Lochinvar CBN497, CBN647, CBN747, CBN987, CBN1257 Installation Manual

...

 WARNING: If the information in

this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

-- This water heater MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

CBX-CWX-I-S_100160893_2000001309_Rev J

Installation & Service Manual

Models: 497 - 2067

-- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

 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

SAFETY INFORMATION ................................................... 4

THE COPPER-FIN -- HOW IT WORKS.......................... 5-7

RATINGS ........................................................................ 8-9

1. DETERMINE UNIT LOCATION

Locating the Unit .............................................................. 10

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

Freeze Protection ........................................................ 11-12

Prevent Combustion Air Contamination ...................... 11-13

Combustion Air Options .............................................. 14-15

2. VENTING

General Venting Information ....................................... 16-17

Vent System Options

Conventional Negative Draft Venting .................... 18-21

Masonry Chimney Installation and Inspection ............ 19

Outdoor Installation Options .................................. 22-23

3. GAS CONNECTIONS

Connecting to Gas Supply ............................................... 24

Gas Pressure Test ........................................................... 24

Gas Piping ........................................................................ 24

Gas Connections / Gas Train and Controls ..................... 25

Combination Gas Valves .................................................. 26

Checking Gas Supply Pressure .................................. 26-27

Gas Manifold Pressure Adjustment ............................ 27-28

4. WATER CONNECTIONS

Inlet & Outlet Connections ............................................... 29

Relief Valve ...................................................................... 29

Heating Boiler Installations .......................................... 29-31

Low Temperature Return Water Systems ........................ 32

Primary/Secondary Piping of a Single Boiler .............. 33

Primary/Secondary Piping of Multiple Boilers ............ 34

Boiler w/Low Temperature Bypass Piping .................. 35

Primary/Secondary Piping with Buffer Tank ............... 36

Installation with a Chilled Water System .......................... 37

Typical Heating Boiler Installations .................................. 37

Boiler Flow Rate / Bypass Requirements ................... 37-38

Temperature/Pressure Gauge and Water Treatment ...... 38

5. ELECTRICAL CONNECTIONS

Connecting to Electrical Supply ....................................... 39

Line Voltage Connections ........................................... 40

EMS Connections ............................................................ 40

Terminal Strip Connection Options ............................. 40-41

Temperature Controls

Temperature Adjustment ............................................ 41

Outdoor Reset Option ................................................. 42

Temperature Control Sensors ............................... 43-44

Hot Surface Ignition System ............................................ 45

Operation and Diagnostic Lights ...................................... 46

6. STARTUP

Operating and Safety Instructions .................................... 47

Check Water Chemistry ................................................... 48

Freeze Protection (when used) ........................................ 48

Fill and Test Water System .............................................. 49

Purge Air from Water System .......................................... 49

Check for Gas Leaks / Thermostat Circuit(s) ................... 50

Check Vent and Air Piping ............................................... 50

Placing the Boiler in Operation ........................................ 50

7. DOMESTIC WATER HEATERS

General ............................................................................. 51

Water Velocity Control ..................................................... 51

Pipe Size Requirements

Typical Water Heater Piping w/ Storage Tank ........... 52

Single Water Heater Piping w/Two Storage Tanks ... 53 Multiple Water Heater Piping w/One Storage Tank ... 54 Multiple Water Heater Piping w/Multi. Storage Tanks .55

Water Chemistry............................................................... 56

Circulating Pump/ Performance ....................................... 56

Heat Exchanger ............................................................... 57

Potable Hot Water Temperature Controls ........................ 57

Location of Cold Water Supply Piping Connections ........ 58

High Water Temperature Limit Control ............................ 59

Optional Relief Valve ........................................................ 59

Thermal Expansion and Cathodic Protection ................... 59

8. MAINTENANCE

Burner Flames .................................................................. 60

Burner Removal and Cleaning Procedures ................ 60-61

Adjusting Differential Air Pressure .............................. 61-62

Servicing a Hot Surface Igniter / Ignition Module ............ 63

Sequence of Operation Overview ............................... 63-64

9. GLOSSARY & NOTES .......................................... 65-67

10. DIAGRAMS ........................................................... 68-71

Revision Notes .................................................. Back Cover

Hazard definitions

The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Please read before proceeding

Special instructions

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.

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

Checking equipment –

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 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.

NOTICE

REMOVAL OF COMBUSTION CHAMBER LINING OR BASE PANELS:

 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 job site 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.

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 guides.

Apply enough water to the combustion chamber lining to prevent airborne dust.

 Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.

• NIOSH stated First Aid: Eye: Irrigate immediately.

Breathing: Fresh 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.

Warranty –

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).

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

Please read before proceeding

Safety information

Installation & Service Manual

 Owner warning –

The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers.

NOTICE

A gas appliance that draws combustion air from the equipment room where it is installed 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 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.

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.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Codes –

The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1. 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 Gas 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 gasfired hot water boilers, ANSI Z21.13 and gas water heaters, ANSI Z21.10.3.

 WARNING

1. This unit is only for use with the type of gas indicated on the rating plate.

2. If you smell gas

• shut off gas supply

• do not try to light any appliance

• do not touch any electrical switch; do not use any phone in your building

• immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions

• if you cannot reach your gas supplier, call the fire department

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

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

5. UNDER NO CIRCUMSTANCES MUST FLAMMABLE MATERIALS SUCH AS GASOLINE OR PAINT THINNER BE USED OR STORED IN THE VICINITY OF THIS APPLIANCE, VENT-AIR INTAKE SYSTEM OR ANY LOCATION FROM WHICH FUMES COULD REACH THE APPLIANCE OR VENT-AIR INTAKE SYSTEM.

6. Appliance surfaces become hot during operation. Be careful not to touch hot surfaces. Keep all adults, children, and animals away from operation of the hot unit. Severe burns can occur.

7. You must take adequate care to prevent scald injury when storing water at elevated temperatures for domestic use.

8. This unit must have an adequate supply of fresh air during operation for proper gas combustion and venting.

9. Make sure all exhaust venting is properly installed and maintained. Improper venting of this unit could lead to increased levels of carbon monoxide.

10. Do not use this boiler if any part has been under water. Immediately call a qualified service technician to replace the boiler. The possible damage to a flooded boiler can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

11. Do not alter this unit in any way. Any change to this unit or its controls can be dangerous.

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

The Copper-fin - How it works...

Installation & Service Manual

1. Heat exchanger

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

2. Inner combustion chamber door

The inner combustion chamber door is a galvanized steel door which allows access for service, maintenance, and removal of the heat exchanger from inside the combustion chamber.

3. Blower

The blower pulls in air and injects air into the individual burners along with gas from the gas manifold where the mix is burned in the combustion chamber.

4. Gas valve

The gas valve allows the proper amount of gas to pass into the burner for combustion. The gas valve is biased with pressure from the combustion chamber to assist in regulation of the gas flow.

5. System / tank temperature sensor (not shown)

When connected, this sensor can be used as a system sensor or a tank sensor.

6. Inlet temperature sensor

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

7. Temperature and pressure gauge (boiler only)

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

8. Diagnostic display

The diagnostic display consists of six (6) lamps used to show all the major steps of operation and control malfunctions.

9. Burner

The burner is a ported stainless steel construction which uses a gas air mix to operate at a fixed input. Banks of burners are turned on or off to vary the firing rate.

10. Water outlet (system supply)

The water outlet is a pipe connection that supplies water to the system with connections for a flow switch (see #25), a relief valve (see #22), and a temperature and pressure gauge (boilers only) (see #7).

11. Water inlet (system return)

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

12. Gas supply pipe

The gas supply pipe on this appliance is 1 1/4'' diameter (Models 497 - 747) and 2" diameter (Models 987 - 2067) NPT. Please reference the National Fuel Gas Code charts for connection details.

13. Two-Stage Electronic Temperature Control

The electronic temperature control provides two-stage (high / low fire) operation by monitoring system demand.

14. Air intake

Fresh air for combustion is drawn through a filter provided at the air intake, located at either the rear or right side of the appliance.

15. Line voltage terminal strip

The line voltage terminal strip provides a location to connect all of the line voltage (120 VAC) contact points to the unit.

16. Low voltage connection board

The low voltage connection board provides a location to tie in all of the low voltage contacts to the appliance. This is where most of the external safety devices are connected to the unit such as the louver proving switch.

17. Front doors - upper and lower

The front doors provide access to the gas train as well as the blower, burners and other key components for service and maintenance.

18. Hot surface igniter (HSI)

The hot surface igniter is a device that is used to ignite the air/gas mixture as well as monitor the performance of the flame during operation. This device acts as a flame sense electrode.

19. Flame inspection window (sight glass)

The flame inspection windows, located on either side of the appliance, allow for visual inspection of the burners and flame during operation.

20. Gas shut off valve (downstream test cock)

The downstream test cock (when supplied) is in the gas train to ensure complete shut off of the gas to the burner in case of

maintenance, inspection, or testing of the valve.

21. Manual high limit

Device that monitors the outlet water temperature to ensure safe operation. If the temperature exceeds its setting (field adjustable), it will break the control circuit, shutting the appliance down.

22. Relief valve

The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Boilers operate on pressure only and are shipped from the factory at a rating of 50 PSI. Water heaters operate on temperature and pressure and are shipped standard as 150 PSI and 210°F (98.9°C).

23. Power switch

The power switch is used to engage and disengage power to the appliance on the 120 VAC circuit.

24. Air pressure switch

The air pressure switch is a safety device which ensures proper blower operation. The air pressure switch is wired in series with the low voltage control circuit in such a way that if the fan does not engage or shuts down prematurely the device will break the control circuit and the unit will shut down.

25. Flow switch

The flow switch is a safety device that ensures flow through the heat exchanger during operation. This appliance is low mass and should never be operated without flow. The flow switch makes contact when flow is detected and allows the unit to operate. If flow is discontinued during operation for any reason the flow switch will break the control circuit and the unit will shut down.

26. Drain port(s)

Location from which the heat exchanger can be drained.

27. Manual shutoff valve (not shown)

Manual valve used to isolate the unit from the gas supply.

28. Flue pipe

A pipe like enclosure that is placed over an appliance to improve natural upward convection of heat and thereby increase the dissipating ability of the appliance.

The Copper-fin - How it works...

Installation & Service Manual

Models 497 - 747 Front View

Models 497 - 747 Rear View

Models 497 - 747 Right Side (inside unit)

Models 497 - 747 Left Side (inside unit)

Installation & Service Manual

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

Models 987 - 2067 Front View

Models 987 - 2067 Rear View

Models 987 - 2067 Right Side (inside unit)

Models 987 - 2067 Left Side (inside unit)

Ratings

HIGH ALTITITUDE LABEL

Installation & Service Manual

Copper-fin

AHRI Rating

Model Number

Note: Change “N” to

“L” for L.P. gas models.

CBN497 250 495 401 349

CBN647 350 645 522 454

CBN747 350 745 603 524

CBN987 360 985 798 694

CBN1257

CBN1437

CBN1797

CBN2067

NOTICE

Input MBH

(Note 4)

Min Max

720 1255 1017 884

720 1435 1162 1010

720 1797 1454 1264

990 2065 1673 1455

Maximum allowed working pressure is located on the rating plate.

Gross

Output

MBH

(Note 1)

Net

AHRI

Ratings

Water,

MBH

(Note 2)

Other Specifications

Boiler Water

Content Gallons

1.9 2" 1 1/4" 6"

2.0 2" 1 1/4" 8"

2.4 2" 1 1/4" 8"

3.3 2 1/2" 2" 10"

3.5 2 1/2" 2" 12"

3.7 2 1/2" 2" 12"

4.1 2 1/2" 2" 14"

4.3 2 1/2" 2" 14"

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

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

5. Ratings have been confirmed by AHRI.

Figure A High altitude label location_boiler

Ratings (continued)

Installation & Service Manual

Model Number

Note: Change “N” to

“L” for L.P. gas models

CWN497

CWN647

CWN747

CWN987

CWN1257

CWN1437

CWN1797

CWN2067

NOTICE

LOW LEAD CONTENT

Copper-fin Specifications

Input MBH

495 1.9 2" 1 1/4" 6"

645 2.0 2" 1 1/4" 8"

745 2.4 2" 1 1/4" 8"

985 3.3 2 1/2" 2" 10"

1255 3.5 2 1/2" 2" 12"

1435 3.7 2 1/2" 2" 12"

1795 4.1 2 1/2" 2" 14"

2065 4.3 2 1/2" 2" 14"

Maximum allowed working pressure is located on the rating plate.

Water

Content Gallons

Water Connections Gas Connections

HLW

Vent Size

(Note 1)

Notes:

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

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

HIGH ALTITUDE LABEL

Figure B High altitude label location_water heater

1 Determine unit location

Installation & Service Manual

Installation

 is unit meets the safe lighting performance criteria with the gas manifold and control assembly provided, as speci ed in the ANSI standards for gas- red units. ANSI Z21.13/CSA 4.9 and ANSI Z21.10.3/CSA 4.3.

Locating the unit

1. Maintain all clearances from combustible construction when locating unit. See Clearances from Combustible Construction, this page.

2. Locate the unit so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, install a suitable drain pan that is well-drained under the unit. The pan must not restrict combustion air flow. The appliance manufacturer is not responsible for water damage in connection with this unit, or any of its components.

3. Install indoor units so that the ignition system components are protected from any water while operating or during service.

4. Appliances located in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have a minimum clearance of not less than 18'' (46cm) above the floor. The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle.

5. DO NOT install this appliance in any location where gasoline or flammable vapors are likely to be present.

6. The appliance must be installed on a level surface.

7. Models 497 - 747 are approved for installation on combustible flooring using the approved combustible floor kits (reference Table 1A). Models 987 - 2067 are approved for installation on combustible flooring. Do not install appliances directly on carpeting.

8. For outdoor models, you must install an optional vent kit. Instructions for mounting the vent kit are included in the venting section. Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block, or other non-combustible pad. Outdoor models have additional special location and clearance requirements. See Outdoor Installation Venting, page 22. A wind proof cabinet protects the unit from weather.

Indoor clearances from combustible construction

Maintain minimum specified clearances for adequate operation. Allow sufficient space for servicing pipe connections, pump and other auxiliary equipment, as well as the unit. See rating plate for specific service clearance requirements.

Right Side 3'' (7.5 cm)

Rear 3'' (7.5 cm) (3'' min. from any surface)*

Left Side 6'' (15 cm) (24'' (0.61 m) suggested for

service)

Front Alcove* (30'' (0.76m) suggested for service)

Top 3'' (7.5 cm)

Flue 1'' (25.4 mm)

Hot Water Pipes 1'' (25.4 mm)

*An Alcove is a closet without a door. Thirty-six inches (36") to rear required for outdoor installation.

Note: No additional clearance is needed on the right side of the unit for the observation port. An observation port is located on both the right and left side of the unit.

Figure 1-1_Indoor clearances from combustible construction

3" MIN REAR

6" MIN LEFT SIDE

3" MIN TOP

3" MIN RIGHT SIDE

30" MIN FRONT

1 Determine unit location (continued)

DRAIN PLUG G (2X)

Installation & Service Manual

TABLE 1A

COMBUSTIBLE FLOOR KITS

Model Kit Number

497 100136977

647 100136978

747 100136979

Freeze protection

Although these units are CSA International designcerti ed for outdoor installations, such installations are not recommended in areas where the danger of freezing exists. You must provide proper freeze protection for outdoor installations, units installed in unheated mechanical rooms or where temperatures may drop to the freezing point or lower. If freeze protection is not provided for the system, a low ambient temperature alarm is recommended for the mechanical room. Damage to the unit by freezing is non-warrantable.

Anytime the temperature measured at any of the sensors (except the outside air temperature sensor) drops below 40°F, the control turns on the pump contact and the alarm relay.  e pump will shut o when both sensors are above 50°F.

Outdoor boiler installation

Adequate hydronic system antifreeze must be used. A snow screen should be installed to prevent snow and ice accumulation around the unit or its venting system.

Shut-down and draining

If for any reason, the unit is to be shut o , the following precautionary measures must be taken:

1. Shut o gas supply.

2. Shut o water supply.

3. Shut o electrical supply

4. Drain the unit completely. Remove one threaded plug or bulbwell from the inlet side of the front header and one from the outlet side of the front header on the heat exchanger. Blow all water out of the heat exchanger (see FIG.'s 1-2A and 1-2B).

5. Drain pump and piping.

Figure 1-2A_Drain the unit_Models 497 - 747

Pump operation

 is unit is equipped with a pump delay of 30 seconds. If continuous operation of the pump is desired, the pump must be electrically connected to another circuit. Connection of the pump to this unit will provide intermittent pump delay operation.

Location

Locate indoor boilers and water heaters in a room having a temperature safely above freezing [32°F (0°C)].

 CAUTION

A mechanical room operating under a negative draft pressure may experience a down draft in the flue of a boiler when it is not firing. The cold outside air pulled down the flue may freeze a heat exchanger. This condition must be corrected to provide adequate freeze protection.

Hydronic systems anti-freeze

Freeze protection for a heating boiler or hot water supply boiler using an indirect coil can be provided by using hydronic system antifreeze. Follow the appliance manufacturers instructions. Do not use undiluted or automotive type antifreeze.

DRAIN PLUG

Figure 1-2B_Drain the unit_Models 987 - 2067

1 Determine unit location

Installation & Service Manual

Freeze Protection for a Heating Boiler System (if required)

 WARNING

1. Use only properly diluted inhibited glycol anti-freeze designed for hydronic systems. Inhibited propylene glycol is recommended for systems where incidental contact with drinking water is possible.

2. A solution of 50% antifreeze will provide maximum protection of approximately -30°F.

3. Follow the instructions from the antifreeze manufacturer. Quantity of antifreeze required is based on total system volume including expansion tank volume.

4. Glycol is denser than water and changes the viscosity of the system.  e addition of glycol will decrease heat transfer and increase frictional loss in the boiler and related piping. A larger pump with more capacity (15% to 25% more) may be required to maintain desired  ow rates and prevent a noise problem in a glycol system.

Do not use undiluted or automotive type anti-freeze.

Combustion and Ventilation Air

Provisions for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA-B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

Provide properly-sized openings to the equipment room to assure adequate combustion air and proper ventilation when the unit is installed with conventional venting or sidewall venting.

*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.

5. Local codes may require a back  ow preventer or actual disconnect from city water supply when antifreeze is added to the system.

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

*Outside Air from

Model

Number

497

647

747

987

1257

1437

1797

2067

2 Openings Directly from

Outdoors

Top

Opening, in

125

163

)

(806 cm

(1052 cm

188

(1213 cm2)

248

315

(1600 cm

(2032 cm

360

(2323 cm2)

450

(2903 cm2)

518

(3342 cm2)

Opening, in

)

Bottom

125

(806 cm2)

163

(1052 cm2)

188

(1213 cm2)

248

(1600 cm2)

315

(2032 cm2)

360

(2323 cm2)

450

(2903 cm2)

518

(3342 cm2)

*Outside Air from

1 Opening Directly

from Outdoors, in

167

(1077 cm2)

217

(1400 cm2)

250

(1613 cm2)

330

(2129 cm2)

420

(2710 cm2)

480

(3097 cm2)

600

(3871 cm2)

690

(4452 cm2)

TABLE 1B

2 Ducts Delivered from

Top

Opening, in

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm2)

495

(3194 cm2)

630

(4065 cm2)

720

(4646 cm2)

900

(5807 cm2)

1035

(6678 cm2)

Inside Air from

Outdoors

Bottom

Opening, in

250

(1613 cm2)

325

(2097 cm2)

375

(2420 cm2)

495

(3194 cm2)

630

(4065 cm2)

720

(4646 cm2)

900

(5807 cm2)

1035

(6678 cm2)

Inside Air from

2 Ducts Delivered from

Interior Space

Top

Opening, in

500

(3226 cm2)

650

(4194 cm2)

750

(4839 cm2)

990

(6388 cm2)

1260

(8130 cm2)

1440

(9291 cm2)

1800

(11614 cm2)

2070

(13356 cm2)

Opening, in

(3226 cm2)

(4194 cm2)

(4839 cm2)

(6388 cm2)

(8130 cm2)

(9291 cm2)

(11614 cm2)

(13356 cm2)

Bottom

500

650

750

990

1260

1440

1800

2070

Installation & Service Manual

1 Determine unit location (continued)

Figure 1-3_Combustion air filter_ Models 497 - 747

NOTICE

CAUTION

Combustion air filter

This unit has a standard air filter located at the combustion air inlet. This filter helps ensure clean air is used for the combustion process. Check this filter every month and replace when it becomes dirty. The filter size on Models 497 - 747 is 12" x 12" x 1" (30.5cm x 30.5cm x 2.5cm) and 16" x 16" x 1" (40.6cm x 40.6cm x 2.5 cm) on Models 987 - 2067. You can find these commercially available filters at any home center or HVAC supply store.

During construction the air filter should be checked more frequently to ensure it does not become clogged with construction dirt and debris.

Sustained operation of an appliance with a clogged burner may result in nuisance operational problems, bad combustion, and non-warrantable component failures.

Figure 1-4_Combustion air filter_ Models 987 - 2067

1 Determine unit location

Installation & Service Manual

Combustion Air Options

 CAUTION

This unit has four combustion air options.

1. Outside Combustion Air, No Ducts

You can direct outside combustion air to this unit using either one or two permanent openings (see FIG. 1-5).

One Opening

The opening must have a minimum free area of one square inch per 3000 Btu input (7 cm2 per kW). You must locate this opening within 12'' (30 cm) of the top of the enclosure.

Figure 1-5_Outside combustion air single opening

Under no circumstances should a mechanical room ever be under a negative pressure. Particular care should be taken when exhaust fans, clothes dryers, compressors, air handling units, etc., take away air from the inlet.

Two Openings

The combustion air opening must have a minimum free area of one square inch per 4000 Btu input (5.5cm per kW). You must locate this opening within 12'' (30cm) of the bottom of the enclosure.

The ventilation air opening must have a minimum free area of one square inch per 4000 Btu input (5.5cm per kW). You must locate this opening within 12'' (30cm) of the top of the enclosure.

Figure 1-6_Outside combustion air, two openings

2. Outside Combustion Air, Using Ducts

You can direct outside combustion air to this unit using two air ducts to deliver the air to the boiler room.

Each of the two openings must have a minimum free area of one square inch per 2000 Btu input (11cm per kW).

Figure 1-7_Outside combustion air, using ducts

1 Determine unit location (continued)

Installation & Service Manual

3. Combustion Air from an Interior Space

You can direct combustion air to this unit using air from an adjoining interior space. You must provide two openings from the boiler room to the adjoining room. Each of the two openings must have a net free area of one square inch per 1000 Btu input (22cm per kW), but not less than 100 square inches (645cm).

Figure 1-8_Combustion air from an interior space

Exhaust Fans

 WARNING

Any fan or equipment which exhausts air from the boiler room may deplete the combustion air supply and/or cause a down draft in the venting system. Spillage of flue products from the venting system into an occupied living space can cause a very hazardous condition that must be corrected immediately. If a fan is used to supply combustion air to the boiler room, the installer must make sure that it does not cause drafts which could lead to nuisance operational problems with the boiler.

All dimensions are based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12'' (30 cm) of the ceiling and one must be within 12'' (30 cm) of the floor of the equipment room. Each opening must have a minimum net free area as specified in TABLE 1B, page 12. Single openings shall be installed within 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, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger finned tubes, headers, flue collectors, and the vent system. The result is improper combustion and a nonwarrantable, premature unit failure.

Installation & Service Manual

2 Venting

General information

You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable local building codes. Vent installations for connection to gas vents or chimneys must be in accordance with Part 7, “Venting of Equipment” of the above-mentioned standards.

NOTICE

 DANGER

Examine the venting system at least once each year. Check all joints and vent pipe connections for tightness. Also check for corrosion or deterioration. If you find any problems, correct them at once.

Failure to use correct venting materials can result in loss of life from flue gas spillage into working or living space.

Venting support

Support horizontal portions of the venting system to prevent sagging. Provide an upward slope of at least 1/4 inch per foot (21mm/m) on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations.

Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney. A water heater shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel. The weight of the venting system must not rest on the unit. Provide adequate support of the venting system. Follow all local and applicable codes. Secure and seal all vent connections. Follow the installation instructions from the vent material manufacturer.

Vertical vent termination clearances and location

The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof within a 10 foot (3.05m) radius of the termination.

The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.

A vertical termination less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet wall.

You must locate the air inlet termination elbow at least 12'' (30cm) above the roof or above normal snow levels. Keep the vent cap clear of snow, ice, leaves, and debris to avoid blocking the flue.

Figure 2-1_Vent termination from peaked roof - 10 ft. or less from ridge

NOTICE

Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent terminations recommended by the vent manufacturer.

Figure 2-2_Vent termination from peaked roof - 10 ft. or more from ridge

2 Venting (continued)

Installation & Service Manual

Figure 2-3_Vent termination from flat roof - 10 ft. or less from parapet wall

 CAUTION

Units which are shut down or will not operate may experience freezing due to convective air flow in flue pipe, through the air inlet, or from negative pressure in the equipment room. In cold climates, operate pump continuously to help prevent freezing of boiler water. Provide proper freeze protection. See Freeze Protection, page 48.

TABLE 2A

FLUE PIPE SIZES

MODEL FLUE SIZE MODEL FLUE SIZE

497 6'' 1257 12'' 647 8'' 1437 12''

747 8'' 1797 14'' 987 10'' 2067 14''

Installer may increase diameter one pipe size for ease of installation, if needed.

Vent system options

Vent System Options

This fan-assisted Category 1 unit has two venting options.

1. Conventional Negative Draft Venting

This option uses a vertical rooftop flue termination.

Combustion air is supplied from the mechanical room. See page 15 for detailed information.

2. Outdoor Installation Venting This option uses the installation of special air inlet and vent caps on the unit.

All units are shipped from the factory equipped for conventional negative draft venting. All other optional vent systems require the installation of specific vent kits and venting materials. The following is a detailed explanation of the installation requirements for each venting system, components used and part numbers of vent kits for each model.

Figure 2-4_Vent termination from flat roof - 10 ft. or more from parapet wall

Barometric damper location

Any venting system option that requires a barometric damper must adhere to the following directions for optimum performance. The preferred location for the barometric damper is in a tee or collar installed in the vertical pipe rising from the unit’s flue outlet. The barometric damper MUST NOT be installed in a bull head tee installed on the unit’s flue outlet. The tee or collar containing the barometric damper should be approximately three feet vertically above the connection to the unit’s flue outlet. This location ensures that any positive velocity pressure from the unit’s internal combustion fan is dissipated and the flue products are rising due to buoyancy generated from the temperature of the flue products. Adjust the weights on the damper to ensure that draft is maintained within the specified ranges.

2 Venting

Installation & Service Manual

1. Conventional negative draft venting

NOTICE

Figure 2-5_Conventional negative draft vertical venting with combustion air louvers

Before installing a venting system, follow all venting clearances and requirements found in the Venting, General Information section, page 16.

Negative draft

The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation (approximately 2 to 5 minutes).

Connect the flue vent directly to the flue outlet opening on the top of the unit. No additional draft diverter or barometric damper is needed on single unit installations with a dedicated stack and a negative draft within the specified range of 0.02 to 0.08 inches w.c. If the draft in a dedicated stack for a single unit installation exceeds the maximum specified draft, you must install a barometric damper to control draft. Multiple unit installations with combined venting or common venting with other Category I negative draft appliances require each boiler to have a barometric damper installed to regulate draft within the proper range.

Do not connect vent connectors serving appliances vented by natural draft (negative draft) to any portion of a mechanical draft system operating under positive pressure. Connecting to a positive pressure stack may cause flue products to be discharged into the living space causing serious health injury.

Flue outlet piping

On a conventionally vented, negative draft appliance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type "B" double wall (or equivalent) vent connectors and must be direct as possible with no reduction in diameter. To properly size all double wall vent connectors and stacks, use the venting tables in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment. The Type "B" vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer's listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes.

Any vent materials used must be listed by a nationally recognized test agency for use as vent material.

0.08 inches w.c.

Common venting systems

You can combine the flue with the vent from any other negative draft, Category I appliance. Using common venting for multiple negative draft appliances requires you to install a barometric damper with each unit. This will regulate draft within the proper range. You must size the common vent and connectors from multiple units per the venting tables for Type-B doublewall vents in the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

Common venting systems may be too large when an existing unit is removed.

2 Venting (continued)

Installation & Service Manual

Common venting systems may be too large when an existing unit is removed.

At the time of removal of an existing appliance, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused opening in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch. Make sure there is no blockage or restriction, leakage, corrosion and other unsafe conditions.

3. If possible, close all building doors and windows. Close all doors between the space in which the appliances remaining connected to the common venting system are located and other building spaces.

4. Turn on clothes dryers and any other appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.

5. Close fire place dampers.

6. Place in operation the unit being inspected. Follow the lighting instructions. Adjust thermostat so unit will operate continuously.

7. Test for spillage at the draft hood/relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

8. After making sure that each appliance remaining connected to the common venting system properly vents when tested as above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances to their previous conditions of use.

9. Correct any improper operation of the common venting system so that the installation conforms to the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA-B149 Installation Code for Gas Burning Appliances and Equipment. When resizing any portion of the common venting system, resize to approach the minimum size as determined using the appropriate tables of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/ CGA-B149 Installation Code for Gas Burning Appliances and Equipment.

Masonry chimney installation

A masonry chimney must be properly sized for the installation of a high efficiency gas-fired appliance. Venting of a high efficiency appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry chimneys, with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature of the flue products from a high efficiency appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft. This will result in condensing of flue products, damage to the masonry flue/tile, insufficient draft and possible spillage of flue products into an occupied living space. Carefully inspect all chimney systems before installation.

CAUTION

Inspection of a masonry chimney

A masonry chimney must be carefully inspected to determine its suitability for the venting of flue products. A clay-tilelined chimney must be structurally sound, straight and free of misaligned tile, gaps between liner sections, missing sections of liner or any signs of condensate drainage at the breaching or clean out. If there is any doubt about the condition of a masonry chimney, it must be relined with a properly-sized and approved chimney liner system.

Vertical vent termination clearances and location

Follow all vertical venting termination information for clearances and location under Vertical Vent Termination Clearances and Location, page 16.

Venting of high efficiency appliances into a masonry chimney without a sealed stainless steel liner can result in operational and safety problems. Any breaks, leaks, or damage to the masonry flue/tile will allow spillage of the positive pressure flue products from the chimney. These flue products can easily escape into an occupied living space causing a health hazard. If there is any doubt about the condition of a masonry chimney, or its acceptability for use after insertion of a corrosion resistant liner system, consult with local code officials.

2 Venting

Figure 2-6 Other than Direct Vent Terminal Clearances

Installation & Service Manual

Table 2B Other than Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²

A =

B =

C =

D =

E = Clearance to unventilated soffit

F = Clearance to outside corner

G = Clearance to inside corner

H =

Clearance above grade, veranda, porch,

deck, or balcony

Clearance to window or door that may

be opened

Clearance to permanently closed

window

Vertical clearance to ventilated soffit

located above the terminal within a

horizontal distance of 2 ft (61 cm) from

the center line of the terminal.

Clearance to each side of center line

extended above meter / regulator

assembly

6 in (15 cm) for appliances < 10,000 Btuh

(3 kW), 12 in (30 cm) for appliances >

10,000 Btuh (3 kW) and < 100,000 Btuh

(30 kW), 36 in (91 cm) for appliances >

12 in (30 cm) 12 in (30 cm)

4 ft (1.2 m) below or to side of opening; 1 ft

(300 mm) above opening

100,000 Btuh (30 kW)

2 Venting (continued)

Table 2B Other than Direct Vent Terminal Clearances (continued)

Installation & Service Manual

I =

J =

K =

L =

M =

Clearance to service regulator vent

outlet

Clearance to nonmechanical air supply

inlet to building or the combustion air

inlet to any other appliance

Clearance to a mechanical air supply

inlet

Clearance above paved sidewalk or

paved driveway located on public

property

Clearance under veranda, porch, deck,

or balcony

Above a regulator within 3 ft (91 cm) horizontally of the vertical center line of the regulator vent outlet to a maximum vertical

distance of 15 ft (4.5 m)

6 in (15 cm) for appliances < 10,000 Btuh

(3kW), 12 in (30 cm) for appliances >

10,000 Btuh (3 kW) and < 100,000 Btuh

(30 kW), 36 in (91 cm) for appliances >

100,000 Btuh (30 kW)

6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)

7 ft (2.13 m)† 7 ft (2.13 m)

12 in (30 cm)‡ *

4 ft (1.2 m) below or to side of opening; 1 ft

(300 mm) above opening

horizontally

* Clearance in accordance with local installation codes and the requirements of the gas supplier.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings

and serves both dwellings.

‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he  oor.

NOTES:

1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code

2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

2 Venting

2. Outdoor installation venting

Installation & Service Manual

NOTICE

 WARNING

Units are self-venting and can be used outdoors when installed with the optional outdoor caps. These caps mount directly to the unit and cover the flue outlet and combustion air inlet openings. No additional vent piping is required.

Combustion air supply must be free of contaminants (see Combustion and Ventilation Air, page 12). To prevent recirculation of the flue products into the combustion air inlet, follow all instructions in this section.

Before installing a venting system, follow all venting clearances and requirements found in the Venting, General Information section, page 16.

Only install outdoor models outdoors and only use the vent caps supplied by the appliance manufacturer. Personal injury or product damage may result if any other cap is used or if an outdoor model is used indoors. Properly install all covers, doors and jacket panels to ensure proper operation and prevent a hazardous condition.

Outdoor vent/air inlet location

Keep venting areas free of obstructions. Keep area clean and free of combustible and flammable materials. Maintain a minimum clearance of 3'' (76mm) to combustible surfaces and 36" clearance to the rear of the unit for outdoor installations. To avoid a blocked air inlet or blocked flue condition, keep the air inlet, flue outlet and drain slot clear of snow, ice, leaves, debris, etc.

NOTICE

CAUTION

Multiple outdoor unit installations require 48'' (1.22m) clearance between each vent cap. Locate the outdoor cap at least 48'' (1.22m) below and 48'' (1.22m) horizontally from any window, door, walkway or gravity air intake.

Locate the unit at least 10 feet (3.05m) away from any forced air inlet.

Locate the unit at least 3 feet (0.91m) outside any overhang.

Clearances around outdoor installations can change with time. Do not allow the growth of trees, shrubs or other plants to obstruct the proper operation of the outdoor vent system.

A minimum of 3 feet must be maintained at all times from outdoor air vent cap surfaces to combustible construction and/or materials.

Do not install in locations where rain from building runo drains will spill onto the unit.

CAUTION

Do not install outdoor models directly on the ground. You must install the outdoor unit on a concrete, brick, block, or other non-combustible pad.

Do not locate unit so that high winds can deflect off of adjacent walls, buildings or shrubbery causing recirculation. Recirculation of flue products may cause operational problems, bad combustion or damage to controls. Locate unit at least 3 feet (0.91m) from any wall or vertical surface to prevent wind conditions from affecting performance.

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