Lochinvar CBN497, CBN647, CBN747, CBN987, CBN1437 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 Rev E
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 .................... 18-19
Masonry Chimney Installation and Inspection ............ 19
Outdoor Installation Options .................................. 20-21
3. GAS CONNECTIONS
Connecting to Gas Supply ............................................... 22
Gas Pressure Test ........................................................... 22
Gas Piping ........................................................................ 22
Gas Connections / Gas Train and Controls ..................... 23
Combination Gas Valves .................................................. 24
Checking Gas Supply Pressure .................................. 24-25
Gas Manifold Pressure Adjustment ............................ 25-26
4. WATER CONNECTIONS
Inlet & Outlet Connections ............................................... 27
Relief Valve ...................................................................... 27
Heating Boiler Installations .......................................... 27-29
Low Temperature Return Water Systems ........................ 30
Primary/Secondary Piping of a Single Boiler .............. 31
Primary/Secondary Piping of Multiple Boilers ............ 32
Boiler w/Low Temperature Bypass Piping .................. 33
Primary/Secondary Piping with Buffer Tank ............... 34
Installation with a Chilled Water System .......................... 35
Typical Heating Boiler Installations .................................. 35
Boiler Flow Rate / Bypass Requirements ................... 35-36
Temperature/Pressure Gauge and Water Treatment ...... 36
5. ELECTRICAL CONNECTIONS
Connecting to Electrical Supply ....................................... 37
Line Voltage Connections ........................................... 38
EMS Connections ............................................................ 38
Terminal Strip Connection Options ............................. 38-39
Temperature Controls
Temperature Adjustment ............................................ 39
Outdoor Reset Option ................................................. 40
Temperature Control Sensors ............................... 41-42
Hot Surface Ignition System ............................................ 43
Operation and Diagnostic Lights ...................................... 44
6. STARTUP
Operating and Safety Instructions .................................... 45
Check Water Chemistry ................................................... 46
Freeze Protection (when used) ........................................ 46
Fill and Test Water System .............................................. 46
Purge Air from Water System .......................................... 46
Check for Gas Leaks / Thermostat Circuit(s) ................... 47
Check Vent and Air Piping ............................................... 47
Placing the Boiler in Operation ........................................ 47
7. DOMESTIC WATER HEATERS
General ............................................................................. 48
Water Velocity Control ..................................................... 48
Pipe Size Requirements
Typical Water Heater Piping w/ Storage Tank ........... 49
Single Water Heater Piping w/Two Storage Tanks ... 50
Multiple Water Heater Piping w/One Storage Tank ... 51
Multiple Water Heater Piping w/Multi. Storage Tanks .52
Water Chemistry............................................................... 53
Circulating Pump/ Performance ....................................... 53
Heat Exchanger ............................................................... 54
Potable Hot Water Temperature Controls ........................ 54
Location of Cold Water Supply Piping Connections ........ 55
High Water Temperature Limit Control ............................ 56
Optional Relief Valve ........................................................ 56
Thermal Expansion and Cathodic Protection ................... 56
8. MAINTENANCE
Burner Flames .................................................................. 57
Burner Removal and Cleaning Procedures ................ 57-58
Adjusting Differential Air Pressure .............................. 58-59
Servicing a Hot Surface Igniter / Ignition Module ............ 60
Sequence of Operation Overview ............................... 60-61
9. GLOSSARY ........................................................... 62-63
10. DIAGRAMS ........................................................... 64-67
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
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
Special instructions
Installation & Service Manual
NOTICE
WARNING
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.
33
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.
Prevention of freezing –
Heat exchangers and headers damaged by freezing are not
covered by warranty.
See Section 6, Startup - Freeze Protection for more information.
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.
4
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.
5
The Copper-fin - How it works...
26
17
17
12
14
22
25
28
13
16
21
15
23
18
20
24
9
2
3
4
8
7
6
19
11
10
1
Installation & Service Manual
12
26
17
Models 497 - 747 Front View
14
17
28
22
25
Models 497 - 747 Rear View
13
16
15
18
6
23
Models 497 - 747 Right Side (inside unit)
24
21
20
10
11
19
Models 497 - 747 Left Side (inside unit)
Installation & Service Manual
14
25
22
7
28
21
4
3
2
9
20
18
24
23
15
16
13
8
6
19
11
10
7
1
12
17
17
26
The Copper-fin - How it works... (continued)
12
26
17
14
28
25
22
17
Models 987 - 2067 Front View
21
13
16
15
23
Models 987 - 2067 Rear View
24
18
20
Models 987 - 2067 Right Side (inside unit)
10
Models 987 - 2067 Left Side (inside unit)
11
19
7
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
1.7 2" 1 1/4" 6"
2.0 2" 1 1/4" 8"
2.1 2" 1 1/4" 8"
2.2 2 1/2" 2" 10"
2.6 2 1/2" 2" 12"
2.9 2 1/2" 2" 12"
3.3 2 1/2" 2" 14"
3.6 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.
8
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 1.7 2" 1 1/4" 6"
645 2.0 2" 1 1/4" 8"
745 2.1 2" 1 1/4" 8"
985 2.2 2 1/2" 2" 10"
1255 2.6 2 1/2" 2" 12"
1435 2.9 2 1/2" 2" 12"
1797 3.3 2 1/2" 2" 14"
2065 3.6 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
9
1 Determine unit location
Installation & Service Manual
Installation
This unit meets the safe lighting performance criteria with the
gas manifold and control assembly provided, as specifi ed in the
ANSI standards for gas-fi 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 20. 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
10
30"
MIN
FRONT
1 Determine unit location (continued)
DRAIN PLUG G (2X)
Installation & Service Manual
TABLE 1A
COMBUSTIBLE FLOOR KITS
Model Kit Number
497 CFK3302
647 CFK3303
747 CFK3304
Freeze protection
Although these units are CSA International designcertifi 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. The
pump will shut off 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 off, the following
precautionary measures must be taken:
1. Shut off gas supply.
2. Shut off water supply.
3. Shut off electrical supply
4. Drain the unit completely. Remove one threaded plug
or bulbwell from the inlet side of the front header and
one from the outlet side of the front header on the heat
exchanger. Blow all water out of the heat exchanger
(see FIG.'s 1-2A and 1-2B).
5. Drain pump and piping.
Figure 1-2A_Drain the unit_Models 497 - 747
Pump operation
This unit is equipped with a pump delay of 30 seconds. If
continuous operation of the pump is desired, the pump must
be electrically connected to another circuit. Connection of
the pump to this unit will provide intermittent pump delay
operation.
Location
Locate indoor boilers and 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
DR
11
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. The addition
of glycol will decrease heat transfer and
increase frictional loss in the boiler and
related piping. A larger pump with more
capacity (15% to 25% more) may be required
to maintain desired fl 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 fl 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
(806 cm2)
163
(1052 cm2)
188
(1213 cm2)
248
(1600 cm2)
315
(2032 cm2)
360
(2323 cm2)
450
(2903 cm2)
518
(3342 cm2)
Bottom
2
Opening, in
(806 cm2)
(1052 cm2)
(1213 cm2)
(1600 cm2)
(2032 cm2)
(2323 cm2)
(2903 cm2)
(3342 cm2)
125
163
188
248
315
360
450
518
*Outside Air from
1 Opening Directly
from Outdoors, in
2
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
2
Top
Opening, in
(1613 cm2)
(2097 cm2)
(2420 cm2)
(3194 cm2)
(4065 cm2)
(4646 cm2)
(5807 cm2)
1035
(6678 cm2)
Inside Air from
Outdoors
2
Opening, in
250
325
375
495
630
720
900
Bottom
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
2
Opening, in
(3226 cm2)
(4194 cm2)
(4839 cm2)
(6388 cm2)
(8130 cm2)
(9291 cm2)
(11614 cm2)
(13356 cm2)
Top
500
650
750
990
1260
1440
1800
2070
2
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
2
12
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
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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 (5.5cm² 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 (5.5cm² 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 (11cm² per kW).
Figure 1-7_Outside combustion air, using ducts
14
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 (22cm² per kW), but not less than 100 square inches
(645cm²).
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.
15
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. 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.
16
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 46.
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 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.
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2 Venting
Installation & Service Manual
1. Conventional negative draft
venting
NOTICE
Figure 2-5_Conventional negative draft vertical venting
with combustion air louvers
This option uses Type-B double-wall flue outlet piping. The
blower brings in combustion air. The buoyancy of the heated
flue products causes them to rise up through the flue pipes. The
flue outlet terminates at the rooftop.
Before installing a venting system, follow
all venting clearances and requirements
found in the Venting, General Information
section, page 16.
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
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.
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.
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.
18
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.
19
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
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 runoff drains will spill onto the
unit.
CAUTION
CAUTION
20
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.
2 Venting (continued)
Installation & Service Manual
3'
3'
3'
3'
3'
3'
Figure 2-6_Outdoor vent cap installed on Models
497 - 747
3'
3'
Figure 2-7_Outdoor vent cap installed on Models
987 - 2067
Outdoor vent kit
The optional outdoor vent kit is available from the appliance manufacturer. The outdoor kit part numbers are listed by unit size.
See Table 2B for kit numbers.
You can install the outdoor vent cap and combustion air inlet panel(s) on the unit (see FIG.’s 2-6 and 2-7).
TABLE 2B
Outdoor Vent Kits
Model
497 ODK3023 ODK3014
647 ODK3024 ODK3015
747 ODK3024 ODK3015
987 ODK3049 ODK3036
1257 ODK3065 ODK3064
1437 ODK3050 ODK3037
1797 ODK30001 ODK30002
2067 ODK30001 ODK30002
* These kits include an outdoor vent cap, air inlet hood(s), and gasket.
Kit*
w/ Pump Cover
Kit*
without Pump Cover
21
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