Lochinvar 2,065,000Btu User Manual
INSTALLATION AND SERVICE MANUAL
Save this manual for future reference.
WARNING: 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.
– Do not store or use
gasoline or other
flammable vapors and
liquids in the vicinity of
this or any other appliance.
WHAT TO DO IF YOU SMELL
GAS
• Do not try to light any
appliance.
• Do not touch any
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: 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 cause
property damage, personal
injury, exposure to
hazardous materials or
loss of life. Refer to this
manual. Installation and
service must be performed
by a qualified installer,
service agency or the gas
supplier. This unit contains
materials that have been
identified as carcinogenic,
or possibly carcinogenic,
to humans.
HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
495,000 - 2,065,000 Btu/hr MODELS
CB-CW(E)-i&s-06
Hydronic Heating Boilers and
Domestic Water Heaters
2
Table of Contents
General Product Information . . . . . . . . . . . . . . . . . . . . . . . . .3
Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Safety Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Product Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Locating Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Clearances from Combustible Construction . . . . . . . . . .6
Base for Combustible Floors . . . . . . . . . . . . . . . . . . . . .6
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Hydronic System Antifreeze . . . . . . . . . . . . . . . . . . . . . .7
Outdoor Boiler Installation . . . . . . . . . . . . . . . . . . . . . . .7
Shutdown and Draining . . . . . . . . . . . . . . . . . . . . . . . . .7
Freeze Protection for a Heating Boiler System . . . . . . . . . . .8
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . .8
Combustion Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Combustion Air Options . . . . . . . . . . . . . . . . . . . . . . . . .9
Exhaust Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Venting Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Vertical Vent Termination Clearances and Location . .10
Vent System Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Barometric Damper Location . . . . . . . . . . . . . . . . . . . .12
1. Conventional Negative Draft Venting . . . . . . . . . . .13
2. Outdoor Installation Venting . . . . . . . . . . . . . . . . . .14
Connecting to Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . .16
Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Connecting Gas Piping to Unit . . . . . . . . . . . . . . . . . . .17
Gas Train and Controls . . . . . . . . . . . . . . . . . . . . . . . . .17
Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . .18
Venting of Combination Gas Valves . . . . . . . . . . . . . .18
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . .18
Gas Manifold Pressure Adjustment . . . . . . . . . . . . . . .19
Connecting to Water Supply . . . . . . . . . . . . . . . . . . . . . . . . .20
Inlet and Outlet Connections . . . . . . . . . . . . . . . . . . . .20
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Water Flow Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Low Water Cutoff . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Connecting to Electrical Supply . . . . . . . . . . . . . . . . . . . . . .21
Terminal Strip Connection Options . . . . . . . . . . . . . . .22
Boiler System Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . .24
Low Temperature Return Water Systems . . . . . . . . . . .25
Radiant Floor and Snow Melt Heating Systems . . . . . .25
Table of Contents
Installation with a Chilled Water System . . . . . . . . . . .26
Boiler Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Boiler Bypass Requirements . . . . . . . . . . . . . . . . . . . . .27
Temperature/Pressure Gauge . . . . . . . . . . . . . . . . . . . . .27
Filling the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . .28
To Turn Off Gas To Appliance . . . . . . . . . . . . . . . . . . .29
Setting Temperature Control . . . . . . . . . . . . . . . . . . . . .29
Locating Temperature Control . . . . . . . . . . . . . . . . . . .29
Temperature Control Settings . . . . . . . . . . . . . . . . . . . .30
Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . .31
Boiler Operating Temperature Control . . . . . . . . . . . . .31
Temperature Control Sensors . . . . . . . . . . . . . . . . . . . .32
Placement of Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Remote Mounting of Sensor . . . . . . . . . . . . . . . . . . . . .33
Hot Surface Ignition System . . . . . . . . . . . . . . . . . . . . . . . . .33
Operation and Diagnostic Lights . . . . . . . . . . . . . . . . . . . . .35
Domestic Water Heaters . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
Water Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . .36
Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Pipe Size Requirements . . . . . . . . . . . . . . . . . . . . . . . .37
Circulating Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Minimum Pump Performance . . . . . . . . . . . . . . . . . . . .38
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Potable Hot Water Temperature Control Settings . . . . .38
Location of Cold Water Supply Piping Connections . .39
High Water Temperature Limit Control . . . . . . . . . . . .39
Optional Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . .39
Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Cleaning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .40
Flue Gas Passageways Cleaning Procedures . . . . . . . . . . . .40
Burner Removal and Cleaning . . . . . . . . . . . . . . . . . . .40
Heat Exchanger Cleaning . . . . . . . . . . . . . . . . . . . . . . .41
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . .41
Adjusting Differential Air Pressure . . . . . . . . . . . . . . . .41
Servicing Hot Surface Igniter and Ignition Module . . .43
Ignition System Checkout . . . . . . . . . . . . . . . . . . . . . . .44
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Schematic/Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . .47
Revision Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . .Back Cover
GENERAL PRODUCT
INFORMATION
Special Instructions
This manual supplies information for the installation, operation
and servicing of the appliance. Read and understand this manual
completely before installing unit.
Installation and service must be performed by a qualified service
installer, service agency, or the gas supplier.
Unpacking
Upon receiving equipment, check for signs of shipping damage.
Pay particular attention to parts accompanying the boiler 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 the carrier.
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 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 and/or CAN/CGA-B149 Installation
Code. 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.
Warranty
Factory warranty (shipped with unit) does not apply to units
installed or operated improperly.
In most cases, improper installation or system design causes
most operating problems.
1. Excessive water hardness causing a lime build up in the
copper tube is not the fault of the equipment and is not
covered under the appliance manufacturer's warranty (see
Water Treatment, page 28 and Water Chemistry, page 37).
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 appliance
manufacturer's warranty (see System Temperature Rise
Chart on page 26 for flow requirements).
SAFETY INFORMATION
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: Read this owner's manual carefully
and completely before trying to install, operate, or
service this unit. Improper use of this unit can
cause serious injury or death from burns, fire,
explosion, electrical shock, and carbon monoxide
poisoning.
DANGER: Carbon Monoxide poisoning may
lead to death!
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 unit.
WARNING: To minimize the possibility of
serious personal injury, fire or damage to your unit,
never violate the following safety rules.
1. This unit is only for use with the type of gas indicated on the
rating plate.
2. If you smell gas
• shut off gas supply
• do not try to light any appliance
• do not touch any electrical switch; do not use any
phone in your building
• immediately call your gas supplier from a neighbor's
phone. Follow the gas supplier's instructions
• if you cannot reach your gas supplier, call the fire
department
Installation and
Service Manual
3
3. 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. Follow all
clearances from combustibles contained in this manual.
4. Never cover your unit, 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.
5. 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 ventair intake system.
6. Appliance surfaces become hot during operation. Be careful
not to touch hot surfaces. Keep all adults, children, and
animals away from an operating hot unit. Severe burns can
occur.
7. You must take adequate care to prevent scald injury when
storing water at elevated temperatures for domestic use.
8. This unit must have an adequate supply of fresh air during
operation for proper gas combustion and venting.
9. Make sure all exhaust venting is properly installed and
maintained. Improper venting of this unit could lead to
increased levels of carbon monoxide.
10. Do not use this boiler if any part has been under water.
Immediately call a qualified service technician to replace the
boiler. The possible damage to a flooded boiler can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
11. Do not alter this unit in any way. Any change to this unit or
its controls can be dangerous.
Hydronic Heating Boilers and
Domestic Water Heaters
4
Installation and
Service Manual
5
Figure 1 – Front and Rear View
Rear View
Front View
PRODUCT
IDENTIFICATION
INSTALLATION
This unit meets the safe lighting performance criteria with the
gas manifold and control assembly provided, as specified in
the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9
and ANSI Z21.10.3/CSA 4.3.
LOCATING UNIT
1. Maintain all clearances from combustible construction when
locating unit. See Clearances from Combustible
Construction, this page.
2. Locate the unit so that if water connections should leak,
water damage will not occur. When such locations cannot
be avoided, install a suitable drain pan that is well-drained
under the unit. The pan must not restrict combustion air
flow. The appliance manufacturer is not responsible for
water damage in connection with this unit, or any of its
components.
3. Install indoor units so that the ignition system components
are protected from any water while operating or during
service.
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. You must install unit on a level, non-combustible floor.
7. Do not install unit directly on carpet or other combustible
material. A concrete-over-wood floor is not considered
non-combustible. Maintain required clearances from
combustible surfaces.
If installing unit in an area with a combustible floor, you
must use a special combustible floor base. See Base for
Combustible Floors, this page.
8. For outdoor models, you must install an optional vent kit.
Instructions for mounting the vent kit are included in the
venting section. Do not install outdoor models directly on
the ground. You must install the outdoor unit on a concrete,
brick, block, or other non-combustible pad. Outdoor
models have additional special location and clearance
requirements. See Outdoor Installation Venting, page 14.
A wind proof cabinet protects the unit from weather.
Clearances from Combustible
Construction
Maintain minimum specified clearances for adequate
operation. Allow sufficient space for servicing pipe
connections, pump and other auxiliary equipment, as well as
the unit. See rating plate for specific service clearance
requirements.
Right Side 3" (7.5 cm)
Rear 3" (7.5 cm) (3" min. from any surface)
Left Side 6" (15cm) (24" (0.61m) suggested for
service)
Front Alcove* (30" (0.76m) suggested for
service)
To p 3" (7.5cm)
Flue 1" (25.4mm)
Hot Water Pipes 1" (25.4mm)
*An Alcove is a closet without a door.
Note: No additional clearance is needed on the right side of the
unit for the observation port. An observation port is located on
both the right and left side of the unit.
Figure 2 - Clearances from Combustible Construction
Base for Combustible Floors
There is no manufactured combustible floor base kit available
for 985,000 - 2,065,000 Btu/hr models. You must construct a
Hydronic Heating Boilers and
Domestic Water Heaters
6
base for combustible floor installation. Install unit over a base
of hollow clay tiles or concrete blocks from 8" to 12" thick and
extending at least 24" beyond the unit sides. Place tiles or
blocks so that the holes line up horizontally to provide a clear
passage through the tiles or blocks. Place a 1/2" fireproof
millboard over the top of the tile or block base. Place a 20gauge sheet metal cover over the fireproof millboard. Center
the unit on the base. Also follow this procedure if electrical
conduit runs through the floor beneath the unit. This base must
meet all local fire and safety codes.
FREEZE PROTECTION
Although these units are CSA International design certified for
outdoor installations, such installations are not recommended
in areas where the danger of freezing exists. You must provide
proper freeze protection for outdoor installations, units
installed in unheated mechanical rooms or where temperatures
may drop to the freezing point or lower. If freeze protection is
not provided for the system, a low ambient temperature alarm
is recommended for the mechanical room. Damage to the unit
by freezing is non-warrantable.
Anytime the temperature measured at any of the sensors
(except the outside air temperature sensor) drops below 40°F,
the control turns on the pump contact and the alarm relay. The
pump will shut off when both sensors are above 50°F.
Pump Operation
This unit is equipped with a pump delay of 30 seconds. If
continuous operation of the pump is desired, the pump must be
electrically connected to another circuit. Connection of the
pump to this unit will provide intermittent pump delay
operation.
Location
Locate indoor boilers and hot water supply boilers in a room
having a temperature safely above freezing [32°F (0°C)].
CAUTION: A mechanical room operating
under a negative pressure may experience a
down draft in the flue of a boiler which is not
firing. The cold outside air pulled down the flue
may freeze a heat exchanger. This condition
must be corrected to provide adequate freeze
protection.
Hydronic System Antifreeze
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 appliance manufacturers
instructions. Do not use undiluted or automotive type
antifreeze.
Outdoor Boiler Installation
Adequate hydronic system antifreeze must be used. A snow
screen should be installed to prevent snow and ice
accumulation around the unit or its venting system.
Shut-Down and Draining
If for any reason, the unit is to be shut off, the following
precautionary measures must be taken:
1. Shut off gas supply.
2. Shut off water supply.
3. Shut off electrical supply
4. 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 water out of the heat exchanger (see
Figure 3).
5. Drain pump and piping.
Figure 3 - Draining Unit
Installation and
Service Manual
7
495,000 CFK3302
645,000 CFK3303
745,000 CFK3304
TABLE - A
COMBUSTIBLE FLOOR KITS
Input Btu/hr Kit Number
INSTALLATION
Continued
Freeze Protection for a Heating
Boiler System (if required)
1. Use only properly diluted inhibited glycol antifreeze
designed for hydronic systems. Inhibited propylene glycol
is recommended for systems where incidental contact with
drinking water is possible.
WARNING: Do not use undiluted or
automotive type antifreeze.
2. A solution of 50% antifreeze will provide maximum
protection of approximately -30°F.
3. Follow the instructions from the antifreeze manufacturer.
Quantity of antifreeze required is based on total system
volume including expansion tank volume.
4. Glycol is denser than water and changes the viscosity of
the system. The addition of glycol will decrease heat
transfer and increase frictional loss in the boiler and related
piping. A larger pump with more capacity (15% to 25%
more) may be required to maintain desired flow rates and
prevent a noise problem in a glycol system.
5. Local codes may require a back flow preventer or actual
disconnect from city water supply when antifreeze is
added to the system.
COMBUSTION AND VENTILATION
AIR
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 CAN/CGAB149 Installation Code for Gas Burning Appliances and
Equipment, or applicable provisions of the local building
codes.
Provide properly-sized openings to the equipment room to
assure adequate combustion air and proper ventilation when
the unit is installed with conventional venting or sidewall
venting.
Combustion Air Filter
The 985,000 - 2,065,00 Btu/hr models have a standard air
filter(s) located behind the combustion air inlet panel(s). This
filter helps ensure clean air is used for the combustion process.
Check this filter every month and replace when it becomes
dirty. The filter size is 12" x 16" x 1" (30.5cm x 40.6cm x
2.5cm) . You can find this commercially available filter at any
home center or HVAC supply store.
Installing Combustion Air Filter
To install the filter(s), remove the combustion air inlet panel(s).
The 985,000 - 1,435,000 Btu/hr models have one combustion air
inlet panel located on the left front of the unit (see Figure 4). The
1,795,000 and 2,065,000 Btu/hr models have two combustion air
inlet panels located on the left and right front of the unit (see
Figure 5).
1. Loosen knurled knob at the bottom of the control panel
cover.
2. Pull the bottom of the panel(s) out and down to remove.
3. Place filter(s) in opening(s).
4. Replace combustion air inlet panel(s).
Figure 4 - Installing Combustion Air Filter, 985,000 1,435,000 Btu/hr Models
Figure 5 - Installing Combustion Air Filters, 1,795,000 and
2,065,000 Btu/hr Models
Hydronic Heating Boilers and
Domestic Water Heaters
8
Combustion Air Options
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.,
take away air from the unit.
1. Outside Combustion Air, No Ducts You can direct
outside combustion air to this unit using either one or two
permanent openings.
One Opening
The opening must have a minimum free area of one square
inch per 3000 Btu input (7cm
2
per kW). You must locate this
opening within 12" (30cm) of the top of the enclosure.
Figure 6 - Outside Combustion Air - Single Opening
Two Openings
The combustion air opening must have a minimum free area of
one square inch per 4000 Btu input (5.5cm
2
per kW). You must
locate this opening within 12" (30cm) of the bottom of the
enclosure.
The ventilation air opening must have a minimum free area of
one square inch per 4000 Btu input (5.5cm
2
per kW). You must
locate this opening within 12" (30cm) of the top of the
enclosure.
Figure 7 - Outside Combustion Air - Two Openings
2. Outside Combustion Air, Using Ducts
You can direct outside combustion air to this unit using two air
ducts to deliver the air to the boiler room.
Each of the two openings must have a minimum free area of
one square inch per 2000 Btu input (11cm
2
per kW).
Figure 8 - Outside Combustion Air Through Ducts
3. Combustion Air from Interior Space
You can direct combustion air to this unit using air from an
adjoining interior space. You must provide two openings from
the boiler room to the adjoining room.
Each of the two openings must have a net free area of one
square inch per 1000 Btu input (22cm
2
per kW), but not less
than 100 square inches (645cm2).
Installation and
Service Manual
9
INSTALLATION
Continued
Figure 9 - Combustion Air from Interior Space
All dimensions are 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 a minimum net
free area as specified in TABLE-C, page 12. Single openings
shall be installed 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 boiler room
may deplete the combustion air supply and/or cause a down
draft 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 corrected immediately. If a
fan is used to supply combustion air to the boiler room, the
installer must make sure that it does not cause drafts which
could lead to nuisance operational problems with the boiler.
VENTING
General Information
You must supply adequate combustion and ventilation air to
this unit. You must provide minimum clearances for the vent
terminal from adjacent buildings, windows that open, and
building openings. Follow all requirements set forth in the
latest edition of the National Fuel Gas Code, ANSI Z223.1, in
Canada, the latest edition of CAN/CGA Standard B149
Installation Code for Gas Burning Appliances and Equipment
or applicable local building codes. Vent installations for
connection to gas vents or chimneys must be in accordance
with Part 7, "Venting of Equipment" of the above-mentioned
standards.
IMPORTANT: Examine the venting system at
least once each year. Check all joints and vent
pipe connections for tightness. Also check for
corrosion or deterioration. If you find any
problems, correct them at once.
Venting Support
Support horizontal portions of the venting system to prevent
sagging. Provide an upward slope of at least 1/4 inch per foot
(21mm/m) on all horizontal runs from the unit to the vertical
flue run or to the vent terminal on sidewall venting
installations.
Do not use an existing chimney as a raceway if another
appliance or fireplace is vented through the chimney. The
weight of the venting system must not rest on the unit. Provide
adequate support of the venting system. Follow all local and
applicable codes. Secure and seal all vent connections. Follow
the installation instructions from the vent material
manufacturer.
Vertical Vent Termination Clearances
and Location
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.
Hydronic Heating Boilers and
Domestic Water Heaters
10
You must locate the air inlet termination elbow at least 12"
(30cm) above the roof or above normal snow levels.
Keep the vent cap clear of snow, ice, leaves, and debris to
avoid blocking the flue.
Figure 10 - Vent Termination from Peaked Roof - 10' or
Less From Ridge
IMPORTANT: Vent terminations are not shown in
Figures 10, 11, 12, and 13. Make sure all vertical
vents are installed with vent terminations
recommended by the vent manufacturer.
Figure 11 - Vent Termination from Peaked Roof More Than
10' From Ridge
Figure 12 - Vent Termination from Flat Roof 10' or Less from
Parapet Wall
Figure 13 - Vent Termination from Flat Roof More Than 10'
from Parapet Wall
CAUTION: Units which are shut down or
will not operate may experience freezing due to
convective air flow in the flue pipe, through the
air inlet, or from negative pressure in the
mechanical room. In cold climates, operate pump
continuously to help prevent freezing of boiler
water. Provide proper freeze protection. See
Freeze Protection, page 7.
TABLE-A
Flue Pipe Sizes
Installation and
Service Manual
11
INSTALLATION
Continued
Input Flue
Btu/hr Size
495,000 6"
645,000 8"
745,000 8"
985,000 10"
1,255,000 12"
1,435,000 12"
1,795,000 14"
2,065,000 14"
Vent System Options
This unit has two venting options.
1. Conventional Negative Draft Venting
This option uses a vertical rooftop flue termination.
Combustion air is supplied from the mechanical room. See
page 13 for detailed information.
2. Outdoor Installation Venting
This option uses the installation of special air inlet and vent
caps on the unit. See page 13 for venting details.
All units are shipped from the factory equipped for
conventional negative draft venting. All other optional vent
systems require the installation of specific vent kits and
venting materials. The following is a detailed explanation of
the installation requirements for each venting system,
components used and part numbers of vent kits for each model.
Barometric Damper Location
Any venting system option that requires a barometric damper
must adhere to the following directions for optimum
performance.
The preferred location for the barometric damper is in a tee or
collar installed in the vertical pipe rising from the unit’s flue
outlet. The barometric damper MUST NOT be installed in a
bull head tee installed on the unit’s flue outlet. The tee or collar
containing the barometric damper should be approximately
three feet vertically above the connection to the unit’s flue
outlet. This location ensures that any positive velocity pressure
from the unit’s internal combustion fan is dissipated and the
flue products are rising due to buoyancy generated from the
temperature of the flue products. Adjust weights on damper to
ensure that draft is maintained within the specified ranges.
Hydronic Heating Boilers and
Domestic Water Heaters
12
TABLE - B
Flue Pipe Sizes
TABLE–C
Minimum Recommended Combustion Air Supply To Boiler Room
Combustion Air Source
Boiler Input Outside Air*/2 Openings Outside Air*/1 Opening Inside Air/2 Openings
495,000 125 in2(806 cm2) 167 in2(1077 cm2) 500 in2(3226 cm2)
645,000 163 in
2
(1052 cm2) 217 in2(1400 cm2) 650 in2(4194 cm2)
745,000 188 in
2
(1213 cm2) 250 in2(1613 cm2) 750 in2(4839 cm2)
985,000 248 in
2
(1,600cm2) 330 in2(2,129cm2) 990 in2(6,388cm2)
1,255,000 315 in
2
(2,032cm2) 420 in2(2,710cm2) 1260 in2(8,130cm2)
1,435,000 360 in2(2,323cm2) 480 in2(3,097cm2) 1440 in2(9,291cm2)
1,795,000 450 in2(2,903cm2) 600 in2(3,871cm2) 1800 in2(11,614cm2)
2,065,000 518 in2(3,342cm2) 690 in2(4,452cm2) 2070 in2(13,356cm2)
*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 units in the boiler room will require
an increase in the net free area to supply adequate combustion air for all units. Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI
Z223.1, in Canada refer to CAN/CGA-B149 Installation Code. Check all local code requirements for combustion air.
1. Conventional Negative Draft
Venting
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information
section, page 10.
Figure 14 - Conventional Negative Draft Vertical Venting
with Combustion Air Louvers
This option uses Type-B double-wall flue outlet piping. The
blower brings in combustion air. The buoyancy of the heated
flue products cause them to rise up through the flue pipe. The
flue outlet terminates at the rooftop.
Negative Draft
The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper
operation. Make all draft readings while the unit is in stable
operation (approximately 2 to 5 minutes).
Connect the flue vent directly to the flue outlet opening on the
top of the unit. No additional draft diverter or barometric
damper is needed on single unit installations with a dedicated
stack and a negative draft within the specified range of 0.02 to
0.08 inches w.c. If the draft in a dedicated stack for a single
unit installation exceeds the maximum specified draft, you
must install a barometric damper to control draft. Multiple unit
installations with combined venting or common venting with
other Category I negative draft appliances require each boiler
to have a barometric damper installed to regulate draft within
the proper range.
Do not connect vent connectors serving appliances vented by
natural draft (negative draft) to any portion of a mechanical
draft system operating under positive pressure. Connecting to
a positive pressure stack may cause flue products to be
discharged into the living space causing serious health injury.
Flue Outlet Piping
With this venting option, you must use Type-B double-wall (or
equivalent) vent materials. Vent materials must be listed by a
nationally-recognized test agency for use as vent materials.
Make the connections from the unit vent to the outside stack as
direct as possible with no reduction in diameter. Use the
National Fuel Gas Code venting tables for double-wall vent to
properly size all vent connectors and stacks. Follow the vent
manufacturer's instructions when installing Type-B vents and
accessories, such as firestop spacers, vent connectors,
thimbles, caps, etc.
Provide adequate clearance to combustibles for the vent
connector and firestop.
When planning the venting system, avoid possible contact with
plumbing or electrical wiring inside walls, ceilings, and floors.
Locate the unit as close as possible to a chimney or gas vent.
Avoid long horizontal runs of the vent pipe, 90° elbows,
reductions and restrictions.
No additional draft diverter or barometric damper is required
on single unit installations with a dedicated stack and a
negative draft maintained between 0.02 to 0.08 inches w.c.
Common Venting Systems
You can combine the flue with the vent from any other
negative draft, Category I appliance. Using common venting
for multiple negative draft appliances requires you to install a
barometric damper with each unit. This will regulate draft
within the proper range. You must size the common vent and
connectors from multiple units per the venting tables for TypeB double-wall vents in the latest edition of the National Fuel
Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation
Code.
Common venting systems may be too large when an existing
unit 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.
1. Seal any unused opening in the common venting system.
2. Visually inspect the venting system for proper size and
horizontal pitch. Make sure there is no blockage or
restriction, leakage, corrosion and other unsafe conditions.
3. If possible, close all building doors and windows. Close all
doors between the space in which the appliances remaining
connected to the common venting system are located and
other building spaces.
Installation and
Service Manual
13
INSTALLATION
Continued
4. 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.
5. Close fire place dampers.
6. Place in operation the unit being inspected. Follow the
lighting instructions. Adjust thermostat so unit will operate
continuously.
7. 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.
8. After making sure that each appliance remaining
connected to the common venting system properly vents
when tested as above, return doors, windows, exhaust fans,
fireplace dampers and other gas burning appliances to their
previous conditions of use.
9. Correct any improper operation of the common venting
system so that the installation conforms to the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada,
the latest edition of CAN/CGA-B149 Installation Code for
Gas Burning Appliances and Equipment. When resizing
any portion of the common venting system, resize to
approach the minimum size as determined using the
appropriate tables of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CAN/CGA-B149 Installation Code for Gas Burning
Appliances and Equipment.
Masonry Chimney Installations
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 products 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 products, damage to the
masonry flue/tile, insufficient draft and possible spillage of
flue products into an occupied living space. Carefully inspect
all chimney systems before installation.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to determine
its suitability for the venting of flue products. 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 breeching or
clean out. If there is any doubt about the condition of a
masonry chimney, it must be relined with a properly-sized and
approved chimney liner system. An unlined masonry chimney
must not be used to vent flue products from this highefficiency unit. 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 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.
Vertical Vent Termination Clearances
and Location
Follow all vertical venting termination information for
clearances and location under Vertical Vent Termination
Clearances and Location, page 10.
2. Outdoor Installation Venting
IMPORTANT: Before installing a venting system,
follow all venting clearances and requirements
found in the Venting, General Information section,
page 10.
Units are self-venting and can be used outdoors when installed
with the optional outdoor caps. These caps mount directly to the
unit and cover the flue outlet and combustion air inlet openings.
No additional vent piping is required.
WARNING: Only install outdoor models
outdoors and only use the vent caps supplied by
the appliance manufacturer. Personal injury or
product damage may result if any other cap is
used or if an outdoor model is used indoors.
Properly install all covers, doors and jacket panels
to ensure proper operation and prevent a
hazardous condition.
Combustion air supply must be free of contaminants (see
Combustion and Ventilation Air, page 8). To prevent recirculation
of the flue products into the combustion air inlet, follow all
instructions in this section.
Hydronic Heating Boilers and
Domestic Water Heaters
14
Outdoor Vent/Air Inlet Location
Keep venting areas free of obstructions. Keep area clean and free
of combustible and flammable materials. Maintain a minimum
clearance of 3" (76mm) to combustible surfaces and a minimum
of 3" (76mm) clearance to the air inlet. To avoid a blocked air
inlet or blocked flue condition, keep the air inlet, flue outlet and
drain slot clear of snow, ice, leaves, debris, etc.
Do not install outdoor models directly on the ground. You must
install the outdoor unit on a concrete, brick, block, or other
non-combustible pad.
Do not locate unit so that high winds can deflect off of adjacent
walls, buildings or shrubbery causing recirculation.
Recirculation of flue products may cause operational
problems, bad combustion or damage to controls. Locate unit
at least 3 feet (0.91m) from any wall or vertical surface to
prevent wind conditions from affecting performance.
Multiple outdoor unit installations require 48" (1.22m)
clearance between each vent cap. Locate the outdoor cap at
least 48" (1.22m) below and 48" (1.22m) horizontally from
any window, door, walkway or gravity air intake.
Locate the unit at least 10 feet (3.05m) away from any forced
air inlet.
Locate the unit at least 3 feet (0.91m) outside any overhang.
Clearances around outdoor installations can change with time.
Do not allow the growth of trees, shrubs or other plants to
obstruct the proper operation of the outdoor vent system.
Do not install in locations where rain from building runoff
drains will spill onto the unit.
TABLE-C
Input Kit* Kit*
Btu/hr w/ Pump without
Cover Pump Cover
495,000 ODK3023 ODK3014
645,000 ODK3024 ODK3015
745,000 ODK3024 ODK3015
985,000 ODK3046 ODK3043
1,255,000 ODK3047 ODK3044
1,435,000 ODK3047 ODK3044
1,795,000 ODK3048 ODK3045
2,065,000 ODK3048 ODK3045
* These kits include an outdoor vent cap, air inlet hood(s), and gasket.
Flue gas condensate can freeze on exterior walls or on the vent
cap. Frozen condensate on the vent cap can result in a blocked
flue condition. Some discoloration to exterior building or unit
surfaces can be expected. Adjacent brick or masonry surfaces
should be protected with a rust resistant sheet metal plate.
The Outdoor Vent Kit
The optional outdoor vent kit is available from the appliance
manufacturer. The outdoor kit part numbers are listed by unit
size. See TABLE-D for kit numbers.
You can install the outdoor vent cap and combustion air inlet
panel(s) on the unit (see Figures 15 and 16).
Figure 15 - Outdoor Vent Cap Installed on
495,000 - 1,435,000 Btu/hr Models
Figure 16 - Outdoor Vent Cap Installed on 1,795,000 and
2,065,000 Btu/hr Models
Installation and
Service Manual
15
TABLE - D
Outdoor Vent Kits
INSTALLATION
Continued
CONNECTING TO GAS
SUPPLY
Only supply the gas type specified on the unit's rating plate.
This unit is orificed for operation up to 2000 feet altitude. If
installing above 2000 feet elevation, consult the appliance
manufacturer.
INLET PRESSURE: Measure inlet pressure at the inlet
pressure tap located upstream of the combination gas valve(s).
See TABLE-E for maximum and minimum inlet pressures. Do
not exceed the maximum. Minimum inlet pressure is for the
purposes of input adjustment.
Input Max. Min.
495,000 - 745,000 Btu/hr
Nat. Gas 10.5" w.c. 4" w.c.
LP Gas 13" w.c. 8" w.c.
985,000 - 2,065,000 Btu/hr
Nat. Gas 10.5" w.c. 4.5" w.c.
LP Gas 13" w.c. 8" w.c.
MANIFOLD PRESSURE: Measure manifold pressure at the
pressure tap on the downstream side of the combination gas
valves. The gas regulator on the unit's combination gas valve
is adjustable to supply proper manifold pressure for normal
operation. See TABLE-I for net manifold pressure settings.
If you must adjust regulator pressure, follow the instructions
under Gas Manifold Pressure Adjustment, page 19. Do not
increase regulator pressure beyond the specified pressure
setting.
Gas Pressure Test
1. Disconnect the unit from the gas supply piping system
during any piping system pressure testing greater than 1/2
PSIG (3.5kPa).
2. Isolate the unit from the gas supply piping system by
closing a manual shutoff valve during any piping system
pressure testing that is equal to or less than 1/2 PSIG
(3.5kPa).
3. Test all gas connections for gas leaks before placing unit in
operation.
Gas Piping
To safely operate this unit, you must properly size the gas
supply piping. See TABLES- F, G, & H for piping and fitting
requirements. Gas pipe size may be larger than heater
connection.
The gas connection for models 495,000 to 745,000 Btu/hr is
1 1/4" NPT and on models 985,000 to 2,065,000 Btu/hr the
gas connection to these units is 2" NPT.
For ease of service, install a union.
Install a manual main gas shutoff valve, outside of the unit gas
connection within six feet of the unit in accordance with the
requirements of the National Fuel Gas Code, ANSI Z223.1.
You must provide a sediment trap (drip leg) in the inlet of the
gas connection to the unit.
Figure 17 - 495,000 - 745,000 Btu/hr Gas Line Connection
Example
Figure 18 - 985,000 - 2,065,000 Btu/hr Gas Line Connection
Example
IMPORTANT: Do not block access to the
electrical cover plate when installing the
sediment trap. The sediment trap must be a
minimum of 12 inches from the appliance.
Hydronic Heating Boilers and
Domestic Water Heaters
16
TABLE - E
Inlet Pressure
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