heat Exchanger/Burner Access.”

m. Loosen mounting screws and remove front control

panel.

n. Loosen screws on the upper front jack et panel and

remove toward front of the appliance. Use caution to
prevent damage to re frac to ry on the doors inner
surface.

o. Check “V” baffles on top of the heat ex chang er.

Remove and clean if necessary.

p. Remove soot from the heat exchanger with a stiff

bristle brush. Soot may also be re moved from the heat
exchanger by washing thoroughly with detergent and
water. Remove the heat exchanger before using water
for cleaning. Rinse thoroughly and dry before
re-installing. Use a vacuum to remove loose soot from
surfaces and in ner chamber.

q. Remove the heat exchanger (HEX) filler bracket

(FIG. 7-2).

r. The heat exchanger can be removed by sliding towards

the front of the appliance. Once the heat exchanger is
removed from the ap pli ance, a garden hose can be used
to wash the tubes to ensure that all soot is removed
from the heat exchanger surfaces.

Installation & Service Manual

48

s. Ensure that all burner ports are cleaned to remove

any soot. See Inspection and Cleaning Procedure,
page 47.

t. Carefully re-install the heat exchanger, “V” baffles,

jacket panels, and wires.

u. Reassemble all gas and water piping. Test for gas

leaks.

v. Cycle the appliance and check for prop er operation.

/

Figure 7-2_Outer Air Deflector and HEX Filler Bracket

Water Circulating Pump

Inspect pump ev ery 6 months and oil if required. Use SAE 30
non-detergent oil or lubricant specified by pump
man u fac tur er.

Clear Area

1. Keep appliance area clear and free from com bus ti ble
materials, gasoline and other flammable vapors and
liquids.

2. Check frequently to be sure the flow of com bus tion and
ventilation air to the boiler is not obstructed.

Inspection of Heat Exchanger Waterways

Appliances operated in hard water areas should have periodic
inspections of the tubes to be sure that no sediment or scale
accumulates on the heat transfer sur fac es. Inspection plugs are
located at both ends of the heat exchanger. In spec tion plugs
should be removed and tubes inspected at the end of the first 45
days of operation and again at the end of 90 days of operation.
If no scale accumulation is ob served, inspections can be made at
the end of each six months of op er a tion.

IMPORTANT

Upon completion of any testing on the
gas system, leak test all gas connections
with a soap solution while main burners
are operating. Im me di ate ly repair any
leak found in the gas train or re lat ed
components. Do Not operate an
appliance with a leak in the gas train,
valves or related piping.

Gas Train and Controls

GAS FLOW

Figure 7-3_Gas Train

Review with owner

1. Review the User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule
specified in the User’s Information Manual (and in this
manual as well).

3. Remind the owner of the need to call a licensed contractor
should the appliance or system exhibit any unusual
behavior.

4. Remind the owner to follow the proper shutdown
procedure and to schedule an annual start-up at the
beginning of the next heating season.

7 Maintenance

OUTER AIR
DEFLECTOR

UPPER FRONT
JACKET PANEL

DETAIL A

LOWER FRONT
JACKET PANEL

HEX FILLER BRACKET

FLAME ROLL-OUT SWITCH
INTERLOCK SWITCH

49

Installation & Service Manual

8 Troubleshooting

Step 1:

Step 2:

Step 3:

Is the spark
ignitor sparking?

No

Yes

Check continuity on the spark
cable. Check for 24 VAC on
the 24v terminal (gray wire)
on the i

g

nition module.

No

Is there 24 VAC (purple
wire) on the 4-pin
connector plug on the
tem

p

erature controller?

Yes

Replace ignition
module.

No

Check 24 VAC at R and W on
the terminal strip.

Check each of the
following for an open:

-white and purple wire on
the LWCO plug

-rollout switch

-manual reset high limit

-spill switch
If any of these devices are
open, press the reset

b

utton.

Yes

Is there 24 VAC (tan
wire) on the 4-pin
connector plug on
the temperature
controller?

Yes

Check each of the
following for an open:

- X and B on the
terminal strip

-purple and gray wires
on the vent damper
plug

-V and P on the
terminal strip

-auto reset high limit

No

Check
voltage to
and from the
transformer.

No

Check incoming
120 VAC.

Check for an open
sensor. If no open
sensor, make sure
there’s a call for
heat. If call for heat
is present, replace
temperature control.

No

Is the pilot
staying on?

No

Yes

Check the pilot
tube for gas.
Check draft.

Is the gas valve
getting 24 VAC
to the MV
terminal?

No

Replace the
ignition
module.

Yes

Check gas pressure
and make sure gas
valve knob is on.

Yes

Troubleshooting Guide: M9 Solution Boilers

50

Installation & Service Manual

Schematic Diagram - M9 Unit

45,000 - 260,000 Btu/hr Models

Wiring Diagram - M9 Unit

45,000 - 260,000 Btu/hr Models

9 Diagrams

51

Notes

Revision A (ECO #C03746) initial release.

SBR-I-S Rev A

5/10