Lochinvar 45, 000—500, 000 Btu/hr Models Installation And Service Manual
1
Installation and service must be performed by a
qualified service installer, service agency or the gas
supplier.
Factory warranty (shipped with appliance) does not
apply to appliances improperly installed or improperly
operated.
Experience has shown that improper installation or
system design, rather than faulty equipment, is the
cause of most operating problems.
1. Excessive water hardness causing a lime
buildup 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).
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.
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying
the appliance which may show signs of being hit or
otherwise being mishandled. Verify total number of
pieces shown on packing slip with those actually
received. In case there is damage or a shortage,
immediately notify carrier.
Hot Water Heating Boiler
Water Heater/Domestic Hot Water Supply Boiler
45,000—500,000 Btu/hr Models
RB/RW-i&s-07
INSTALLATION AND SERVICE MANUAL
WARRANTY
NOTE: Retain this manual for future reference.
SPECIAL INSTRUCTIONS TO OWNER
WARNING:
Improper Installation, Adjustment,
Alteration, Service or Maintenance
can cause injury or property damage.
Refer to this manual. For assistance or
additional information consult a qualified
installer, service agency or the gas supplier.
CHECKING EQUIPMENT
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.
DO NOT
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
The 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.
-
• Do not try to light any appliance.
• Do not touch any electric switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
Installation and service must be performed by a
qualified installer, service agency or the gas
supplier.
WARNING:
— WHAT TO DO IF YOU SMELL GAS —
2
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.
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.
1. Boilers and water heaters are heat producing
appliances. To avoid damage or injury, do not store
materials against the appliance or the vent-air intake
system. Use proper care to avoid unnecessary
contact (especially children) with the appliance and
vent-air intake components.
2. Never cover your appliance, lean anything
against it, store trash or debris near it, stand on it or
in any way block the flow of fresh air to
your 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.
The equipment shall be installed in accordance with
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
CONTENTS
Warranty
Safety Warnings ......................................................................1
Codes ..................................................................................2
Location ..................................................................................3
Clearances................................................................................4
Combustion/Ventilation Air Requirements ............................4
Conventional Venting ..............................................................7
Masonry Chimney Installations ............................................10
Sidewall Venting ....................................................................10
Automatic Vent Damper........................................................11
Gas Supply ............................................................................12
Gas Pressures & Piping..........................................12
Manifold Pressure Adjustment ..............................15
Supply Pressure Measurement ..............................16
Water Connections ................................................................17
Relief Valve............................................................................19
Flow Switch ..........................................................................19
Gas Valve ..............................................................................20
Electrical Requirements ........................................................21
Temperature Adjustment ......................................................22
Temperature Limit Control....................................................22
Blocked Vent and Flame Roll-out System............................22
Lighting Instructions ............................................................24
Ignition & Control Timings ..................................................29
Freeze Protection ..................................................................29
Maintenance ..........................................................................30
Flame Patterns........................................................30
Burner Cleaning ....................................................31
Heat Exchanger Inspection ....................................32
Lubrication ............................................................32
Gas Train................................................................................33
Heating Boiler ......................................................................34
Installation Requirements ......................................34
Pump Requirements ..............................................34
Pressure Drop Chart ..............................................34
Boiler Pump Operation ..........................................34
Typical Piping ........................................................35
Bypass Requirements ............................................35
Low Temperature Systems ....................................36
Boiler Flow Rates ..................................................37
Temperature Rise Chart ........................................38
Placing Boiler in Operation ..................................38
Boiler Temperature Control ..................................40
Remote Thermostat Control Connection ............................40
Water Heater/Domestic Hot Water Supply Boiler................40
Water Velocity Control ..........................................41
Temperature Rise....................................................41
Water Chemistry ....................................................42
Piping Requirements ..............................................42
Pump Requirements ..............................................43
Temperature Adjustment ........................................43
Risk of Scald Warnings..........................................44
USER WARNING
IMPORTANT:
Consult and follow local
Building and Fire Regulations and other Safety
Codes that apply to this installation. Consult
your local gas utility company to authorize and
inspect all gas and flue connections.
WARNING:
Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. Instead, shut off the gas
supply at a location external to the appliance.
WARNING:
To minimize the possibility of serious personal
injury, fire or damage to your appliance, never
violate the following safety rules.
CODES
3
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. The appliance must be installed on a level,
noncombustible floor. A concrete over wood
construction is not considered a noncombustible
floor. Maintain required clearances from
combustible surfaces.
7. The appliance must not be installed on carpet or
other combustible material.
8. For installation on a combustible floor only when
installed on special base:
Appliances installed over a combustible floor MUST
use the Special Combustible Floor Base Kit. The
appliance must be centered on the base as shown in
Figure 4. The correct part number for the
required base kit is noted on the rating plate of each
appliance and listed in Table A.
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/CGA-B149.1 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.
INSTALLATION PROCEDURE
FIG. 2
Front View
399,000—500,000
Btu Models
Front View
45,000—360,000
Btu Models
FIG. 3
Rear View
45,000—500,000
Btu Models
LOCATION OF UNIT
FIG. 1
4
Clearances from Combustible Construction:
Right Side - 6"
Rear - 6"
Left Side - 6" (24" suggested for service)
Front - (24" suggested for service)
45,000 - 180,000 BTU Models - 6"
199,000 - 500,000 BTU Models - ALCOVE*
Top - (measured from draft hood)
45,000 - 180,000 BTU Models - 14"
199,000 - 500,000 BTU Models - 29"
*An ALCOVE is a closet enclosure without a front door.
Allow sufficient space for servicing pipe connections,
pump and other auxiliary equipment, as well as the
appliance.
TABLE - A
COMBUSTIBLE FLOOR BASE KITS
Input BTU/hr Kit Number
45,000 CFK3045
75,000 CFK3090
90,000 CFK3090
135,000 CFK3135
180,000 CFK3180
199,000 CFK3225
225,000 CFK3225
270,000 CFK3270
315,000 CFK3315
360,000 CFK3360
399,000 CFK3399
500,000 CFK3500
CLEARANCES FROM
COMBUSTIBLE CONSTRUCTION
FIG. 4
FIG. 5A
Provisions for combustion and ventilation air must be
in accordance with Section 5.3, Air for Combustion and
Ventilation, of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition
of CGA Standard B149 Installation Code for Gas
Burning Appliances and Equipment, or applicable
provisions of the local building codes.
The mechanical room MUST be provided with properly
sized openings to assure adequate combustion air and
proper ventilation when the appliance is installed with
conventional venting.
COMBUSTION AND VENTILATION
AIR REQUIREMENTS
FOR CONVENTIONALLY
VENTED APPLIANCES
FIG. 5B
Clearances
Models
45,000–180,000
Clearances
Models
199,000–500,000
Combustion
Floor Base
29"
6"
6"
6"
14"
5
1. If air is taken directly from outside the building
with no duct, provide two permanent openings:
a. Combustion air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5cm
2
per kW). This opening must be located
within 12" (30 cm) of the bottom of the
enclosure.
b. Ventilation air opening, with a minimum
free area of one square inch per 4000
Btu/hr input (5.5cm
2
per kW). This opening
must be located within 12" (30cm) of the
top of the enclosure.
2. If combustion and ventilation air is taken from
the outdoors using a duct to deliver the air
to the mechanical room, each of the two
openings should be sized based on a minimum
free area of one square inch per 2000 Btu/hr
(11cm
2
per kW).
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
(645 cm
2
).
4. If a single combustion air opening is provided
to bring combustion air in directly from the
outdoors, the opening must be sized based on a
minimum free area of one square inch per 3000
Btu/hr (7cm
2
per kW). This opening must be
located within 12" (30cm) of the top of the
enclosure.
Combustion Air Direct from Outside
FIG. 6
Combustion Air Through Ducts
Combustion Air from Interior Space
Combustion Air from Outside
Single Opening
FIG. 8
FIG. 7
FIG. 9
6
*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 appliance only, additional gas fired
appliances in the mechanical room will require an
increase in the net free area to supply adequate combustion air for all appliances. Combustion air requirements
are based on the latest edition of the National Fuel Gas
Code, ANSI Z223.1, in Canada refer to National
Standard CAN B149.1 or B149.2. Check all local code
requirements for combustion air.
All dimensions based on net free area in square inches.
Metal louvers or screens reduce the free area of a
combustion air opening a minimum of approximately
25%. Check with louver manufacturers for exact net
free area of louvers. Where two openings are provided,
one must be within 12" (30 cm) of the ceiling and one
must be within 12" (30 cm) of the floor of the
mechanical room. Each opening must have net free area
as specified in the chart above. Single openings shall be
located within 12" (30 cm) of the ceiling.
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, trichlorethylene,
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.
EXHAUST FANS: Any fan or equipment which
exhausts air from the mechanical room may deplete the
combustion air supply and/or cause a down
draft in the venting system, spilling flue products into
the room. 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
TABLE - B
MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY
TO MECHANICAL ROOM
Combustion Air Source
Input Outside Air*/2 Outside Air*/1 Inside Air/2
Btu/hr Openings Openings Openings
45,000 12 in
2
15 in
2
100 in
2
75,000 19 in
2
25 in
2
100 in
2
90,000 23 in
2
30 in
2
100 in
2
135,000 34 in
2
45 in
2
135 in
2
180,000 45 in
2
60 in
2
180 in
2
199,000 50 in
2
67 in
2
200 in
2
225,000 56 in
2
75 in
2
225 in
2
270,000 68 in
2
90 in
2
270 in
2
315,000 79 in
2
105 in
2
315 in
2
360,000 90 in
2
120 in
2
360 in
2
399,000 100 in
2
133 in
2
400 in
2
500,000 125 in
2
167 in
2
500 in
2
CAUTION:
Under no circumstances should the mechanical
room ever be under a negative pressure. Particular care should be taken where exhaust fans, attic
fans, clothes dryers, compressors, air handling
units, etc., may take away air from the unit.
7
mechanical room, the installer must make sure that it
does not cause drafts which could lead to nuisance
operational problems with the appliance.
Vent installations for connection to gas vents or
chimneys must be in accordance with Part 7, “Venting
of Equipment,” of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment or applicable provisions of
the local building codes.
Adequate combustion and ventilation air must be
supplied to the mechanical room in accordance with the
latest edition of the National Fuel Gas Code, ANSI
Z223.1, in Canada, the latest edition of CGA Standard
B149 Installation Code for Gas Burning Appliances and
Equipment, or applicable provisions of the local
building codes.
The distance of the vent terminal from adjacent
buildings, windows that open and building openings
MUST comply with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CGA Standard B149 Installation Code for
Gas Burning Appliances and Equipment.
Vent connection is made directly to the top of the
appliance. This appliance is designed with a
built-in draft diverter. No additional draft diverter is
required. The connection from the appliance vent to the
common vent or chimney must be made as
direct as possible.
The negative draft in a conventional vent installation
must be within the range of a negative 0.02 to 0.05
inches water to insure proper operation. All draft
readings are made while the appliance is in stable
operation (approximately 2 to 5 minutes).
Multiple appliance installations with combined venting
or common venting with other negative
draft appliances require that each appliance must have
draft within the proper range. If the draft measured
above the appliance’s built-in draft hood exceeds the
specified range in a dedicated chimney for a single
appliance installation or in combined venting with other
negative draft appliances, a barometric damper must be
installed to control draft.
On a conventionally vented, negative draft appliance,
the connection from the vent to the chimney or vent
termination on the outside of the building MUST be
made with listed Type “B” doublewall (or equivalent)
vent connectors and must be direct as possible with no
reduction in diameter. Use the National Fuel Gas Code
venting tables for doublewall vent to properly size all
vent connectors and stacks. The Type “B” vent and
accessories, such as firestop spacers, thimbles, caps,
etc., MUST be installed in accordance with the
manufacturer’s listing. The vent connector and firestop
must provide correct spacing to combustible surfaces
and seal to the vent connector on the upper and lower
sides of each floor or ceiling through which the vent
connector passes.
VENTING
TABLE - C
VENT PIPE SIZES
Input BTU/hr Flue Size
45,000 3"
75,000 5"
90,000 5"
135,000 5"
180,000 6"
199,000 6"
225,000 7"
270,000 7"
315,000 8"
360,000 8"
399,000 10"
500,000 10"
Conventional Negative Draft
Vertical Venting
FIG. 10
A CONVENTIONAL NEGATIVE DRAFT
VENTING SYSTEM
8
Any vent materials used must be listed by a nationally
recognized test agency for use as vent material.
Locate appliance as close as possible to chimney or gas
vent.
Avoid long horizontal runs of the vent pipe, 90° elbows,
reductions and restrictions. Horizontal portions of the
venting system shall be supported to prevent sagging.
Horizontal runs must slope upwards not less than 1/4
inch per foot (21 mm/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 system 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 natural
draft shall not be connected to any portion of a
mechanical draft system operating under positive
pressure. Connection to a positive pressure chimney
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 connected 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 exhaust 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 five 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
appliances 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
National 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
portion of the common venting system, the
common venting system should be resized to
approach the minimum size as determined
using the appropriate tables in Part 11 in 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.
9
The vent terminal should be vertical and exhaust outside
the building at least 2 feet (0.61m) above the highest
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 termination 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, regulators
and relief equipment.
The venting system shall terminate at least 3 feet (0.9m)
above any forced air inlet within 10 feet (3.05m).
VENTING TERMINATION
FIG. 11
Vent Termination from Peaked Roof
10’ or Less from Ridge
FIG. 12
Vent Termination from Peaked Roof
More Than 10’ from Ridge
RIDGE
MORE THAN 10'
3' MIN
2' MIN
10'
CHIMNEY
FIG. 13
Vent Termination from Flat Roof
10’ or Less from Parapet Wall
Vent Termination from Flat Roof
More Than 10’ from Parapet Wall
10’ OR LESS
3’
WALL OR
PARAPET
CHIMNEY
NOTE:
NO HEIGHT ABOVE
PARAPET REQUIRED
WHEN DISTANCE
FROM WALLS OR
PARAPETS IS MORE
THAN 10’.
FIG. 14
10
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, stairwell,
alcove, courtyard or other recessed area. The vent can
not terminate below grade. The bottom 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 surfaces 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 building surfaces.
Adjacent brick or masonry surfaces should be protected
with a rust resistant sheet metal plate.
A masonry chimney must be properly sized for the
installation of a high efficiency gas fired appliance.
Venting of a high efficiency appliance into a cold or
oversized masonry chimney can result in operational
and safety problems. Exterior masonry chimneys, with
one or more sides exposed to cold outdoor temperatures,
are more likely to have venting problems. The
temperature of the flue gases from a high efficiency
appliance may not be able to sufficiently heat the
masonry structure of the chimney to generate proper
draft. This will result in condensing of flue gases,
damage the masonry flue/tile, insufficient draft and
possible spillage of flue gases into an occupied living
space. Carefully inspect all chimney systems before
installation. If there is any doubt about the sizing or
condition of a masonry chimney, it must be relined with
a properly sized and approved chimney liner system.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to
determine its suitability for the venting of flue gases. A
clay tile lined chimney must be structurally sound,
straight and free of misaligned tile, gaps between
liner sections, missing sections of liner or any signs
of condensate drainage at the breaching or clean
out. If there is any doubt about the condition of a
masonry chimney, it must be relined. An unlined
masonry chimney must not be used to vent flue
gases from this high efficiency appliance. An
unlined chimney must be relined with an approved
chimney liner system when a new appliance is being
attached to it. Metallic liner systems (Type “B”
doublewall, 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.
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. A properly sized and installed induced draft
fan may also be used to vent the flue gases vertically if
required by jobsite restrictions. The induced draft fan
must be listed by a nationally recognized test agency, be
properly sized and installed per the recommendations of
the induced draft fan manufacturer and meet local code
requirements. Use care to ensure that the mechanically
supplied draft does not exceed the range of a negative
IMPORTANT:
Examine the venting system at least once a year.
Check all joints and vent pipe connections for
tightness. Also check for corrosion or
deterioration. Immediately correct any problems
observed in the venting system.
MASONRY CHIMNEY
INSTALLATION
SIDEWALL VENTING
Sidewall Venting with an
Induced Draft Fan
FIG. 15
11
0.02 to 0.05 inches water to ensure proper operation. If
draft exceeds the specified range, the fan must be
adjusted or the installation of a barometric damper in
the flue may be required to properly control draft. An
induced draft fan MUST be interlocked into the
appliance’s control circuit to start when the appliance
calls for heat. The induced draft fan MUST also be
equipped with a proving switch, properly interlocked
into the appliance’s control circuit to prove fan
operation before the main burners are allowed to fire. A
vertical or sidewall vent termination for an induced draft
fan MUST be installed per the recommendations of the
fan manufacturer and provide proper clearances from
any combustion or ventilation openings, windows,
doors or other openings into the building. All induced
draft fan installations must comply with local code
requirements. Consult factory for kits available.
This heating boiler is design certified for use with the
automatic vent damper, 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
270,000 Btu/hr. A vent damper is optional on heating
boilers with inputs of 315,000 and 360,000 Btu/hr. A
vent damper is also available as an option on water
heater models with inputs of 90,000 thru 360,000
Btu/hr.
The vent damper is a useful tool for saving energy when
installed inside the building envelope where air can
circulate freely around the appliance. The vent damper
will not save as much, if any, energy if it is installed in
locations such as:
- Closet with solid, rather than louvered doors
- Outdoors
-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 properly
installed and the wire harness plugged into the terminal
on the side of the control panel to allow the boiler to
function. Larger input heating boilers and water heaters
will have a plug installed in the damper terminal to
allow operation without a damper. Remove damper plug
from terminal to connect an optional vent damper wire
harness. Damper plug MUST be in place if an optional
vent damper is not used on water heaters and larger
input heating boilers.
Install the vent damper to service only the single
appliance for which it is intended. If improperly
installed, a hazardous condition such as an explosion or
carbon monoxide poisoning could result.
The damper position indicator must be in a visible
location with access for service following installation.
The damper must be in 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. DAMPER
REGULATIONS PER THE LATEST EDITION OF
ANSI Z21.66.
AUTOMATIC VENT DAMPER
FIG. 16
CAUTION:
Do not install the vent damper within 6" (152 mm) of
combustible materials.
Automatic Vent Damper
12
.
Verify that the appliance is supplied with the type gas
specified on the rating plate. This appliance is orificed
for operation up to 2000 feet altitude. The appliance will
be derated 4% per 1000 feet above 2000 feet elevation.
Consult the factory for installations above 2000 feet
elevation. Field conversions for operation at high
altitude must be performed by factory authorized
personnel only. The appliance will be marked to indicate
suitability for high altitude operation.
INLET PRESSURE: Measured at the inlet pressure tap
located upstream of the combination gas valve(s).
Nat. Gas LPG
Max.(Inches-Water Column) 10.5"w.c. 13"w.c.
Min. (Inches-Water column) 5"w.c. 11"w.c.
Maximum inlet gas pressure must not exceed the value
specified. Minimum value listed is for the purposes of
input adjustment.
MANIFOLD PRESSURE: Measured at the pressure
tap on the downstream side of the combination gas
valve(s). The gas regulator on the appliance’s
combination gas valve(s) is adjustable to supply proper
manifold pressure for normal operation. If adjustment of
regulator pressure is required, see Manifold Adjustment
Procedure. Do not increase regulator pressure
beyond specified pressure setting.
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.
FIG. 17
CAUTION:
An appliance which is shut down or will not operate
may experience freezing due to convective air flow
down the flue pipe connected to the unit. Proper
freeze protection must be provided, see Freeze
Protection Section.
Vent damper must be installed directly on the flue
outlet located on the top of the draft hood (see Figure
17). Do not alter the wire harness supplied with the
vent damper. Follow the instructions supplied with
the vent damper.
WARNING:
GAS SUPPLY
TABLE - D
SUPPLY PRESSURE
GAS PRESSURE TEST
TABLE - E
MANIFOLD PRESSURE
BTU/hr Regulator Settings
Input Gas Natural Gas L.P.
45,000 3.5" 10"
75,000 2.3" 6.9"
90,000 - 180,000 3.5" 10"
199,000 2.7" 7.7"
225,000 - 500,000 3.5" 10"
13
1. Safe operation of the appliance requires
properly sized gas supply piping. See data
in Table F.
2. Gas pipe size may be larger than appliance
gas connection.
3. Installation of a union is suggested for ease
of service.
4. Install a manual main gas shutoff valve,
outside of the appliance gas connection and
before the gas valve or manifold connection,
when local codes require.
5. A trap (drip leg) MUST be provided in the
inlet of the gas connection to the appliance.
6. The combination gas valve has an integral
vent limiting device and does not require
venting to atmosphere, 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.
GAS CONNECTION
TABLE - F
SUGGESTED GAS PIPE SIZE
SINGLE APPLIANCE INSTALLATIONS
Btu/hr DISTANCE FROM METER
INPUT 0-50' 51'-100' 101'-200' 201'-300' 301'-500'
45,000 1/2" 1/2" 3/4" 1" 1 1/4"
75,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
90,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
135,000 3/4" 1" 1 1/4" 1 1/4" 1 1/2"
180,000 1" 1" 1 1/4" 1 1/2" 1 1/2"
199,000 1" 1" 1 1/4" 1 1/2" 2"
225,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
270,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
315,000 1 1/4" 1 1/2" 1 1/2" 1 1/2" 2"
360,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
399,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
500,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
For each elbow or tee, add equivalent straight pipe to total length from Table G.
TABLE - G
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'
14
All gas connections must be made with pipe joint
compound resistant to the action of liquefied petroleum
and natural gas. All piping must comply with local
codes. Tubing installations must comply with approved
standards and practices.
Install Piping to Control
1. The gas line should be a separate line direct
from the meter unless the existing gas line is of
sufficient capacity. Verify pipe size with your gas
supplier.
2. Use new, properly threaded black iron pipe free
from chips. If tubing is used, make sure the
ends are 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 manifold inlet.
TABLE- H
MULTIPLE APPLIANCE INSTALLATIONS
GAS PIPING SIZE CHART
Length of Pipe in Straight Feet
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
Nominal
Iron Pipe
Size, Inches
Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 14 Inches Water Column
(0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on the calorific value of Natural Gas, 1025
Btu/ft
3
@ 0.60 Specific Gravity)
GAS PIPING
FIG. 18
Gas Line Connection
Gas Cock
Sediment
Trap
15
4. Install a sediment trap in the supply line to the gas
valve or manifold assembly (see Figure 18).
5. Thread pipe the proper amount for insertion into gas
valve or manifold inlet as shown in Table-I.
DO NOT THREAD PIPE TOO FAR. Valve
distortion or malfunction may result if the pipe is
inserted too deeply into the gas valve.
TABLE - I
LENGTH OF STANDARD
NPT PIPE THREADS (Inches)
Pipe Size Effective Length of Thread Overall Length of Thread
1/2" 1/2" 3/4"
3/4" 9/16" 13/16"
1" 9/16" 1"
6. Apply a moderate amount of good quality pipe
compound (DO NOT use Teflon tape) to pipe
only, leaving two end threads bare.
7. Remove seal over gas valve or manifold inlet.
8. Connect pipe to gas valve or manifold inlet. Use
wrench to square ends of the gas valve.
9. For L.P. gas, consult your L.P. gas supplier for
expert installation.
1. Turn the power “OFF” at the main disconnect
switch.
2. Turn gas valve control knob to “PILOT” position
on standing pilot models. Ensure that the standing
pilot remains on. If the pilot goes out, follow the
“Lighting Instructions” for standing pilot models
to light the pilot. Turn gas valve control knob to
“OFF” position on spark ignition models.
3. Remove the 1/8" hex plug located on the outlet side
of the gas valve and install a fitting suitable to
connect to a manometer or magnahelic gauge. See
Figure 20. Minimum range of scale should be up
to 5" w.c. for Natural gas models and 10" w.c. for
L.P. gas models.
4. The 399,000 and 500,000 Btu/hr models will have
two gas valves with a pressure regulator on each
valve. Repeat the following adjustment procedure
to set the manifold pressure on each gas valve. The
manifold pressure for each valve should set at 3.5"
w.c. for Natural gas and 10" w.c. for L.P. gas.
5. Remove the pressure regulator adjustment cap
screw on the gas valve. See Figures 26, 27 and 28
for location.
6. Turn the power “ON” at the main disconnect
switch.
IMPORTANT:
Upon completion of any piping connections to the gas
system, leak test all gas connections with a soap
solution while system is under pressure. Immediately
repair any leak found in the gas train or related
components.
Do Not operate an appliance with a
leak in the gas train, valves or related piping.
GAS MANIFOLD PRESSURE
ADJUSTMENT PROCEDURE
APPLY
WRENCH
FROM TOP
OR BOTTOM
OF CONTROL
TO EITHER
SHADED
AREA
FIG. 19
Gas Valve
FIG.20
Manifold Pressure Adjustment
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