Lochinvar CBN045, CBN075, CBN090, CBN135, CBN180 Installation Manual

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SBRX-I-S_100161690_2000017139_Rev G

Installation & Service Manual

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

 WARNING:

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.

Save this manual for future reference.

Contents

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

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

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

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

1. DETERMINE BOILER LOCATION

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

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

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

2. VENTING

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

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

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

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

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

3. GAS CONNECTIONS

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

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

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

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

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

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

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

4. WATER CONNECTIONS

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

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

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

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

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

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

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

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

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

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

Full System Flow ........................................................ 32

5. ELECTRICAL CONNECTIONS

Room Thermostat or Remote Thermostat Connection .... 33

Auxiliary Device Connection to Terminal Strip ................. 33

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

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

Additional Temperature Controls ................................ 34-35

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

Temperature Control Settings .......................................... 36

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

Wiring of the Outdoor Air Sensor ..................................... 38

6. STARTUP

Initial Startup .................................................................... 39

Lighting Instructions for Spark Ignition Pilot Models (M9) ....... 39

Safety Shutoff Test for Spark Ignition Pilot System ............ 40

Water Treatment ............................................................................. 41

Intermittent Pilot Spark Ignition System (M9) ........................ 43

Freeze Protection ........................................................................... 43

7. MAINTENANCE

Maintenance and Annual Startup ................................ 44-49

8. TROUBLESHOOTING

Checking Temperature Sensors ...................................... 50

Troubleshooting Guide: M9 Solution Boilers .................. 51

9. DIAGRAMS .................................................................. 52

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.

Please read before proceeding

Installation & Service Manual

NOTICE

 WARNING

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.

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.

 WARNING

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

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.

 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.

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).

IMPORTANT

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

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.

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.

Please read before proceeding

Installation & Service Manual

 WARNING

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

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

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

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

Codes –

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

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

Boiler water –

Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

Prevention of freezing –

Heat exchangers and headers damaged by freezing are not covered by warranty.

See Section 6, Start-Up - Freeze Protection for more information.

Ratings

Installation & Service Manual

Solution Boiler

AHRI Rating

Model Number

Note: Change

“N” to “L”

for LP gas

models

CBN045 23 45 37 32

CBN075 38 75 62 54

CBN090 45 90 75 65

CBN135 68 135 112 97

CBN180 90 180 149 130

CBN215 108 215 178 155

CBN260 130 260 216 188

NOTICE

Maximum allowed working pressure is located on the rating plate.

Input MBH

(Note 4)

Min Max

Gross

Output

MBH

(Note 1,5)

Net

AHRI

Ratings

Water,

MBH

(Note 1,5)

Other Specifications

Boiler Water

Content Gallons

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

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

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

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

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

1.06 2" 3/4" 8"

Water

Connections

Gas

Connections

Vent Size

(Note 3)

Notes:

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

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

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

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

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

UNIT EQUIPPED FOR

HIGH ALTITUDE

UP TO 2000 FT.

Figure A High Altitude Label Location

The Solution - How it works...

Installation & Service Manual

1. Control panel cover

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

2. Burner (not shown)

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

3. Drain port

Location from which the heat exchanger can be drained.

4. Flue outlet

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

5. Gas connection

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

6. Gas valve

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

7. Heat exchanger

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

8. High limit sensor

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

the control circuit, shutting the appliance down.

9. Ignition module

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

16. Sight Glass

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

and the pilot flame.

17. Temperature and pressure gauge

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

18. Temperature sensor

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

19. Terminal strip

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

20. Top panel

Removable panel to gain access to the internal components.

21. Thermostat

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

22. Transformer The transformer reduces 120 VAC supply voltage to 24 VAC for the

control circuit.

23. Water inlet (system return)

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

24. Water outlet (system supply)

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

10. Junction box

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

11. Performance loop

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

12. Performance Loop Pump

The pump ensures adequate flow to operate the unit.

13. Pilot (not shown) The pilot is a spark ignition device used to light a pilot flame which

in turn is used to light the main burners.

14. Pump relay

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

15. Relief valve

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

25. Gas manifold pipe

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

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

Installation & Service Manual

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

Models 45,000 - 90,000 Rear View

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

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

The Solution - How it works...

Installation & Service Manual

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

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

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

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

1 Determine boiler location

Installation & Service Manual

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.

Recommended Service Clearances:

Left - 24” Front - 24”

14" TOP

6 " RIGHT

6 " REAR

18 " FRONT

18 " LEFT

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

Recommended Service Clearances:

Left - 24” Front - 24”

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.

NOTICE

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

29" TOP

6 " RIGHT

6 " REAR

18 " FRONT

18 " LEFT

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

1 Determine boiler location

Combustion and ventilation air requirements for conventionally vented appliances

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

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

Installation & Service Manual

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 1-3_Combustion Air Direct from Outside

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 cm2 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 located within 12" (30 cm) of the ceiling.

per kW). This opening must be

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).

Installation & Service Manual

1 Determine boiler location (continued)

Figure 1-6_Combustion Air from Outside Single Opening

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 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6).

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

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

 CAUTION

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.

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.

1 Determine boiler location

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

Installation & Service Manual

Input

Btu/hr

45,000

75,000

90,000

135,000

180,000

215,000

260,000

*Outside Air from

2 Openings Directly from

Outdoors

Top

Opening, in

(78 cm2)

(123 cm2)

(148 cm2)

(220 cm2)

(291 cm2)

(349 cm2)

(420 cm2)

Bottom

Opening, in

(78 cm2)

(123 cm2)

(148 cm2)

(220 cm2)

(291 cm2)

(349 cm2)

(420 cm2)

*Outside Air from 1 Opening Directly from Outdoors, in

(97 cm2)

(162 cm2)

(194 cm2)

(291 cm2)

(388 cm2)

(465 cm2)

(562 cm2)

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

(149 cm2)

(246 cm2)

(291 cm2)

(439 cm2)

(581 cm2)

108

(697 cm2)

130

(839 cm2)

Bottom

Opening, in

(149 cm2)

(246 cm2)

(291 cm2)

(439 cm2)

(581 cm2)

(697 cm2)

(839 cm2)

108

130

**Inside Air from

2 Ducts Delivered from

Interior Space

Top

Opening, in

(646 cm2)

(871 cm2)

(1,162 cm2)

(1,388 cm2)

(1,678 cm2)

100

135

180

215

260

Bottom

Opening, in

100

(646 cm2)

100

(646 cm2)

100

(646 cm2)

135

(871 cm2)

180

(1,162 cm2)

215

(1,388 cm2)

260

(1,678 cm2)

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

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

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

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

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

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

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. and Equipment, or applicable pro vi sions of the local building codes.

2 Venting

Installation & Service Manual

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 readings 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.

TABLE - 2A

VENT PIPE SIZES

Input Btu/hr Flue Size

45,000 4"

75,000 5"

90,000 5"

135,000 6"

180,000 7"

215,000 7"

260,000 8"

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

Figure 2-1_Conventional Negative Draft Vertical Venting

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

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.

Installation & Service Manual

(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.

(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.

2 Venting (continued)

Vertical Vent Termination Clearances

Installation & Service Manual

10' OR LESS

2' MIN

RIDGE

CHIMNEY

3' MIN

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

MORE THAN 10'

10'

2' MIN

RIDGE

CHIMNE

3' MIN

2' MIN

CHIMMEY

WALL OR PARAPET

2' MIN

3' MIN

CHIMMEY

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

10' OR MORE

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

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

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.

WALL OR PARAPET

CHIMNEY

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

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 Venting

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 - Negative Draft

This appliance is NOT approved for sidewall venting as shipped from the factory. If installation requires that the flue gases be vented out a sidewall, either an induced draft fan or a power venter MUST be used. A power venter that plugs directly into the vent damper plug is available for models up to 135,000 Btu/hr and may be used for both sidewall and vertical venting configurations, see Fan Assisted Venting. Larger models may use an induced draft fan, which will connect to the terminal strip on the side of the boiler, see Auxiliary Power Venting Connection to Terminal Strip, page 33 for more information. A properly sized and in stalled induced draft fan may also be used to vent the flue gases ver ti cal ly if required by jobsite re stric tions. The induced draft fan must be listed by a nationally recognized test agency, be properly sized and installed per the rec om men da tions of the in duced draft fan manufacturer and meet local code requirements. Use care to ensure that the me chan i cal ly supplied draft operates within 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.

Fan Assisted Venting

A Power Venter Kit is available on Models 45,000 - 135,000 Btu/hr only

(see Table 2B).

TABLE 2B - VENT MATERIALS

Kit

Number

KIT3103

KIT3104

Minimum Vent Length = 12 Equivalent Feet*

Maximum Vent Length = 25 Equivalent Feet*

CAUTION

NOTE: In Canada, CPVC and PVC vent pipe,  ttings and

cement/primer must be ULC-S636 certi ed.

 WARNING

Figure 2-6_Unit with Fan Assisted Venting

Input

Btu/hr

45,000 PVC Rated (CPVC Optional) 75,000 PVC Rated (CPVC Optional) 90,000 CPVC Rated

135,000 CPVC Rated

(ALL UNITS)

* Equivalent Feet: 90° Elbow = 5 Feet 45° Elbow = 3 Feet

DO NOT use Radel or cellular (foam) core PVC or CPVC pipe.

DO NOT insulate PVC or CPVC venting materials. Use of insulation will cuase increased vent wall temperatures, which could result in vent pipe failure.

Material

2 Venting (continued)

Automatic Vent Damper

Installation & Service Manual

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

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

- Unheated garage

- Attic

- Crawlspace

- Mechanical room that is vented outdoors

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

Residential heating boilers with inputs of less than 300,000 Btu/hr must have the vent damper prop er ly installed and the vent damper wire harness plugged into the ter mi nal block on the side of the control panel to allow the boiler to function.

 CAUTION

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

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

VENT DAMPER

SECURE EXCESS SLACK WITH WIRE CLIP (PICTURED) OR ZIP TIES

DIR #2000556517 00

IR #2000556517 00

Figure 2-7_Vent Damper and Vent Damper Terminal Block

 WARNING

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

 CAUTION

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

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.

If there is excess slack in the vent damper wire after vent damper installation, use the kit-provided wire clip or zip ties to secure the wire. If using the kit-provided wire clip, fasten the wire clip to the side of the boiler using the kit-provided screw. Loop the excess wire and secure it in the wire clip. If using the kit-provided zip ties, loop the excess slack and secure it with the zip ties.

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.

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