Lochinvar CP-5M-4-08 User Manual
Installation and service must be performed by a
qual i fied service installer, service agency or the gas
supplier.
Factory warranty (shipped with appliance) does not
apply to appliances improperly installed or im prop er ly
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
buildup 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 re quire ments).
This manual supplies information for the in stal la tion,
operation and servicing of the appliance. It is strong ly
recommended that this manual be re viewed com plete ly
before proceeding with an in stal la tion.
Upon receiving equipment, check for signs of ship ping
damage. Pay particular attention to parts ac com pa ny ing
the appliance which may show signs of being hit or
otherwise being mis han dled. Verify total num ber of
pieces shown on packing slip with those ac tu al ly
received. In case there is damage or a short age,
immediately notify carrier.
INSTALLATION AND SERVICE MANUAL
HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
45,000 - 500,000 Btu/hr MODELS
RSB-i&s-05
WARRANTY
SPECIAL INSTRUCTIONS TO OWNER
Note: Retain this manual for future reference.
Improper Installation, Adjustment,
Alteration, Service or Main te nance
can cause injury or prop er ty dam age.
Refer to this man u al. For as sis tance or
additional information consult a qualified
installer, service agen cy or the gas supplier.
WARNING
CHECKING EQUIPMENT
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 ap pli ance that has been un der
water must be re placed.
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 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.
• 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
neighbors 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 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.
IMPORTANT:
Warranty ..................................................................................1
Safety Warnings ......................................................................1
Codes ..................................................................................3
Location ..................................................................................3
Clearances................................................................................4
Combustion/Ventilation Air Requirements ............................4
Conventional Venting ..............................................................7
Masonry Chimney Installations ............................................10
Sidewall Venting....................................................................10
Automatic Vent Damper ........................................................11
Gas Supply ............................................................................12
Gas Pres sures & Piping..........................................12
Manifold Pressure Adjustment ..............................15
Supply Pres sure Measurement ..............................16
Gas Valves ............................................................................17
Relief Valve ..........................................................................18
Flow Switch ..........................................................................18
Electrical Connections ..........................................................19
Temperature Adjustment ......................................................20
Temperature Limit Control....................................................22
Blocked Vent and Flame Roll-Out System ..........................23
Lighting Instructions ............................................................24
Ignition & Control Timings ..................................................28
Freeze Protection ..................................................................28
Maintenance ..........................................................................29
Flame Patterns........................................................29
Inspection Cleaning Procedure ............................................30
Heat Ex chang er/Burner Access ............................30
Inspection and Cleaning ........................................30
Gas Train................................................................................32
Heating Boiler ......................................................................32
Installation Requirements ......................................32
Pump Requirements ..............................................32
Pressure Drop Chart ..............................................33
Boiler Pump Operation ..........................................33
Typical Piping ........................................................33
Bypass Requirements ............................................33
Low Tem per a ture Systems ....................................35
Boiler Flow Rates ..................................................35
Placing Boiler in Operation ..................................36
Temperature Rise Chart ........................................37
Boiler Temperature Control ..................................38
Remote Thermostat Control Connection ............................38
Power Venter Connection......................................................38
Domestic Water Heater..........................................................38
Water Velocity Control ..........................................39
Temperature Rise ..................................................39
Water Chemistry ....................................................40
Pump Operation ....................................................40
Risk of Scald Warnings..........................................42
Troubleshooting ....................................................................44
Wiring Diagrams ..................................................................46
Revision Notes ...................................................... Back Cover
The information contained in this manual is
in tend ed for use by qualified professional in stall ers,
service technicians or gas suppliers. Con sult your
local expert for proper installation or service
procedures.
2
CONTENTS
USER WARNING
Consult and follow local Building and Fire
Regulations and other Safety Codes that apply to
this installation. Consult your local gas utility
company to authorize and inspect all gas and flue
connections.
Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. Instead, shut off the gas supply
at a location external to the appliance.
To minimize the possibility of serious personal
injury, fire or damage to your unit, never violate the
following safety rules.
1.Boilers and water heaters are heat producing
appliances. To avoid damage or injury, do not
store materials against the appliance or the ventair intake system. Use proper care to avoid
unnecessary contact (especially children) with
the appliance and vent-air intake components.
2.Never cover your appliance, lean anything
against it, store trash or debris near it, stand on it
or in any way block the flow of fresh air to
your ap pli ance.
3.UNDER NO CIRCUMSTANCES must
flammable materials such as gasoline or paint
thinner be used or stored in the vicinity of this
appliance, vent-air intake system or any location
from which fumes could reach the appliance or
vent-air intake system.
WARNING
WARNING
IMPORTANT
Your conventionally vented gas appliance must have
a supply of fresh air circulating around it during
burner operation for proper gas combustion and
proper venting.
IMPORTANT
The equipment shall be installed in accordance with
installation regulations in force in the local area where
the installation is to be made. These reg u la tions shall
be carefully followed in all cases. Au thor i ties having
jurisdiction shall be consulted be fore installations are
made. In the absence of such requirements, the in stal la tion shall conform to the latest edition of the Na tion al
Fuel Gas Code, ANSI Z223.1. Where re quired by the
authority having jurisdiction, the installation must
conform to Amer i can Society of Mechanical En gi neers
Safety Code for Controls and Safety Devices for Au to mat i cal ly Fired Boilers, ASME CSD-1. All boilers
conform to the latest edition of the ASME Boiler and
Pres sure Vessel Code, Section IV. Where required by
the authority having jurisdiction, the installation must
comply with the Canadian Association Code,
CAN/CGA-B149.1 and/or B149.2 and/or local codes.
This appliance meets the safe lighting performance
cri te ria with the gas manifold and control assembly
pro vid ed as specified in the ANSI standards for
gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.
FIG. 1 Typical (Front View) Cabinet Construction
FIG. 2 Typical Boiler (Rear View) Cabinet Construction
1. Locate the appliance so that if water connections
should leak, water damage will not occur. When
such locations can not be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the appliance. The pan
must not re strict combustion air flow. Under no
cir cum stanc es is the manufacturer to be held
re spon si ble for water damage in con nec tion with
this appliance, or any of its components.
2. The appliance must be installed indoors where it is
protected from exposure to wind, rain and weather.
3. The appliance must be installed so that the ignition
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service (cir cu la tor replacement,
control replacement, etc.,).
4. Appliances located in a residential garage and in
adjacent spaces that open to the garage and are not
part of the living space of a dwelling unit must be
installed so that all burners and burner ignition
devices have a minimum clearance of not less than
18" (46cm) above the floor. The appliance must be
located or protected so that it is not subject to
physical damage by a moving vehicle.
5. DO NOT install this appliance in any location
where gasoline or flammable vapors are likely to
be present.
3
CODES
INSTALLATION PROCEDURE
LOCATION OF UNIT
Clearances from Combustible Construction:
Right Side - 6"
Rear - 6"
Left Side - 18" (24" suggested for service)
Front - 18" (24" suggested for service)
Top - (measured from the top of the unit)
45,000 - 180,000 Btu/hr Models - 14"
199,999 - 500,000 Btu/hr Models - 29"
All units have been approved for alcove installation (an
ALCOVE is a closet enclosure without a front door).
The boiler must not be installed on carpeting.
All units have been approved for use on combustible
surfaces.
Allow sufficient space for servicing pipe con nec tions,
pump and other auxiliary equipment, as well as the
appliance.
FIG. 3 Clearances Models 45,000 - 180,000 Btu/hr
FIG. 4 Clearances Models 199,999 - 500,000 Btu/hr
Provisions for combustion and ventilation air must be in
accordance with Section 5.3, Air for Com bus tion and
Ventilation, of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Standard B149 In stal la tion Code for Gas Burning
Appliances and Equip ment, or ap pli ca ble provisions of
the local building codes.
The room where the appliance is installed MUST be
provided with prop er ly sized openings to assure
adequate combustion air and proper ventilation when
the appliance is in stalled with conventional venting.
4
CLEARANCE FROM
COMBUSTIBLE CONSTRUCTION
COMBUSTION AND VENTILATION AIR
REQUIREMENTS FOR
CONVENTIONALLY VENTED
APPLIANCES
29"
14"
6"
18"
6"
18"
6"
18"
6"
18"
FIG. 5 Combustion Air Direct from Outside
1. If air is taken directly from outside the building
with no duct, provide two permanent openings:
a. Combustion air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5cm
2
per kW). This opening must be located
with in 12" (30cm) of the floor.
b. Ventilation air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5cm
2
per kW). This opening must be located
with in 12" (30cm) of the ceiling.
FIG. 6 Combustion Air Through Ducts
2. If combustion and ventilation air is taken from
the outdoors using a duct to deliver the air
to the room where the appliance is installed, each of
the two openings should be sized based on a
minimum free area of one square inch per
2000 Btu/hr (11cm2per kW).
FIG. 7 Combustion Air from Interior Space
3. If air is taken from another interior space that is
adequately ventilated, each of the two openings
specified above should have a net free area of one
square inch for each 1000 Btu/hr (22cm2per kW)
of input, but not less than 100 square inches
(645cm
2
).
FIG. 8 Combustion Air from Outside Single Opening
4. If a single combustion air opening is provided to
bring combustion air in directly from the outdoors,
the opening must be sized based on a minimum free
area of one square inch per 3000 Btu/hr
(7cm
2
per kW). This opening must be located
within 12" (30cm) of the ceiling.
5
6
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 Open ings. Table A lists the
re quire ments for the ap pli ance only, additional gas fired
appliances located in the same room will require an
increase in the net free area to supply adequate
com bus tion air for all appliances. Combustion air
require ments are based on the latest edition of the
National Fuel Gas Code, ANSI Z223.1, in Canada refer
to National Standard CAN B149.1 or B149.2. Check all
local code re quire ments for combustion air.
All dimensions are based on net free area in square
inch es. Metal louvers or screens reduce the free area of
a combustion air opening a minimum of approximately
25%. Check with louver manufacturers for exact net
free area of louvers. Where two openings are pro vid ed,
one must be within 12" (30 cm) of the ceiling and one
must be within 12" (30 cm) of the floor of the room
where the appliance is installed. Each opening must
have a net free area as specified in Table A. Single
openings shall be located with in 12" (30 cm) of the
ceiling.
The combustion air supply must be completely free of
any flammable vapors that may ignite or chemical
fumes which may be corrosive to the appliance.
Common corrosive chemical fumes which must be
avoided are fluorocarbons and other halogenated
compounds, most commonly present as refrigerants or
solvents, such as freon, tricholorethylene,
perchlorethylene, chlorine, etc. These chemicals, when
burned, form acids which quickly attack the heat
exchanger finned tubes, headers, flue collectors, and the
vent system. The result is improper combustion and a
non-warrantable, premature appliance failure.
45,000 12 in
2
15 in
2
100 in
2
75,000 19 in
2
25 in
2
100 in
2
90,000 23 in
2
30 in
2
100 in
2
135,000 34 in
2
45 in
2
135 in
2
180,000 45 in
2
60 in
2
180 in
2
199,999 50 in
2
67 in
2
200 in
2
215,000 55 in
2
74 in
2
224 in
2
225,000 56 in
2
75 in
2
225 in
2
260,000 67 in
2
89 in
2
269 in
2
270,000 68 in
2
90 in
2
270 in
2
315,000 79 in
2
105 in
2
315 in
2
360,000 90 in
2
120 in
2
360 in
2
399,999 100 in
2
133 in
2
400 in
2
500,000 125 in
2
167 in
2
500 in
2
TABLE - A
MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY
Combustion Air Source
Input Outside Air/2 Outside Air/1 Inside Air/2
Btu/hr Openings Opening Openings
Under no circumstances should the room where
the appliance is installed ever be under a
negative pressure. Particular care should be
taken where exhaust fans, attic fans, clothes
dryers, compressors, air handling units, etc.,
may take away air from the appliance.
CAUTION
EXHAUST FANS: Any fan or equipment which ex hausts air from the room where the appliance is installed
may deplete the combustion air supply and/or cause a
down draft in the venting system, spilling flue products
into the room. Spillage of flue products from the
venting system into an occupied living space can cause
a very hazardous condition that must be corrected im me di ate ly. If a fan is used to supply com bus tion air to
the room where the appliance is installed, the installer
must make sure that it does not cause drafts which could
lead to nuisance operational problems with the
appliance.
Vent installations for connection to gas vents or
chimneys must be in accordance with Part 7, “Vent ing
of Equipment,” of the latest edition of the Na tion al Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edi tion of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment or applicable pro vi sions of
the local building codes.
Adequate combustion and ventilation air must be
sup plied to the room where the appliance is installed in
accordance with the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Stan dard B149 Installation Code for Gas Burning
Ap pli anc es and Equipment, or applicable pro vi sions of
the local building codes.
The distance of the vent terminal from adjacent
build ings, windows that open and building open ings
MUST comply with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CGA Standard B149 In stal la tion Code for
Gas Burn ing Appliances and Equip ment.
Vent connection is made directly to the top of the
ap pli ance. This appliance is designed with a built-in
draft diverter. No additional external draft hood is re quired. The connection from the appliance vent to the
common vent or chimney must be made as direct as
possible.
FIG. 9 Conventional Negative Draft Vertical Venting
The negative draft in a conventional vent in stal la tion
must be within the range of a negative 0.02 to 0.05
inches water column to ensure proper operation. All
draft read ings are made while the appliance is in stable
op er a tion (approximately 2 to 5 minutes).
Multiple appliance installations with combined vent ing
or common venting with other negative draft ap pli anc es require that each appliance must have draft with in
the proper range. If the draft mea sured above the
appliance’s built-in draft diverter ex ceeds the specified
range in a dedicated chimney for a single appliance
installation or in combined venting with other negative
draft appliances, a baro met ric damper must be in stalled
to control draft.
7
VENTING
A CONVENTIONAL NEGATIVE DRAFT
VENTING SYSTEM
Input Btu/hr Flue Size
45,000 4"
75,000 5"
90,000 5"
135,000 6"
180,000 7"
199,999 7"
215,000 7"
260,000 8"
315,000 8"
360,000 9"
399,999 10"
500,000 10"
TABLE - B
VENT PIPE SIZES
On a conventionally vented, negative draft ap pli ance,
the connection from the vent to the chimney or vent
termination on the outside of the building MUST be
made with listed Type “B” double wall (or equivalent)
vent connectors and must be direct as possible with no
reduction in diameter. Use the National Fuel Gas Code
venting tables for dou ble wall vent to properly size all
vent connectors and stacks. The Type “B” vent and
accessories, such as firestop spacers, thim bles, caps,
etc., MUST be installed in accordance with the
manufacturer’s list ing. The vent connector and firestop
must provide correct spacing to combustible surfaces
and seal to the vent connector on the upper and lower
sides of each floor or ceiling through which the vent
connector passes.
Any vent materials used must be listed by a na tion al ly
recognized test agency for use as vent ma te ri al.
Locate appliance as close as possible to a chimney or
gas vent.
Avoid long horizontal runs of the vent pipe, 90° el bows,
reductions and restrictions. Horizontal por tions of the
venting system shall be supported to prevent sagging.
Horizontal runs must slope up wards not less than 1/4
inch per foot (21 mm/m) from the appliance to the vent
terminal. Follow manufacturer’s instructions.
Do not use an existing chimney as a raceway for a flue
pipe if another appliance or fireplace is vented through
the chimney.
The weight of the venting system must not rest on the
appliance. Adequate support of the venting sys tem must
be provided in compliance with local codes and other
applicable codes. All connections should be secured
with rustproof sheet metal screws.
Vent connectors serving appliances vented by nat u ral
draft shall not be connected to any portion of a
me chan i cal draft system operating under positive
pres sure. Connection to a positive pressure chim ney
may cause flue products to be discharged into the living
space causing serious health injury.
Common venting systems may be too large when an
existing appliance is removed. At the time of removal
of an existing appliance, the following steps shall be
followed with each appliance remaining connected to
the common venting system placed in operation, while
other appliances remaining con nect ed to the common
venting system are not in operation.
(a) Seal any unused opening in the common
venting system.
(b) Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition.
(c) Insofar as is practical, close all building doors
and windows and all doors between the space in
which the appliances remaining connected to
the common venting system are located and
other spaces of the building. Turn on clothes
dryers and any other appliances not connected
to the common venting system. Turn on any
exhaust fans, such as range hoods and
bathroom exhausts, so they will operate at
maximum speed. Do not operate a summer ex haust fan. Close fireplace dampers.
(d) Place in operation the appliance being
inspected. Follow the lighting instructions.
Adjust thermostat so appliance will operate
continuously.
(e) Test for spillage at the draft hood/relief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
(f) After it has been determined that each
appliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, fireplace dampers and other gas burning
ap pli anc es to their previous conditions of use.
(g) Any improper operation of the common
venting system should be corrected so that the
installation conforms to the latest edition of the
Na tion al Fuel Gas Code, ANSI Z223.1. In
Canada, the latest edition of CGA Standard
B149 Installation Code for Gas Burning
Appliances and Equipment. When resizing any
por tion of the common venting system, the
common venting system should be resized to
ap proach the min i mum size as determined
using the appropriate tables in Part 11 in the
latest edition of the National Fuel Gas Code,
ANSI Z223.1. In Canada, the latest edition of
CGA Stan dard B149 Installation Code for Gas
Burning Appliances and Equipment.
8
FIG. 10 Vent Termination from Peaked Roof 10’ or Less
from Ridge
FIG. 11 Vent Termination from Peaked Roof More Than 10’
from Ridge
The vent terminal should be vertical and exhaust
outside the building at least 2 feet (0.61m) above the
high est point of the roof within a 10 foot (3.05m) radius
of the termination. The vertical termination must be a
minimum of 3 feet (0.91m) above the point of exit.
A vertical terminal less than 10 feet (3.05m) from a
parapet wall must be a minimum of 2 feet (0.61m)
higher than the parapet wall.
FIG. 12 Vent Termination from Flat Roof 10’ or Less from
Parapet Wall
FIG. 13 Vent Termination from Flat Roof More Than 10’ from
Parapet Wall
The vent cap should have a minimum clearance of 4
feet (1.22m) horizontally from and in no case above or
below, unless a 4 foot (1.22m) horizontal distance is
maintained from electric meters, gas meters, reg u la tors
and relief equipment.
The venting system shall terminate at least 3 feet (0.9m)
above any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m)
below, 4 feet (1.2m) horizontally from, or 1 foot (30cm)
above any door, window or gravity air inlet into any
building.
Do not terminate the vent in a window well, stair well,
alcove, courtyard or other recessed area. The vent can
not terminate below grade. The bot tom of the vent
terminal shall be located at least 12 inches (30cm)
above grade.
9
VENTING TERMINATION
RIDGE
MORE THAN 10'
3' MIN
2' MIN
10'
CHIMNEY
NOTE:
NO HEIGHT ABOVE
PARAPET REQUIRED
WHEN DISTANCE
FROM WALLS OR
PAR A PETS IS MORE
THAN 10’.
WALL OR
PARAPET
10’ OR MORE
3’
CHIMNEY
To avoid a blocked vent condition, keep the vent cap
clear of snow, ice, leaves, debris, etc.
Flue gases will form a white plume in winter. Plume
could obstruct window view.
Flue gas condensate can freeze on exterior sur fac es or
on the vent cap. Frozen condensate on the vent cap can
result in a blocked vent condition. Flue gas condensate
can cause discoloration of exterior build ing surfaces.
Adjacent brick or masonry sur fac es should be protected
with a rust resistant sheet metal plate.
A masonry chimney must be properly sized for the
installation of a gas fired appliance. Venting of an
appliance into a cold or oversized masonry chimney can
result in op er a tion al and safety problems. Exterior
masonry chim neys, with one or more sides exposed to
cold out door tem per a tures, are more likely to have
venting problems. The temperature of the flue gases
from an appliance may not be able to suf fi cient ly heat
the ma son ry structure of the chim ney to generate proper
draft. This will result in condensing of flue gases,
damage the masonry flue/tile, insufficient draft and
possible spill age of flue gases into an occupied living
space. Care ful ly in spect all chimney systems before
installation. If there is any doubt about the sizing or
condition of a masonry chimney, it must be relined with
a prop er ly sized and approved chimney liner system.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to
determine its suitability for the venting of flue gas es. A
clay tile lined chimney must be structurally sound,
straight and free of misaligned tile, gaps between
liner sections, missing sections of liner or any signs
of con den sate drainage at the breaching or clean
out. If there is any doubt about the condition of a
masonry chimney, it must be relined. An unlined
masonry chimney must not be used to vent flue
gases from this appliance. An unlined chimney must be
relined with an approved chimney liner system when a
new appliance is be ing attached to it. Metallic liner
systems (Type “B” double wall or flexible or rigid
metallic liners) are recommended. Consult with local
code officials to determine code requirements or the
advisability of using or relining a masonry chimney.
FIG. 14 Sidewall Venting with an Induced Draft Fan
This appliance is NOT approved for sidewall venting
with the negative draft venting system as shipped from
the factory. An induced draft fan MUST be used if the
installation requires that the flue gases be vented out a
sidewall. A properly sized and in stalled induced draft
fan may also be used to vent the flue gases ver ti cal ly if
required by jobsite re stric tions. The induced draft fan
must be listed by a nationally recognized test agency, be
properly sized and installed per the rec om men da tions of
the in duced draft fan manufacturer and meet local code
requirements. Use care to ensure that the me chan i cal -
ly supplied draft does not exceed the range of a
negative 0.02 to 0.05 inches water column to ensure
proper operation. If draft exceeds the spec i fied range,
the fan must be adjusted or the installation of a baro met ric damper in the flue may be required to prop er ly
control draft. An induced draft fan MUST be
interlocked into the appliance’s control circuit to start
when the appliance calls for heat. The in duced draft fan
MUST also be equipped with a prov ing switch,
properly interlocked into the ap pli ance’s con trol circuit
to prove fan operation before the main burn ers are
allowed to fire. A vertical or sidewall vent termination
for an induced draft fan MUST be in stalled per the
recommendations of the fan manufacturer and provide
proper clearances from any combustion or ventilation
openings, win dows, doors or other open ings into the
building. All induced draft fan in stal la tions must
comply with local code requirements.
10
SIDEWALL VENTING
Examine the venting system at least once a year.
Check all joints and vent pipe con nec tions for
tightness. Also check for corrosion or
de te ri o ra tion. Immediately correct any problems
ob served in the venting system.
IMPORTANT
MASONRY CHIMNEY
INSTALLATION
This heating boiler is design certified for use with the
automatic vent damper (FIG. 15) part number printed on
the boiler’s rating plate. A vent damper must be
installed on all residential heating boilers with inputs of
less than 300,000 Btu/hr to comply with minimum
efficiency requirements. A vent damper is factory
supplied with residential heating boilers with inputs of
45,000 thru 260,000 Btu/hr. A vent damper is optional
on all heating boilers above 260,000 Btu/hr. A vent
damper is available as an option on all water heaters.
The vent damper is a useful tool for saving energy when
installed inside the living space where air can
cir cu late freely around the appliance. The vent damper
will not save as much, if any, energy if it is installed in
locations such as:
-Unheated garage
-Attic
-Crawlspace
-Mechanical room that is vented outdoors
For installation and maintenance on the vent damper, refer
to the instructions supplied with the vent damper.
Residential heating boilers with inputs of less than
300,000 Btu/hr must have the vent damper prop er ly
installed and the vent damper wire harness plugged into
the ter mi nal block on the side of the control panel to
allow the boiler to function. Larger input heating
boilers and water heaters will have a jumper plug
installed in the ter mi nal block to allow operation
without a damper. Remove the jumper plug from the
terminal block to connect an optional vent damper wire
harness. The jumper plug MUST be in place if an
optional vent damper is not used on water heaters and
larger input heating boilers.
Install the vent damper to service only the single
ap pli ance for which it is intended. If improperly
installed, a hazardous condition such as an ex plo sion or
carbon monoxide poisoning could result.
The damper position indicator must be in a visible
lo ca tion with access for service following in stal la tion.
The damper must be in an open position when appliance
main burners are operating.
The part number for the automatic vent damper
required on this heating boiler is printed on the rating
plate. Vent damper regulations are design certified per
the latest edition of ANSI Z21.66.
FIG. 15 Vent Damper and Vent Damper Terminal Block
11
AUTOMATIC VENT DAMPER
Do not install the vent damper within 6" (152 mm)
of combustible materials.
CAUTION
The vent damper must be installed directly on the
flue outlet located on the top of the draft hood (see
Figure 15). Do not alter the wire har ness sup plied
with the vent damper. Follow the instructions
supplied with the vent damper.
WARNING
An appliance which is shut down or will not
operate may experience freezing due to con vec tive
air flow down the flue pipe connected to the unit.
Proper freeze protection must be pro vid ed, see
Freeze Pro tec tion.
CAUTION
Verify that the appliance is supplied with the type gas
spec i fied on the rating plate. This appliance is orificed
for operation up to 2000 feet altitude. The ap pli ance
will be derated 4% per 1000 feet above 2000 feet el e va tion. Consult the factory for installations above 2000
feet elevation. Field conversions for operation at high
altitude must be performed by certified per son nel only.
The appliance will be marked to indicate suitability for
high al ti tude operation.
GAS SUPPLY PRESSURE: Measured at the inlet
pres sure tap located upstream of the combination gas
valve(s) see Figures 20 - 22, page 17.
Maximum inlet gas pressure must not exceed the val ue
specified. Minimum value listed is for the purposes of
input adjustment.
MANIFOLD PRESSURE: Measured at the pres sure
tap on the downstream side of the com bi na tion gas
valve(s) (see Figures 20 - 22 on page 17). The gas
regulator settings for single stage and two stage
operation are factory set to supply proper manifold
pressure for normal operation. To check manifold
pressure, see Manifold Ad just ment Procedure. Do not
increase manifold pressure beyond spec i fied
pressure settings shown below in Table D.
1. The appliance must be disconnected from the
gas supply piping system during any pressure
testing of that system at a test pressure in
excess of 1/2 PSIG (3.5kPa).
2. The appliance must be isolated from the gas
supply piping system by closing a manual
shutoff valve during any pressure testing
of the gas supply piping system at test
pressures equal to or less than 1/2 PSIG
(3.5kPa).
3. The appliance and its gas connection must
be leak-tested before placing it in operation.
1. Safe operation of the appliance requires
properly sized gas supply piping. See data
in Table E.
2. Gas pipe size may be larger than appliance
gas connection.
3. Installation of a union is suggested for ease
of service, see Figure 16 on page 14.
4. Install a manual main gas shutoff valve,
outside of the appliance gas connection and
before the gas valve or manifold connection,
when local codes require.
5. A trap (drip leg) MUST be provided by the
installer in the inlet of the gas connection to the
appliance, see Figure 16 on page 14.
6. The combination gas valve has an integral
vent lim it ing device and does not require
venting to atmosphere, outside the building.
12
GAS PRESSURE TEST
GAS CONNECTION
GAS SUPPLY
Nat. Gas LP Gas
Max. (Inches Water Column) 10.5 13
Min. (Inches Water Column) *4.5 11
Min. (Inches Water Column) **5.0 11
*Models 45,000 - 360,000 Btu/hr Only
**Models 399,999 - 500,000 Btu/hr Only
TABLE - C
GAS SUPPLY PRESSURE
Single and Two-Stage Two Stage
Btu/hr Full or High Fire Settings Low Fire Settings
Input Gas Natural Gas L.P. Gas Natural Gas L.P. Gas
45,000 3.5" 10" 0.9" 2.5"
75,000 2.4" 7" 0.9" 2.5"
90,000 - 180,000 3.5" 10" 0.9" 2.5"
199,999 2.9" 7.5" 0.9" 2.5"
215,000 - 399,999 3.5" 10" 0.9" 2.5"
500,000 3.5" 10" (two valves) N/A N/A
TABLE - D
MANIFOLD PRESSURE
7. Optional gas controls may require routing
of bleeds and vents to the atmosphere,
outside the building when required by local
codes.
13
Btu/hr DISTANCE FROM METER (In Feet)
INPUT 0-50 51 - 100 101 - 200 201 - 300 301 - 500
45,000 1/2" 1/2" 3/4" 1" 1 1/4"
75,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
90,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
135,000 3/4" 1" 1 1/4" 1 1/4" 1 1/2"
180,000 1" 1" 1 1/4" 1 1/2" 1 1/2"
199,999 1" 1" 1 1/4" 1 1/2" 2"
215,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
260,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
315,000 1 1/4" 1 1/2" 1 1/2" 1 1/2" 2"
360,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
399,999 1 1/4" 1 1/2" 2" 2" 2 1/2"
500,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
For each elbow or tee, add equivalent straight pipe from Table F to total length .
TABLE - E
SUGGESTED GAS PIPE SIZE
SINGLE APPLIANCE INSTALLATIONS
Diameter Pipe (inches)
3/4 1 1 1/4 1 1/2 2 3 4 5
Equivalent length of Straight Pipe (feet)
2 2 3 4 5 10 14 20
TABLE - F
FITTINGS TO EQUIVALENT
STRAIGHT PIPE
45,000 - 135,000 1/2"
180,000 - 315,000 3/4"
360,000 - 500,000 1"
TABLE G
GAS CONNECTIONS
FIG. 16 Gas Line Connection
All gas connections must be made with pipe joint
com pound resistant to the action of liquefied pe tro leum
and natural gas. All piping must comply with local
codes. Tubing installations must com ply with ap proved
standards and practices. Reference Figure 16 for a
typical installation.
Install Piping to Control
1. The gas line should be a separate line direct
from the meter unless the existing gas line is of
sufficient capacity. Verify pipe size with your gas
sup pli er.
2. Use new, properly threaded black iron pipe free
from chips. If tubing is used, make sure the ends
are cut squared, deburred and clean. All tubing
bends must be smooth and without deformation.
Avoid flexible gas connections. Internal diameter
of flexible lines may not provide proper volume of
gas.
3. Run pipe or tubing to the gas valve or manifold
inlet. If tubing is used, obtain a tube to pipe
coupling to connect the tubing to the gas valve
or man i fold inlet.
4. Thread pipe the proper amount for insertion into gas
valve or manifold inlet as shown in Table H.
DO NOT OVER TIGHTEN. Over tightening may
result in damage to the gas valves. Valve distortion
or malfunction may result if the pipe is inserted too
deeply into the gas valve.
5. Apply a moderate amount of good quality pipe
compound (DO NOT use Teflon tape) to pipe
only, leaving two end threads bare.
6. Remove seal over gas valve or manifold inlet.
7. Connect pipe to gas valve or manifold inlet. Use
wrench to square ends of the gas valve (FIG. 17).
14
Nominal
Iron Pipe Length of Pipe in Straight Feet
Size, Inches
10 20 30 40 50 60 70 80 90 100 125 150 175 200
3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74
1 697 477 384 328 292 267 246 226 210 200 179 164 149 138
1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287
1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441
2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820
2 1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300
3 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340
4 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720
Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 13.5 Inches Water Col umn
(0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on the calorific value of Natural Gas,
1025 Btu/ft
3
@ 0.60 Specific Gravity)
TABLE - H
MULTIPLE APPLIANCE INSTALLATIONS
GAS PIPING SIZE CHART
GAS PIPING
FIG. 17 Wrench
8. For L.P. gas, consult your L.P. gas supplier for
expert installation.
FIG. 18 Manifold Pressure Adjustment
1. Turn the power “OFF” at the main dis con nect
switch.
2. Turn gas valve control knob to “PILOT” po si tion
on standing pilot models. Ensure that the stand ing
pilot remains on. If the pilot goes out, follow the
“Lighting Instructions” for standing pi lot models
to light the pilot. Turn gas valve control knob to
“OFF” po si tion on spark ignition models.
3. Remove the 1/8" hex plug located on the out let
side of the gas valve and install a fitting suitable to
connect to a manometer or magnahelic gauge. See
Figure 18. Minimum range of scale should be up
to 5" w.c. for Natural gas mod els and 10" w.c. for
L.P. gas models.
4. The 500,000 Btu/hr model will have two gas
valves with a pressure regulator on each valve.
Repeat the following adjustment pro ce dure to set
the manifold pressure on each gas valve.
5. Remove pressure regulator adjustment cap screw
on the gas valve. See Figure 18 for location.
6. Turn the power “ON” at the main dis con nect
switch.
7. Turn gas valve control knob to “ON” po si tion.
8. Set the thermostat(s) to call for heat.
9. Observe gas regulator pressure when all burn ers
are firing. See Table D, Manifold Pressure for
proper regulator pressure settings.
10. If adjustment is necessary, turn regulator
ad just ment screw clockwise to raise regulator gas
pres sure, counterclockwise to lower gas pres sure,
to proper setting. Note: Adjustment fitting is
plas tic and may require slightly greater turning
force than a metal fitting.
11. Turn the power “OFF” at the main dis con nect
switch.
12. Turn gas valve control knob to “PILOT” po si tion
on standing pilot models. Turn gas valve control
knob to “OFF” position on spark ignition models.
13. Remove fitting from the gas valve and re place the
1/8" hex plug that was previously removed and
tighten.
15
Upon completion of any piping con nec tions to the
gas system, leak test all gas con nec tions with a soap
solution while system is un der pressure.
Immediately repair any leaks found in the gas train
or related components.
Do Not op er ate an
appliance with a leak in the gas train, valves or
related piping.
IMPORTANT
GAS MANIFOLD PRESSURE
ADJUSTMENT PROCEDURE
Do not increase regulator pres sure beyond specified
pressure setting.
NOTE:
Pressure Regulator Adjustment
(under cap screw)
Manometer
4
3
2
1
3.5"
0
1
2
3
4
Gas Valve
14. Repeat the adjustment procedure for the sec ond
gas valve on the 500,000 Btu/hr model.
15. Turn the gas valve control knob(s) to “ON”
position.
16. Turn the power “ON” at the main dis con nect
switch. The appliance is now ready to op er ate.
If manifold pressure can not be properly adjusted, use
the following procedure to check gas supply pressure
with a manometer connected to the inlet pressure tap on
the gas control.
FIG. 19 Gas Supply Pressure
1. Turn the power “OFF” at the main dis con nect
switch.
2. Turn gas valve control knob(s) to the “OFF”
position.
3. The 500,000 Btu/hr model will have two gas
valves. Turn the gas valve control knob on each
valve to the “OFF” position.
4. Shut off gas supply at the manual valve in the gas
piping to the appliance. If fuel supply is L.P. gas,
shut off gas supply at the tank.
5. Remove the 1/8" hex plug, located on the “inlet”
side of the gas valve and install a fitting suitable to
connect to a manometer or magnahelic gauge. On
two gas valve models, remove the hex plug from
the gas valve closest to the gas sup ply connection.
Range of scale should be 14" w.c. or greater to
check inlet pressure. See Figures 18 and 19 for
location.
6. Turn on gas supply at the manual valve, turn on
L.P. gas at tank if required.
7. Turn the power “ON” at the main dis con nect
switch.
8. Turn gas valve control knob to “PILOT”
po si tion on standing pilot models. Follow the
“Lighting Instructions” for standing pilot models
to light the pilot. Turn gas valve control knob to
the “ON” po si tion when the pilot is established.
Turn gas valve control knob(s) to the “ON”
position on spark ig ni tion models.
9. Set the thermostat(s) to call for heat.
10. Observe the gas supply pressure with all burn ers
firing. Ensure inlet pressure is within
specified range. Check gas supply pressure with all
other gas fired appliances in operation to en sure
prop er gas volume during periods of peak gas
usage.
11. If gas pressure is out of range, contact gas utility,
gas supplier, qualified installer or service agen cy
to determine necessary steps to provide prop er gas
pressure to the control.
12. If the gas supply pressure is within the spec i fied
range, proceed with the following steps to return
the appliance to service.
13. Turn the power “OFF” at the main dis con nect
switch.
14. Turn gas valve control knob to “PILOT” po si tion on
standing pilot models. Turn gas valve control
knob(s) to “OFF” position on spark ig ni tion mod els.
15. Shut off gas supply at the manual valve in the gas
piping to the appliance. If fuel supply is
L.P. Gas, shut off gas supply at the tank.
16. Remove the manometer and related fittings from
the “inlet” side of the gas valve, replace 1/8" hex
plug in gas valve.
17. Turn on gas supply at the manual valve, turn on
L.P. Gas at tank if required.
18. Turn the power “ON” at the main dis con nect
switch.
19. Turn the gas valve control knob(s) to the “ON”
position. If the pilot is not burning, follow the
“Light ing Instructions” for standing pilot models to
light the pilot. Spark ignition models will au to mat i cal ly light the pilot on a call for heat.
16
CHECKING GAS SUPPLY PRESSURE
Gas Supply Pressure
Manometer
8
7
6
5
4
3
2
1
0
1
2
3
4
5
6
7
8
Gas Valve
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