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

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

2

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.

33

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.

4

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"

0.91 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

5

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.

6

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

10

17

15

8

3

5

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

4

20

1

19

Models 45,000 - 90,000 Rear View

23

11

14

16

25

22

21

7

18

9

12

6

24

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

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

7

The Solution - How it works...

Installation & Service Manual

10

17

15

8

3

5

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

4

1

19

20

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

11

23

14

21

25

22

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

7

9

3

3

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

18

12

6

24

8

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

9

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.

2

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).

10

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.

11

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

12

(78 cm2)

19

(123 cm2)

23

(148 cm2)

34

(220 cm2)

45

(291 cm2)

54

(349 cm2)

65

(420 cm2)

Bottom

2

Opening, in

(78 cm2)

(123 cm2)

(148 cm2)

(220 cm2)

(291 cm2)

(349 cm2)

(420 cm2)

12

19

23

34

45

54

65

*Outside Air from
1 Opening Directly
from Outdoors, in

2

15

(97 cm2)

25

(162 cm2)

30

(194 cm2)

45

(291 cm2)

60

(388 cm2)

72

(465 cm2)

87

(562 cm2)

2

*Outside Air from

2 Ducts Delivered from

Outdoors

Top

Opening, in

23

(149 cm2)

38

(246 cm2)

45

(291 cm2)

68

(439 cm2)

90

(581 cm2)

108

(697 cm2)

130

(839 cm2)

Bottom

2

Opening, in

(149 cm2)

(246 cm2)

(291 cm2)

(439 cm2)

(581 cm2)

(697 cm2)

(839 cm2)

23

38

45

68

90

108

130

**Inside Air from

2 Ducts Delivered from

Interior Space

Top

2

Opening, in

(646 cm2)

(646 cm2)

(646 cm2)

(871 cm2)

(1,162 cm2)

(1,388 cm2)

(1,678 cm2)

100

100

100

135

180

215

260

2

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)

2

*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.

12

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.

13

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.

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

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

(d) Place in operation the appliance being inspected.

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

14

Y

2 Venting (continued)

Vertical Vent Termination Clearances

Installation & Service Manual

10' OR LESS

10' OR LESS

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

3'

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.

15

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)

(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

16

D

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.

17

3 Gas connections

Installation & Service Manual

Gas Supply

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

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

TABLE - 3A

GAS SUPPLY PRESSURE

Natural Gas LP Gas

Max. (Inches Water Column)

Min. (Inches Water Column) 4.5 11

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

14 14

Gas Pressure Test

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

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

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

Gas Connection

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

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

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

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

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

TABLE - 3B

MANIFOLD PRESSURE

Single and
Two-Stage

Input Gas

Btu/hr

45,000 3.5" 10" 0.9" 2.5"

75,000 2.4" 7" 0.9" 2.5"

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

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

Full or High Fire

Settings

Natural

Gas

LP Gas

Two Stage

Low Fire Settings

Natural

Gas

LP Gas

5. A trap (drip leg) MUST be provided by the installer in
the inlet of the gas connection to the appliance, see
FIG. 3-1 on page 19.

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

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

TABLE - 3C

FITTINGS TO EQUIVALENT STRAIGHT PIPE

Diameter Pipe (inches)

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

Equivalent Length of Straight Pipe (feet)

2 2 3 4 5 10 14 20

TABLE - 3D

GAS CONNECTIONS

18

Btu/hr

INPUT

45,000 - 135,000 1/2"

180,000 - 260,000 3/4"

Pipe Size

Installation & Service Manual

3 Gas connections (continued)

TABLE 3E - GAS PIPING SIZE CHART

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour

(based on .60 specific gravity, 0.30" w.c. pressure drop)

Pipe

Size

(Inches)

1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A

1 514 353 284 243 215 195 179 167 157 148 131 119 109 102

1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209

1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313

2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602

2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960

3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700

4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460

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

Length of Pipe in Straight Feet

Gas Piping

GAS VALVE

GAS SHUTOFF VALVE

TRAP
(DRIP LEG)

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.

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).

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.

19

3 Gas connections

Installation & Service Manual

WHEN FLANGE

IS USED

WHEN FLANGE IS

NOT USED

APPLY WRENCH

TO FLANGE ONLY

APPLY WRENCH FROM TOP OR B OTTOM

OF GAS CONTROL TO EITHER SHADED AREA

Figure 3-2_Wrench

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

IMPORTANT

Upon completion of any piping con­nec 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

PRESSURE REGULATOR ADJUSTME NT
(UNDER CAP SCREW)

INLET
PRESSURE TAP

OUTLET
PRESSURE TAP

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

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

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

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

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

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

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

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

9. If adjustment is necessary, turn regulator ad just ment screw
clockwise to raise regulator gas pres sure, counterclockwise
to lower gas pres sure, to proper setting.

Note: Adjustment fitting is plas tic and may require

slightly greater turning force than a metal fitting.

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

NOTICE

Do not increase regulator pres sure beyond
specified pressure setting.

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

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

PILOT OUTLET

GAS CONTROL KNOB

RED RESET BUTTON

MANOMETER

3.5"

GAS VALVE

Figure 3-3_Manifold Pressure Adjustment

20

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

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

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

3 Gas connections (continued)

Installation & Service Manual

Checking Gas Supply Pressure

GAS SUPPLY PRESSURE

MANOMETER

GAS VALVE

Figure 3-4_Gas Supply Pressure

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

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

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

4. Remove the 1/8" hex plug, located on the “inlet” side
of the gas valve and install a fitting suitable to connect
to a manometer or magnahelic gauge. Range of scale
should be 14" w.c. or greater to check inlet pressure.
See FIG.’s 3-3 and 3-4 for location.

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

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

7. Follow the “Lighting Instructions” in Section 6 - Startup
to light the pilot . Turn gas valve control knob to the
“ON” position.

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

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

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

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

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

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

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

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

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

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

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

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

IMPORTANT

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

Check burner performance by cycling the system while you
observe burner response. Burners should ignite promptly.
Flame pattern should be stable, see the “Main te nance Section

-Normal Flame Pattern”. Turn system off and allow burners
to cool, then cycle burners again to en sure proper ignition and
flame characteristics.

21

3 Gas connections

Combination Gas Valves

PRESSURE REGULATOR
ADJUSTMENT
(UNDER CAP SCREW)

INLET PRESSURE TAP

GAS CONTROL KNOB

Figure 3-5_M9 Gas Valve

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

WIRING TERMINALS

OUTLET
PRESSURE TAP

PILOT OUTLET

Installation & Service Manual

Venting of Combination Gas Valves

The combination gas valve regulator used on all
mod els is equipped with an integral vent limiting
orifice. The vent limiter ensures that the volume
of gas emitted from the valve does not exceed the
maximum safe leak age rate allowed by agency
re quire ments. Com bi na tion gas valve/regulators
equipped with integral vent limiters are not
re quired to have vent or relief lines piped to
the outdoors. A dust cap is provided at the vent
termination point on the valve to prevent block age
of the vent limiter by foreign material. The com bi na­tion gas valve regulator with an integral vent limiter
complies with the safety code requirements of CSD­1, CF-190(a) as shipped from the manufacturer
with out the in stal la tion of additional vent lines.

Two Stage Burner Control System

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

22

4 Water connections

Installation & Service Manual

Relief Valve

RELIEF VALVE

Figure 4-1_Relief Valve

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

 CAUTION

Avoid contact with hot discharge water.

Water Flow Switch (if equipped)

FLOW SWITCH

FLOW

Figure 4-2_Water Flow Switch - Top Connections

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

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

23

4 Water connections

Installation & Service Manual

Low Water Cutoff (if equipped)

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

TABLE - 4A

MINIMUM REQUIRED FLOW

FOR HEATING BOILER

Input Btu/hr GPM Flow

45,000 1.9

75,000 3.1

90,000 3.7

135,000 5.6

180,000 7.4

215,000 8.9

260,000 10.7

NOTICE

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

Typical Heating Boiler Installations

General Plumbing Rules

1. Check all local codes.

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

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

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

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

6. Support all water piping.

Placing the Boiler in Operation

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

1. Close all drain cocks and air vents.

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

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

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

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

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

B. Repeat this procedure for each circuit.

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

24

NOTICE

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

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

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

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

4 Water connections (continued)

Installation & Service Manual

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

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

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

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

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

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

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

Piping of the Boiler System

The drawings in this section (see FIG’s 4-5 thru 4-9) show
typical heating boil er piping installations. Before beginning
the in stal la tion, consult local codes for specific plumb ing
re quire ments. The installation should provide unions and
valves at the inlet and outlet of the boil er so it can be isolated for
service. The boiler cir cu lat ing pump, air sep a ra tor, expansion
tank and oth er components required for proper installation
must be purchased locally. An air separation device must be
supplied in the in stal la tion piping to eliminate trapped air in
the system. Lo cate a system air vent at the highest point in the
sys tem. The system must also have a properly sized expansion
tank installed. Typically, an air charged di a phragm-type
expansion tank is used. The expansion tank must be installed
close to the boiler and on the suction side of the system pump
to ensure proper op er a tion. A water meter to monitor makeup
water is recommended. Makeup water volume should not
exceed 5% of total system per year. Install a Y-strainer or
equivalent multi-purpose strainer just before the boiler pump
at the inlet of the heat exchanger. This item is used to remove
system debris from older hydronic systems and to protect newer
systems.

 CAUTION

This boiler system should not be operated
at less than 12 PSIG (83 kPa) (Non-metallic
system piping must have an oxygen barrier
to be considered a closed loop)..

TABLE - 4B

SYSTEM TEMPERATURE RISE CHART

Based on Boiler Output in Btu/hr

Btu/hr

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

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

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

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

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

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

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

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

10°F T 20°F T 30°F T 40°F T

25

Head Loss, FT/HD

Flow Rate, GPM

CB135

CB180

CB260

0.0

1.0

2.0

3.0

4.0

5.0

0 5 10 15 20 25 30

CB045

CB075

CB090

CB215

0.0

0.5

1.0

1.5

0 5 10 15 20

4 Water connections

Installation & Service Manual

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

 CAUTION

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

Water Connections

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

 CAUTION

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

TABLE - 4C

HEAT EXCHANGER PRESSURE DROP CHART

Circulator Pump Requirements

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

Example: The boiler inlet tem per a ture is 160°F and the boiler
outlet temperature is 180°F, this means that there is a 20°F
tem per a ture rise across the boiler.

26

4 Water connections (continued)

Installation & Service Manual

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

Circulator Pump Specifications

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

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

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

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

Circulator Pump Operation

Boilers are equipped with a relay for controlling the circulation
pump for the hot water loop. The operating temperature
control will energize the pump relay, which energizes the
pump on a call for heat. The relay turns ON and OFF in
response to the “W1” input from the wall thermostat or zone
control. The pump will operate whenever the “W1” terminal
is energized.

On boilers with the system pump delay option, the temperature
control will de-energize the pump relay approximately 30
seconds after the call for heat ends.

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

See Pump Wiring for a Heating Boiler, on page 34 for
additional information.

120V

SUPPLY

PERFORMANCE LOOP

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

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

NOTICE

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

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

2. The system set point is 140°F or higher.

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

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

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

NOTICE

 WARNING

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

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

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

Primary/Secondary Boiler Piping

TO

UNIT

TO

CIRCULATION

PUMP

TO PERFORMANCE

LOOP PUMP

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

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

27

4 Water connections

Primary/Secondary Boiler Piping (continued)

Installation & Service Manual

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

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

Low Temperature Bypass Requirements

For systems which require lower operating temperatures, a bypass
must be installed to guarantee the boiler inlet water temperature is
above 140°F (60°C). Inlet water temperatures below 140°F (60°C) can
excessively cool the prod ucts of combustion re sult ing in condensation on
the heat exchanger and in the flue. Condensation can cause operational
problems, bad combustion, sooting, flue gas spillage and reduced service
life of the vent system and related components. The bypass allows part
of the boiler discharge water to be mixed with the cooler boiler return
water to in crease the boiler inlet temperature above 140°F (60°C). This
should prevent the prod ucts of com bus tion from condensing in most
in stallations.

Systems requiring a low temperature bypass should use the provided
system sensor and VAL30000 (1 1/2" LTV Valve Kit) piped in a Primary/
Secondary arrangement as shown in FIG. 4-5. It is recommended to
install the system sensor a minimum distance of 10 pipe diameters from
the boiler piping. The Low Temperature Valve (LTV) is ready to install
with a non-adjustable 140°F return temperature setting. It is important
thtat the valve is installed with the proper port orientation. Failure to
observe port markings on the valve body prior to installation could result
in damage to the unit. The recommended maximum high temperature
to the valve is 175°F (79°C).

Boiler Flow Rates

 CAUTION

A boiler operated with an inlet temperature of less
than 140°F (60°C) must have a bypass to prevent
problems with condensation. A bypass as shown in
FIG. 4-5 (see page 30) must be piped into the system
at the time of installation.

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

Full Flow Application

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

1. The performance loop is in place and functional.

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

3. The boiler set point is 140°F or higher.

4. Boiler return water temperatures are 140°F or
higher.

 WARNING

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

TABLE - 4D

MAXIMUM FLOW FOR HEATING BOILER

The maximum flow rate through the boiler with a copper

heat exchanger must not exceed the following:

Model Maximum Flow

45,000 - 260,000 30 GPM 38 GPM

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

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

Maximum Flow for

CuNi Heat Exchanger

28

4 Water connections (continued)

Primary / Secondary Piping

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

Installation & Service Manual

MAKE UP

WATER

TO

SYSTEM

PRESSURE

REDUCING VALVE

WATER
METER

BACKFLOW

PREVENTER

SYSTEM

CIRCULATOR

BALL VALVE

(TYPICAL)

AIR

SEPARATOR

PRESSURE

GAUGE

EXPANSION

MINIMUM 10 PIPE

SYSTEM

SENSOR

(OPTIONAL)

TANK

UNION

(TYPICAL)

ø

FROM

MAX 4 PIPE

OR 12" APART

FLOW

CHECK

VALVE

Y-STRAINER

ø

SYSTEM

TEMPERATURE

& PRESSURE

GAUGE

(PROVIDED)

PRESSURE

RELIEF VALVE

(PROVIDED)

DRAIN

BOILER

CIRCULATOR

SOLUTION

BOILER

DIR #2000548532 00

29

Installation & Service Manual

4 Water connections

Primary / Secondary Piping

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

WATER
METER

MAKE UP

WATER

TO

SYSTEM

BALL VALVE

(TYPICAL)

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

SEPARATOR

SYSTEM

CIRCULATOR

AIR

PRESSURE

GAUGE

EXPANSION

MINIMUM 10 PIPE

SYSTEM

SENSOR

(REQUIRED)

TANK

UNION

(TYPICAL)

MAX 4 PIPE

OR 12" APART

ø

ø

FROM

SYSTEM

LOW TEMP.

BYPASS

(LTV VALVE)

FLOW CHECK

VALVE

Y-STRAINER

30

TEMPERATURE

& PRESSURE

GAUGE

(PROVIDED)

PRESSURE

RELIEF VALVE

(PROVIDED)

DRAIN

SOLUTION

BOILER

BOILER

CIRCULATOR

DIR #2000548527 00

4 Water connections (continued)

Primary / Secondary Piping

Figure 4-6_Multiple Boilers Zoned with Circulators

ZONE #1

Installation & Service Manual

MINIMUM 10 PIPE

(OPTIONAL)

UNION

(TYPICAL)

PRESSURE

RELIEF VALVE

(PROVIDED)

MAKE UP

SYSTEM
SENSOR

PREVENTER

WATER METER

WATER

MAX 4 PIPE

OR 12" APART

ø

BACKFLOW

EXPANSION

DRAIN POINT

(TYPICAL)

BOILER

CIRCULATOR

AIR SEPARATOR

TANK

ø

MAY SUBSTITUTE

LOW LOSS HEADER

PRESSURE

REDUCING VALVE

PRESSURE

GAUGE

FLOW

CHECK

VALVE

Y-STRAINER

(TYPICAL)

TEMPERATURE

& PRESSURE

GAUGE

(PROVIDED)

ZONE CIRCULATORS

(TYPICAL)

RELIEF

VALVE

BALL VALVE

(TYPICAL)

ZONE #2

HOT

WATER

OUT

TANK

AQUASTAT

ZONE #3 ZONE #4

COLD

WATER

IN

ANTI-SCALD

MIXING VALVE

RECIRCULATION

LOOP

(RECOMMENDED)

NOTICE

COLD

WATER

IN

BOILER 2

BOILER 1

INDIRECT

DHW TANK

DIR #2000548535 00

Please note that systems using DHW priority MUST use mixing valves to protect low temperature zones.

31

4 Water connections

Full System Flow

Figure 4-7_Single Boiler Full System Flow

PRESSURE

REDUCING VALVE

WATER METER

MAKE UP

WATER

TO

SYSTEM

BACKFLOW

PREVENTER

SYSTEM

CIRCULATOR

BALL VALVE

(TYPICAL)

AIR

SEPARATOR

PRESSURE

GAUGE

MINIMUM 10 PIPE

SYSTEM

SENSOR

(OPTIONAL)

Installation & Service Manual

ø

FROM

SYSTEM

EXPANSION

TANK

(TYPICAL)

DRAIN

TEMPERATURE

& PRESSURE

GAUGE

(PROVIDED)

PRESSURE

RELIEF VALVE

(PROVIDED)

UNION

Y-STRAINER

32

SOLUTION

BOILER

DIR #2000548531 00

5 Electrical connections

Installation & Service Manual

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

1. All wiring between the appliance and field
in stalled devices shall be made with type T wire
[63° F(35° C) rise].

2. Line voltage wire exterior to the appliance must be
enclosed in approved conduit or approved metal clad
cable.

3. The pump must run continuously when the appliance is
being fired.

4. To avoid serious damage, DO NOT en er gize the
appliance until the system is full of water. Serious
damage may result.

5. Provide the unit with proper overload protection.

6. Install a wall thermostat on the inside wall. DO NOT
install the thermostat in an area affected by drafts,
sunlight, light fixtures, hot or cold water pipes or near a
fireplace. See “Room Thermostat or Remote Thermostat
Connection to Terminal Strip” (this page), for prop er
wiring con nec tion.

Room Thermostat or Remote Thermostat
Connection to Terminal Strip

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

Remove the jumper between the R1 and W1 terminals on
the terminal strip. Refer to the chart in this section (Table
5A) to determine maximum allowable length and wire gauge
recommended to connect the switching con tacts of the room
thermostat to the R1 and W1 terminals on the terminal strip.
Connection to the terminal strip will allow the room thermostat
to make and break the 24VAC boiler control circuit turning
the boiler on and off based on the room ambient temperature
re quire ments. Set the boiler operating temperature control as
described in Temperature Control Settings on page 36.

A

B

IMG00278

Figure 5-1_Terminal Strip Connections

TABLE - 5A

TERMINAL STRIP WIRING

Wire Gauge

Allowable Length

12 GA 100 ft.

14 GA 75 ft.

16 GA 50 ft.

18 GA 30 ft.

Auxiliary Power Venting Connection to
Terminal Strip

A terminal connection strip is provided for ease of connection
of auxiliary power venting systems, see FIG. 5-1, inset B. A field
supplied power venter can be interlocked into the appliance’s
control circuit via a 24 VAC relay, which will be powered from
this location when a call for heat has been established. A device
proving switch can be interlocked back to the appliance to
ensure its operation before the appliance is allowed to fire. For
additional information, reference the wiring diagram on page
51 of this manual.

Maximum

33

5 Electrical connections

Pump Wiring for a Heating Boiler

The heating boiler circulating pump must be purchased
locally. Follow all manufacturer’s installation and
maintenance instructions provided with the pump. Solution
boilers are equipped with a pump relay, located near the
two-stage thermostat in the control panel (FIG. 5-2). The
temperature controller energizes the pump relay, which
operates the pump on a call for heat. The pump will operate
either continuously from a 120V supply, or whenever the
“W1” terminal from the wall thermostat or zone control is
energized. The maximum load for the pump switched by
the internal pump relay must not exceed 1 HP. The current
draw for a field installed 120 VAC pump MUST be added to
the boiler’s current draw to determine the minimum wire size
for 120 volt service. Reference Table 5B for boiler operating
control current draw data.

IGNITION MODULE

TST20036-2

Installation & Service Manual

The installation of outdoor air reset is necessary to comply with
the United States Energy Policy and Conservation Act, and the
boiler will not function if both boards are not installed. In the
event that the outdoor air sensor is not functioning, a flashing
red light will indicate fault and the boiler operating temperature
will default to maximum set point.

DHW Priority

A boiler used in water heating applications should be piped
as a hot water loop (zone) in a Primary/Secondary piping
arrangement (see FIG. 4-6 on page 31). A DHW priority
function on the Solution boiler is available by connecting a field
supplied tank Aquastat to the upper control board (TST20036-

2). When the control receives a DHW call for heat, the boiler
set point will change to 180°F (82°C). The boiler will operate
at this set point until the DHW demand is satisfied. In the
absence of water heating demand, the operating set point is
based on the outdoor air reset curve. For boilers using DHW
priority, mixing valves are required for the protection of low
temperature zones.

Additional Temperature Controls

MANUAL RESET

HIGH LIMIT

(IF EQUIPPED)

PUMP RELAY

TST20036-1

TRANSFORMER

IMG00280

Figure 5-2_Intermittent Pilot System M9 Control Panel

TABLE - 5B

AMP DRAW DATA

45,000 thru 260,000 Btu/hr Models

MAXIMUM

FIRING CONTROLS

M9 with Performance Loop Pump 1.25

Boiler Operating Temperature Control

The two-stage thermostat is located in the control panel,
behind the control panel front access door. To access the
temperature control, remove the control panel door on the
front of the unit. The temperature controller operates a
two-stage firing system, which increases system efficiency by
starting the boiler on low fire and turning on high fire only
when extra capacity is needed. After the water temperature
reaches the operating set point, the temperature control shuts
off the burners.

The Solution boiler is also equipped with outdoor air
reset, a feature that saves energy by reducing the boiler
water temperature as the heating load decreases (reference
Temperature Adjustment section on page 35). The thermostat
control consists of two interconnected boards. The upper
board controls outdoor air reset and DHW priority functions,
while the lower board manages burner and pump operation.

TOTAL AMPS

@ 120 VAC

High Water Temperature Limit Control

The appliance is supplied with a fixed setting, auto-reset
high water temperature limit control. The setting of this
control limits maximum discharge water temperature. If water
temperature exceeds the setting, the limit will break the control
circuit and shut down the appliance. The limit control will only
be reset after the water temperature has cooled well below the
setting of the limit. The auto-reset high water temperature limit
control is mounted in the outlet side of the front header.

Blocked Vent and Flame Roll-Out / Flame Interlock

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

34

5 Electrical connections (continued)

17

0

18

0

10

Installation & Service Manual

Figure 5-3_Blocked Vent Switch Location

BLOCKED VENT SWITCH

DETAIL A

DRAFT HOOD

(INVERTED TO SHOW
RESET UNDERNEATH)

A

T

I

N

U

F

O

T

N

O

R

F

IMG00281

Figure 5-4_Flame Roll-Out / Flame Interlock Switch
Location

UPPER FRONT
JACKET PANEL

OUTER
AIR DEFLECTOR

FLAME ROLL-OUT /
INTERLOCK SWITCH

DETAIL A

LOWER FRONT
JACKET PANEL

IMG00282

HEX FILLER
BRACKET

A

Temperature Adjustment

NOTICE

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

In Compliance with Energy Conservation Standards, the
Solution boiler comes equipped with outdoor air reset, a
feature that increases the temperature setting of the boiler as
outside temperatures drop and decreases the boiler set point as
outdoor temperatures rise. To use this feature, the outdoor air
sensor provided with the boiler must be properly installed. If
the sensor or sensor wiring is defective, a flashing LED light on
the controller will signify the feature is not functioning (FIG.
5-5). A boiler that is not receiving input from the outdoor air
sensor will operate at maximum set point until the sensor is
reconnected.

The temperature controller calculates boiler set point using the
outdoor air temperature and the outdoor air reset curve. The
curve is adjustable and defined by the maximum and minimum
set points. An appropriate operating set point is based on
individual system’s requirements. Refer to Temperature
Control Settings for help with set point determination.

The boiler water sensing element is factory installed in the inlet
bulbwell on the heat exchanger. An optional system sensor
may be installed for use as a remote sensor in a boiler system.
The boiler set point can be adjusted by using the maximum
set point dial to modify the outdoor air reset curve. To ensure
proper operation, use the temperature and pressure gauge
located in the header of the heat exchanger to observe the
boiler discharge temperature and system water pressure after
set point adjustment.

OUTDOOR AIR SENSOR

CN2

LED1

W3

W2

W1

5

0
HIGH-FIRE
OFFSET °F

FAULT INDICATION

CN3

INLET

PROBE

CN4

CN5

SYS/

TANK

CN6

CN9

15

20

IMG00275

TST20036-1

TST20036-2

(c)2002 L.C.

(c)2002 L.C.

CN7

PUMP

RELAY

CN8

CN12

CN1

160

150

OFF

MAX SETPOINT °F

190

200

MIN SETPOINT °F

CN11CN10

OUTDOOR

TANK

SENSOR

AQUA-

STAT

FAULT

125

120 130

115

110 140

135

TST20036

Figure 5-5_Two-Stage Thermostat

 WARNING

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

35

5 Electrical connections

Temperature Control Settings

Residential heating boilers with inputs of less than
300,000 Btu/hr must be equipped with a control
that automatically adjusts boiler water temperature
in reference to heat load. The Solution boiler is
equipped with outdoor air reset, a feature that
increases the temperature setting of the boiler as
outside temperatures drop and decreases the
boiler set point as outdoor temperatures rise. The
temperature control settings on the Solution boiler
can be customized to meet system requirements.

The two-stage thermostat allows knob adjustment of
up to three parameters: Maximum Set Point (at Low
Outdoor Air), Minimum Set Point (at High Outdoor
Air), and High Fire Offset. The low and high outdoor
air temperatures are factory set at 0°F (-18°C) and 70°F
(21°C) respectively. The heating boiler operating set
point is dependent upon the outdoor air temperature
and the outdoor air reset curve. The reset curve
can be designed to meet system requirements by
specifying the target boiler water temperature at
low and high outdoor air temperatures. Reference
FIG. 5-6 and Table 5C to help determine the proper
settings for your system. If return water temperatures
of less than 140°F are required, follow the instructions
for Low Temperature Bypass Requirements.

Installation & Service Manual

Maximum Set Point (Low
Outdoor Air Temperature)

Figure 5-6_Outdoor Air Reset Curve

°F

BOILER

SET POINT

Max. Set Point

(Low Outdoor Air Temp.)

150° - 200°F

Max. Set Point Range

110° - 140°F

Min. Set Point Range

Low Outdoor Air

Temp.= 0°F

OUTDOOR AIR TEMPERATURE

When the outdoor temperature
drops to 0°F (-18°C), the boiler water
temperature will be at the maximum
set point. This is the maximum
heating boiler set point and can be
set using the left-hand knob on the
temperature control (FIG. 5-5). If
outdoor temperatures continue to
drop, the temperature control will
not continue to increase boiler set
point. The temperature range of this
parameter is 150°F (66°C) to 200°F

Min. Set Point

(High Outdoor Air Temp.)

(93°C). If DHW priority is used, the
controller will change boiler set point
to 180°F (82°C) until water heating
demand is satisfied.

High Outdoor Air

°F

Temp.= 70° F

IMG00274

36

5 Electrical connections (continued)

Installation & Service Manual

Minimum Set Point (High Outdoor Air Temperature)

If the inlet sensor is used to determine set point, the
minimum set point is fixed at 140°F (60°C). If a system
sensor is used the range of this parameter is 110°F (43°C) to
140°F (60°C) and can be adjusted using the middle knob on
the temperature controller. The two-stage thermostat will
apply the outdoor air reset set point to the system sensor,
while also applying a fixed 140°F (60°C) set point to the inlet
sensor. If inlet water temperature drops below 140°F (60°C)
the temperature controller will force the boiler to high fire.
Requiring a minimum 140°F (60°C) inlet water temperature
will help prevent problems with condensation. For systems
requiring return temperatures less than 140°F (60°C), a
bypass must be installed. Reference Low Temperature Bypass
Requirements for additional information.

High Fire Offset

The temperature controller operates a two-stage firing system,
which enables the boiler to start on low fire and continue on
to high fire when there is a greater heat demand. High fire
operates all burners at full rate, while low fire operates the
burners at approximately one-half rate. Operating at high fire
only when extra capacity is needed increases overall system
efficiency. The High Fire Offset knob specifies the number
of degrees below boiler set point that the high fire stage shuts
down. At that point, the unit will continue to operate at the
low fire stage until the set point is reached. The High Fire
Offset knob has temperature settings between 0°F and 20°F.
If the control is set above 0°F, the high fire delay will be 120
seconds. If the control is set to 0°F, the high fire offset is
disabled and the unit will operate at high fire until the set
point is reached.

Differential

The differential specifies the number of degrees below the set
point the control will allow the water temperature to drop
before it brings the unit back on again. The differential is
factory set at 12°F (7°C).

Temperature Control Sensors

The two-stage temperature control regulates the burner
ignition and pump functions, and can measure up to four (4)
different sensor inputs. Standard boiler units are equipped
with an inlet water temperature sensor and an outside air
temperature sensor. A system sensor is also provided for
use as a remote sensor. If this sensor is connected to the
control board, the boiler will operate based on system water
temperature set point. A field supplied tank Aquastat may
also be used for water heating applications. The four available
sensor inputs are as follows:

1. Inlet Water Temperature Sensor

2. System Sensor

3. Outside Air Temperature Sensor

4. Tank Aquastat

Inlet Water Temperature Sensor

This sensor measures the inlet water temperature coming into
the unit. The inlet water temperature sensor is placed into
the inlet bulbwell on the boiler. This sensor is installed by the
factory in new units and should not be removed. A fixed 140°F
minimum set point is applied to this sensor.

System Sensor

This sensor can be used as a remote system sensor in a boiler
system. When this sensor is connected the temperature control
applies the outdoor air reset set point to the system sensor
and a minimum 140°F set point to the inlet sensor. Systems
requiring return temperatures less than 140°F should install a
low temperature bypass. A bypass allows the unit to operate
at a lower system set point, while maintaining the minimum
inlet water temperature. Connect the system sensor to the SYS/
TANK contacts on the control board. For more information,
reference the Installation of System Sensor section on page 38.

Outdoor Air Temperature Sensor

This sensor ties boiler operating set point to the outdoor air
temperature. As outdoor temperatures drop and there is greater
heat demand, the control will increase the temperature setting
of the boiler. The boiler set point will decrease as outdoor
temperatures rise, resulting in more energy efficient operation.
The sensor comes with a housing that helps protect the sensor
from the elements. Mount the air sensor housing outdoors,
under the eve of the roof. Make sure the housing is out of direct
sunlight. This will ensure that the sensor will accurately read the
true outdoor temperature. Connect the outdoor air temperature
sensor to the terminal block on the upper temperature control
board. In the event the outdoor air sensor is not functioning,
the temperature control will indicate a fault with a flashing red
light and the boiler set point will default to Maximum Set Point.
For more information on wiring the sensor, see Wiring of the
Outdoor Air Sensor on page 38.

Tank Aquastat

An indirect water heater can be connected to the boiler with a
field supplied Aquastat. When there is a water heating demand
the temperature control will increase boiler set point to 180°F
(82°C). Follow the manufacturer’s instructions supplied with
the Aquastat for proper installation and adjustment. Determine
the location of the tank and measure the amount of wire needed
to connect the Aquastat to the control. Reference the terminal
strip wiring chart (Table 5A) to determine maximum allowable
length and wire gauge recommended. Ensure all wire insulation
is trimmed to reveal at least 3/8" of exposed wire. Feed the wires
through the access hole located on the side of the unit and secure
the connectors to the Tank Aquastat terminal block CN10 on
the upper temperature control board. Reference the Wiring of
Outdoor Air Sensor section for additional wiring guidelines.

37

5 Electrical connections

Wiring of Outdoor Air Sensor

Follow the guidelines in this section when wiring remote
sensors. Use shielded, 2-wire twisted pair cable. Take care
to correctly wire sensors to the unit. Erratic temperature
readings can be caused by poor wiring practices. If the
outdoor air sensor is unable to provide input to the
control, the boiler will default to the maximum set point.
For proper boiler operation it is important to follow all
wiring guidelines.

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

2. Remove the upper front door panel from the appliance to
gain access to the temperature control.

3. Locate the outdoor air temperature sensor provided
in the kit. Determine the location of the remote sensor
and measure the amount of wire needed to connect
the sensor to the thermostat. The sensor should be placed
on a north wall, under the eve of the roof. Make sure the
housing is out of direct sunlight.

4. Do not route temperature sensor wiring with building
power wiring.

5. Do not locate temperature sensor wiring next to control
contactors.

6. Do not locate temperature sensor wiring near electric
motors.

7. Do not locate temperature sensor wiring near welding
equipment.

8. Make sure good mechanical connections are made to
the sensor, any interconnecting wiring and the
controller.

9. Do not mount sensor with lead wire end pointing up in
an area where condensation can occur.

10. Use 18 gauge or larger shielded, twisted pair cable
to connect the sensor to the control. This provides
protection against some types of electrical
interferences.

11. Remove the cover of the outdoor air temperature
sensor and route the wires through either the bottom
or the back of the sensor. Connect the wires to the
sensor and replace the cover (FIG. 5-8).

12. Run the shielded sensor wiring through the access hole
located on the back of the unit to CN11 on the upper
control board TST20036-2.

Figure 5-7_Outdoor Air Temperature Sensor (TST2311)

OUTDOOR AIR
RESET SENSOR
(TST2311)

ROUTE TO CN11
ON TST20036-2

Installation & Service Manual

NOTICE

13. Replace the side access panel.

14. Turn ON the main electrical power and the main manual
gas shutoff to the appliance.

Installation of System Sensor

1. Turn OFF the main electrical power and the main manual

gas shutoff to the appliance.

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

access to the thermostat.

3. Locate the sensor provided in the kit. Determine the

location of the remote sensor and measure the amount of
wire needed to connect the sensor to the thermostat. See
Wiring of the Outdoor Air Sensor for guidelines.

4. Use twisted pair wire, minimum 18 gauge or larger.

Ensure all wire insulation is trimmed to reveal at least 3/8"
of exposed wire.

5. Connect the measured wire to the sensor wire using wire

caps. Install .250 x .032 insulated female quick connect
terminals to the end of the wires. Feed the wires through
the access hole located on the back of the unit and secure
the connectors to the thermostat connections (SYS/TANK)
CN5 and CN6 located in the upper right-hand of the
thermostat.

6. Turn on the electrical power and the main manual gas

shutoff to the appliance.

7. Replace the side access panel.

8. Fire the appliance and resume operation.

Figure 5-8_Installation of Remote Sensors

ACCESS
HOLE

CONNECT

OUTDOOR AIR

SENSOR
AND TANK
AQUASTAT

TO TST20036-2

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

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

38

CONNECT

SYSTEM

SENSOR TO

TST20036-1

IMG00279

IMG00276

6 Start-up

Initial Start-up

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

A. On boilers with the system pump delay option,

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

On boilers, the pump will operate whenever the “W”

terminal is energized.

Installation & Service Manual

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

7. Check carefully for gas leaks.

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

Lighting Instructions for Spark Ignition
Pilot Models

FOR YOUR SAFETY READ BEFORE
OPERATING

B. Location - The appliance should be located within

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

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

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

1. Shut off gas supply,

2. Shut off water supply.

3. Shut off electrical supply.

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

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

Pre-start Checklist

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

2. Inspect the pilot gas line, thermocouple leads, ignition

leads and wire connections to the gas valve to be sure
none were damaged during shipment.

3. Check to ensure that gas connections have been made

properly and the gas line is purged of air.

4. Check to ensure that water connections are tight and the

appliance and piping system have been properly filled.

5. Ensure that discharge from the relief valve has been

piped to a floor drain.

 WARNING

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

A. This appliance is equipped with an ignition device

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

B. BEFORE OPERATING, smell around the appliance

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

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use any phone

in your building.

Immediately call your gas supplier from a near by

phone. Follow the gas supplier’s instructions.

If you cannot reach your gas supplier, call the fire

department.

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

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

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

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

39

6 Start-up

Installation & Service Manual

Operating Instructions

1. STOP! Read the safety information first.

2. Remove the control panel door.

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

4. Turn off all electrical power to the appliance.

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

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

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

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

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

7. Wait five (5) minutes to clear out any gas, then smell for
gas, including near the floor. If you smell gas, STOP!
Follow the steps in the “What To Do If You Smell Gas”
section in the safety information on page 39. If you do
not smell gas go on to the next step.

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

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

To Turn Off Gas to Appliance

1. Set the thermostat to the OFF position.

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

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

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

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

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

 WARNING

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

Safety Shutoff Test for Spark Ignition
Pilot System

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

2. Turn the minimum set point to the lowest setting and the
maximum set point to the highest setting to initiate a call
for heat.

3. Turn electric power “ON”.

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

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

9. Turn on all electric power to the appliance.

10. Set the thermostat to the desired setting.

11. Re-install the control panel door.

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

4. Pump relay pulls in to start pump.

5. The ignition will begin sparking at the pilot.

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

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

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

9. Turn “ON” gas supply.

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

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

40

6 Start-up (continued)

Installation & Service Manual

Pre-Commissioning Cleaning

1. Prior to fill and start-up, flush the entire heating system.

2. Clean the entire heating system with an approved pre­commissioning cleaner (comparable to Sentinel X300
or Fernox F3) in accordance with the manufacturer’s
recommendation to remove debris and prolong the life of
the heat exchanger.

3. Clean all water filtering devices in the system.

4. Flush the cleaning solution out of the entire system and
refill.

Fill water

Check/control fill water chemistry

IMPORTANT

The manufacturer recommends the following for properly
filling your boiler with the appropriate water chemistry for
closed loop boilers. Good fill water quality will help extend
the life of the appliance by reducing the effects of lime scale
buildup and corrosion in closed loop systems.

Hardness between 5 and 15 grains per gallon

1. Consult local water treatment companies for hard water
areas (above 15 grains per gallon hardness).

2. Hardness levels that are above 15 grains/gallon can lead
to lime scale buildup throughout the boiler system. If the
fill water is below 5 grains/gallons, usually due to use of a
water softener, it is recommended to mix in some potable
water at the inlet to increase the hardness of the water to
above 5 grains/gallons.

pH between 6.5 and 8.5

1. pH levels below 6.5 can cause an increase in the rate of
corrosion. pH of 8.5 or higher can potentially cause lime
scale buildup.

Total Dissolved Solids (TDS) less than 350 ppm

1. Total dissolved solids are all minerals, salts, metals, and
charged particles that are dissolved in water.

2. The greater the amounts of TDS present, the higher the
corrosion potential due to increased conductivity in the
water.

Chlorine concentration less than 150 ppm

1. Do not fill boiler or operate with water containing
chlorine in excess of 150 ppm.

2. Filling with fresh drinking water should be acceptable.

3. Do not use the boiler to directly heat swimming pool or
spa water.

Conduct water quality testing prior to
installing the appliance. Various solutions
are available to adjust water quality.

Boiler water

CAUTION

Table 6A Boiler Water Chemistry

Speci cation Range

Dissolved Solids < 2000 ppm

• Monitoring pH, chlorides, TDS, and hardness
levels can prolong the life of the appliance by reducing
lime scale buildup, corrosion, and erosion. Check for
leaks to ensure that fresh water is not entering the
system.

• Continual fresh makeup water will reduce boiler life.

• Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure.

• The addition of oxygen carried in by makeup water
can cause internal corrosion in system components.

• Leaks in the boiler or piping must be repaired at
once to prevent excessive makeup water. For this
purpose, it is recommended to install a water meter
to easily check the amount of makeup water entering
the system. Makeup water volume should not exceed
5% of the total system volume per year. NOTE: When
makeup water is added, make sure the chemical
additives are added to maintain the correct level.

• An approved multi-metal corrosion inhibitor
(comparable to Sentinel X100 or Fernox F1) is
recommended at the correct concentration and in the
manner recommended by the manufacturer.

Do not use petroleum based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.

DO NOT use "homemade cures" or "boiler
patent medicines". Serious damage to
boiler, personnel, and/or property may
result.

BOILER WATER CHEMISTRY

pH Level 6.5 to 9.5

Chloride < 150 ppm

Freeze protection for a heating
boiler system (if required)

 WARNING

Ethylene glycol is toxic, DO NOT use as
your freeze protection. Ethylene glycol has a
sweet aroma which children and pets could
mistake as food and ingest; leading to death.

41

6 Start-up

1. Use glycol only if needed for freeze protection.

Installation & Service Manual

Fill and test water system

2. Propylene glycol is the recommended freeze protection.

3. Make sure to flush the boiler system before adding glycol.

4. Determine the freeze protection fluid quantity using
system water content, following the fluid manufacturer's
instructions. Boiler water content is listed on page 6.
Remember to include expansion tank water content.

5. Local codes may require a backflow preventer or actual
disconnect from city water supply.

6. When using freeze protection fluid with automatic fill, it is
suggested to install a water meter to monitor water makeup.
Freeze protection fluid may leak before the water begins to
leak, causing the concentration to drop, which reduces the
freeze protection level.

7. The freeze protection set points may be lowered when
freeze protection fluid is used .

8. Consult the glycol manufacturer for details on the suggested
mix of glycol and water for the desired freeze protection
level and the de-rate effect it will have on the boiler output.

Test / replace freeze protection fluid

1. For systems using freeze protection fluids, follow the fluid
manufacturer's instructions.

2. Freeze protection fluid must be replaced periodically due to
degradation of inhibitors over time.

3. It is recommended to test the glycol concentration annually
and adjust within the desired set points.

Oxygen prevention

CAUTION

Dissolved oxygen can have a negative effect on the boiler
system. Oxygen can cause iron oxide to generate iron deposits.
Oxygen may also increase the rate of corrosion on non-stainless
steel parts of the system. A low pH level combined with oxygen
further enhances its corrosive effects. After boiler installation,
check for air leaks in the following areas:

• Suction gasket

• Pump

• Air valve

• O-ring gaskets

Precautions include installing a water meter to evaluate the
fresh water volume entering the system (should be no more
than 5% system volume). Additional volumes of fresh water
could indicate that a leak is present.

Eliminate all system leaks. Continual
fresh makeup water will reduce boiler
life. Minerals can build up in the heat
exchanger, reducing heat transfer,
overheating the heat exchanger, and
causing heat exchanger failure.

1. Fill system only after ensuring the water meets the
requirements of this manual.

2. Close automatic and manual air vents and boiler drain
valve.

3. Fill to correct system pressure. Correct pressure will vary
with each application.

a. The minimum cold water fill pressure for a system is

12 psi.

b. Pressure will rise when the boiler is turned ON and

system water temperature increases.

4. At initial fill and during boiler startup and testing, check
the system thoroughly for any leaks. Repair all leaks before
proceeding further.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve (see purge/drain

valve in the piping diagrams on pages 29 through 32).
Route the hose to an area where water can drain and be
seen.

b. Close the boiler or system isolation valve between the

purge valve and fill connection to the system.

c. Close zone isolation valves.
d. Open the quick-fill valve on the cold water makeup

line.

e. Open purge valve.
f. Open the isolation valves one zone at a time. Allow

water to run through the zone, pushing out the air.
Run until no noticeable air flow is present. Close
the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch that
system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located
throughout the system.

i. If purge valves are not installed in the system, open the

manual air vents in the system one at a time, beginning
with the lowest floor. Close the vent when water
squirts out. Repeat with remaining vents.

2. Open the automatic air vent (diaphragm-type or bladder
type expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Refill to correct pressure.

42

6 Start-up (continued)

Installation & Service Manual

Check for gas leaks

 WARNING

 WARNING

Before starting the boiler, and during initial
operation, smell near the floor and around the
boiler for gas odorant or any unusual odor.
Remove the front access panel and smell the
interior of the boiler enclosure. Do not proceed
with startup if there is any indication of a gas
leak. Use an approved leak detection solution.
Repair any leaks at once.

Propane boilers only – Your propane supplier
mixes an odorant with the propane to make
its presence detectable. In some instances, the
odorant can fade, and the gas may no longer
have an odor. Before startup (and periodically
thereafter), have the propane supplier verify
the correct odorant level in the gas.

Intermittent Pilot Spark Ignition
System

 WARNING

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

Freeze Protection

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

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

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

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

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

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

(a) Shut off gas supply.

(b) Shut off water supply.

(c) Shut off electrical supply.

(d) Drain the unit completely. Remove one threaded

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

(e) Drain pump and piping.

43

7 Maintenance

Maintenance and annual startup

Table 7A_Service and Maintenance Schedules

Installation & Service Manual

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if
necessary;

• Check for leaks (water, gas, flue)

• Examine venting system

• Check system water pressure/system
piping/expansion tank

• Check fill water meter

• Test boiler water. When test indicates,
clean system water with approved
system restorer following manufacturer’s
information.

ANNUAL START-UP

• Check control settings

Owner maintenance

(see the User’s Information Manual for instructions)

• Check appliance area

Daily

Monthly

• Check pressure/temperature
gauge

• Check vent piping

• Check relief valve

• Check wiring and connections

• Flame inspection (stable, uniform)

• Check flue gas passageways

• Inspect and clean the burners

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

If combustion or performance
indicate need:

• Clean heat exchanger

• Remove and wash burners

44

Periodically

Every

6 months

End

of season

months

• Test low water cutoff (if used)

• Reset button (low water cutoff)

• Check appliance piping (gas and
water) for leaks

• Operate relief valve

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

7 Maintenance (continued)

Installation & Service Manual

 WARNING

 WARNING

 WARNING

 CAUTION

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

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

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

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

Address reported problems

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

Inspect appliance area

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

Inspect appliance interior

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

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

Flue vent system and air supply

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

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

 WARNING

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

Check all piping for leaks

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

 WARNING

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

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

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

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

Check water system

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

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

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

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

45

7 Maintenance

Installation & Service Manual

Check Expansion Tank

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

Check fill water meter

1. Check fill water meter for water usage. If the amount
exceeds 5% of your system volume, you could have a
leak. Have the system checked for leaks and fixed by a
qualified service technician.

Test boiler water

1. Test boiler water. Reference the Copper-Fin Installation
and Operation Manual for guidelines. When test
indicates, clean system water with approved system
restorer following the manufacturer’s information.

Check Relief Valve

 WARNING

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

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

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

 WARNING

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

46

7 Maintenance (continued)

Installation & Service Manual

Check All Wiring

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

Check Control Settings

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

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

Perform Start-up and Checks

1. Start appliance and perform checks and tests specified in

Section 6 - Start-up.

2. Verify cold fill pressure is correct and that operating

pressure does not go too high.

Check Burner Flame

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

 WARNING

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

Combustion Air

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

Check Flue Gas Passageways

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

NOTICE

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

Heat Exchanger / Burner Access

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

NORMAL

A

C

YELLOW FLAME

YELLOW TIP

B

D

FLAME LIFT

Figure 7-1_Flame Pattern Illustration

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

Yellow Tip: Yellow tip can be caused by blockage or partial
obstruction of air flow to the burner(s).

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

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

 WARNING

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

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

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

47

7 Maintenance

Installation & Service Manual

 Avoid breathing dust and contact with skin and eyes.

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

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

 Apply enough water to the combustion chamber lining to

prevent airborne dust.

Remove combustion chamber lining from the appliance

and place it in a plastic bag for disposal.

 Wash potentially contaminated clothes separately from

other clothing. Rinse clothes thoroughly.

 NIOSH stated First Aid:

Eye: Irrigate immediately.

Breathing: Fresh air.

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

Inspection and Cleaning

j. Check the heat exchanger surface for sooting. The

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

k. Remove soot from burners and bottom of the finned

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

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

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

appliance.

c. Remove the control panel door.

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

e. Disconnect gas valve wiring and remove gas manifold

assembly.

f. Remove ignition wire leading to the pilot assembly

from the ignition module.

g. Disconnect the wiring from the flame rollout/interlock

switch, see FIG. 7-2, page 49.

h. Remove the lower front jacket panel.

i. Remove the control panel mounting screws. When

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

Remove the combustion chamber door. Use caution

to prevent damage to burn ers, refractory, pilot or
wiring.

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

“Heat Exchanger/Burner Access.”

m. Loosen mounting screws and remove front control

panel.

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

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

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

Remove and clean if necessary.

p. Remove soot from the heat exchanger with a stiff

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

q. Remove the heat exchanger (HEX) filler bracket

(FIG. 7-2).

r. The heat exchanger can be removed by sliding towards

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

48

7 Maintenance (continued)

Installation & Service Manual

s. Ensure that all burner ports are cleaned to remove

any soot. See Inspection and Cleaning Procedure,
page 48.

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

jacket panels, and wires.

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

leaks.

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

UPPER FRONT
JACKET PANEL

OUTER
AIR DEFLECTOR

FLAME ROLLOUT /
INTERLOCK SWITCH

HEX FILLER
BRACKET

A

IMG00282

DETAIL A

LOWER FRONT
JACKET PANEL

Figure 7-2_Outer Air Deflector and HEX Filler Bracket

Water Circulating Pump

Inspection of Heat Exchanger Waterways

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

IMPORTANT

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

Gas Train and Controls

GAS FLOW

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

Clear Area

1. Keep appliance area clear and free from com bus ti ble

materials, gasoline and other flammable vapors and
liquids.

2. Check frequently to be sure the flow of com bus tion and

ventilation air to the boiler is not obstructed.

Figure 7-3_Gas Train

Review with owner

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

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

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

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

49

Installation & Service Manual

8 Troubleshooting

Checking Temperature Sensors

The boiler temperature sensors (inlet water, system water, and outdoor air) are all resistance type devices. The following tables
show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known
temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor.

Table 8-1A - Inlet Water/System Sensor Resistance vs.
Temperature

Temperature Resistance Temperature Resistance

50 19,553 158 2,004

68 12,690 176 1,464

86 8,406 194 1,084

104 5,715 212 816

122 3,958

140 2,786

Table 8-1B - Outdoor Air Sensor Resistance vs.
Temperature

Temperature Resistance Temperature Resistance

-50 490,813 20 46,218

-40 336,606 30 34,558

-30 234,196 40 26,099

-20 165,180 50 19,900
10 118,018 60 15,311

0 85,362 70 11,883

10 62,465 80 9,299

50

8 Troubleshooting (continued)

Troubleshooting Guide: M9 Solution Boilers

Installation & Service Manual

Step 1:

Step 2:

Step 3:

Are Wires W1 – W3 on TST20036-2

plugged into CN9 on TST20036-1
(see FIG. 5-5)?

YES

Is the Spark

Ignitor sparking?

YES

Is the pilot staying

on?

YES

NO

•Check the pilot
tube for gas

•Check draft

NO

NO

NO

Is there continuity on the

Spark cable?

•Check for 24 VAC on 24V
terminal (Gray Wire) on
Ignition Module

NO

Is there 24 VAC (Purple Wire)

NO

Is there 24 VAC

at R1 and W1 on

the terminal strip?

on the 4-Pin connector plug

(CN1) on TST20036-1 (see FIG. 5-5)?

YES

Plug connector into

controller

Replace

YES

Ignition

Module

Step 4:

•Check voltage to and
from the transformer

•Check incoming
120 VAC

Is the gas valve

getting 24 VAC

to the MV

terminal?

YES

•Check gas pressure

•Make sure Gas Valve
knob is "ON"

NO

Replace

Ignition
Module

YES

Check each of

the following for

an open:

•Brown and
Purple Wire on
the LWCO plug

•Rollout Switch

•Manual Reset
High Limit

•Spill Switch
If any of these

devices are

open, press the

reset button

Is there 24 VAC

(Tan Wire) on the

4-Pin connector plug

(CN1) on TST20036-1

(see FIG. 5-5)?

YES

Check each of

the following for

an open:

•X and B on terminal
strip

•Purple and Black
Wires on the Vent
Damper Plug

•V and P on terminal
strip

•Auto-Reset High
Limit

NO

Check for an

open sensor

•If there is no open
sensor, make sure
there's a call for
heat

•If a call for heat is
present, replace
the temperature
controller

IMG00286

51

17

18

10

9 Diagrams

Installation & Service Manual

Schematic Diagram - M9 Unit

45,000 - 260,000 Btu/hr Models

CN12-2

G

W

W

W BN

Y

SPILL

SWITCH

B

C

P

GND

SPARK

BL

PILOT

120V

NEUTRAL

CN12-1

PR

Y

GY

Y

CHASSIS
GROUND

W

PR

120V

120V

LINE

GROUND

G

GROUND

BK

BL

BL

BL

24VDC RELAY

PUMP DELAY

BK

24VAC RELAY

BYPASS PUMP

BK

PK

PK

BK

BL

CN1-1 CN1-2

OPERATOR

1

LOW WATER

CUTOFF

BK

120V

24V

2

CIRCULATION

PUMP

BYPASS PUMP

PK

TRANSFORMER

Y

Y

Y

MOT

MOT

W

Y

TANK

AQUASTAT

BL

CN10-1

Y

CN10-2

OPERATOR

CN12-3

2

BN

LOW WATER

3

DAMPER

5

CUTOFF

VENT

3

R

4

PR

BN

PR

R1

PR

ROLLOUT

SWITCH

THERMOSTAT

24VAC RELAY

BYPASS PUMP

MANUAL

RESET

HIGH LIMIT

C

W1

R

1

PR

PR

OPERATOR

CN1-4

PR

24V

IGNITION
MODULE

R

OPERATOR

CN2-1

LBL20293 REV A

=

BK

=

BL

=

BN

=

G

4

BLACK
BLUE
BROWN
GREEN

POWER

VENTER

VENT

DAMPER

GY

PV

BL

MV

CN2-2

CN3

CN4

CN5

CN6

CN7

CN8

CN11-1

CN11-2

CN1-3

R

24VDC RELAY

GY
OR

PK
PR

T

1

BK

AUTO-RESET

HIGH LIMIT

GAS VALVE

PV

PILOT

MV

LOW

HIGH

OR

BK

INLET SENSOR

BK

SYSTEM SENSOR

PUMP DELAY

OUTDOOR SENSOR

=

GRAY

=

ORANGE

=

PINK

=

PURPLE

X

PR

W

R
T

Y

C

R

=

RED

=

TAN

=

WHITE

=

YELLOW

FLOW

SWITCH

C

POWER VENTER

V

W

GROUND

W2

P

R2

T

T

T

NO

VENTER RELAY

R

VENTER
PROVING

GY

IGNITION

MV/

MODULE

PV

BURNER

GND

HIGH

FIRE

BOX DEPICTS

OPTIONAL ITEMS

Wiring Diagram - M9 Unit

45,000 - 260,000 Btu/hr Models

MODULE

MV

PV

MV/PV

R

W

BL

IGNITION

GND

24V

Y

GY

SPARK

BURNER GND

G

Y

GY G

R

W

BL

MV

C

PV

HI

GAS

VALVE

P

W2R2

R

FLOW

SWITCH

NOC

X

R1

R

B

W1

T

W

PR

HIGH FIRE

OR

T

Y

R

W

BL

SENSOR

OUTDOOR

R OR

OR

W3W1

W2

LED1

CN11CN10

FAULT

SENSOR

OUTDOOR

STAT

TANK

AQUA-

R

R

T

Y

W

BL

TST20036-2

CN12

R

BN

R

W

W

C

12

PR

TANK

AQUASTAT

BN

SPILL

RESET

MANUAL

HIGH LIMIT

PR

SWITCH

ROLLOUT

PR

Y

BN

PR YBN

PR

Y

PR

24VAC

RELAY

(GRAY)

TRANSFORMER

BK

PK

BK PK

SWITCH

PR

T
Y

BL

Y

BL

BL
Y

BN

PR

Y

BL

W

BK

W

W

BYPASS PUMP

PK

W

W

BK

PK

W

BK

PK

BK

PILOT

BOX DEPICTS

OPTIONAL TE MS

BL

LBL20294 REV A

Y

Y

HIGH LIMIT

AUTO-RESET

C

Y

P

GY

V

BK

Y

BK

CN2

OR

Y GYPR

BK

BL PR

YBKBNBN OR

PRBL R Y BK

54321

VENT

PLUG

DAMPER

BK

SYS/

TANK

INLET

PROBE

FIRE

HIGH

FIRE

LOW

PUMP

RELAY

OR

CN1

T

Y

BL

PR

R

POWER

VENTER

POWER

VENTER

VENT

DAMPER

INLET

SENSOR

SYSTEM

SENSOR

CN9

15

20

HIGH-FIRE

0

OFFSET °F

5

135

125

TST20036

110 140

120 130

115

MIN SETPOINT °F

TST20036-1

190

200

OFF

150

MAX SETPOINT °F

160

DISCONNECT POWER BEFORE SERVICING

T

PLUG

P2 A

CUTOFF

LOW WATER

1

2

3

W

4

BK

W

G

G

JUNCTION BOX

POWER SUPPLY

RESET

MANUAL

BK

Y

21P1

OR

BN

1

YOR BKBNYOR BK

2

3

4

BN

PUMP

DELAY

PK

OR

OR

AUTO

RESET

LOW WATER CUTOFF

OR

OR

24VDC

RELAY

BK

W

CIRCULATION

BK

TEMPERATURE AND GAUGE

WIRE OF EQUAL OR HIGHER

WHEN REPLACING W IRING, USE

(BLACK)

YELLOW

RED

TAN

WHITE
=

=

=

=
T

Y

R

W

GRAY

ORANGE

PINK

PURPLE

=

=

=

=

PK

PR

GY

OR

PUMP

BLACK

BLUE

BROWN

GREEN

=

=

=

=
G

BL

BK

BN

52

Notes

53

Notes

54

Notes

55

Revision A (ECO #C11102) initial release
Revision B (ECO C12077) reflects the update of ignition timing

information on pages. 40 and 41.
Revision C (ECO C13462) reflects the addition of the Checking

Temperature Sensors Section on page 48.
Revision D (ECO C14226) reflects the addition of cautionary statements

and notes on page 16 beneath the “Vent Materials” table.
Revision E (ECO C17014) reflects the update of Table 3E on page 19.
Revision F (PCP #3000021634 / CN #500011858) reflects changes

made to water chemistry information on pages 4, 25, 28-32, 41-44,
and 46.

Revision G (PCP #3000023937 / CN #500013881) reflects an update to
the vent damper information on page 17.

SBRX-I-S_MM #100161690_DIR #2000017139_Rev G

04/18