Lochinvar CWN090, CWN135, CWN180, CWN199, CWN225 Installation Manual

CFA-I-S_100160907_2000001336_Rev H

Installation & Service Manual

Models: 90,000 - 500,000 Btu/hr

WARNING:

This manual supplies information for the installation, operation, and servicing of the appliance. It is strongly recommended that this manual be reviewed completely before proceeding with an installation. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Save this manual for future reference.

Contents

HAZARD DEFINITIONS ....................................................	2
PLEASE READ BEFORE PROCEEDING .....................	3-4
RATINGS ........................................................................	5-6
THE COPPER-FIN -- HOW IT WORKS ...............................	7-9
1. DETERMINE UNIT LOCATION
Location of Unit ................................................................	10
Clearances from Combustible Construction .....................	10
Combustion and Ventilation Air..................................	11-13
2. VENTING
A Conventional Negative Draft Venting System .........	14-15
Vertical Vent Termination Clearances .............................	16
Masonry Chimney Installation ..........................................	17
Inspection of a Masonry Chimney ..............................	17
Automatic Vent Damper ...................................................	20
3. GAS CONNECTIONS
Gas Supply.......................................................................	21
Gas Pressure Test ...........................................................	21
Gas Connection ...............................................................	21
Gas Piping........................................................................	22
Gas Manifold Pressure Adjustment Procedure................	23
Checking Gas Supply Pressure .......................................	24
Combination Gas Valves..................................................	25
4. HYDRONIC PIPING
Relief Valve ......................................................................	26
Water Flow Switch (if equipped) ......................................	26
Low Water Cutoff (if equipped) ........................................	27
Typical Heating Boiler Installations .............................	27-28
Piping of the Boiler System..............................................	28
Water Connections Heating Boilers Only.........................	29
Circulator Pump Requirements ........................................	29
Circulator Pump Specifications ......................................	29
Circulator Pump Operation (Heating Boilers Only)........	29
Primary/Secondary Boiler Piping .....................................	30
Low Temperature Bypass Requirements.........................	31
Three Way Valves............................................................	31
Boiler Flow Rates .............................................................	31
Figure 4-4_Prim. / Sec. Piping of a Single Boiler.......	32
Figure 4-5_Prim. / Sec. Piping w/Low Temp. Bypass 33
Figure 4-6_Multiple Boilers Zoned w/Circulators........	34

5. ELECTRICAL CONNECTIONS
Boiler Operating Temperature Control.............................	35
Room Thermostat or Remote Thermostat Connection....	35
Power Venter Connection to Terminal Strip ....................	35
Pump Wiring for a Heating Boiler ....................................	36
Temperature Adjustment..................................................	36
Temperature Control Settings ..........................................	37
Maximum Set Point Determination ..................................	37
Outdoor Air Reset Option.................................................	38
Additional Temperature Controls ................................	40-41
Blocked Vent and Flame Roll-Out / Flame Interlock Switch . 41
6. STARTUP
Initial Startup ....................................................................	42
Lighting Instructions for Standing Pilot Models (F1) ...	42-44
Safety Shutoff Test for Standing Pilot Ignition System ....	44
Lighting Instructions for Spark Ignition Pilot Models (F9/M9) 45-46
Safety Shutoff Test for Spark Ignition Pilot System............	46
Intermittent Pilot Spark Ignition System (F9/M9) .................	46
Freeze Protection ...........................................................................	46
Water Treatment .......................................................................	47-49
7. DOMESTIC WATER HEATERS
Water Velocity Control .....................................................	50
Required Temperature Rise.............................................	50
Water Chemistry...............................................................	51
Softened Water Systems .................................................	51
Pump Operation ...............................................................	51
Figure 7-1_Single Water Heater Piping w/Single Tank... 52
Figure 7-2_Single Water Heater Piping w/Multiple Tanks 53
Figure 7-3_Multiple Water Heater Piping w/Single Tank. 54
Remote Sensor Installation ..............................................	55
Heat Exchanger ...............................................................	55
Thermostat Settings ....................................................	55-56
Optional Relief Valve........................................................	57
Thermal Expansion ..........................................................	57
Cathodic Protection..........................................................	57
8. MAINTENANCE
Maintenance and Annual Startup................................	58-64
9. TROUBLESHOOTING............................................	65-66
10. DIAGRAMS............................................................	67-70

Hazard definitions

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

DANGER

WARNING

CAUTION CAUTION NOTICE

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

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

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

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

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

2

Installation & Service Manual

Please read before proceeding

	NOTICE	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.

WARNING If the information in these instructions is not followed exactly, a fire or explosion may

result causing property damage, personal injury, or death.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present, unless the installation is such to eliminate the probable ignition of gasoline or flammable vapors.

What to do if you smell gas –

• Do not try to light any appliance.

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

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

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

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

Warranty –

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

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

Experience has shown that improper installation or system design, rather than faulty equipment, is the cause of most operating problems.

1.Excessive water hardness causing a lime/scale build-up in the copper tube is not the fault of the equipment and is not covered under the manufacturer’s warranty (see

Water Treatment and Water Chemistry).

2.Excessive pitting and erosion on the inside of the copper tube may be caused by too much water velocity through the tubes and is not covered by the manufacturer’s warranty (see Boiler Flow Rates and Temperature Rise for flow requirements).

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

Checking equipment –

Upon receiving equipment, check for signs of shipping damage. Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled. Verify total number of pieces shown on the packing slip with those actually received. In case there is damage or a shortage, immediately notify the carrier.

Do not use this appliance if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Owner warning –

NOTE: Retain this manual for future reference.

The information contained in this manual is intended for use by qualified professional installers, service technicians, or gas suppliers. Consult your local expert for proper installation or service procedures.

Consult and follow all local Building and IMPORTANT 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.

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.

Should overheating occur or the gas supplyWARNING 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.

3

Installation & Service Manual

Please read before proceeding

WARNING To minimize the possibility of serious personal injury, fire, or damage to your appliance, 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 vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components.

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

3.UNDER NO CIRCUMSTANCES must flammable materials such as gasoline or paint thinner be used or stored in the vicinity of this appliance, vent-air intake system or any location from which fumes could reach the appliance or vent-air intake system.

Codes –

The equipment shall be installed in accordance with those installation regulations in force in the local area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made. In the absence of such requirements, the installation shall conform to the latest edition of the National Fuel Gas Code, ANSI Z223.1. Where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, ASME CSD-1. All boilers conform to the latest edition of the ASME Boiler and Pressure Vessel Code, Section IV. Where required by the authority having jurisdiction, the installation must comply with the Canadian Association Code, CAN/CGAB149.1 and/or local codes.

This appliance meets the safe lighting performance criteria with the gas manifold and control assembly provided as specified in the ANSI standards for gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.

Boiler water –

Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high-efficiency heat exchanger can be damaged by build-up or corrosion due to sediment.

NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

Prevention of freezing –

Heat exchangers and headers damaged by freezing are not covered by warranty.

See Section 6, Start-Up - Freeze Protection for more information.

4

Ratings

Copper-Fin

AHRI Rating

	Input				Net
Model Number				Gross	AHRI
	MBH			Output	Ratings
Note: Change	(Note 4)			MBH	Water,
“N” to “L” for					MBH
L.P. gas models	MIN		MAX	(Note 1)	(Note 2)
CBN315	158		315	258	224
CBN360	180		360	295	257
CBN399	200		399	328	285
CBN500	250		500	410	357

Installation & Service Manual

Other Specifications

Boiler
Water	Water	Gas	Vent Size
Content	Connections	Connections
Gallons
			(Note 3)
1.2	2"	3/4"	8"
1.2	2"	1"	9"
1.3	2"	1"	10"
1.4	2"	1"	10"

NOTICE Maximum allowed working pressure is located on the rating plate.

Notes:

1.	The ratings are based on standard test procedures
	prescribed by the United States Department of Energy.
2.	Net AHRI ratings are based on net installed radiation of
	sufficient quantity for the requirements of the building
	and nothing need be added for normal piping and pickup.
	Ratings are based on a piping and pickup allowance of 1.15.
3.	Copper-fins require special gas venting. Use only the vent
	materials and methods specified in the Installation and
	Service Manual.
4.	The Copper-fin is orificed for operation up to 2000 Figure A High Altitude Label Location
	feet altitude. The appliance will be derated 4% per 1000
	feet above 2000 feet elevation. Consult the factory for
	installations above 2000 feet elevation.

UNIT EQUIPPED FOR

HIGH ALTITUDE

UPTO2000 FT.

5. Ratings have been confirmed by AHRI.

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Installation & Service Manual

Ratings

HLW LOW LEAD CONTENT

Copper-fin Specifications

Model Number						Vent Size
		Input	Water	Water Connections	Gas Connections
Note: Change “N” to		MBH	Content Gallons			(Note 1)
“L” for L.P. gas models
CWN090		90	1.0	2"	1/2"	5"
CWN135		135	1.0	2"	1/2"	6"
CWN180		180	1.1	2"	3/4"	7"
CWN199		199	1.1	2"	3/4"	7"
CWN225		225	1.1	2"	3/4"	7"
CWN270		270	1.1	2"	3/4"	8"
CWN315		315	1.2	2"	3/4"	8"
CWN360		360	1.2	2"	1"	9"
CWN399		399	1.3	2"	1"	10"
CWN500		500	1.4	2"	1"	10"
	Maximum allowed working pressure is located on the rating plate.
NOTICE

Notes:

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

2.The Copper-fin is orificed for operation up to 2000 feet altitude. The appliance will be derated 4% per 1000 feet above 2000 feet elevation. Consult the factory for installations above 2000 feet elevation.

UNIT EQUIPPED FOR

HIGH ALTITUDE

UPTO2000 FT.

Figure B High Altitude Label Location

6

Installation & Service Manual

The Copper-fin - How it works...

1.Control panel cover

The control panel cover provides access to the thermostat, ignition module, and transformer.

2.Drain port (not shown)

Location from which the heat exchanger can be drained.

3.Flue outlet

The flue outlet allows the connection of the vent pipe to the unit.

4.Gas connection pipe

The gas pipe connection on this appliance should be connected to the incoming gas supply for the purpose of delivering gas to the appliance.

5.Gas valve

The gas valve allows the proper amount of gas to pass into the burner for combustion.

6.Heat exchanger

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

7.High limit sensor

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

8.Ignition module (F9 and M9 models only)

The ignition module responds to a call for heat signal to provide burner operation .

9.Junction box

The junction box contains the connection points for the line voltage power and the pump.

10.Relief valve

The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded. Water heaters are supplied with a temperature and pressure relief valve.

15.Water inlet

The water inlet is a 2" pipe connection that receives water from the system and delivers it to the heat exchanger.

16.Water outlet

The water outlet is a 2" pipe connection that supplies water to the system .

17.Burner (not shown)

The burner is a cylindrical stainless steel tube used to regulate burner flame.

18.Pilot (not shown)

( F9 and M9 models only)

The pilot is a spark ignition device is used to light a pilot flame which in turn is used to light the main burners.

( F1 models only)

The pilot uses a standing flame to light the main burner.

19.Sight Glass (not shown)

The sight glass provides a view of the burner surface, burner flame, and the pilot flame.

20.Temperature and pressure gauge (CB models only)

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

21.Pump (shipped with CW models only)

The pump ensures adequate flow to operate the unit.

22.Pump relay

The pump relay energizes the pump on a call for heat.

23.Temperature sensor

This sensor monitors inlet water temperature. If selected as the controlling sensor, the appliance will maintain the setpoint at this sensor.

11.Terminal strip

The boiler is equipped with a terminal strip on the left side of the control panel to allow easy connection to contact points on the unit.

12.Thermostat

The thermostat monitors the water temperature via a temperature sensor and will initiate a call for heat when the water temperature drops below the setpoint plus the differential on the thermostat.

13.Temperature gauge (CW models only)

The temperature gauge monitors the inlet temperature of the water heater as well as the outlet temperature.

14.Transformer

The transformer reduces 120 VAC supply voltage to 24 VAC for the

control circuit.

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Installation & Service Manual

The Copper-fin - How it works...

3

3

10	1

1 10

		16
16
		9
21	11	21	9
15	5		11
		5
		15
Models CWN270 Front View		Model CWN399 Front View

6

6

7

8

13

12

23

14

22

4

13

7

23

12

8

14

22

4

Model CWN270 (inside unit)	Model CWN399 (inside unit)

8

Installation & Service Manual

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

3

1

20

10

16

15	9

11

5

Model CBN399 Front View

6

12

8

7

14

23

4

22

Models CBN399 (inside unit)

3

20

1

10

16

15

9

11

5

Model CBN500 Front View

6

12

8

7

14

23

22

4

Model CBN500 (inside unit)

9

1 Determine unit location

Location of unit

1.Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

2.The appliance must be installed indoors where it is protected from exposure to wind, rain and weather.

3.The appliance must be installed so that the ignition system components are protected from water (dripping, spraying, rain, etc.,) during appliance operation and service (circulator replacement, control replacement, etc.,).

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

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

6.All units have been approved for alcove installation (an ALCOVE is a closet enclosure without a front door).

7.The appliance must not be installed on carpet.

8.All units have been approved for use on combustible surfaces.

9.Allow sufficient space for servicing pipe connections, pump and other auxiliary equipment, as well as the appliance.

NOTICE	Clearances from combustible construction
	are noted on the appliance rating plate.

Installation & Service Manual

14 " TOP

6 " RIGHT

6 " REAR

24"	24"
FRONT	LEFT

Figure 1-1_Alcove installation, 90,000 - 180,000 Btu/hr

29" TOP

6

" RIGHT

6 "

REAR

	24"	24"
	FRONT
		LEFT

Figure 1-2_Alcove Installation, 225,000 - 500,000 Btu/hr

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Installation & Service Manual

1 Determine unit location (continued)

Combustion and ventilation air requirements for conventionally vented appliances

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

The room where the appliance is installed MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation when the appliance is installed with conventional venting.

Figure 1-3_Combustion Air Direct from Outside

1. If air	is	taken	directly from outside the building
with	no	duct,	provide two permanent openings
(see FIG. 1-3):

(a)Combustion air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the floor.

(b)Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input

(5.5 cm2 per kW). This opening must be located within 12" (30 cm) of the ceiling.

Figure 1-4_Combustion Air Through Ducts

2.If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the room where the appliance is installed, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11cm2 per kW) (see FIG. 1-4).

Figure 1-5_Combustion Air from Interior Space

3.If air is taken from another interior space that is adequately ventilated, each of the two openings specified above should have a net free area of one square inch for each 1000 Btu/ hr (22cm2 per kW) of input, but not less than 100 square inches (645cm2) (see FIG. 1-5).

11

1 Determine unit location

Figure 1-6_Combustion Air from Outside Single Opening

4.If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12" (30 cm) of the top of the enclosure (see FIG. 1-6).

Combustion air requirements are based on the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada refer to National Standard CAN B149.1. Check all local code requirements for combustion air.

All dimensions are based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12" (30 cm) of the ceiling and one must be within 12" (30 cm) of the floor of the room where the appliance is installed. Each opening must have a net free area as specified in Table 1B (on page 13). Single openings shall be located within 12" (30 cm) of the ceiling.

Installation & Service Manual

CAUTION	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.

The combustion air supply must be completely free of any flammable vapors that may ignite or chemical fumes which may be corrosive to the appliance. Common corrosive chemical fumes which must be avoided are fluorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as freon, tricholorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger finned tubes, headers, flue collectors, and the vent system. The result is improper combustion and a non-warrantable, premature appliance failure.

The result is improper combustion and a non-warrantable, premature appliance failure.

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

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Installation & Service Manual

1 Determine unit location (continued)

TABLE - 1B

MINIMUM RECOMMENDED COMBUSTION

AIR SUPPLY TO EQUIPMENT ROOM

		*Outside Air from			*Outside Air from		**Inside Air from
	Input	2 Openings Directly from		*Outside Air from	2 Ducts Delivered from		2 Ducts Delivered from
		Outdoors		1 Opening Directly	Outdoors		Interior Space
	Btu/hr
		Top	Bottom	from Outdoors, in2	Top	Bottom	Top	Bottom
		Opening, in2	Opening, in2		Opening, in2	Opening, in2	Opening, in2	Opening, in2
	90,000	23	23	30	45	45	100	100
		(148 cm2)	(148 cm2)	(194 cm2)	(291 cm2)	(291 cm2)	(646 cm2)	(646 cm2)
	135,000	34	34	45	68	68	135	135
		(220 cm2)	(220 cm2)	(291 cm2)	(439 cm2)	(439 cm2)	(871 cm2)	(871 cm2)
	180,000	45	45	60	90	90	180	180
		(291 cm2)	(291 cm2)	(388 cm2)	(581 cm2)	(581 cm2)	(1,162 cm2)	(1,162 cm2)
	199,999	50	50	67	100	100	200	200
		(323 cm2)	(323 cm2)	(433 cm2)	(646 cm2)	(646 cm2)	(1,291 cm2)	(1,291 cm2)
	225,000	57	57	75	113	113	225	225
		(368 cm2)	(368 cm2)	(484 cm2)	(730 cm2)	(730 cm2)	(1,452 cm2)	(1,452 cm2)
	270,000	68	68	90	135	135	270	270
		(439 cm2)	(439 cm2)	(581 cm2)	(871 cm2)	(871 cm2)	(1,742 cm2)	(1,742 cm2)
	315,000	79	79	105	158	158	315	315
		(510 cm2)	(510 cm2)	(678 cm2)	(1,020 cm2)	(1,020 cm2)	(2,033 cm2)	(2,033 cm2)
	360,000	90	90	120	180	180	360	360
		(581 cm2)	(581 cm2)	(775 cm2)	(1,162 cm2)	(1,162 cm2)	(2,323 cm2)	(2,323 cm2)
	399,999	100	100	134	200	200	400	400
		(646 cm2)	(646 cm2)	(865 cm2)	(1,291 cm2)	(1,291 cm2)	(2,581 cm2)	(2,581 cm2)
	500,000	125	125	167	250	250	500	500
		(807 cm2)	(807 cm2)	(1,078 cm2)	(1,613 cm2)	(1,613 cm2)	(3,226 cm2)	(3,226 cm2)

*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.

**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”. For buildings of *“Tight Construction”, provide air openings into the building from outside.

*No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.

* “Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).

Vent installations for connection to gas vents or chimneys must be in accordance with “Venting of Equipment,” of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment or applicable provisions of the local building codes.

Adequate combustion and ventilation air must be supplied 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 Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

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Installation & Service Manual

2 Venting

The distance of the vent terminal from adjacent buildings, windows that open and building openings MUST comply with the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment.

Vent connection is made directly to the top of the appliance. This appliance is designed with a built-in draft diverter. No additional external draft hood is required. The connection from the appliance vent to the common vent or chimney must be made as direct as possible.

A Conventional Negative Draft

Venting System

The negative draft in a conventional vent installation must be within the range of a negative 0.02 to 0.05 inches water column to ensure proper operation. All draft readings are made while the appliance is in stable operation (approximately 2 to 5 minutes).

Multiple appliance installations with combined venting or common venting with other negative draft appliances require that each appliance must have draft within the proper range. If the draft measured above the appliance’s built-in draft diverter exceeds the specified range in a dedicated chimney for a single appliance installation or in combined venting with other negative draft appliances, a barometric damper must be

installed to control draft.

Figure 2-1_Conventional Negative Draft Vertical Venting

TABLE - 2A

VENT PIPE SIZES

Input Btu/hr	Flue Size
90,000	5"
135,000	6"
180,000	7"
199,999	7"
225,000	7"
270,000	8"
315,000	8"
360,000	9"
399,999	10"
500,000	10"

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

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

14

2 Venting (continued)

Locate appliance as close as possible to a chimney or gas vent.

Avoid long horizontal runs of the vent pipe, 90° elbows, reductions and restrictions. Horizontal portions of the venting system shall be supported to prevent sagging. Horizontal runs must slope upwards 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. A water heater shall not be connected to a chimney flue serving a separate appliance designed to burn solid fuel.

The weight of the venting system must not rest on the appliance. Adequate support of the venting system 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 natural draft shall not be connected to any portion of a mechanical draft system operating under positive pressure. Connection to a positive pressure chimney 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 connected 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 exhaust fan. Close fireplace dampers.

(d)Place in operation the appliance being inspected.

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

Installation & Service Manual

(e)Test for spillage at the draft hood/relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

(f)After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and other gas burning appliances 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 National 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 portion of the common venting system, the common venting system should be resized to approach the minimum 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 Standard B149 Installation Code for

Gas Burning Appliances and Equipment.

15

Installation & Service Manual

2 Venting

Vertical Vent Termination Clearances

10' OR LESS

CHIMNEY

2' MIN

3' MIN

RIDGE

Figure 2-2_Vent Termination from Peaked Roof 10' or Less from Ridge

MORE THAN 10'
10'
2' MIN	CHIMNEY
RIDGE
	3' MIN

Figure 2-3_Vent Termination from Peaked Roof More than 10' from Ridge

The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof within a 10 foot (3.05m) radius of the termination. The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.

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

The vent cap should have a minimum clearance of 4 feet (1.22m) horizontally from and in no case above or below, unless a 4 foot (1.22m) horizontal distance is maintained from electric meters, gas meters, regulators and relief equipment.

The venting system shall terminate at least 3 feet (0.9m) above any forced air inlet within 10 feet (3.05m).

10' OR LESS	10' OR LESS
2' MIN	2' MIN

3' MIN

CHIMMEY WALL OR	CHIMMEY
PARAPET

Figure 2-4_Vent Termination from Flat Roof 10' or Less from Parapet Wall

10' OR MORE

3'

NOTE:

NO HEIGHT ABOVE

PARAPET REQUIRED

WHEN DISTANCE

FROM WALLS OR

PARAPETS IS MORE

THAN 10'.

WALL OR

PARAPET CHIMNEY

Figure 2-5_Vent Termination from Flat Roof More Than 10' from Parapet Wall

The vent can not terminate below grade. The bottom of the vent terminal shall be located at least 12 inches (30cm) above grade.

To avoid a blocked vent condition, keep the vent cap clear of snow, ice, leaves, debris, etc.

Flue gases will form a white plume in winter. Plume could obstruct window view.

Flue gas condensate can freeze on exterior surfaces 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 building surfaces. Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate.

	The venting system shall terminate at least 4 feet (1.2m)	NOTICE	Examine the venting system at least once
			a year.	Check all joints	and vent pipe
	below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above
			connections for tightness. Also check for
	any door, window or gravity air inlet into any building.
			corrosion	or deterioration.	Immediately
	Do not terminate the vent in a window well, stairwell, alcove,
			correct any problems observed in the
	courtyard or other recessed area.		venting system.

16

2 Venting (continued)

Masonry Chimney Installation

A masonry chimney must be properly sized for the installation of a gas fired appliance. Venting of an appliance into a cold or oversized masonry chimney can result in operational and safety problems. Exterior masonry chimneys, with one or more sides exposed to cold outdoor temperatures, are more likely to have venting problems. The temperature of the flue gases from an appliance may not be able to sufficiently heat the masonry structure of the chimney to generate proper draft. This will result in condensing of flue gases, damage the masonry flue/tile, insufficient draft and possible spillage of flue gases into an occupied living space. Carefully inspect 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 properly 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 gases. 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 condensate 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 being attached to it. Metallic liner systems (Type “B” double wall or flexible or rigid metallic liners) are recommended. Consult with local code officials to determine code requirements or the advisability of using or relining a masonry chimney.

Sidewall Venting

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 installed induced draft fan may also be used to vent the flue gases vertically if required by job site conditions. The induced draft fan must be listed by a nationally recognized test agency, be properly sized and installed per the recommendations of the induced draft fan manufacturer and meet local code requirements. Use care to ensure that the mechanically 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 specified range, the fan must be adjusted or the installation of a barometric damper in the flue may be required to properly control draft.

Installation & Service Manual

An induced draft fan MUST be interlocked into the appliance’s control circuit to start when the appliance calls for heat. The induced draft fan MUST also be equipped with a proving switch, properly interlocked into the appliance’s control circuit to prove fan operation before the main burners are allowed to fire. A vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommendations of the fan manufacturer and provide proper clearances from any combustion or ventilation openings, windows, doors or other openings into the building. All induced draft fan installations must comply with local code requirements. See FIG. 2-7 for minimum sidewall venting clearances.

Fan Assisted Venting

A Power Venter kit is available on models 90,000 - 135,000

Btu/hr, water heaters only.

TABLE 2B - VENT MATERIALS

	Kit	Input	Material
	Number	Btu / hr
	100157734	90,000	CPVC Rated
		135,000	CPVC Rated

Minimum Vent Length = 12 Equivalent Feet *

(ALL UNITS)

Maximum Vent Length = 25 Equivalent Feet * *

(ALL UNITS)

*Equivalent Feet: 90° Elbow = 5 Feet

45° Elbow = 3 Feet

	CAUTION	DO NOT use Radel or cellular (foam) core
		PVC or CPVC pipe.

NOTE: In Canada, CPVC and PVC vent pipe, fittings and cement/primer must be ULC-S636 certified.

WARNING	DO NOT insulate PVC or CPVC venting
	materials. Use of insulation will cuase
	increased vent wall temperatures, which
	could result in vent pipe failure.

Figure 2-6_CW135 with Fan Assisted Venting

17

Installation & Service Manual

2 Venting

Figure 2-7 Other than Direct Vent Terminal Clearances

Table 2C Other than Direct Vent Terminal Clearances

			Canadian Installations¹	US Installations²
	A =	Clearance above grade, veranda, porch,	12 in (30 cm)	12 in (30 cm)
		deck, or balcony
			6 in (15 cm) for appliances < 10,000 Btuh
		Clearance to window or door that may	(3 kW), 12 in (30 cm) for appliances >	4 ft (1.2 m) below or to side of opening; 1 ft
	B =		10,000 Btuh (3 kW) and < 100,000 Btuh
		be opened		(300 mm) above opening
			(30 kW), 36 in (91 cm) for appliances >
			100,000 Btuh (30 kW)
	C =	Clearance to permanently closed	*	*
		window
		Vertical clearance to ventilated soffit	*	*
	D =	located above the terminal within a
		horizontal distance of 2 ft (61 cm) from
		the center line of the terminal.
	E =	Clearance to unventilated soffit	*	*
	F =	Clearance to outside corner	*	*
	G =	Clearance to inside corner	*	*
		Clearance to each side of center line	*	*
	H =	extended above meter / regulator
		assembly

18

Installation & Service Manual

2 Venting (continued)

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

		Above a regulator within 3 ft (91 cm)	*
I =	Clearance to service regulator vent	horizontally of the vertical center line of the
	outlet	regulator vent outlet to a maximum vertical
		distance of 15 ft (4.5 m)
		6 in (15 cm) for appliances < 10,000 Btuh	4 ft (1.2 m) below or to side of opening; 1 ft
	Clearance to nonmechanical air supply	(3kW), 12 in (30 cm) for appliances >	(300 mm) above opening
J =	inlet to building or the combustion air	10,000 Btuh (3 kW) and < 100,000 Btuh
	inlet to any other appliance	(30 kW), 36 in (91 cm) for appliances >
		100,000 Btuh (30 kW)
K =	Clearance to a mechanical air supply	6 ft (1.83 m)	3 ft (91 cm) above if within 10 ft (3 m)
	inlet		horizontally
	Clearance above paved sidewalk or	7 ft (2.13 m)†	7 ft (2.13 m)
L =	paved driveway located on public
	property
M =	Clearance under veranda, porch, deck,	12 in (30 cm)‡	*
	or balcony
*	Clearance in accordance with local installation codes and the requirements of the gas supplier.
†	A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
‡	and serves both dwellings.
	Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he floor.
NOTES:
1)	In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2)	In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code

19

2 Venting

Automatic Vent Damper

This heating boiler is design certified for use with the automatic vent damper (FIG. 2-8) part number printed on the boiler’s rating plate. A vent damper is optional on heating boilers above 360,000 Btu/hr. Automatic vent dampers are not required or furnished on potable water heaters. Water heaters with inputs of 360,000 Btu/hr and less may be ordered with the vent damper as an option. A vent damper is a useful tool for saving energy when installed inside the living space where air can circulate 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.

Larger input heating boilers and water heaters will have a jumper plug installed in the terminal block to allow operation without a damper. Remove the jumper plug from the terminal block to connect an optional vent damper wire harness (water heater shown in FIG. 2-9). The jumper plug MUST be in place if an optional vent damper is not used on water heaters and larger input heating boilers.

WARNING

DANGER

Do not install the vent damper within 6" (152 mm) of combustible materials.

Install the vent damper to service only the single appliance for which it is intended. If improperly installed, a hazardous condition such as an explosion or carbon monoxide poisoning could result.

The damper position indicator must be in a visible location with access for service following installation. 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.

Installation & Service Manual

Figure 2-8_CB with Vent Damper and Vent Damper Terminal Block

VENT DAMPER

TERMINAL

BLOCK

Figure 2-9_CW with Vent Damper

VENT DAMPER

	WARNING	The vent damper must be installed directly
		on the flue outlet located on the top of
		the draft hood (see FIG. 2-8). Do not alter
		the wire harness supplied with the vent
		damper. Follow the instructions supplied
		with the vent damper.
		An appliance which is shut down or will
	CAUTION
		not operate may experience freezing due to
		convective air flow down the flue pipe
		connected to the unit. Proper freeze
		protection must be provided, see Freeze
		Protection in the Startup Section of this
		manual.

20

Installation & Service Manual

3 Gas connections

Gas Pressure Test

Gas Supply

Verify that the

appliance is

supplied with

the type gas

1. The appliance must be disconnected from the gas supply

specified on the rating plate. This appliance is orificed for

piping system during any pressure testing of that system at

operation up to

2000 feet altitude. The

appliance will be

a test pressure in excess of 1/2 PSIG (3.5kPa).

derated 4% per 1000 feet above 2000 feet elevation. Consult

2.

The appliance must be isolated from the gas supply piping

the factory for installations above 2000 feet elevation. Field

system by

closing a manual

shutoff valve during

any

conversions for operation at high altitude must be performed

pressure testing

of the gas

supply piping system

at

test

by certified personnel only. The appliance will be marked to

pressures equal to or less than 1/2 PSIG (3.5kPa).

indicate suitability for high altitude operation.

3. The appliance and its gas connection must be leak-tested

GAS SUPPLY PRESSURE: Measured

at the inlet pres-

before placing it in operation.

sure tap located upstream of the combination gas valve(s)

see FIG.’s 3-5 and 3-6, page 25.

Gas Connection

TABLE - 3A

1.

Safe operation of the appliance requires properly sized gas

GAS SUPPLY PRESSURE

supply piping.

2.

Gas pipe size may be larger than appliance gas connection.

Natural Gas

LP Gas

3.

Installation of a union is suggested for ease of service, see

Max. (Inches Water Column)

14

14

FIG. 3-1 on page 22.

4.

Install a manual

main gas

shutoff

valve,

outside

of

the

Min. (Inches Water Column)

*4.5

11

appliance gas connection and before the gas valve or

Min. (Inches Water Column)

**5.0

11

manifold connection, when local codes require.

5.

A trap (drip leg) MUST be provided by the installer in

*Models 90,000 - 360,000 Btu/hr Only

**Models 399,999 - 500,000 Btu/hr Only

the inlet of the gas connection to the appliance, see

Maximum inlet gas pressure must not exceed the value

FIG. 3-1 on page 22.

6.

The combination gas valve has an integral vent limiting

specified. Minimum value listed is for the purposes of input

adjustment.

device and does not require venting to atmosphere,

MANIFOLD PRESSURE: Measured at

the

pressure tap

outside the building.

7. Optional gas controls may require routing of bleeds and

on the downstream side of the combination

gas valve(s)

vents to the atmosphere,

outside

the building

when

(see FIG.’s 3-5 and 3-6, page 25). The gas regulator settings

required by local codes.

for single stage and two stage operation are factory set to

supply proper manifold pressure for normal operation. To

TABLE - 3C

check manifold pressure, see Manifold Adjustment Procedure.

Do not increase manifold pressure beyond specified pressure

FITTINGS TO EQUIVALENT STRAIGHT PIPE

settings shown below in Table 3B.

Diameter Pipe (inches)

TABLE - 3B

3/4

1

1 1/4

1 1/2

2

3

4

5

MANIFOLD PRESSURE

Equivalent Length of Straight Pipe (feet)

Input Gas

Single and Two-Stage

Two Stage

2

2

3

4

5

10

14

20

Full or High Fire Settings

Low Fire Settings

Btu/hr

Natural Gas

LP Gas

Natural Gas

LP Gas

TABLE - 3D

90,000 - 180,000

3.5"

10"

0.9"

2.5"

GAS CONNECTIONS

199,999

2.9"

7.5"

0.9"

2.5"

Btu/hr

Pipe Size

215,000 - 399,999

3.5"

10"

0.9"

2.5"

INPUT

90,000 - 135,000

1/2"

500,000

3.5"

10"

N/A

N/A

(two valves)

180,000 - 315,000

3/4"

360,000 - 500,000

1

21

Installation & Service Manual

3 Gas connections

TABLE - 3E

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour (based on .60 specific gravity, 0.30" w.c. pressure drop)

Pipe						Length of Pipe in Straight Feet
Size
	10	20	30	40	50	60	70	80	90		100	125	150	175	200
(Inches)
1/2	131	90	72	62	55	N/A	N/A	N/A	N/A		N/A	N/A	N/A	N/A	N/A
3/4	273	188	151	129	114	104	95	89	83		79	70	63	58	N/A
1	514	353	284	243	215	195	179	167	157		148	131	119	109	102
1 1/4	1,060	726	583	499	442	400	368	343	322		304	269	244	224	209
1 1/2	1,580	1,090	873	747	662	600	552	514	482		455	403	366	336	313
2	3,050	2,090	1,680	1,440	1,280	1,160	1,060	989	928		877	777	704	648	602
2 1/2	4,860	3,340	2,680	2,290	2,030	1,840	1,690	1,580	1,480		1,400	1,240	1,120	1,030	960
3	8,580	5,900	4,740	4,050	3,590	3,260	3,000	2,790	2,610		2,470	2,190	1,980	1,820	1,700
4	17,500	12,000	9,660	8,270	7,330	6,640	6,110	5,680	5,330		5,040	4,460	4,050	3,720	3,460

Gas Piping

GAS VALVE

GAS SHUTOFF

UNION

TRAP ( DRIP LEG )

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 manifold inlet.

4.DO NOT OVER TIGHTEN. Over tightening may result in damage to the gas valves. Valve distortion or malfunction may result if the pipe is inserted too deeply into the gas valve.

Figure 3-1_Gas Line Connection

All gas connections must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas. All piping must comply with local codes. Tubing installations must comply with approved standards and practices. Reference FIG. 3-1 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 supplier.

5.Apply a moderate amount of good quality pipe compound (DO NOT use Teflon tape) to pipe only, leaving two end threads bare.

6.Remove seal over gas valve or manifold inlet.

7.Connect pipe to gas valve or manifold inlet. Use wrench to square ends of the gas valve (FIG. 3-2).

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

22