Page 1
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:
Page 2
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
Page 3
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
Page 4
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"
Page 5
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
Page 6
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
Page 7
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
Page 8
On a conventionally vented, negative draft ap pli ance,
the connection from the vent to the chimney or vent
termination on the outside of the building MUST be
made with listed Type “B” double wall (or equivalent)
vent connectors and must be direct as possible with no
reduction in diameter. Use the National Fuel Gas Code
venting tables for dou ble wall vent to properly size all
vent connectors and stacks. The Type “B” vent and
accessories, such as firestop spacers, thim bles, caps,
etc., MUST be installed in accordance with the
manufacturer’s list ing. The vent connector and firestop
must provide correct spacing to combustible surfaces
and seal to the vent connector on the upper and lower
sides of each floor or ceiling through which the vent
connector passes.
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
Page 9
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
Page 10
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
Page 11
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
Page 12
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
Page 13
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
Page 14
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
Page 15
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
Page 16
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
Page 17
20. Set the thermostat to call for heat. The appliance
is now ready to operate.
Check burner performance by cycling the system while
you observe burner response. Burners should ignite
promptly. Flame pattern should be stable, see
“Main te nance-Normal Flame Pattern.” Turn system
off and allow burners to cool, then cycle burners again
to en sure proper ignition and flame characteristics.
FIG. 20 F1 Gas Valve 90,000 - 270,000 Btu/hr Models
FIG. 21 F9 Gas Valve 90,000 - 500,000 Btu/hr Models
FIG. 22 M9 Gas Valve 45,000 - 399,999 Btu/hr Models
Each unit has a combination gas valve(s) to control the
gas supply to the burners. The 500,000 Btu/hr model
has two combination gas valves to supply gas to the
burners. The com bi na tion valve con sists of a gas
regulator and two valve seats to meet the requirements
for redundant gas valves. The valve has a gas control
knob that must remain in the open po si tion at all times
when the appliance is in service. Each gas valve has
pres sure taps located on the inlet and outlet sides.
Manifold pressure is adjusted using the regulator
located on the valve. The manifold pres sure is pre set at
the factory and adjustment is not usu al ly re quired. If
the manifold pressure is to be ad just ed, follow the “Gas
Manifold Pressure Ad just ment Pro ce dure”, page 15 for
proper adjustment.
Venting of Combination Gas Valves
The combination gas valve regulator used on all mod els
is equipped with an integral vent limiting orifice. The
vent limiter ensures that the volume of gas emitted from
the valve does not exceed the maximum safe leak age
rate allowed by agency re quire ments. Com bi na tion gas
valve/regulators equipped with integral vent limiters are
not re quired to have vent or relief lines piped to the
outdoors. A dust cap is provided at the vent termination
point on the valve to prevent block age of the vent
limiter by foreign material. The com bi na tion gas valve
regulator with an integral vent limiter complies with the
safety code requirements of CSD-1, CF-190(a) as
shipped from the manufacturer with out the in stal la tion
of additional vent lines.
17
Upon completion of any testing on the gas system,
leak test all gas connections with a soap solution
while main burners are operating. Im me di ate ly
repair any leak found in the gas train or re lat ed
components. Do Not operate an appliance with a
leak in the gas train, valves or related piping.
IMPORTANT
COMBINATION GAS VALVES
Pressure Regulator
I
P
T
p
nlet
ressure
ap
Adjustment (under cap screw)
Outlet Pressure Ta
Red Reset Button
Gas Control
Knob
Pilot Outlet
Page 18
FIG. 23A Relief Valve - Water Heater
FIG. 23B Relief Valve - Boiler
This appliance is supplied with a relief valve(s) sized in
accordance with ASME Boiler and Pressure Ves sel
Code, Section IV (“Heating Boilers”). The re lief
valve(s) is mounted directly into the heat ex chang er
inside the header. To pre vent water damage, the dis charge from the relief valve shall be piped to a suit able
floor drain for disposal when relief occurs. No reducing
couplings or other restrictions shall be installed in the
discharge line. The discharge line shall allow complete
drainage of the valve and line. Relief valves should be
manually operated at least once a year.
FIG. 24A Water Flow Switch Water Heater - Side Connections
FIG. 24B Water Flow Switch Boiler - Top Connections
A water flow switch is available as a factory sup plied
option on all heating boilers and water heaters. The
flow switch should be wired between terminals X and
B. Remove the jumper between the X and B terminals
on the terminal strip. This wiring connection installs
the flow switch in the 24 VAC safety cir cuit to prove
water flow before main burner ig ni tion. A flow switch
installed with the fac to ry sup plied minimum adjustment
setting requires a spe cif ic minimum flow to make the
switch and start burner operation. The minimum flow
requirement to actuate the switch is specified in Table I.
The flow rate required is a function of the diameter of
pipe and tee used for installation. Ensure that the pump
installed on the boiler or water heater will supply
adequate flow to make the flow switch con tacts and
operate the boil er.
18
RELIEF VALVE
Avoid contact with hot discharge water.
CAUTION
WATER FLOW SWITCH (IF EQUIPPED)
RELIEF
VALV E
FLOW SWITCH
FLOW
Page 19
A water flow switch meets most code re quire ments
for a low-water cut off device on boil ers requiring
forced cir cu la tion for operation.
A hot water boiler installed above radiation level must be
provided with a low water cutoff device either as part of
the unit or installed at the time the boiler is installed. An
electronic low water cutoff is available as a kit on all
units. Low water cutoffs should be in spect ed every six
months, including flushing of float types.
The 45,000 thru 500,000 Btu/hr boilers (M9) are
equipped with a two stage burner control system. The
45,000 thru 399,999 Btu/hr models will be equipped
with a two stage gas valve to control high/low burner
op er a tion. The 500,000 Btu/hr mod el achieves two
stage burner firing by staging the operation of the two
combination gas valves.
This appliance is wired for 120 VAC service. The
appliance, when installed, must be electrically
ground ed in accordance with the requirements of the
authority having jurisdiction or in the absence of such
re quire ments, with the latest edition of the National
Electrical Code ANSI/NFPA No. 70. When the unit is
in stalled in Canada, it must conform to the CSA C22.1,
Ca na di an Electrical Code, Part 1 and/or local Electrical
Codes.
1. All wiring between the appliance and field
in stalled devices shall be made with type T wire
[63° F(35° C) rise].
2. Line voltage wire exterior to the appliance must be
enclosed in approved conduit or approved metal
clad cable.
3. The pump must run continuously when the
appliance is being fired.
4. To avoid serious damage, DO NOT en er gize the
appliance until the system is full of water.
Serious damage may result.
5. Provide the unit with proper overload protection.
6. Install a wall thermostat on the inside wall. DO
NOT install the thermostat in an area affected by
drafts, sunlight, light fixtures, hot or cold water
pipes or near a fireplace. See “Terminal Strip Con -
nec tion of a Room Thermostat”, page 38 for prop er
wiring con nec tion.
Pump Wiring for a Heating Boiler
The heating boiler circulating pump must be pur chased
locally. The max i mum load for the pump switched by
the internal pump relay must not exceed 1 HP. The
current draw for a field installed 120 VAC pump MUST
be add ed to the boiler’s current draw to de ter mine the
minimum wire size for 120 volt service.
FIG. 25 Standing Pilot System F1 Control Panel
19
Pipe Size GPM Flow Rate
1 1/2" 13
2" 18
TABLE I
MINIMUM FLOW RATE REQUIRED TO
ACTUATE FLOW SWITCH
LOW WATER CUTOFF (IF EQUIPPED)
TWO STAGE BURNER
CONTROL SYSTEM
ELECTRICAL CONNECTIONS
MAXIMUM
FIRING TOTAL AMPS
CONTROLS @ 120 VAC
F1 Standing Pilot (Single Stage
90,000 - 260,000 Btu/hr) 2.5
F9 Intermittent Pilot (Single Stage
90,000 - 399,999 Btu/hr) 2.5
F9 Intermittent Pilot (Single
Stage/2 valves 500,000 Btu/hr) 2.5
M9 with Internal Pump
(45,000 - 260,000 Btu/hr) 2.0
M9 Intermittent Pilot (Two Stage
Valve 315,000 - 399,999 Btu/hr) 2.0
M9 Intermittent Pilot (Two Stage/2
valves 500,000 Btu/hr) 2.0
TABLE J
AMP DRAW DATA
45,000 thru 500,000 Btu/hr Models
Page 20
FIG. 26 Intermittent Pilot System F9/M9 Control Panel
FIG. 27 Control Panel Assembly 500,000 Btu/hr
Operating Temperature Control
Locating Temperature Control
Remove the control panel door on the front of the unit in
order to locate and access the temperature control.
Temperature Control Settings
There are three setting knobs on the temperature control
unless your unit is specified as a boiler only with an
outdoor air reset option. If your unit is a boiler only with an
outdoor air reset option, there are additional controls for
this option. They are explained under Outdoor Air Reset
Option, page 22.
The three setting knobs on the temperature control are for
Set point, Differential, and High-Fire Offset (see
Figure 28).
FIG. 28 Temperature Control
Maximum Set Point Determination
The maximum set point for the control is factory set.
Boilers can be set to 240°F max., water heaters are set to
190°F max., and specialty state and local codes to 200°F.
These maximum set points are established by cutting the
OJ1 and OJ2 jumpers located on the right side of the
temperature controller. The maximum set point is
determined as shown below in TABLE-K.
20
TEMPERATURE ADJUSTMENT
The temperature controller is pre-set at the factory with
test settings. You may need to adjust the settings to meet
your specific needs.
Return water temperatures must not be less than
140°F. If lower return water temperatures are
required, follow the instructions for Low
Temperature Bypass Requirements or Three-Way
Valves, see page 35.
WARNING
Max.
OJ1 OJ2 Set Point
Connected Connected 240°F
Cut Connected 190°F
Connected Cut 200°F
Cut Cut 160°F
TABLE K
Maximum Set point Determination
Anytime that OJ1 is the only jumper cut, a new
overlay is required under the Set Point knob on the
temperature controller because the scale has changed
to a maximum of 190°F.
Anytime the OJ2 jumper is cut (with or without OJ1),
a new overlay is required under the Set Point knob on
the temperature controller because the scale has
changed to a maximum of 200°F.
NOTE:
NOTE:
Page 21
Set Point
The Set Point knob specifies the target outlet water
temperature in degrees, Fahrenheit. After the water
temperature reaches the set point, the temperature control
shuts off the burners.
Differential
The Differential specifies the number of degrees below the
set point that the control will allow the water temperature
to drop before it brings the unit back on again.
High-Fire Offset
The temperature control operates a two-stage firing system.
The two stages are High-Fire and Low-Fire. High-Fire
operates all burners at full rate while Low-Fire operates the
burners at approximately one-half rate.
The High-Fire Offset knob specifies the number of degrees
below set point that the High-Fire stage shuts down. At that
point, the unit will continue to operate at the Low-Fire
stage until the set point is reached.
The High-Fire Offset knob has settings between 0°F and
20°F. If set at 0°F, the High-Fire Offset is disabled and the
unit will operate the High-Fire stage until the set point is
reached and the temperature control shuts the unit off.
No matter what the High-Fire Offset knob is set to, the unit
will light at Low Fire and operate for approximately 10 to
120 seconds before the High-Fire stage actuates.
Boiler Application
Standard boiler units are shipped with one sensor, the inlet
water temperature sensor. An optional sensor can be
purchased and installed for use as a remote system sensor.
Boilers with the outdoor air reset option also have an
outside air temperature sensor.
Water Heater Application
Water heater units are shipped with two sensors; the inlet
water temperature sensor and the multi-purpose
temperature sensor to be used as a tank sensor.
Temperature Control Sensors
This is a two-stage temperature control that controls the
burner ignition and pump functions. This temperature
controller can measure up to three different sensor inputs,
depending upon how the unit is set up. They are as follows:
1. Inlet Water Temperature Sensor
2. Multi-Purpose Temperature Sensor
3. Outside Air Temperature Sensor
Inlet Water Temperature Sensor
This sensor measures the inlet water temperature coming
into the unit.
The inlet water temperature sensor is placed into the inlet
bulbwell on the boiler. This sensor is installed by the
factory in new units.
Multi-Purpose Temperature Sensor
Depending upon how your unit is set up, this sensor can be
used as a system sensor in a boiler system or a tank sensor
for water heater applications. Connect this sensor to the
two blue wires in the upper left-hand corner of the control
panel.
Outdoor Air Temperature Sensor
The outside air temperature sensor will only be used for
boiler systems. The outside air sensor is optional. This
sensor allows you to tie boiler operation to the outdoor air
temperature. As outside temperatures drop, the control will
increase the temperature setting of the boiler. As outdoor
temperatures rise, the control will decrease the temperature
to the selected set point of the boiler. You can set the
control to shut the boiler off when a desired outdoor air
temperature level is reached.
You must purchase the sensor from the appliance
manufacturer. The sensor comes with a housing that helps
protect the sensor from the elements. Mount the air sensor
housing outdoors, under the eve of the roof. Make sure the
housing is out of direct sunlight. This will ensure that the
sensor will accurately read the true outdoor temperature.
Connect the outdoor air temperature sensor to the terminal
block on the outdoor air reset board. For more information
on wiring the sensor, see Wiring of Remote Sensors, this
page.
Installation of Remote Sensors
Make sure to insert the sensor all the way into the bulbwell,
leaving no air pocket between the front surface of the
sensor and the back of the bulbwell. Air pockets are
thermally non-conductive and will cause sensors to read
inaccurately.
System Sensor
The system sensor is used for boiler applications. Install
the sensor in the system supply to the building.
Tank Sensor
The tank sensor is used in water heating applications.
Install the sensor in a water storage tank to measure water
temperature. For more information on wiring the sensor,
see Wiring of Remote Sensors below.
Wiring of Remote Sensors
To wire remote sensors, follow the guidelines below. Take
care to correctly wire sensors to the unit. Erratic
temperature readings can be caused by poor wiring
practices. Twist the wires between the unit and the remote
sensor. Turn wires at least three or four turns per linear foot
of wiring. This provides protection against some types of
electrical interferences.
1. Do not route temperature sensor wiring with building
power wiring.
2. Do not locate temperature sensor wiring next to control
contactors.
3. Do not locate temperature sensor wiring near electric
motors.
4. Do not locate temperature sensor wiring near welding
equipment.
21
Page 22
5. Make sure good mechanical connections are made to
the sensor, any interconnecting wiring and the
controller.
6. Do not mount sensor with leadwire end pointing up in
an area where condensation can occur.
7. Use shielded wiring to connect the sensor to the control
when the possibility of an electrically noisy
environment exists. Shielded cable is recommended on
all cable runs of more than 25 feet in length.
Outdoor Air Reset Option
For boilers ordered with the Outdoor Air Reset option,
there is an additional control (FIG. 29). There are three
setting knobs for Shutdown, Outdoor Air Max., and Ratio.
There is also a switch to turn the outdoor air shutdown
feature On or Off. An O.A. Sensor is also included.
FIG. 29 Optional Outdoor Air Reset Control
Shutdown
The Shutdown knob specifies the outdoor air lockout
temperature at which the control would prevent the unit
from operating.
Outdoor Air Max (O.A. Max)
The O.A. Max knob allows a reset up to the maximum
outdoor air temperature specified by this knob setting.
When the outdoor air temperature is above the specified
setting, the unit will not function in the O.A. Reset Mode,
but will continue to run at the selected set point
temperature.
Note that the set point knob will now indicate the
“minimum” boiler temperature. Target temperature is
determined by the ratio and outdoor air temperature below
the O.A. Max setting.
Ratio
The Ratio knob allows control over the reset ratio to be
used during Outdoor Air Reset. The allowable ratios are as
low as 0.5:1 or as high as 1.5:1.
Selecting the 0.5:1 ratio will increase the set point 0.5° for
every 1.0° drop in outdoor air temperature up to the
maximum set point temperature.
Selecting the 1.5:1 ratio will increase the set point 1.5° for
every 1.0° drop in outdoor air temperature up to the
maximum set point temperature.
If the outdoor design and boiler design temperatures are
known, the Ratio setting can be calculated using the
following formula:
Ratio = (boiler design temperature - operator set point)
(O.A. Max. setting - outdoor design temperature)
Note that the reset set point cannot exceed the maximum
set point of the boiler thermostat.
These settings are illustrated graphically in Figure 30.
FIG. 30 Outdoor Air Control Example Chart
Outdoor Air Shutdown Enable/Disable Switch
The Outdoor Air Shutdown Enable/Disable switch turns
the outdoor air shutdown feature On and Off. Disabling the
Outdoor Air Shutdown feature allows the unit to operate
regardless of the outdoor air temperature. This is needed
for indirect domestic hot water systems for example.
High Water Temperature Limit Con trol
The appliance is supplied with a fixed setting, auto-reset
high water temperature limit control. The setting of this
control limits max i mum discharge water tem per a ture. If
water temperature exceeds the setting, the limit will
break the con trol circuit and shut down the appliance.
The limit control will only be reset after the water tem per a ture has cooled well below the setting of the limit.
The auto-reset high water temperature limit control is
mount ed in the outlet side of the front header.
22
OUTDOOR AIR RESET OPTION
R6
R8
R16
R15
C7
C9
C10
VR2
VR3
OJ1
OJ2
D4
J4
CN1
CN2
CN9
CN7
CN8
CN3
CN4
CN5
CN6
W1
TST2314
20
15
10
5
(F-)0
15
14
13
12
11
10
9
8
7
6
5
OFF
120
240
220
200
160
140
SETPOINT
DIFFERENTIAL
HIGH-FIRE
OFFSET
(c)2002 L.C.
Ground the cable shield at the connection to the boiler
temperature control only. Do not ground the shielded
cable at the sensor end.
To maintain temperature accuracy, sensor wires should
be 18 AWG two conductor (18/2). Use shielded wire if
required.
NOTE:
ADDITIONAL TEMPERATURE
CONTROLS
(c)2002 L.C.
CN7
CN8
CN1
140
120
D4
W1
160
OFF
SETPOINT
55
50
45
VR3
SHUTDOWN
55
50
45
VR1
40
O.A. MAX.
240
60
65
7040
60
65
70
200
220
DIFFERENTIAL
CN1
O.A. SENSOR
ON
ENABLE
SW1
DISABLE
O.A. SHUTDOWN
0.9
0.8
0.7
0.6
0.5
RATIO
11
9
8
7
6
VR2
5
TST2314
1.0
VR2
15
12
1.1
13
14
1.2
1.4
1.5
1.3
W1 W2
5
R16
R15
(F-)0
HIGH-FIRE
CN2
R4R4R6
C7
W3
10
VR3
OFFSET
CN3
CN4
CN5
CN6
OJ1
C10
OJ2
C9
J4
R8
CN9
15
20
Page 23
Manual Reset High Water Temperature Limit
Control (
Standard Fixed Settings on Water Heaters and
Optional Adjustable Settings on Boilers and Water Heaters)
Water heaters are supplied with a fixed setting, manual
reset high water temperature limit control. This manual
reset temperature limit control has a fixed limit setting
of 230°F (110°C). If water tem per a ture ex ceeds this
setting, the limit will break the control circuit and shut
down the unit. The limit control can only be reset after
the water tem per a ture has cooled well below the setting
of the lim it. Reset of the limit con trol is accomplished
by push ing the Red Reset But ton (Manual Reset High
Limit) (see Figures 25 - 27 on pages 19 and 20) located
on the front side of the control panel. A label on the
control panel indicates the exact lo ca tion of the manual
reset high water temperature limit control.
FIG. 31 Blocked Vent Switch Location
FIG. 32 Flame Roll-Out/Flame Interlock Switch Location
All units are equipped with manual reset blocked vent
and flame roll-out / flame interlock switches. These
temperature switches are located in the controls
compartment and in the relief opening of the boiler’s
built-in draft hood. Each switch has a red reset button.
In the event the system has actuated to shut off the main
burner gas supply, wait for the boiler to cool, then press
the red reset to return the boiler to operation. Op er a tion
of a blocked vent and/or flame roll-out / interlock
switch usually indicates a problem with the venting
system, obstruction of the heat ex chang er flue gas
passageway and/or a combustion air supply prob lem.
The cause for operation of the blocked vent and/or
flame roll-out / interlock switch must be determined and
corrected. If the boiler cannot be restored to normal
operation, contact a qualified ser vice in stall er, service
agency or the gas supplier.
Follow the Lighting Instructions on the label applied to
the appliance.
A. On water heaters and boilers with the system
pump delay option, the operating temperature
control will energize the pump relay which
energizes the pump on a call for heat. The
operating temperature control will de-energize
the pump relay approximately 30 seconds after
the call for heat ends. If either the inlet sensor
or the optional multi-purpose temperature
sensor reads below 40°F, the pump relay will
turn ON. When the temperature rises above
50°F the pump relay will turn OFF.
23
INITIAL START-UP
BLOCKED VENT AND FLAME
ROLL-OUT/FLAME INTERLOCK SWITCH
FLAME ROLL-OUT SWITCH /
INTERLOCK SWITCH
Page 24
On boilers, the pump will operate whenever the
“W” terminal is energized.
B. Location - The appliance should be located
within a room having a temperature safely
above freezing [32°F(0°C)].
C. Shutdown and Draining - If, for any rea son,
the appliance is shut off, the following
pre cau tion ary measures must be taken:
1. Shut off gas supply,
2. Shut off water supply.
3. Shut off electrical supply.
4. Drain the heat exchanger completely. Re move one 3/8" NPT plug or bulb well from the
inlet side and one from the outlet side of the
front head er of the heat exchanger.
5. Drain the pump. Remove the 3/4" plug in
the bypass loop.
1. Inspect the burners to be sure they are prop er ly
aligned.
2. Inspect the pilot gas line, thermocouple leads,
ignition leads and wire connections to the gas
valve to be sure none were damaged during
shipment.
3. Check to ensure that gas connections have been
made properly and the gas line is purged of air.
4. Check to ensure that water connections are tight
and the appliance and piping system have been
properly filled.
5. Ensure that discharge from the relief valve has
been piped to a floor drain.
6. Verify that properly sized combustion and
ven ti la tion air openings are provided and not
obstructed in any way.
7. Check carefully for gas leaks.
8. Read the appliance’s safety warnings, light ing
instructions and check out procedure carefully,
be fore firing the system.
A. This appliance has a pilot which must be
ig nit ed by hand. When lighting the pilot,
follow these instructions exactly.
B. BEFORE OPERATING, smell around the
appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air
and will settle to the floor.
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
neigh bor’s phone. Follow the gas supplier’s
instructions.
If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to push in or turn the gas
control knob. Never use tools. If the knob will
not turn by hand, don’t try to repair it, call a
qualified ser vice technician. Force or attempted
repair may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance. The
pos si ble damage to a flooded appliance can be
extensive and present numerous safety hazards.
Any appliance that has been under water must
be replaced.
1. STOP! Read the safety information.
2. Remove the control panel door.
24
PRE-START CHECKLIST
LIGHTING INSTRUCTIONS FOR
STANDING PILOT MODELS (F1)
MODELS 90,000 THRU 270,000 Btu/hr
INPUT FOR YOUR SAFETY READ
BEFORE OPERATING
If you do not follow these in struc tions exactly, a
fire or explosion may result causing prop er ty
damage, personal injury or loss of life.
WARNING
WHAT TO DO IF YOU SMELL GAS
LIGHTING INSTRUCTIONS
Page 25
25
3. Set the thermostat to the lowest setting (OFF).
4. Turn off all electrical power to the appliance.
5. Turn the gas control knob on the gas valve
clockwise to the “OFF” position.
FIG. 33 F1 Gas Valve 90,000 - 270,000 Btu/hr Models
6. Wait five (5) minutes to clear out any gas, then
smell for gas, including near the floor. If you smell
gas, STOP! Follow the steps in the“What To Do If
You Smell Gas” section in the safety information
on page 24. If you do not smell gas go on to the
next step.
7. Remove the lower panel door to gain access to the
pilot.
8. Find the pilot - Follow the metal tube from the gas
valve to the pilot. The pilot is located on the right
side of the burner approximately centered in the
burner tray.
FIG. 34 Pilot Location
9. Turn the control knob on the gas valve
coun ter clock wise to the “PILOT” position.
FIG. 35 Lighting Wand
10. Use the loop end of the wire lighting wand,
shipped with the instruction pack age, to hold the
match and reach the pi lot. An access slot is
provided in the lower front jacket panel, beside the
burner, to insert the lighting wand and match to the
pilot. Lift the pilot cover (FIG. 35) to access the
pilot. Push down and hold in the red button on the
gas valve. This should start gas flow to the pilot.
Con tin ue to hold the red button in for about one (1)
minute after the pilot is lit. Release the button and
it will pop back up. The pilot should remain lit. If
the pilot goes out, repeat steps 5 through 10.
If the red button does not pop up when re leased,
stop and immediately call your gas supplier.
If the pilot will not stay lit after sev er al tries, turn
the gas control to “OFF” and call your
service technician or gas supplier.
11. Turn the gas control knob on the gas valve
counterclockwise to the “ON” position.
12. Turn on all electric power to the appliance.
13. Re-install the lower panel door.
14. Set the thermostat to the desired setting.
15. Re-install the control panel door.
The information package shipped with the
appliance contains a wire lighting wand. The loop
end of the wand will hold a match. The wand
extends your reach to the pilot and makes lighting
the pilot easier.
NOTE:
Page 26
26
1. Set the thermostat to the OFF position.
2. Turn off all electric power to the appliance if
service is to be performed.
3. Turn the gas control knob on the gas valve
clockwise to the “OFF” position. Do not force.
FIG. 36 Pilot with Thermocouple and Spark Ignition
1. With the main burners on and firing, un screw the
thermocouple connection from the gas valve
(FIG 36) and remove from the fitting. See Figure
25 to locate the thermocouple outlet connection on
the gas valve.
2. The main gas valve should extinguish the burn ers
immediately after removal of the thermocouple.
3. If burners do not extinguish, immediately fol low
steps in “To Turn Off Gas To Appliance”.
4. Immediately call a qualified serviceman or
in stall er to repair an ignition system that fails to
op er ate properly and shut down the burners.
5. After successful completion of test, turn the
control knob on the gas valve clockwise to the
“OFF” position. Do not force.
6. Carefully reconnect the thermocouple to the gas
valve.
7. Follow the Lighting Instructions to relight the pilot
and establish normal operation.
A. This appliance is equipped with an ignition
device which automatically lights the pilot. Do
not try to light the pilot by hand.
B. BEFORE OPERATING, smell around the
appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air
and will settle to the floor.
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
neighbor’s phone. Follow the gas supplier’s
instructions.
If you cannot reach your gas supplier, call the
fire department.
C. Use only your hand to turn the gas control
knob. Never use tools. If the knob will not turn
by hand, don’t try to repair it, call a qualified
ser vice technician. Force or attempted repair
may result in a fire or explosion.
D. Do not use this appliance if any part has been
under water. Immediately call a qualified
service technician to inspect the appliance. The
possible damage to a flooded boiler can be
extensive and present numerous safety hazards.
Any appliance that has been under water must
be re placed.
LIGHTING INSTRUCTIONS FOR SPARK
IGNITION PILOT MODELS (F9/M9)
MODELS 45,000 THRU 500,000 Btu/hr
INPUT FOR YOUR SAFETY READ
BEFORE OPERATING
If you do not follow these instructions exactly, a fire
or explosion may result causing property damage,
personal injury or loss of life.
WARNING
WHAT TO DO IF YOU SMELL GAS
TO TURN OFF GAS TO APPLIANCE
SAFETY SHUTOFF TEST FOR
STANDING PILOT IGNITION SYSTEM
Should overheating occur or the gas fail to shut
off, turn off the external manual gas valve to the
appliance.
WARNING
Page 27
27
1. STOP! Read the safety information first.
2. Remove the control panel door.
3. Set the thermostat to the lowest setting (OFF).
4. Turn off all electrical power to the appliance.
5. This appliance is equipped with an ignition device
which automatically lights the pilot. DO NOT try
to light the pilot by hand.
6a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr
models, rotate the gas control knob on the gas
valve clockwise to the “OFF” position.
6b. 180,000 - 360,000 Btu/hr models, rotate the gas
control knob on the gas valve clockwise to the line
on the collar around the knob. Depress the knob
and continue rotation to the “OFF” position.
7. Wait five (5) minutes to clear out any gas, then
smell for gas, including near the floor. If you smell
gas, STOP! Follow the steps in the “What To Do
If You Smell Gas” section in the safety information
on page 26. If you do not smell gas go on to the
next step.
8a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr
models, rotate the gas control knob on the gas
valve counterclockwise to the “ON” position.
8b. 180,000 - 360,000 Btu/hr models, rotate the gas
control knob on the gas valve counterclockwise to the line on the collar around the knob.
Al low the knob to “pop” up, and continue rotation
to the “ON” position.
9. Turn on all electric power to the appliance.
10. Set the thermostat to the desired setting.
11. Re-install the control panel door.
12. If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” and
call your service technician or gas supplier.
1. Set the thermostat to the OFF position.
2. Turn off all electric power to the appliance if
service is to be performed.
3a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr
models, rotate the gas control knob on the gas
valve clockwise to the “OFF” position. Do not
force.
3b. 180,000 - 360,000 Btu/hr models, rotate the gas
control knob on the gas valve clockwise to the line
on the collar around the knob. Depress the knob
and continue rotation to the “OFF” position. Do
not force.
1. Turn “OFF” gas supply to the appliance.
2. Turn thermostat to highest setting.
3. Turn electric power “ON”.
4. Pump relay pulls in to start pump.
5. The ignition will begin sparking at the pilot.
6. The ignition module will lock out after the 90
second trial for ignition period on the 45,000 thru
399,999 Btu/hr models and after the 15 sec ond
trial for ignition period on the 500,000 Btu/hr
model.
7. Immediately call a qualified serviceman or
in stall er to repair an ignition system that fails to
lock out and properly shut down burner operation.
8. After successful completion of the test, re ad just
the thermostat to normal setting.
9. Turn “ON” gas supply.
10. Turn power “OFF” then “ON” to reset ignition
module.
OPERATING INSTRUCTIONS
TO TURN OFF GAS TO APPLIANCE
Should overheating occur or the gas fail to shut off,
turn off the external manual gas valve to the
appliance.
WARNING
SAFETY SHUTOFF TEST FOR SPARK
IGNITION PILOT SYSTEM
Page 28
28
11. If ignition system fails to operate properly, re pair
work must be performed by a qualified
serviceman or installer.
The ignition module is not repairable. Any mod i fi ca tion
or repairs will invalidate the warranty and may create
hazardous conditions that result in prop er ty damage,
personal injury, fire, explosion and/or toxic gases. A
faulty ignition module must be re placed with a new
module.
F1 Standing Pilot Models (thermocouple supervised)
Pilot Flame Failure Response Time - 180 Seconds
Maximum
F9/M9 Intermittent Spark Ignition Pilot Mod els
Pilot Trial for Ignition Period - 90 Seconds
(45,000 thru 399,999 Btu/hr models)
Pilot Trial for Ignition Period - 15 Seconds
(500,000 Btu/hr model)
Pilot Failure Response Time - 0.8 Seconds at less than
1.0 µA flame current
Pump Delay Timing (Standard on Water Heaters and
Optional on Boilers) - 30 Seconds after burner shut down
1. For water heaters, and boilers with the pump delay
option, if either the inlet sensor or the optional
multi-purpose temperature sensor reads below
40°F, the pump relay will turn ON. When the
temperature rises above 50°F the pump relay will
turn OFF.
2. Location - Heating boilers and water heaters must
be located in a room having a temperature safely
above freezing [32°F(0°C)].
3. Caution - A room where the appliance is installed
and operating under a negative pressure may
experience a downdraft in the flue of an appliance
which is not firing. The cold outside air pulled
down the flue may freeze a heat exchanger. This
condition must be cor rect ed to provide adequate
freeze protection.
4. Freeze protection for a heating boiler or hot water
supply boiler using an indirect coil can be provided
by using hydronic system antifreeze. Follow the
manufacturers instructions. DO NOT use
un di lut ed or automotive type antifreeze.
5. A snow screen should be installed to pre vent snow
and ice accumulation around the appliance vent ing
system in cold climates.
6. Shut-down and Draining - If for any rea son, the
appliance is to be shut off, the following
precautionary measures must be taken:
(a) Shut off gas supply.
(b) Shut off water supply.
(c) Shut off electrical supply.
(d) Drain the unit completely. Remove one
threaded plug or bulb well from the inlet
side of the front header and one from the
outlet side of the front header on the heat
exchanger. Blow all wa ter out of the heat
exchanger.
(e) Drain pump and piping.
1. Use only properly diluted inhibited glycol an ti 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% propylene glycol will pro vide
maximum protection of approximately -30°F.
3. Follow the instructions from the glycol an ti freeze
manufacturer. The quantity of glycol an ti freeze
required is based on total system volume including
ex pan sion tank volume.
4. Glycol is more dense than water and chang es the
viscosity of the system. The addition of glycol
will decrease heat transfer and in crease frictional
loss in the heating boiler and re lat ed piping. A
larg er pump with more capacity may be required to
maintain desired flow rates in a glycol system.
FREEZE PROTECTION FOR A HEATING
BOILER SYSTEM (If Required)
DO NOT use undiluted or automotive type
antifreeze.
CAUTION
INTERMITTENT PILOT
SPARK IGNITION SYSTEM (F9/M9)
IGNITION and CONTROL TIMINGS
FREEZE PROTECTION
Page 29
5. Local codes may require a back flow preventer or
actual disconnect from city water supply when
glycol antifreeze is added to the system.
In hard water areas, water treatment should be used to
reduce the introduction of minerals to the sys tem.
Minerals in the water can collect in the heat exchanger
tubes and cause noise on operation. Excessive build up
of minerals in the heat ex chang er can cause a
non-warrantable failure.
Listed below are items that must be checked to en sure
safe reliable operation. Verify proper op er a tion after
servicing.
1. Examine the venting system at least once a year.
Check more often in the first year to de ter mine
in spec tion interval. Check all joints and pipe
connections for tightness, corrosion or
deterioration. Clean louvers and/or screens in the
combustion air intake system as required. Have
the entire system, including the venting system,
periodically inspected by a qualified service
agency.
2. Visually check main burner flames at each start up
after long shutdown periods or at least every six
months.
FIG. 37 Burner Flames
a. Normal Flame: A normal flame is blue, with
slight yellow tips, with a well defined inner
cone and no flame lifting.
b. Yellow Tip: Yellow tip can be caused by
blockage or partial obstruction of air flow to
the burner(s).
c. Yellow Flames: Yellow flames can be caused
by blockage of primary air flow to the
burner(s) or excessive gas input. This
condition MUST be cor rect ed immediately.
d. Lifting Flames: Lifting flames can be caused
by over firing the burner(s) or excessive
primary air.
If improper flame is observed, examine the venting
system, ensure proper gas supply and ad e quate supply
of combustion and ventilation air.
3. Combustion Air Adjustment: This ap pli ance uses
an atmospheric combustion process. Combustion
air is provided to the burners by the gas injection
pressure into the venturi of the burn ers. The
burners do not have an adjustable air shutter.
Ad e quate combustion air must be supplied to the
room where the appliance is installed to ensure
proper burner operation. Check frequently to be
sure the flow of com bus tion and ventilation air to
the unit is not obstructed. When the main burn ers
light, observe the burn er flame. Flames should be
light blue in color with slight yellow tips; flames
should be settled on burner head with no lifting
when supplied with correct vol ume of combustion
air.
4. Flue Gas Passageways Cleaning Pro ce dures: Any
sign of soot around the outer jacket, at the burn ers
or in the areas between the fins on the cop per heat
exchanger indicates a need for cleaning. The
following cleaning procedure must only be
per formed by a qualified serviceman or installer.
Prop er service is required to maintain safe
operation. Properly installed and ad just ed
appliances sel dom need flue cleaning.
All gaskets on disassembled components must be
replaced with new gaskets on re as sem bly. Gasket kits
are available from your distributor.
29
MAINTENANCE
Label all wires prior to dis con nec tion when
servicing controls. Wiring errors can cause
improp er and dangerous operation.
CAUTION
WARNING: The area around the burners is hot and direct contact could result in burns!
WATER TREATMENT
Page 30
REMOVAL OF COMBUSTION CHAMBER LINING
OR BASE PANELS:
• Avoid breathing dust and contact with skin and eyes.
• Use NIOSH certified dust respirator (N95)
(http://www.cdc.gov/niosh/homepage.html).
• Lightly mist with water (only those areas being handled)
the combustion chamber lining or base insulation to
prevent airborne fibers.
• Remove combustion chamber lining or base insulation
from the boiler and place it in a plastic bag for disposal.
• Wash potentially contaminated clothes separately from
other clothing. Rinse clothes thoroughly.
• NIOSH stated First Aid:
Eye: Irrigate immediately.
Breathing: Fresh air.
HEAT EXCHANGER/BURNER ACCESS
a. Turn “OFF” main power to the appliance.
b. Turn “OFF” external manual gas shutoff valve
to appliance.
c. Remove the control panel door.
d. Remove the outer air deflector (FIG.38A )
e. Disconnect gas valve wiring and remove gas
manifold assembly.
f. Remove ignition wire leading to the pilot
assembly from the ignition module.
g. Disconnect the wiring from the flame roll-
out/interlock switch, see Figure 32, page 23.
h. Remove the lower front jacket panel.
i. Remove the control panel mounting screws.
When removing the control panel, lay the
control panel to the side with the wiring intact,
being careful not to damage any of the wiring.
Remove the combustion chamber door. Use
caution to prevent damage to burn ers,
refractory, pilot or wiring.
INSPECTION AND CLEANING
j. Check the heat exchanger surface for sooting.
The external surfaces of the copper tubes
should be free of any soot deposits. (A slight
black smudge is normal with some types of
gases.) If abnormal soot deposits are present,
the heat exchanger must be cleaned and the
cause of the soot problem corrected. Proceed as
follows:
k. Remove soot from burners and bottom of the
finned tubes with a stiff bristle brush. Dirt
may also be removed from burner ports by
rinsing the burner thor ough ly with water.
Drain and dry burners before re-installing.
Damaged burners must be re placed.
An appliance installed in a dust or dirt con tam i nat ed
atmosphere will require cleaning of the burners on a 3
to 6 month schedule or more often, based on severity of
contamination. Contaminants can be drawn in with the
combustion air. Non-combustible particulate mat ter
such as dust, dirt, concrete dust or dry wall dust can
block burner ports and cause non-warrantable failure.
Use extreme care when operating an appliance for
temporary heat during new construction. The burners
will probably re quire a thorough cleaning before the
appliance is placed in service.
l. Remove gas manifold as described in steps a.
thru e. in “Heat Exchanger/Burner Access.”
m. Loosen mounting screws and remove front
control panel.
n. Loosen screws on the upper front jack et panel
and remove toward front of the appliance. Use
caution to prevent damage to re frac to ry on the
doors inner surface.
30
INSPECTION CLEANING PROCEDURE
The combustion chamber lining in this appliance
contains ceramic fiber materials. Ceramic fibers can
transform into cristobalite (crystalline silica) when
exposed to temperatures above 2192°F (1200°C)
dependent upon the length of exposure time.*
The International Agency for Research on Cancer
(I.A.R.C.) has concluded, "Crystalline silica inhaled in
the form of quartz or cristobalite from occupational
sources is carcinogenic to humans."**
Testing has confirmed that the ceramic fibers in this
application do not reach 2192°F (1200°C).
*Reference Dyson, D., Butler, M., Hughes, R., Fisher,
R., and Hicks, G. The Devitrification of Aluminosilicate Ceramic Fiber Materials - The Kinetics of the
Formation of Different Crystalline Phases, Ann.
Occup. Hyg. Vol. 41, No. 55, 1997.
**Reference I.A.R.C. Monograph 68, June 1997.
WARNING
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.
NOTE:
Page 31
o. Check “V” baffles on top of the heat
ex chang er. Remove and clean if necessary.
p. Remove soot from the heat exchanger with a stiff
bristle brush. Soot may also be re moved from the
heat exchanger by washing thoroughly with
detergent and water. Remove the heat exchanger
before using water for cleaning. Rinse thoroughly
and dry before re-installing. Use a vacuum to
remove loose soot from surfaces and in ner
chamber.
q. Remove the heat exchanger (HEX) filler bracket
(FIG. 38A).
r. The heat exchanger can be removed by sliding
towards the front of the appliance. Once the
heat exchanger is removed from the ap pli ance,
a garden hose can be used to wash the tubes to
ensure that all soot is removed from the heat
exchanger surfaces.
s. Ensure that all burner ports are cleaned to
remove any soot. See Inspection and Cleaning
Procedure, page 30.
t. Carefully re-install the heat exchanger, “V”
baffles, jacket panels, and wires.
u. Reassemble all gas and water piping. Test for
gas leaks.
v. Cycle the appliance and check for prop er
operation.
FIG. 38A Outer Air Deflector and HEX Filler Bracket
5. Water Circulating Pump: Inspect pump ev ery 6
months and oil if required. Use SAE 30
non-detergent oil or lubricant specified by pump
man u fac tur er.
6. Keep appliance area clear and free from
com bus ti ble materials, gasoline and other
flammable vapors and liquids.
7. Check frequently to be sure the flow of com bus tion and ventilation air to the boiler is not
obstructed.
8. Inspection of Heat Exchanger Waterways:
Appliances operated in hard water areas should
have periodic inspections of the tubes to be sure
that no sediment or scale accumulates on the heat
transfer sur fac es. Inspection plugs are located at
both ends of the heat exchanger. In spec tion plugs
should be removed and tubes inspected at the end
of the first 45 days of operation and again at the
end of 90 days of operation. If no scale
accumulation is ob served, inspections can be made
at the end of each six months of op er a tion.
9. Pilot Flame Adjustment Procedure - The pi lot
flame should envelop 3/8" to 1/2" (10 to 13mm) of
the tip of the thermocouple (see Figure 38B).
FIG. 38B Pilot Flame on Thermocouple
a. Remove pilot adjustment cover screw on gas
valve. See Gas Valve Illustrations in the
Lighting Instructions section for lo ca tion of
cover screw.
b. Turn inner adjustment screw clock wise to
decrease or counterclockwise to increase pilot
flame.
c. If difficulty is experienced in ad just ing the
pilot flame, a tee may be installed in the pilot
line from the gas valve to the pilot burn er.
d. Replace pilot adjustment cover screw on valve.
Tighten firmly after adjustment to prevent gas
leakage.
31
UPPER FRONT
JACKET PANEL
OUTER AIR
DEFLECTOR
HEX FILLER
BRACKET
FLAME ROLL-OUT SWITCH /
INTERLOCK SWITCH
LOWER FRONT
JACKET PANEL
"
Page 32
FIG. 39 Gas Train 45,000 - 399,999 Btu/hr Models
FIG. 40 Gas Train 500,000 Btu/hr Model
The drawings in this section show typical heating
boil er piping installations. Before beginning the in stal la tion, consult local codes for specific plumb ing
re quire ments. The installation should provide unions
and valves at the inlet and outlet of the boil er so it can
be isolated for service. The boiler cir cu lat ing pump, air
sep a ra tor, expansion tank and oth er components
required for proper installation must be purchased
locally. An air separation device must be supplied in
the in stal la tion piping to eliminate trapped air in the
system. Lo cate a system air vent at the highest point in
the sys tem. The system must also have a properly sized
expansion tank installed. Typically, an air charged
di a phragm-type expansion tank is used. The expansion
tank must be installed close to the boiler and on the
suction side of the system pump to ensure proper
op er a tion. Caution: This boiler system should not be
operated at less than 12 PSIG. Hot water pip ing must
be supported by suitable hangers or floor stands, NOT
by the boiler. Copper pipe systems will be subject to
considerable expansion and con trac tion. Rigid pipe
hangers could allow the pipe to slide in the hanger
resulting in noise transmitted into the system. Padding
is recommended on rigid hangers installed with a
copper system. The boiler pressure relief valve must be
piped to a suitable floor drain. See the relief valve
section in the In stal la tion and Service Manual.
Heating Boilers with inputs of 45,000 - 260,000 Btu/hr
have 1 1/2" NPT inlet and outlet connections. Heating
boilers with inputs of 315,000 - 500,000 Btu/hr have 2"
NPT. All water heaters have 2" NPT. Cau tion: Field
installed reducing bushings may de crease flow re sult ing
in boiler noise or flashing to steam.
This is a low mass, high efficiency hot water boil er
which must have adequate flow for quiet, efficient
op er a tion. The boiler circulating pump must be
pur chased locally. The boiler circulator pump must
operate con tin u ous ly while the boiler is firing. Pump
selection is critical to achieve proper op er a tion. A
pump should be selected to achieve proper system
design water temperature rise. A heat ex chang er
pressure drop chart (Table L) is provided to assist in
proper pump selection. Also provided is a System
Temperature Rise Chart (Table N). This table provides
GPM and boiler head-loss at various temperature rises
for each boiler based on Btu/hr input. Temperature rise
is the difference in boiler inlet temperature and boiler
outlet temperature while the boiler is firing. Example:
The boiler inlet tem per a ture is 160°F and the boiler
outlet temperature is 180°F, this means that there is a
20°F tem per a ture rise across the boiler.
32
A leak in a boiler system will cause the system to
intake fresh water constantly, which will cause the
tubes to accumulate a lime/scale build up. This will
cause a
NON-WARRANTABLE FAILURE.
CAUTION
WATER CONNECTIONS
HEATING BOILERS ONLY
CIRCULATOR PUMP REQUIREMENTS
GAS TRAIN AND CONTROLS
PIPING OF THE BOILER SYSTEM
Upon completion of any testing on the gas system,
leak test all gas connections with a soap solution
while main burners are operating. Im me di ate ly
repair any leak found in the gas train or re lat ed
components.
Do Not operate an appliance with a
leak in the gas train, valves or related piping.
IMPORTANT
Page 33
1. Maximum operating pressure for the pump must
exceed system operating pressure.
2. Maximum water temperature should not ex ceed
nameplate rating.
3. Cast iron circulators may be used for closed loop
systems.
4. A properly sized expansion tank must be in stalled
near the boiler and located on the suction side of
the pump.
Boilers are equipped with a relay for controlling the
circulation pump for the hot water loop. The relay turns
ON and OFF in response to the “W” input from the wall
thermostat or zone control.
The field installed boiler pump MUST NOT exceed
1 h.p. For continuous pump operation, wire the system
pump to the 120V supply. The pump should be
connected at the junction box as shown in Figure 41.
FIG. 41 Boiler Wiring - Circulation Pump to Junction Box
PUMP INSTALLATION AND MAIN TE NANCE: The
boiler circulating pump must be purchased lo cal ly. For
installation and maintenance information on the
circulator pump, refer to the pump man u fac tur ers
in struc tion package included with the pump.
These units are equipped with an integral bypass pump,
which is designed to provide efficiency optimization by
maintaining a constant flow through the unit’s heat
exchanger loop when building system flow is reduced.
The bypass pump assembly is standard equipment and is
NOT to be used as a system pump.
FIG. 42 - Single Boiler Full System Flow
33
CIRCULATOR PUMP SPECIFICATIONS
CIRCULATOR PUMP OPERATION
(Heating Boilers Only)
TABLE - L
HEAT EXCHANGER PRESSURE DROP CHART
FOOT HEAD LOSS
BYPASS PUMP 45,000 - 260,000 Btu/hr
(Heating Boilers Only)
The bypass pump is dedicated to the unit and does not
affect the building’s system or primary/secondary
flow characteristics and will not circulate the
building.
NOTE:
EXPANSION TANK
MAKE-UP WATER
AIR SEPARATOR
HEATING SUPPLY LOOP
HEATING RETURN
LOOP
Page 34
FIG. 43 Primary/Secondary Piping of a Single Boiler
Heating boilers with inputs of 315,000 - 500,000 Btu/hr
or larg er installed on multiple zone systems are rec om mend ed to be installed with a primary/sec ond ary piping
sys tem as shown in Figure 43. A pri ma ry/secondary
pip ing system may also be in stalled on smaller input
boil ers to ensure proper boiler flow rates. Primary/sec ond ary piping is also ideal for systems using a mixture of
propylene glycol and water. A primary/secondary piping
system uses a dedicated pump to supply flow to the
boiler only. This pump is sized based on de sired boiler
flow rate, boiler head loss and head loss in the sec ond ary
system piping only. The secondary pump, in stalled in
the boiler piping, ensures a constant wa ter flow rate to
the boiler for proper operation. Boiler installation with a
primary/secondary piping sys tem can prevent noise
problems caused by low sys tem water flows. A
primary/secondary piping system is recommended on
any boiler where low water flow conditions may present
an operational problem.
A primary/secondary piping system is ideal for sys tems
filled with a propylene glycol and water mix ture. A
glycol and water mixture is more dense than water only
and may result in a lower boiler flow rate. A lower
boiler flow may cause noise on operation or short
cycling of the burners. A larger secondary pump may
be used on a primary/sec ond ary system to pro vide an
increased boiler flow rate. A glycol and water system
may require from 10 to 20% more flow to compensate
for the in creased density of the glycol and its effect on
the heat transfer process in the boiler. The exact
in crease in flow that may be required is based on the
type and percentage of glycol added to the boiler
system. Consult the manufacturer of the glycol for
additional recommendations when using a gly col and
water fill for your boiler system.
The installer must ensure that the boiler has ad e quate
flow without excessive temperature rise. The
tem per a ture rise on a multiple zone system should be
made when only the zone with the longest length and/or
high est head loss is open. Low system flow can result
in overheating of the boiler water which can cause short
burner on cycles, system noise and in extreme cases, a
knocking flash to steam. These conditions indicate the
need to open the bypass adjustment valve, in stal la tion
of a larger circulator pump or installation of the boiler
with a primary/secondary piping system. Sys tem noise
may also indicate an oversized boiler.
FIG. 44 Boiler with Low Temperature Bypass Piping - Models
315,000 - 500,000 Btu/hr
A boiler operated with an inlet temperature of less than
140°F (60°C) must have a bypass to prevent problems
with condensation. A bypass as shown in Figure 44
must be piped into the system at the time of installation.
34
At no time should the system pressure be less than
12 PSIG.
CAUTION
PRIMARY/SECONDARY
BOILER PIPING
MAKE-UP
WATER
PRV
TO SYSTEM
SYSTEM
PUMP
AIR SEPARATOR
EXPANSION TANK
LWCO
(OPTIONAL)
12"
FROM
SYSTEM
BYPASS
SECONDARY
BOILER PUMP
Page 35
This piping is like a primary/secondary boiler
installation with a bypass in the secondary boil er
piping. Inlet water temperatures below 140°F (60°C)
can excessively cool the prod ucts of combustion
re sult ing in condensation on the heat exchanger and in
the flue. Condensation can cause operational prob lems,
bad combustion, sooting, flue gas spillage and reduced
service life of the vent system and related components.
The bypass allows part of the boiler discharge water to
be mixed with the cooler boiler return water to in crease
the boiler inlet temperature above 140°F (60°C). This
should prevent the prod ucts of com bus tion from
condensing in most in stal la tions. The bypass should be
fully sized with a bal anc ing valve to allow for proper
adjustment. A valve must also be provided on the boiler
discharge, after the by pass. Closing this discharge
valve forces water through the bypass. Start boiler
adjustment with the bypass valve in the full open
position and the boiler discharge valve half open. A
small amount of the high er temperature boiler discharge
water is mixed with the system water to maintain the
de sired lower system tem per a ture. A remote low tem per a ture range operator is recommended to control the
boiler operation based on the lower system tem per a ture.
This remote op er a tor should be wired across the R and
W terminals (see Room Ther mo stat Connection and
Terminal Strip Instructions).
FIG. 45 Boiler Piping with a 3-Way Valve
The installation of a three way valve on this boiler is not
generally recommended because most piping meth ods
allow the three way valve to vary flow to the boil er.
This boiler is a low mass, high ef fi cien cy unit which
requires a constant water flow rate for proper op er a tion.
Low flow rates can re sult in overheating of the boiler
water which can cause short burner on cycles, system
noise and in extreme cases, a knocking flash to steam.
These conditions can cause operational prob lems and
non-warrantable failures of the boiler. If a three way
valve must be installed, please pipe in a
primary/secondary system as shown in Figure 45.
Based on boiler sizing and system flow requirements,
this piping may still result in boiler short cycling.
FIG. 46 Boiler Bypass Piping
The heat exchanger is generally capable of op er at ing
within the flow rates of a residential heating system.
Should the flow rate exceed the maximum allowable
flow rate through the boiler (30 GPM) an external
bypass must be installed. The bypass should be fully
sized with a balancing valve to al low for proper
ad just ment of flow. Flow rate can be determined by
measuring the temperature rise through the boiler.
The basic guide for minimum flow in this boiler is
based on a 40°F temperature rise in most in stal la tions.
Low er flow and a higher temperature rise is acceptable
if the boiler system is specifically de signed for the
char ac ter is tics of a higher tem per a ture rise. A system
not specifically designed for a higher temperature rise
may experience over heat ing of the boiler water. This
can cause short burn er on cycles, system noise and in
ex treme cases, a knocking flash to steam. These
con di tions can lead to operational problems and
non-war rant able fail ures of the boiler. High
temperature rise systems must be designed by a
qualified engineer.
35
BOILER FLOW RATES
The maximum flow rate through the boil er with a
copper heat exchanger must not ex ceed 30 GPM.
CAUTION
MAKE-UP WATER
PRV
EXPANSION TANK
FROM SYSTEM
BYPASS VALVE
AIR SEPARATOR
SYSTEM PUMP
TO SYSTEM
LWC O
(OPTIONAL)
LOW TEMPERATURE BYPASS
REQUIREMENTS
THREE WAY VALVES:
SECONDARY
BOILER PUMP
EXPANSION
TAN K
TO SYSTEM
PRV
SYSTEM PUMP
LWC O
(OPTIONAL)
AIR SEPARATOR
MAKE-UP
WATER
THREE-WAY VALVE
SLOW
OPENING/SLOW
CLOSING
FROM
SYSTEM
Page 36
General Plumbing Rules
1. Check all local codes.
2. For serviceability of the boiler, always install
unions.
3. Always pipe pressure relief valves to an open
drain.
4. Locate system air vents at the highest point of the
system.
5. Expansion tank must be installed near the boil er
and on the suction side of the pump.
6. Support all water piping.
Filling the System: All air must be purged from the
system for proper operation. An air scoop and air vent
must be located close to the boiler outlet and there
should be a minimum distance between the cold water
feed and the system purge valve.
1. Close all drain cocks and air vents.
2. Open the makeup water valve and slowly fill the
system.
3. If a makeup water pump is employed, ad just the
pressure to provide a minimum of 12 psi at the
highest point in the system. If a pressure regulator
is also installed in the line, it should be adjusted to
the same pressure.
4. Close all valves. Purge one circuit at a time as
follows:
A. Open one circuit drain valve and let the water
drain for at least five minutes. Ensure that
there are no air bubbles visible in the wa ter
stream before closing the drain valve.
B. Repeat this procedure for each circuit.
5. Open all valves after all circuits have been purged.
Make sure there are no system leaks.
6. Run the system circulating pump for a min i mum of
30 minutes with the boiler turned off.
7. Open all strainers in the system and check for
debris.
8. Recheck all air vents as described in step 4,
General Plumbing Rules.
9. Inspect the liquid level in the expansion tank. The
system must be full and under normal operating
pressure to ensure proper water level in the
expansion tank. Ensure that diaphragm type
ex pan sion tanks are properly charged and not
water logged.
36
PLACING THE BOILER IN OPERATION
45,000 1.9
75,000 3.1
90,000 3.7
135,000 5.6
180,000 7.4
215,000 8.9
260,000 10.7
315,000 13.0
360,000 14.9
399,999 16.5
500,000 20.7
TABLE - M
MINIMUM REQUIRED FLOW FOR
HEATING BOILER
Input Btu/hr GPM Flow
Minimum flow is based on a 40°F tem per a ture rise
across the boiler. Minimum flow may not prove a
flow switch installed in the boiler piping. Use care
when operating a boiler at or near the min i mum
recommended flow because conditions unique to the
installation (system pressure, operation of multiple
zone valves, glycol, variations in flow, etc.,) may
result in overheating of the boiler water caus ing
noise or nui sance operation of safety limit
con trols. Typical heat ing boiler applications will
op er ate with a 20°F to 30°F temperature rise across
the boiler.
NOTE:
TYPICAL HEATING BOILER
INSTALLATIONS
Do not use petroleum based stop leak products. All
system leaks must be repaired. The constant
addition of make-up water can cause damage to the
boiler heat exchanger due to scale accumulation.
Scale reduces flow and heat transfer, causing
overheating of the heat exchanger.
NOTE:
Page 37
10. Start the boiler according to the “Start-Up
Instructions” in this manual. Operate the system,
including the pump, boiler and radiation units, for
one hour.
11. Recheck the water level in the expansion tank. If
it exceeds half the tank volume, open the tank to
reduce the water level. Recheck pres sure charge
on diaphragm type tanks.
12. Shut down the entire system and vent all ra di a tion
units and high points in the system.
13. Close the water makeup valve and check the
strainer and pressure reducing valve for sediment
or debris. Reopen the water makeup valve.
14. Verify system pressure with the boiler pres sure
gauge before beginning regular operation.
15. Within three days of start-up, recheck and bleed all
air vents and the expansion tank using these
instructions.
FIG. 47 Installation with a Chilled Water System
Pipe refrigeration systems in parallel. Install duct coil
downstream at the cooling coil. Where the hot water
heat ing boiler is connected to a heating coil located in
the air handling units which may be ex posed to
re frig er a tion air circulation, the boiler pip ing system
must be equipped with flow control valves or other
automatic means to prevent gravity circulation of the
boiler wa ter during the cooling cycle. The coil must be
vented at the high point and hot water from the boiler
must enter the coil at this point. Due to the fast heating
capacity of the boiler, it is not necessary to provide a
ductstat to delay circulator operation. Also, omit
ther mo stat flow checks as the boiler is cold when
heating ther mo stat is satisfied. This provides greater
econ o my over maintaining standby heat.
37
INSTALLATION WITH A CHILLED
WATER SYSTEM
F
Btu/hr 10°F T 20°F T 30°F T 40°F T 50°F T
Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd
45,000 36,900 7.4 0.6 3.7 0.2 2.5 0.2 1.9 0.2 -- --
75,000 61,500 12.3 1.3 6.2 0.4 4.1 0.3 3.1 0.2 -- --
90,000 73,800 14.9 1.4 7.4 0.5 5.0 0.3 3.7 0.2 -- --
135,000 110,700 22.3 3.2 11.1 1.2 7.4 0.6 5.6 0.3 -- --
180,000 147,600 29.7 5.1 14.9 1.6 9.9 0.7 7.4 0.4 -- --
215,000 176,300 -- -- 17.0 1.3 11.8 0.8 8.9 0.4 -- --
260,000 213,200 -- -- 21.5 2.1 14.3 0.9 10.7 0.5 -- --
315,000 258,300 -- -- 26.0 4.1 17.3 2.2 13.0 1.3 -- --
360,000 295,200 -- -- 29.7 5.4 19.8 2.5 14.9 1.5 -- --
399,999 327,180 -- -- 33.0 8.1 22.0 3.6 16.5 2.0 13.2 1.7
500,000 410,000 -- -- -- -- 27.6 6.6 20.7 3.5 16.6 2.1
TABLE - N
SYSTEM TEMPERATURE RISE CHART
Based on Boiler Output in Btu/hr
EXPANSION
TANK
LOW WATER
LOW SWITCH
OUT
BOILER
IN
GAS
SUPPLY
PUMP
WATER
SUPPLY
HEATING AND
COOLING COIL
CHILLER
Page 38
The operating temperature control is located in the
control panel, behind the control panel front ac cess door.
The sensing element for the operator is placed in a bulb
well installed in the heat exchanger. Carefully observe
the dis charge water temperature on the initial boiler on
cycles. The exact temperature set point is based on your
system’s requirements. Turn the con trol set point dial to
the desired operating water tem per a ture. Observe the
boiler discharge tem per a ture after each set point
adjustment to ensure prop er operation.
A room thermostat or remote temperature control may
be connected to the boiler. The room ther mo stat should
be installed on an inside wall, away from the influences
of drafts, hot or cold water pipes, lighting fixtures,
televisions, sun rays or fire plac es. Follow the
manufacturers instructions supplied with the ther mo stat
for proper installation and ad just ment. The boiler is
equipped with a terminal strip on the left side of the
control panel to allow easy connection (Figure 48).
Remove the jumper between the R and W terminals on
the terminal strip. Refer to the chart in this section to
determine maximum allowable length and wire gauge
recommended to connect the switching con tacts of the
room thermostat to the R and W terminals on the
terminal strip. Connection to the terminal strip will
allow the room thermostat to make and break the
24VAC boiler control circuit turning the boiler on and
off based on the room ambient temperature
re quire ments. Set the boiler operating temperature
control as described in this section
FIG. 48 Terminal Strip Connections
A terminal connection strip is provided for ease of
connection for Power Venting Systems, see Figure 48,
inset A.
This section applies only to those units used to sup ply
direct fired domestic hot water and installed with a
storage tank(s). The use of a properly sized pump and
the control of water velocity, as ex plained in the Water
Velocity Control section, are important for correct
operation of your hot water heater.
38
Wire Gauge Maximum
Allowable Length
12 GA 100 ft
14 GA 75 ft
16 GA 50 ft
18 GA 30 ft
TABLE - O
TERMINAL STRIP WIRING
BOILER OPERATING
TEMPERATURE CONTROL
ROOM THERMOSTAT OR REMOTE
THERMOSTAT CONNECTION
TO TERMINAL STRIP
DOMESTIC WATER HEATERS
90,000 - 500,000 Btu/hr MODELS
POWER VENTER CONNECTION
TO TERMINAL STRIP
A
Page 39
This section contains specific instructions for those
units used to supply domestic hot water. All warn ings,
cau tions, notes and instructions in the gen er al
installation and service sections apply to these
instructions. Water heat ers are designed for installation
with a storage tank. The use of a properly sized pump
and the control of water velocity, as ex plained below, is
important for correct operation of your water heater.
IMPORTANT - To ensure proper velocity through the
heat exchanger, it is necessary to regulate the
tem per a ture rise across the heat exchanger from inlet to
outlet. This must be done on initial in stal la tion and
periodically rechecked. With the correct temperature
rise across the heat exchanger, you may be assured of
the proper velocity in the tubes. This will yield long life
and economical operation from your water heater.
Excessive lime build-up in the tube is a result of too
little velocity in the tubes. Excessive pit ting or erosion
in the tube is caused by too much ve loc i ty through the
tubes. Care should be taken to measure tem per a ture rise
and maintain a velocity as follows:
1. The pump must run continuously when the burners
are firing.
2. With the pump running and the water heat er off,
the inlet and outlet ther mom e ters should read the
same temperatures. If they do not, an adjustment
must be made to your final calculation.
3. Turn the water heater on and allow time for the
temperature to stabilize. Record the difference
between the inlet and outlet temperatures. This
difference will be the “tem per a ture rise.”
4. Compare the temperature rise on the heater with
the required temperature rise in Table P. Should
adjustment be needed, proceed as fol lows:
If the temperature rise is too high, the water ve loc i ty is
too low. Check the following:
1. Check for restrictions in the outlet of the wa ter
heater.
2. Be sure all valves are open between the water
heater and the tank.
3. Check the pump to be sure it is running prop er ly
and that the pump motor is running in the proper
direction.
4. Be sure the circulation pipes between the wa ter
heater and storage tank are not less than 1 1/2"
diameter for a single unit installation.
5. Common manifold piping for multiple unit in stal la tions will require larger minimum pipe siz es to
tank tappings to ensure proper flow. See Table Q
on page 40.
6. Multiple unit installations may also require a larger
circulating pump to achieve the specified flow
against the increased head loss of a multiple unit
com mon manifold piping.
If the temperature rise is too low, the water ve loc i ty is
too high. Adjust as follows:
1. Slowly throttle the valve on the outlet side of the
water heater until the temperature rise is steady at
the required tem per a ture rise as noted in Table P.
2. Sustained high water velocity and low tem per a ture
rise may result in pitting or erosion of the
copper tubes in the heat exchanger. This is a
non-warrantable failure. Temperature rise must be
properly adjusted to achieve the specified flow
rate.
Temperature rise is based on the hardness of the potable
water to be heated. A different temperature rise is
specified for soft water with a hardness of 0 to 7 grains
per gallon or for unsoftened water with a hardness of 8
to 25 grains per gallon. The total dissolved solids shall
not exceed 350 ppm. If there is any doubt about the
hardness or total dissolved solids content of the
water to be heated, follow the temperature
guidelines for water with 8 to 25 grains of hardness
in Table P below. The majority of all potable water
supplies will fall within the range of 8 to 25 grains of
hardness. See Water Chemistry, page 40.
39
WATER VELOCITY CONTROL
Btu/hr 0 to 7 Grains 8 to 25 Grains
Hardness Hardness
INPUT Temp. Rise oF Temp. Rise °F
90,000 8 5
135,000 12 7
180,000 15 10
199,999 17 11
225,000 20 12
270,000 22 15
315,000 25 17
360,000 30 20
399,999 35 22
500,000 40 28
TABLE - P
REQUIRED TEMPERATURE RISE
REQUIRED TEMPERATURE RISE
Page 40
The required temperature rise and the standard pump
sizing are based on the heating of potable water with
chemistry within the specified limits. Caution should
be used when heating water softened to less than 5
grains per gallon. Many commercial water softeners
reduce hardness to 0 grains which may result in long
term problems in the system. Softened water will
usually have a lower pH which can be aggressive and
corrosive causing non-warrantable damage to the
heater, pump, and associated piping.
Corrosion due to water chemistry generally shows up
first in the hot water system because heated water
increases the rate of corrosive chemical reactions.
Follow the temperature rise recommendations when
heating soft water. Unsoftened water with a hardness of
8 to 25 grains per gallon and/or total dissolved solids
not exceeding 350 ppm requires a higher velocity and
lower temperature rise. As water is heated it becomes
less soluble. The dissolved minerals and solids will
precipitate and collect as scale if water velocity is not
properly controlled. Follow the temperature rise
requirements for unsoftened water. Consult the
manufacturer when heating potable water with hardness
or total dissolved solids exceeding these specifications.
Heating of high hardness and/or high total dissolved
solids water may require a larger circulating pump, an
optional cupro-nickel heat exchanger and a revised
temperature rise specification based on the water
chemistry of the water to be heated.
Decreasing the flow rate will reduce the erosion
process, however the heat exchanger should be
monitored to ensure the scale/liming process is not
made worse. The unit should be placed on a
comprehensive inspection schedule until optimum flow
rates can be established. Problematic water areas may
require heat exchanger inspection every two weeks.
The total scale accumulation should never exceed the
thickness of a piece of paper. Should scale
accumulation exceed this thickness the flow rate will
need to be increased. The tubes should not have a
bright shiny copper look. This would indicate that the
erosion process has begun and the flow rate will need to
be decreased. Once the proper flow rates have been
established the inspection intervals can be increased to
every 30 days, once a quarter, or to a bi-annual
inspection. This procedure should ensure proper
operation of the unit as long as the water quality stays
consistent.
FIG. 49 Typical Water Heater Piping with Storage Tank
1. The water heater/hot water supply boiler must be
connected to a properly sized pump that circulates
water between the heater and storage tank.
2. Pump is sized to heater input and water hard ness.
Care should be taken to size the pump
correctly. See “Water Chemistry”, this page.
40
HOT WA TER SUPPLY
COLD WA TER SUPPLY
RELIEF
VALVE
LOCK-TEMP
STORAGE
TANK
DRAIN
RELIEF
VALVE
CIRCULATING PUMP
EXPANSION TANK (IF REQUIRED)
BUILDING
RETURN
Pipe sizing chart provides minimum pipe size for
com mon manifold piping and tank tappings to in sure ad e quate flow.
Number of Units Common Manifold Size (Min)
1 2"
2 2"
3 2 1/2"
4 3"
5 3 1/2"
6 3 1/2"
TABLE - Q
COMMON WATER MANIFOLD SIZE FOR
MULTIPLE HOT WATER SUPPLY BOILER
INSTALLATIONS
PUMP OPERATION
Lower flows with soft water mean a higher
temperature rise. A higher temperature rise may
cause nuisance tripping of a high limit or opening
of a relief valve when providing very hot water. If
this presents a problem, increase the flow to the
temperature rise specified for 8 to 25 grains
hardness water.
NOTE:
WATER CHEMISTRY
SOFTENED WATER SYSTEMS
Page 41
3. The pump must run continuously when the burners
are firing.
4. Lubricate the pump to the manufacturers rec om men da tions. Pump damage due to inadequate lu bri ca tion is non-warrantable.
5. A standard water heater/hot water supply boiler is
furnished with a 1/6 HP, 120 VAC, 3.6 AMP
circulating pump to be mounted on the units in let
water connection. This pump is sized based on
installation of a single storage tank and heat er in
close proximity. If the number of fit tings and
straight pipe exceeds the quantities shown in this
sec tion, a larger pump will be required.
The standard pump selection is based on the fol low ing
pipe and fittings from the unit to the stor age tank:
6 - 90° elbows 2 - ball valves
2 - unions 1 - cold water tee
Plus the following length of straight pipe based on the
heater size:
90,000 thru 360,000 Btu/hr Models
Not more than 45 feet of straight pipe
399,999 thru 500,000 Btu/hr Models
Not more than 25 feet of straight pipe
For every elbow and tee in excess of those shown
above, DEDUCT 5 FEET from maximum allowable
straight pipe in heater to tank circulating loop.
Based on heating potable water with a hardness of 8 to
25 grains per gallon and total dissolved solids not
exceeding 350 ppm. See “Water Chemistry”, page 40.
BTU/hr INPUT
GPM Ft. Hd.
90,000 - 500,000 30 8
Water heaters are provided with an extra temperature
sensor that MUST BE field installed. The sensor is
shipped loose in the I & O packet. This remote
mounted sensor will be the primary temperature sensor
which will inform the appliance’s built-in thermostat
control. For domestic water heating, the sensor MUST
BE installed into a bulbwell on the storage tank. This
is required to maintain the desired temperature in the
tank and reduce cycling of the heater.
The sensor must also be connected to two blue wires
provided in the upper left-hand corner of the control
panel. It will be necessary to add additional wire to
reach from the appliance to the remote water source.
Use twisted pair wire, minimum 18 gauge or larger. See
Table O, page 38 regarding distance versus wire gauge.
FIG. 50 External Sensor for Tank, System, or Pump Delay
This is a highly sophisticated heat exchanger, de signed
to carry water in such a way that it gen er ates a scour ing
action which keeps all interior sur fac es free from
build-up of impurities. The straight-line, two pass
de sign of the tubes sends water into the headers at a
properly rated velocity. The configuration of the
head ers, in turn, creates a high degree of turbulence
which is sufficient to keep all contaminants in
suspension. This “scouring action” provides greater
cost savings for owners. Tubes are always able to
transfer heat at peak ef fi cien cy. Every surface within
this water con tain ing section is of a nonferrous material,
providing clear, clean, rust-free hot water. Straight
copper tubes-finned on the outside for maximum heat
transfer-glass lined cast iron one piece cored head ers
make up an entirely rustproof unit. On all mod els,
header inspection plugs can be removed for field
in spec tion and cleaning of copper tubes. The entire
heat exchanger may be easily removed from the unit.
1. The thermostat is adjusted to a low test set ting
when shipped from the factory.
2. Set the thermostat to a maximum water
temperature of 125°F which will satisfy hot water
demands and prevent risk of scald injury.
Households with small children or invalids may
require 120°F or lower temperature setting to
re duce risk of scald in ju ry. Some states may
require a lower temperature setting. Check with
41
MINIMUM PUMP PERFORMANCE
EXTERNAL SENSOR FOR TANK, SYSTEM OR PUMP DELAY
REMOTE SENSOR CONNECTOR IS
LOCATED ON SIDE OF UNIT.
NOTE: COLOR OF WIRES AND
LEAD STYLES MAY VARY
WITH SENSOR PROVIDED.
CONNECTIONS ARE POLARITY
INSENSITIVE.
SIDE PANEL
HEAT EXCHANGER
THERMOSTAT SETTINGS
REMOTE SENSOR
INSTALLATION INSTRUCTIONS
Page 42
42
your gas supplier for local re quire ments governing
the tem per a ture setting. Re mem ber, no water
heating sys tem will provide exact tem per a ture at
all times. Allow a few days of operation at this
setting to de ter mine the correct temperature set ting
consistent with your needs.
Incorrect piping of the cold water supply to the sys tem
may result in excessive low temperature op er a tion
causing condensate formation on the heat ex chang er
and operational problems. The cold water supply
piping must be installed in the dis charge piping from
the heater to the storage tank. This allows the cold water
to be tempered in the storage tank before entering the
heater. See typ i cal installation drawings provided with
the unit for correct piping. Higher wa ter temperatures
reduce condensate formation.
The manufacturer recommends the use of a prop er ly
sized thermostatic mixing valve to supply do mes tic hot
water at temperatures less than 140°F. Storing the
water at a higher temperature and ther mo stat i cal ly
mixing the water will increase the avail able quantity of
mixed hot water, greatly reduce the possibility of
con den sate formation on the heat exchanger and help
pre vent the growth of water born bacteria. Adequate
care MUST be taken to prevent potential scald injury
when storing water at 140°F and hotter.
Automatic vent dampers are not required or fur nished
on potable water heaters. All water heaters will have a
plug installed in the damper terminal on the side of the
control panel to allow operation with out a vent damper.
The damper plug MUST be in place if an optional vent
damper is not used on a water heater. Water heaters with
inputs of 360,000 Btu/hr and less may be ordered with
the vent damp er as an option. Remove the damper plug
from the terminal to connect an optional vent damper
wire harness. The optional damp er must be properly
installed and the wire har ness plugged into the terminal
on the side of the con trol panel to allow the unit to
func tion. See the “Au to mat ic Vent Damper” section in
the basic portion of the manual.
This water heater/hot water supply boiler is nor mal ly
supplied with a temperature and pressure re lief valve(s)
sized in accordance with applicable codes. Units may
be supplied with an optional pres sure only relief
valve(s). When a water heater/hot water supply boil er
equipped with this optional re lief valve is piped to a
separate storage vessel, the storage vessel must have a
properly installed tem per a ture and pressure relief valve
which complies with local codes.
SHOULD OVERHEATING OC CUR OR THE
GAS SUPPLY FAIL TO SHUT OFF, DO NOT
TURN OFF OR DISCONNECT THE
ELEC TRI CAL SUPPLY TO THE PUMP.
INSTEAD, SHUT OFF THE GAS SUPPLY AT
A LOCATION EXTERNAL TO THE
AP PLI ANCE.
WARNING
AUTOMATIC VENT DAMPERS
Do not install an optional vent damper within 6"
(152mm) of combustible materials.
CAUTION
OPTIONAL RELIEF VALVE
Setting the temperature selector to high er settings
provides hotter water, which in creas es the risk of
scald injury.
CAUTION
(1) This water heater, when set at the low er
temperature setting, is not capable of producing
hot water of sufficient temperature for sanitizing
pur pos es. (2) Higher stored water temperature
in creas es the ability of the water heater to supply
desired quantities of hot water, however
remember:
Hotter water increases the risk of scald
injury.
NOTE:
CAUTION
• Water temperature over 125°F (52°C)
can cause severe burns instantly or
death from scalds.
• Children, disabled and elderly are
at highest risk of being scalded.
• See instruction manual before
setting temperature at heating
appliance.
• Feel water before bathing or showering.
• If this appliance is used to produce
water that could scald if too hot,
such as domestic hot water use,
adjust the outlet control (limit) or use
temperature limiting valves to obtain
a maximum water temperature of
125°F (52°C).
Page 43
A relief valve which discharges periodically may be due
to thermal expansion in a closed system. A hot water
supply boiler installed in a closed sys tem, such as one
with a backflow preventer or check valve in stalled in
the cold water supply, shall be provided with means to
control expansion. Con tact the water sup pli er or local
plumbing inspector on how to correct this situation.
Do not plug or cap the relief valve discharge!
Hydrogen gas can be produced in a hot water sys tem
that has not been used for a long period of time
(gen er al ly two weeks or more). Hydrogen gas is
ex treme ly flammable. To prevent the pos si bil i ty of
injury under these conditions, we rec om mend the hot
water faucet be open for several minutes at the kitch en
sink before you use any electrical ap pli ance which is
connected to the hot water sys tem. If hydrogen is
present, there will be an un usu al sound such as air
escaping through the pipe as the hot water begins to
flow. There should be no smoking or open flames near
the faucet at the time it is open.
43
THERMAL EXPANSION
CATHODIC PROTECTION
Page 44
44
Is the spark
igniter sparking?
NO
Check continuity of the spark
cable. Check for 24VAC on
the TH terminal (gray wire) on
the ignition module.
Is the pilot
staying ON?
STEP 1:
STEP 2:
Check the pilot
tube for gas.
Check for draft.
NO
NO
YES
Replace ignition
module.
Is there 24 VAC (purple
wire) on the 4-pin
connector plug on the
temperature controller?
YES
Is there 24VAC
(tan wire) on the
4-pin connector
plug on the
temperature
controller?
NO
Check for an open
sensor. If not open,
replace temperature
controller.
Is the gas valve
getting 24VAC?
STEP 3:
Replace ignition
module.
NO
YES
Check X and B on the
terminal strip if the flow
switch is installed. Check
for an open auto reset high
limit.
Check vent damper, 3-pin
louver relay connectors, and
venter proving.
Check 24VAC at R and W on
the (EMS) terminal strip.
NO
Check the vent damper or
the vent damper plug and
the voltage to and from the
transformer.
YES
Check all safety limit devices.
Check 4-pin low water cutoff
connector.
YES
YES
NO
TROUBLESHOOTING GUIDE
45,000 - 500,000 Btu/hr Models - Boilers & Water Heaters F9/M9
Page 45
45
TROUBLESHOOTING GUIDE
90,000 - 270,000 Btu/hr Models - Water Heaters F1
Is the pilot lit?
NO
Check for gas. Check the pilot
assembly and thermocouple.
Check the gas valve for proper
operation. Clean and replace.
Is the gas valve
getting 24VAC?
STEP 1:
STEP 2:
NO
Is there 24 VAC
(purple wire) on the 4pin connector plug on
the temperature
controller?
YES
Is there 24VAC
(tan wire) on the
4-pin connector
plug on the
temperature
controller?
NO
Check for an open
sensor. If not open,
replace temperature
controller.
Unit is running.
STEP 3:
NO
YES
Check X and B on the
terminal strip if the flow
switch is installed. Check for
an open auto reset high limit.
Check vent damper 3-pin,
louver relay connectors, and
venter proving.
Check 24VAC at R and W on
the (EMS) terminal strip.
Check the vent damper or
the vent damper plug and
the voltage to and from the
transformer.
YES
Check all safety limit devices.
Check 4-pin low water cutoff
connector.
NO
YES
YES
Page 46
46
Schematic Diagram - F1 Unit
90,000 - 270,000 Btu/hr Models
Wiring Diagram - F1 Unit
90,000 - 270,000 Btu/hr Models
Page 47
47
Schematic Diagram - F9 Unit
90,000 - 399,999 Btu/hr Models
Wiring Diagram - F9 Unit
90,000 - 399,999 Btu/hr Models
Page 48
48
Schematic Diagram - M9 Unit
45,000 - 399,999 Btu/hr Models
Wiring Diagram - M9 Unit
45,000 - 399,999 Btu/hr Models
Page 49
49
Schematic Diagram - F9/M9 Unit
500,000 Btu/hr Models
Wiring Diagram - F9/M9 Unit
500,000 Btu/hr Models
Page 50
50
NOTES
Page 51
51
NOTES
Page 52
52
Revision 4 (RSB-i&s-04) reflects the removal of the inlet
pipe and installing the inlet sensor inside the header.
Revision 5 (RSB-i&s-05) reflects changes made to the
O.A. section.
RSB-i&s-05
CP-5M-4/08
Loading...