Lochinvar 90,000Btu Service Manual

Installation & Service Manual

Models: 90,000 - 500,000 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.

CFA-I-S Rev A

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6

THE COPPER-FIN --HOW IT WORKS . . . . . . . . . . . . . . . . . 7-9

1. DETERMINE UNIT LOCATION

Locate of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Clearances from Combustible Construction . . . . . . . . . . .10

Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . . 11-13

2. VENTING

A Conventional Negative Draft Venting System . . . . . . . 14-15

Vertical Vent Termination Clearances . . . . . . . . . . . . . . . 16

Masonry Chimney Installation . . . . . . . . . . . . . . . . . . . . . 17

Inspection of a Masonry Chimney . . . . . . . . . . . . . . . 17

Automatic Vent Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3. GAS CONNECTIONS

Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Gas Manifold Pressure Adjustment Procedure . . . . . . . . 21

Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . 22

Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 23

4. HYDRONIC PIPING

Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Water Flow Switch (if equipped) . . . . . . . . . . . . . . . . . . . 24

Low Water Cutoff (if equipped) . . . . . . . . . . . . . . . . . . . . 25

Typical Heating Boiler Installations . . . . . . . . . . . . . . . . . 25-26

Piping of the Boiler System . . . . . . . . . . . . . . . . . . . . . . . 26

Water Connections Heating Boilers Only . . . . . . . . . . . . 27

Circulator Pump Requirements . . . . . . . . . . . . . . . . . . . . 27

Circulator Pump Specifications . . . . . . . . . . . . . . . . . . . 27

Circulator Pump Operation (Heating Boilers Only) . . . . 27

Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . . . . 28

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

Three Way Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Figure 4-6_Prim. / Sec. Piping of a Single Boiler . . . 30 Figure 4-7_Prim. / Sec. Piping w/Low Temp. Bypass 31

Figure 4-8_Multiple Boilers Zoned w/Circulators . . . . 32

5. ELECTRICAL CONNECTIONS

Boiler Operating Temperature Control . . . . . . . . . . . . . . . 33

Room Thermostat or Remote Thermostat Connection . . 33

Power Venter Connection to Terminal Strip . . . . . . . . . . . 33

Pump Wiring for a Heating Boiler . . . . . . . . . . . . . . . . . . 34

Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 34

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

Maximum Set Point Determination . . . . . . . . . . . . . . . . . 35

Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . . . 36

Additional Temperature Controls . . . . . . . . . . . . . . . . . . . 38-39

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

6. STARTUP

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

Lighting Instructions for Standing Pilot Models (F1) . . . . 40-42

Safety Shutoff Test for Standing Pilot Ignition System . . 42 Lighting Instructions for Spark Ignition Pilot Models (F9/M9) . 43-44

Safety Shutoff Test for Spark Ignition Pilot System . . . . . . 44

Intermittent Pilot Spark Ignition System (F9/M9) . . . . . . . . . 44-45

Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

7. DOMESTIC WATER HEATERS

Water Velocity Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Required Temperature Rise . . . . . . . . . . . . . . . . . . . . . . . 46

Water Chemistry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Softened Water Systems . . . . . . . . . . . . . . . . . . . . . . . . . 47

Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Figure 7-1_Single Water Heater Piping w/Single Tank . . 48 Figure 7-2_Single Water Heater Piping w/Multiple Tanks 49 Figure 7-3_Multiple Water Heater Piping w/Single Tank . 50

Remote Sensor Installation . . . . . . . . . . . . . . . . . . . . . . . 51

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Thermostat Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51-52

Optional Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Thermal Expansion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

Cathodic Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

8. MAINTENANCE

Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 54-60

9. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 61-62

10. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63-66

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 cause injury or 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.

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 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.

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 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.

Ratings

Maximum allowed working pressure is located on the rating plate.

NOTICE

Installation & Service Manual

Copper-fin

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)

Net

I=B=R

Ratings

Water,

MBH

(Note 2)

CBN315 158 315 258 224

CBN360 180 360 295 257

CBN399 200 399 328 285

CBN500 250 500 410 357

Other Specifications

Boiler Water

Content Gallons

Water

Connections

Gas

Connections

Vent

Size

(Note 3)

1.09

2" 3/4" 8"

1.12

2" 1" 9"

1.22

2" 1" 10"

1.30

2" 1" 10"

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. Copper-fins require special gas venting. Use only the vent materials and methods specified in the Installation and Service Manual.

4. The Copper-fin 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 AHRI.

Figure A High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

UP TO 2000 FT.

Ratings

Installation & Service Manual

Notes:

1. Copper-fins require special gas venting. Use only the vent materials and methods specified in the Installation and Service Manual.

2. The Copper-fin 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.

Figure B High Altitude Label Location

UNIT EQUIPPED FOR

HIGH ALTITUDE

UP TO 2000 FT.

Copper-fin Specifications

Model Number

Note: Change “N” to

“L” for L.P. gas models

Input MBH

Water

Content Gallons

Water Connections Gas Connections

Vent Size

(Note 1)

CWN090 90 .91 2” 1/2” 5”

CWN135 135 .95 2” 1/2” 6”

CWN180 180 .99 2” 3/4” 7”

CWN199 199 1.02 2” 3/4” 7”

CWN225 225 1.02 2” 3/4” 7”

CWN270 270 1.06 2” 3/4” 8”

CWN315

315 1.09 2" 3/4" 8"

CWN360

360 1.12 2" 1" 9"

CWN399

399 1.22 2" 1" 10"

CWN500

500 1.30 2" 1" 10"

Maximum allowed working pressure is located on the rating plate.

NOTICE

Installation & Service Manual

The Copper-fin - How it works...

1. Control panel cover

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

2. Drain port (not shown)

Location from which the heat exchanger can be drained.

3. Flue outlet

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

4. Gas connection pipe

The gas pipe connection on this appliance should be connected to the incoming gas supply for the purpose of delivering gas to the appliance.

5. Gas valve

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

6. 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.

7. 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.

8. Ignition module (F9 and M9 models only)

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

9. Junction box

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

10. Relief valve

The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Water heaters are supplied with a temperature and pressure relief valve.

11. Terminal strip

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

12. 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.

13. Temperature gauge (CW models only)

The temperature gauge monitors the inlet temperature of the water heater as well as the outlet temperature.

14. Transformer

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

15. Water inlet

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

16. Water outlet

The water outlet is a 2" pipe connection that supplies water to the system .

17. Burner (not shown)

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

18. Pilot (not shown)

( F9 and M9 models only)

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

( F1 models only)

The pilot uses a standing flame to light the main burner.

19. Sight Glass (not shown)

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

20. Temperature and pressure gauge (CB models only)

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

21. Pump (shipped with CW models only)

The pump ensures adequate flow to operate the unit.

22. Pump relay

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

23. Temperature sensor

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

Installation & Service Manual

Models CWN270 Front View

Model CWN399 (inside unit)

Model CWN399 Front View

Model CWN270 (inside unit)

The Copper-fin - How it works...

Installation & Service Manual

The Copper-fin - How it works... (continued)

Model CBN500 (inside unit)

Model CBN500 Front View

Models CBN399 (inside unit)

Model CBN399 Front View

Installation & Service Manual

1 Determine unit 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, 90,000 - 180,000 Btu/hr

Figure 1-2_Alcove Installation , 225,000 - 500,000 Btu/hr

14 " TOP

6" REAR

24"

FRONT

24" LEFT

29" TOP

6" RIGHT

REAR

24"

FRONT

24" LEFT

RIGHT

Installation & Service Manual

1 Determine boiler location

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 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

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

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 (11cm2 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 (22cm2 per kW) of input, but not less than 100 square inches (645cm2) (see FIG. 1-5).

1 Determine boiler location

Installation & Service Manual

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

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 13). 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.

1 Determine boiler location (continued)

Installation & Service Manual

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

*Outside Air from

2 Ducts Delivered from

Outdoors

**Inside Air from

2 Ducts Delivered from

Interior Space

To p

Opening, in

Bottom

Opening, in

To p

Opening, in

Bottom

Opening, in

To p

Opening, in

Bottom

Opening, in

90,000

(148 cm

)

(148 cm

)

(194 cm

)

(291 cm

)

(291 cm

)

100

(646 cm

)

100

(646 cm

)

135,000

(220 cm

)

(220 cm

)

(291 cm

)

(439 cm

)

(439 cm

)

135

(871 cm

)

135

(871 cm

)

180,000

(291 cm2)

(388 cm2)

(581 cm2)

180

(1,162 cm2)

180

(1,162 cm2)

199,999

(323 cm

)

(323 cm

)

(433 cm

)

100

(646 cm

)

100

(646 cm

)

200

(1,291 cm

)

200

(1,291 cm

)

225,000

(368 cm2)

(484 cm2)

113

(730 cm2)

113

(730 cm2)

225

(1,452 cm2)

225

(1,452 cm2)

270,000

(439 cm2)

(581 cm2)

135

(871 cm2)

135

(871 cm2)

270

(1,742 cm2)

270

(1,742 cm2)

315,000

(510 cm

)

(510 cm

)

105

(678 cm

)

158

(1,020 cm

)

158

(1,020 cm

)

315

(2,033 cm

)

315

(2,033 cm

)

360,000

(581 cm

)

(581 cm

)

120

(775 cm

)

180

(1,162 cm

)

180

(1,162 cm

)

360

(2,323 cm

)

360

(2,323 cm

)

399,999

100

(646 cm2)

100

(646 cm2)

134

(865 cm2)

200

(1,291 cm2)

200

(1,291 cm2)

400

(2,581 cm2)

400

(2,581 cm2)

500,000

125

(807 cm2)

125

(807 cm2)

167

(1,078 cm2)

250

(1,613 cm2)

250

(1,613 cm2)

500

(3,226 cm2)

500

(3,226 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).

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 Standard B149 Installation Code for Gas Burning Ap pli anc es and Equipment, or applicable pro vi sions of the local building codes.

Installation & Service Manual

2 Venting

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 Equipment.

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.

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

90,000 5"

135,000 6"

180,000 7"

199,999 7"

225,000 7"

270,000 8"

315,000 8"

360,000 9"

399,999 10"

500,000 10"

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.

2 Venting (continued)

Installation & Service Manual

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.

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.

2 Venting

Installation & Service Manual

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

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

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

WALL OR PARAPET

CHIMNEY

2 Venting (continued)

Installation & Service Manual

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

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 in stalled induced draft fan may also be used to vent the flue gases ver ti cal ly if required by job site conditions. 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. 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.

TABLE - 7B

VENT MATERIALS

Kit

Number

Input

Btu / hr

Material

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

Figure 2-6_CW135 with Fan Assisted Venting

Fan Assisted Venting

A Power Venter kit is available on models 90,000 - 135,000 Btu/hr, water heaters only.

2 Venting

Installation & Service Manual

Automatic Vent Damper

This heating boiler is design certified for use with the automatic vent damper (FIG. 2-7) part number printed on the boiler’s rating plate. A vent damper is optional on heating boilers above 360,000 Btu/hr. Automatic vent dampers are not required or fur nished on potable water heaters. Water heaters with inputs of 360,000 Btu/hr and less may be ordered with the vent damp er as an option. A 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.

Larger input heating boilers and water heaters 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 (water heater shown in FIG. 2_8). The jumper plug MUST be in place if an optional vent damper is not used on water heaters and larger input heating boilers.

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

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.

Figure 2-7_CB with 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 in the Startup Section of this manual.

 DANGER

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.

 WARNING

Figure 2-8_CW with Vent Damper

VENT DAMPER

TERMINAL

BLOCK

VENT DAMPER

Installation & Service Manual

3 Gas connections

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.’s 3-5 and 3-6, page 23.

TABLE - 3A

GAS SUPPLY PRESSURE

Max. (Inches Water Column)

Natural Gas LP Gas

14 14

Min. (Inches Water Column) *4.5 11

Min. (Inches Water Column) **5.0 11

*Models 90,000 - 360,000 Btu/hr Only

**Models 399,999 - 500,000 Btu/hr Only

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.’s 3-5 and 3-6, page 23). 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

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

199,999 2.9" 7.5" 0.9" 2.5"

215,000 - 399,999 3.5" 10" 0.9" 2.5"

500,000 3.5"

10"

(two valves)

N/A N/A

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.

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 20.

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 20.

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

90,000 - 135,000 1/2"

180,000 - 315,000 3/4"

360,000 - 500,000 1

3 Gas connections

Installation & Service Manual

TABLE - 3E

MULTIPLE APPLIANCE INSTALLATIONS

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

TRAP ( DRIP LEG )

UNION

3 Gas connections (continued)

Installation & Service Manual

APPLY WRENCH TO FLANGE ONLY

WHEN FLANGE

IS USED

APPLY WRENCH FROM

BOTTOM OF GAS CONTROL

TO EITHER SHADED AREA

WHEN FLANGE

IS NOT 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

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 “PILOT” po si tion on standing pilot models. Ensure that the stand ing pilot remains on. If the pilot goes out, follow the “Lighting Instructions” in Section 6 - Startup for standing pi lot models to light the pilot. Turn gas valve control knob to “OFF” po si tion on spark ignition models.

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. The 500,000 Btu/hr model will have two gas valves with a pressure regulator on each valve. Repeat the following adjustment pro ce dure to set the manifold pressure on each gas valve.

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

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

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

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

9. Observe gas regulator pressure when all burn ers are firing. See Table 3B, Manifold Pressure (page 19) for proper regulator pressure settings.

10. 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. N

OTE: Adjustment

fitting is plas tic and may require slightly greater turning force than a metal fitting.

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

NOTICE

Do not increase regulator pres sure beyond specified pressure setting.

12. Turn gas valve control knob to “PILOT” po si tion on standing pilot models. Turn gas valve control knob to “OFF” position on spark ignition models.

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

14. Repeat the adjustment procedure for the sec ond gas valve on the 500,000 Btu/hr model.

15. Turn the gas valve control knob(s) to “ON” position.

16. 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 22 to check gas supply pressure with a manometer connected to the inlet pressure tap on the gas control.

INLET

PRESSURE

TAP

MANOMETER

PRESSURE REGULATOR

ADJUSTMENT

(UNDER SCREW CAP)

OUTLET

PRESSURE TAP

PILOT OUTLET

GAS CONTROL KNOB

RED RESET BUTTON

UNION

GAS VALVE

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