Lochinvar NKB80N, NK110N, NK150N, NKC110N, NKC150N Installation Manual

...
Page 1
100275091_2000533998_Rev V
FIRE TUBE
Noble Fire Tube Boiler and Combi
Installation & Service Manual
NKC 110 - 199
NKB 80 - 150
WARNING
Save this manual for future reference.
This manual must only be used by a qualified heating installer / service technician. Read all instructions in this manual before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.
Page 2
Contents
HAZARD DEFINITIONS................................................................. 2
PLEASE READ BEFORE PROCEEDING .............................. 3
THE NOBLE FIRE TUBE -- HOW IT WORKS ....................... 4-5
RATINGS ............................................................................................ 6
1. DETERMINE BOILER LOCATION
Provide Clearances .............................................................................. 7
Provide Air Openings to Room ......................................................... 9
Wall Mounting Location ................................................................... 9
Residential Garage Installation .......................................................... 9
Vent and Air Piping ............................................................................ 9
Prevent Combustion Air Contamination ........................................ 9
Corrosive Contaminants and Sources ............................................ 10
Using an Existing Vent System to Install a New Boiler ............... 10
Removing a Boiler from Existing Common Vent ........................ 11
2. PREPARE BOILER
Remove Boiler from Wood Pallet ................................................... 12
Gas Conversions .......................................................................... 12-13
Mounting the Boiler .......................................................................... 13
3. GENERAL VENTING
Direct Venting Options .................................................................... 14
Install Vent and Combustion Air Piping ....................................... 15
Sizing ................................................................................................... 16
Max. Allowable Vent Piping Lengths ............................................. 16
Materials .............................................................................................. 16
Optional Room Air ............................................................................ 17
PVC/CPVC ......................................................................................... 18
Polypropylene ......................................................................................19
Stainless Steel Vent ............................................................................ 20
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall .............................................. 21-23
Determine Location ............................................................... 21-22
Prepare Wall Penetrations .......................................................... 23
Multiple Vent/Air Terminations ..................................................... 23
Sidewall Termination - Optional Concentric Vent ................ 24-26
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical ............................................... 27-28
Determine Location ..................................................................... 27
Prepare Roof Penetrations .......................................................... 28
Multiple Vent/Air Terminations ..................................................... 28
Vertical Termination - Optional Concentric Vent ................. 29-30
Alternate Vertical Concentric Venting .................................... 31-32
6A. HYDRONIC PIPING
System Water Piping Methods ........................................................ 33
Low Water Cutoff Device ................................................................. 33
Chilled Water System ........................................................................ 33
Freeze Protection ............................................................................... 33
General Piping Information ............................................................. 33
Near Boiler Piping Components ..................................................... 34
Hydronic Piping Diagrams ......................................................... 36-44
6B. DOMESTIC WATER PIPING
Scalding ............................................................................................... 45
Water Chemistry ................................................................................ 45
Near Heater Piping Components .................................................... 45
DHW Pressure Drop Chart...............................................................46
Combi Sequence of Operation .......................................................... 46
Domestic Water Piping Diagrams ............................................ 47-49
7. GAS CONNECTIONS
Connecting Gas Supply Piping ........................................................ 50
Natural Gas ......................................................................................... 51
Pipe Sizing for Natural Gas ........................................................ 51
Natural Gas Supply Pressure Requirements ............................ 51
Propane Gas ........................................................................................ 51
Pipe Sizing for Propane Gas ....................................................... 51
Propane Supply Pressure Requirements ................................... 51
Check Inlet Gas Supply ............................................................... 52-53
Gas Pressure ....................................................................................... 53
Gas Valve Replacement .................................................................... 53
8. FIELD WIRING
Line Voltage Connections ................................................................ 54
Low Voltage Connections ................................................................ 54
9. CONDENSATE DISPOSAL
Condensate Drain .............................................................................. 58
10. STARTUP ............................................................................ 59-67
11. OPERATING INFORMATION
General ................................................................................................ 68
Menus ............................................................................................. 68-69
Control Inputs and Outputs .......................................................69-71
Cascade ................................................................................................. 72
Protection Features ....................................................................... 72-73
Sequence of Operation ................................................................ 73-75
12. MAINTENANCE
Maintenance and Annual Startup ............................................. 76-81
13. TROUBLESHOOTING .................................................... 82-94
14. DIAGRAMS
Ladder Diagram (Standard)_Combi Only ..................................... 95
Wiring Diagram (Standard)_Combi Only ..................................... 96
Ladder Diagram (Standard)_Boiler Only .......................................97
Wiring Diagram (Standard)_Boiler Only .......................................98
Revision Notes .................................................................... Back Cover
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
2
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.
Page 3
Please read before proceeding
FIRE TUBE
Installation & Service Manual
WARNING
NOTICE
WARNING
WARNING
Installer – Read all instructions, in this manual before installing. Perform steps in the order given.
User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.
Have this boiler serviced/inspected by a qualified service technician, at least annually.
Failure to comply with the above could result in severe personal injury, death or substantial property damage.
When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.
Consider piping and installation when determining boiler location.
Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.
Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.
Failure to adhere to the guidelines on this page can result in severe personal injury, death, or substantial property damage.
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.
WHAT TO DO IF YOU SMELL GAS
WARNING
DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.
When servicing boiler –
• To avoid electric shock, disconnect electrical supply before performing maintenance.
• To avoid severe burns, allow boiler to cool before performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to the boiler.
• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.
• Do not use this boiler 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.
Boiler water –
• Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
• 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.
3
Page 4
FIRE TUBE
Installation & Service Manual
The Noble Fire Tube - How it works...
1. Heat exchanger
Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.
2. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.
3. Gas valve
The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.
4. Venturi
The venturi controls air and gas flow into the burner.
5. Flue gas sensor (limit rated)
This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.
6. Boiler outlet temperature sensor (limit rated)
This sensor monitors boiler outlet water temperature (system supply). The control module will adjust boiler firing rate so the outlet temperature is correct.
7. Boiler inlet temperature sensor
This sensor monitors return water temperature (system return).
8. Temperature and pressure gauge (field installed, not shown)
Monitors the outlet temperature of the boiler as well as the system water pressure.
9. Electronic LCD display
The electronic display consists of five (5) buttons, and a liquid crystal display. The display is used to make adjustments and read boiler status.
10. Flue pipe adapter
Allows for the connection of the vent pipe system to the boiler.
11. Burner (not shown)
Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.
12. Boiler water outlet
The boiler water outlet is the boiler water connection for water leaving the boiler and entering the system.
13. Domestic Hot Water (DHW) water outlet (Combi Only)
The DHW water outlet is the water connection for domestic water leaving the boiler and entering the system.
14. Boiler water inlet
The boiler water inlet is the boiler water connection for water entering the boiler from the system.
15. Domestic Hot Water (DHW) water inlet (Combi Only)
The DHW water inlet is the water connection for domestic water entering the boiler from the system.
16. Gas connection pipe
Threaded pipe connection of 1/2". This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.
17. Boiler control module
The boiler control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the demand.
18. Air intake adapter
Allows for the connection of the air intake pipe to the boiler.
19. High voltage junction box
The junction box contains the connection points for the line voltage power and all pumps.
20. Low voltage connection board
The connection board is used to connect external low voltage devices.
21. Low voltage wiring connections
Conduit connection points for the low voltage connection board.
22. Condensate drain connection
The condensate drain connection provides a connection point to install a condensate drain line.
23. Front access cover
Provides access to all internal components.
24. Ignition / flame sense electrode
Used by the control module to detect the presence of burner flame.
25. Flame inspection window
The quartz glass window provides a view of the burner surface and flame.
26. Relief valve
Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 psi on Combi models and 30 psi on Boiler models.
27. Line voltage wiring connections (inside junction box)
Conduit connection points for the high voltage junction box.
28. Air pressure switch
The air pressure switch detects blocked conditions.
29. Transformer
The transformer provides 24V power to the integrated control.
30. Pump (Combi Only)
Provides flow through the unit for space heating and domestic water applications. Serves as the boiler and DHW pump.
31. Diverter valve (Combi Only)
Diverts boiler water from the heating loop to the DHW heat exchanger.
32. DHW Flow switch (Combi Only)
The DHW flow switch detects a DHW draw and signals the boiler to fire.
33. Domestic Hot Water (DHW) sensor (Combi Only)
This sensor monitors DHW water temperature. The control module will adjust boiler firing rate so the DHW temperature is correct.
34. Condensate trap
The condensate trap is sized for a 3/4" PVC outlet connection pipe. Note: The Noble Combi trap is factory installed whereas the Noble Boiler trap is factory supplied, but field installed.
4
Page 5
FIRE TUBE
Installation & Service Manual
The Noble Fire Tube - How it works... (continued)
NOTICE
18
2
23
9
Front Outside View
The Noble Combi Boiler is shown throughout the manual unless otherwise noted.
Bottom View - Boiler Only
10
26
16
LEFT RIGHT
FRONT
19
BACK
13
12
16
DIR #2000528036
LEFT RIGHT
Bottom View - Combi Only
FRONT
21
14
12
22
21
15
14
19
DIR #2000528036 00
5
28
29
BACK
22
1
27
DIR #2000528036 00
Front Inside View
Side_Rear View
5
Page 6
Ratings
A
S
M
E
H
FIRE TUBE
Installation & Service Manual
LOW LEAD CONTENT
AHRI Rating
Model Number
Note: Change “N” to “L” for L.P. gas
models.
NKB80N 8.3 80 74 64 95.0
NK(B,C)110N 11 110 102 89 95.0
NK(B,C)150N 15 150 139 121 95.0
NK(C)199N 20 199 185 161 95.0
NOTICE
Input MBH
(Note 5)
Min
Max
Maximum allowed working pressure is located on the rating plate.
Heating
Capacity
MBH
(Note 2, 7)
Notes:
1. As an Energy Star Partner, the manufacturer has determined that Noble Fire Tubes meet the Energy Star guidelines for energy efficiency.
2. The ratings are based on standard test procedures prescribed by the United States Department of Energy.
3. 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.
4. Noble Fire Tubes require special gas venting. Use only the vent materials and methods specified in the Noble Fire Tube Installation and Service Manual.
5. Standard Noble Fire Tubes are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.
6. High altitude Noble Fire Tubes are equipped to operate from 3,000 to 9,600 feet.  e boiler will de-rate 1.7% between 5,000 to 9,600 feet. For any units installed past 9,600 feet there is an additional de-rate of 4% per 1,000 feet beyond 9,600 feet per the National Fuel Gas Code. Appliances con gured for high altitude shall not be installed below 3000 feet.
The operation given in this manual remains the same as the
standard boilers. A high altitude label (as shown in FIG. A) is also affixed to the unit.
De-rate values are based on proper combustion calibration
and
CO2’s adjusted to the recommended levels.
For installations above 9,600 feet, please consult the factory.
Net
AHRI
Ratings
Water,
MBH
(Note 3, 7)
6
AFUE
%
(Note 1, 7)
Other Specifications
SH Water
Boiler Water
Content Gallons
1.2 1" -- 1/2" 3"
1.4 1" 3/4" 1/2" 3"
2.0 1" 3/4" 1/2" 3"
2.7 1" 3/4" 1/2" 3"
Connections
NPT = Combi
Sweat = Boiler
7. Ratings have been confirmed by the Hydronics Institute, Section of AHRI.
8. The manual reset high limit provided with the Noble Fire Tube is listed to UL353.
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 9,600 FT.
Figure A High Altitude Label Location (Combi Only)
Note: Combi models approved for high altitude. Not available on Boiler models.
DHW Water Connections
Combi Only
Gas
Connections
Vent/Air
Size
(Note 4)
Page 7
1 Determine boiler location
FIRE TUBE
Installation & Service Manual
Installation must comply with:
• Local, state, provincial, and national codes, laws, regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.
NOTICE
The Noble Fire Tube gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. 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.
3. Check area around the boiler. Remove any combustible
materials, gasoline and other flammable liquids.
WARNING
4. The Noble Fire Tube must be installed so that gas control
system components are protected from dripping or spraying water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.
• Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.
6. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1A on page
10). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.
WARNING
Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.
DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.
WARNING
WARNING
This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.
Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.
This appliance requires a special venting system. The vent connection to the appliance is made of CPVC. Field supplied vent fittings must be cemented to the CPVC fitting on the boiler. Use only the vent materials, primer, and cement specified in the manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Closet and alcove installations
A closet is any room the boiler is installed in which is less than 93 cubic feet for NKC110 models, and 102 cubic feet for NKC150 - 199 models, and 69 cubic feet for NKB80 - 150 models.
An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.
Example: Room dimensions = 4 feet long, 3 feet wide, and 7 foot ceiling = 4 x 3 x 7 = 84 cubic feet. This would be considered a closet for a Noble Fire Tube.
WARNING
For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC, polypropylene or stainless steel vent material must be used inside the structure. The two ventilating air openings shown in FIG. 1-1 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" from combustible materials.
2. Vent pipe – at least 1" from combustible materials.
3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.
Clearances for service access
1. See page 9 for recommended service clearances. If you
do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.
7
Page 8
A
1 Determine boiler location
Figure 1-1 Closet Installation - Minimum Required Clearances
LEFT
0"
MINIMUM
1" MINIMUM CLEARANCE
AROUND VENT PIPE
TOP
6"
MINIMUM
6"
FIRE TUBE
Installation & Service Manual
WARNING
For closet installations, CPVC, polypropylene, or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.
VENTING* OPENING
BOTTOM
0"
MINIMUM
1/4"MINIMUM CLEARANCE
ROUND HOT WATER PIPES
FRONT
6"
MINIMUM
6"
VENTING* OPENING
DIR #2000534543 00
Figure 1-2 Alcove Installation - Minimum Required Clearances
1" MINIMUM CLEARANCE
LEFT
0"
MINIMUM
AROUND VENT PIPE
TOP
6"
MINIMUM
Minimum Clearances to Combustible
Materials
Location Clearances
From Top of the Unit 6"
From Front of the Unit 6"
From Flue or Vent Connector
in any Direction
From Back of the Unit 0"
From the Left Side of the Unit 0"
From the Right Side of the Unit 0"
Type of Floor - Combustible
Note: Service clearances are recommendations only.
WARNING
For alcove installations, CPVC, polypropylene, or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow
RIGHT 0" MINIMUM
this warning could result in fire, personal injury, or death.
1"
OPEN DOOR
BOTTOM
0"
MINIMUM
1/4"MINIMUM CLEARANCE AROUND HOT WATER PIPES
FRONT
6"
MINIMUM
DIR #2000534544 00
Note: Service clearances are recommendations only.
8
Page 9
FIRE TUBE
1 Determine boiler location (continued)
Installation & Service Manual
NOTICE
Recommended clearances for service access
- Front ............................................................................. 24"
- Left ................................................................................ 12"
- Right ............................................................................. 12"
- Bottom .......................................................................... 24"
If you do not provide the recommended service clearances shown, it may not be possible to service the boiler without removing it from the space.
Provide air openings to room:
Boiler alone in boiler room
1. No air ventilation openings into the boiler room are needed when clearances around the Noble Fire Tube are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.
Boiler in same space with other gas or oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ ventilation air openings into the space.
WARNING
2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Noble Fire Tube because it takes its combustion air from outside (direct vent installation).
The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Noble Fire Tube.
Do not install the boiler in an attic.
Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.
Wall mounting location
Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or wooden studs spaced 16" apart from center. Ensure the wall is capable of supporting at least 200 pounds.
If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.
Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves, pumps, etc.
Residential garage installation
Precautions
Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.
• The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.
Vent and air piping
The Noble Fire Tube requires a special vent system, designed for pressurized venting.
The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 3, General Venting. Note prevention of combustion air contamination below when considering vent/ air termination.
Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Noble Fire Tube using any other means.
Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in this manual.
Prevent combustion air contamination
Install air inlet piping for the Noble Fire Tube as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.
WARNING
You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.
9
Page 10
1 Determine boiler location
FIRE TUBE
Installation & Service Manual
Table 1A Corrosive Contaminants and Sources
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms
Adhesives used to fasten building products and other similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
When using an existing vent system to install a new boiler:
WARNING
Check the following venting components before installing:
• Material - For materials listed for use with this appliance, see Section 3 - General Venting.
• Size - To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.
• Manufacturer - For a polypropylene or stainless steel application, you must use only the listed manufacturers and their type product listed in Tables 3E and 3G for CAT IV positive pressure venting with flue producing condensate.
• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slip, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.
• Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3H for the manufacturer of the installed vent.
Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
10
• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.
With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 18.
WARNING
If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
Page 11
FIRE TUBE
Installation & Service Manual
1 Determine boiler location (continued)
When removing a boiler from existing common vent system:
DANGER
WARNING
At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.
a. Seal any unused openings 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, or other deficiencies, which could cause an unsafe condition.
c. Test vent system – 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 appliance 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.
Do not install the Noble Fire Tube into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.
Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. 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 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.
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 herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.
11
Page 12
2 Prepare boiler
Remove boiler from wood pallet
1. After removing the outer shipping carton from the boiler, remove the parts box.
2. To remove the boiler from the pallet:
a. Remove the two (2) lag bolts securing the
bottom of the unit to the pallet.
b. Lift the boiler off the wall bracket mounted to
the pallet (FIG. 2-1).
CAUTION
CAUTION
Figure 2-1 Boiler Mounted on Shipping Pallet
3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-4).
NOTICE
Gas conversions
WARNING
You must install a propane venturi to operate the Noble Fire Tube on propane gas. Verify when installing that the venturi label marking matches the boiler size. Refer to the Replacement Parts List for the appropriate LP Conversion Kit applicable to your unit's size and serial number.
Do not attempt to use the water pipe fittings or gas pipe to lift the boiler.
Do not attempt to lift the boiler using the gas pipe as a handle.
REMOVE SHIPPING
(WALL) BRACKET
DO NOT DISCARD.
WILL BE NEEDED TO
SECURE THE BOILER
TO THE WALL.
DIR #2000528206 00
Do not drop the boiler. Damage to the boiler can result.
For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual.
Failure to comply could result in severe personal injury, death, or substantial property damage.
FIRE TUBE
Installation & Service Manual
1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow the boiler to cool before proceeding.
2. Remove the front access cover from the unit (no tools required for removal).
3. Using a 5/16" nut driver, loosen the rachet clamp securing the air intake fitting to the venturi assembly. Slide the rubber boot off the venturi.
4. Using an adjustable wrench, loosen the union between the gas valve adapter and the venturi assembly. Remove the gasket between the gas piping and venturi (FIG. 2-2).
5. Using a 3 mm Allen wrench, remove the three (3) screws securing the venturi to the fan assembly and proceed to remove the natural gas venturi from the unit, making sure not to damage the blower O-ring gasket (FIG. 2-2).
6. Install the air shutter.
a. Disconnect the wiring from the fan and remove the
bolts securing the fan to the heat exchanger top plate.
b. Remove the fan and gasket, and install the air shutter
provided in the kit. Note: On NKC110 models, the air shutter MUST be installed in the proper direction. Install the air shutter so that the hole in the corner is oriented towards the back right corner of the unit (opposite the front door and gas piping).
c. Replace all torn or damaged gaskets. Reassemble the
fan assembly and reconnect the wiring harnesses before operation.
7. Install the propane venturi and verify the following:
a. The UP arrow on the plastic housing is pointing
upward.
b. The threaded connection for the gas piping is facing
towards the LEFT of the unit.
8. Reassemble the unit by following the previous steps in reverse order, taking care to ensure that the venturi adapter gasket is seated properly before tightening the nut on the venturi. NOTE: Replace any torn or damaged gasket(s) that may have been damaged or torn during installation.
9. After installation is complete, fill out the gas conversion label (in the conversion kit bag) and affix it to the unit to the right of the control display as shown in FIG. 2-3.
10. Replace the front access cover removed in Step 2 and resume operation.
DANGER
When removing the natural gas venturi, inspect the gasket at the gas connection and the O-ring at the blower. These gaskets must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.
12
Page 13
FIRE TUBE
Installation & Service Manual
2 Prepare boiler (continued)
WARNING
Figure 2-2 Remove Natural Gas Venturi
Figure 2-3 Gas Conversion Label Location
After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.
NATURAL GAS VENTURI
DISCONNECT GAS PIPING
AIR SHUTTER
DIR #2000534767 00
GAS CONVERSION LABEL (AFFIX TO UNIT AS SHOWN)
DIR #2000536093 00
2. Mount the wall bracket using the 2 1/4" lag bolts provided. Make sure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.
3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) additional lag bolts provided.
WARNING
The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.
Mounting to a concrete wall:
1. Mount the wall bracket using the two (2) wedge anchor bolts provided with the bracket (FIG. 2-4). To mount the wedge anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and insert anchor. Hang the bracket from the anchor and secure with the two nuts provided. Make sure the top edge of the bracket is away from the wall. Ensure bracket is level when mounted. Note: If wall thickness does not allow a 1 1/8" deep hole, field supplied hardware suitable for the application should be provided.
2. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) remaining anchors, following the instructions above.
Mounting to a metal studded wall:
1. The wall mount bracket is designed for a stud spacing of 16 inches from center (FIG. 2-4). For other stud spacing a solid mounting surface must be provided by the installer.
WARNING
Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.
2. Mount the wall bracket using two (2) field supplied toggle bolts capable of supporting 100 pounds each. Ensure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.
3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) field supplied toggle bolts.
Mounting the boiler
See page 9 of this manual for boiler mounting location instructions.
NOTICE
Mounting to a wood studded wall:
1. The wall mount bracket is designed for a stud spacing of 16 inches from center (FIG. 2-4). For other stud spacing a solid mounting surface must be provided by the installer.
WARNING
The Noble Fire Tube is not intended for floor installation.
Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.
Figure 2-4 Mounting the boiler
FASTENERS
APPROPRIATE FOR WALL TYPE
QTY: 4
WALL:
WOOD OR METAL STUDS
ON 16" CENTERS -OR­MASONRY / POURED CONCRETE
MOUNTING BRACKET
(FACTORY SUPPLIED)
DIR #2000528235 00
13
Page 14
3 General venting
Direct venting options - Sidewall Vent
FIRE TUBE
Installation & Service Manual
DIR #2000534593 00
Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details
Direct venting options - Vertical Vent
DIR #2000534592 00
Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 25 for more details
DIR #2000534588 00
Figure 3-3 Two-Pipe Vertical Termination - See page 28 for more details
14
DIR #2000534590 00
Figure 3-4 PVC/CPVC Concentric Vertical Termination - See page 30 for more details
DIR #2000534587 00
Figure 3-5 Vertical Vent, Sidewall Air
Page 15
3 General venting (continued)
Install vent and combustion air piping
FIRE TUBE
Installation & Service Manual
DANGER
WARNING
WARNING
NOTICE
WARNING
CAUTION
The Noble Fire Tube must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.
Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.
Failure to provide a properly installed vent and air system will cause severe personal injury or death.
This appliance requires a special venting system. Use only approved PVC, CPVC,
polypropylene or stainless steel pipe and fittings listed in Tables 3D, 3E, and 3G for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.
DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the
living space. Mixing of venting materials will void the warranty and certification of the appliance.
Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.
For closet and alcove installations, CPVC, polypropylene or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.
Improper installation of venting systems may result in injury or death.
The Noble Fire Tube vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.
You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Noble Fire Tube using any other means.
You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 17 of this manual. The resultant installation is direct vent (sealed combustion) .
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6)
- Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.
2. Vent Connector (FIG.'s 3-6 thru 3-10) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.
Figure 3-6 Near Boiler Air Piping
AIR
NOTICE
WARNING
Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.
Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.
DIR #2000528317 00
15
Page 16
3 General venting
FIRE TUBE
Installation & Service Manual
Sizing
The Noble Fire Tube uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.
Table 3A Air Intake/Vent Piping Sizes
Model 2" Max Vent/Air 3" Max Vent/Air
80 - 110 100 feet 100 feet
150 60 feet 100 feet
199 N/A 100 feet
NOTICE
Minimum / Maximum allowable combustion air and vent piping lengths are as follows:
Combustion Air = 7 equivalent feet minimum / 100 equivalent feet maximum
Vent = 7 equivalent feet minimum / 100 equivalent feet maximum
When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (100140480) = 49 equivalent feet of piping.
NOTICE
Table 3B Concentric Vent Kit Equivalent Vent Lengths
Model
80 - 150 100140485 3 feet 2 inch
80 - 199 100140480 3 feet 3 inch
Increasing or decreasing combustion air or vent piping sizes is not authorized unless otherwise specified in this manual.
The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.
Kit
Number
Equivalent Vent
Length
Vent
Size
WARNING
NOTICE
Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of horizontal runs.
c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.
When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.
Using air intake materials other than those specified can result in personal injury, death or property damage.
The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.
Materials
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:
PVC, CPVC, Polypropylene or ABS Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.
*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.
16
DANGER
Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.
Page 17
3 General venting (continued)
Optional room air
NOTICE
Commercial applications utilizing the Noble Fire Tube may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.
The unit MUST be installed with the appropriate room air kit (Table 3C).
• The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.
There will be a noticeable increase in the noise level during normal operation from the inlet air opening.
Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.
Vent system and terminations must comply with the standard venting instructions set forth in this manual.
Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.
FIRE TUBE
Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.
WARNING
WARNING
Installation & Service Manual
If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.
To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.
If contaminants are found, you MUST:
• Remove contaminants permanently. —OR—
• Relocate air inlet and vent terminations to other areas.
WARNING
Table 3C Optional Room Air Kit
Air contamination
Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.
When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, 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.
Model Kit Number Air Size
80 - 150 100157614 2" 80 - 199 100157615 3"
17
Page 18
3 General venting
PVC/CPVC:
This product has been approved for use with the PVC/CPVC vent materials listed in Table 3D.
Installing vent and air piping
WARNING
NOTICE
NOTICE
WARNING
WARNING
WARNING
Examples: 1. Seven (7) feet vertical
2. Connector + 90° elbow + 2 feet horizontal
3. One (1) foot vertical + 90° elbow + 1 foot horizontal
Use only the vent materials, primer, and cement specified in Table 3D to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.
Use only cleaners, primers, and solvents that are approved for the materials which are joined together.
All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).
Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
For installations using 2" vent, the first seven (7) equivalent feet of vent must be CPVC (field supplied). See examples below.
When transitioning from 2" to 3" vent diameter, a 2" pipe section and 2" to 3" increaser are required to be CPVC when PVC/CPVC vent is used.
FIRE TUBE
Installation & Service Manual
1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.
2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even cement distribution when joining.
4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)
5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.
6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth.
c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.
e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.
g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.
Figure 3-7 Near Boiler PVC/CPVC Venting
Table 3D PVC/CPVC Vent Pipe, and Fittings
Approved PVC/CPVC Vent Pipe and Fittings
Item Material Standard
PVC Schedule 40, 80 ANSI/ASTM D1785
Vent pipe
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
PVC Schedule 40 ANSI/ASTM D2466
Vent fittings
PVC Schedule 80 ANSI/ASTM D2467
CPVC Schedule 80 ANSI/ASTM F439
PVC - DWV ANSI/ASTM D2665
Pipe Cement /
Primer
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
NOTE: In Canada, CPVC and PVC vent pipe,  ttings and cement/ primer must be ULC-S636 certi ed.
18
VENT
AIR
DIR #2000528318 00
Page 19
3 General venting (continued)
FIRE TUBE
Installation & Service Manual
Polypropylene:
This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E.
All terminations must comply with listed options in this manual and be a single-wall vent offering.
For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.
When determining equivalent combustion air and vent length for polypropylene single-wall piping:
Flexible polypropylene
For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations (FIG. 3-8).
Figure 3-8 Near Boiler Flexible Polypropylene Venting
CHIMNEY
CAP
B
A
Duravent 3”
“A” DIM
3” RIGID
10 FT 20 FT 30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT
Centrotherm 3”
“A” DIM
3” RIGID
10 FT 20 FT
30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT
“B” DIM
3” FLEX
60 FT 53 FT 47 FT 40 FT 33 FT 27 FT 20 FT 13 FT
7 FT
“B” DIM
3” FLEX
45 FT 40 FT
35 FT 30 FT 25 FT 20 FT 15 FT 10 FT
5 FT
4” FLEX
90 FT 80 FT
70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT
4” FLEX
90 FT 80 FT 70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT
NOTICE
The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters.
NOTICE
All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-9).
WARNING
Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.
WARNING
Use only the adapters and vent system listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.
NOTICE
Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.
NOTICE
Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.
Figure 3-9 Near Boiler Polypropylene Venting Model 199
*NOTES: 1) FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION
2) ALL VENT LENGTHS REPRESENTED IN ABOV E CHARTS ARE EQUIVALENT LENGTHS.
3) SECTION A IS EQUIVALENT FEET OF RIGID PIPE, WHICH MAY INCLUDE 45 AND 90° ELBOWS. PLEASE SEE SIZING SECTION FOR DETERMINING EQUIVALENT FEET.
IMG00840
Table 3E Polypropylene Vent Pipe and Fittings
Approved Polypropylene Vent Manufacturers
Make Model
Centrotherm Eco Systems
Duravent (M & G Group)
PolyPro Single-Wall / PolyPro Flex
InnoFlue SW/Flex
Table 3F Approved Polypropylene Terminations and Adapters
Centrotherm InnoFlue SW Duravent Polypro
Model
80 - 199
* These parts are only needed if the alternate sidewall termination assembly is used.
Polypropylene Adapter/
Flue Clamp
Joint Connector
Sidewall Retaining
Bracket*
ISAG0303 w/IAFC03 IANS03 IATP0303 ISTAGL0303 3PPS-LB? 3PPS-HLKL?
JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM
CENTROTHERM PVC ADAPTER (SEE TABLE 3F FOR MORE DETAILS)
DIR #2000528329 00
Sidewall Adapter* Joint Connector Sidewall Kit*
19
Page 20
3 General venting
FIRE TUBE
Installation & Service Manual
Stainless steel vent:
This product has been approved for use with stainless steel using the manufacturers listed in Table 3G.
WARNING
NOTICE
NOTICE
Use only the materials, vent systems, and terminations listed in Tables 3G and 3H. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.
The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3H for approved vent adapters.
Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.
NOTICE
Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.
Figure 3-10 Near Boiler Stainless Steel Venting
VENT
UNIVERSAL ADAPTER (FACTORY SUPPLIED)
DIR #2000528338 00
Table 3G Stainless Steel Vent Pipe and Fittings
Approved Stainless Steel Vent Manufacturers
Make Model
Dura Vent (M & G Group) FasNSeal Vent / FasNSeal Flex* Vent
Z-Flex (Nova Flex Group) Z-Vent
Heat Fab (Selkirk Corporation) Saf-T Vent
*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.
Table 3H Approved Stainless Steel Terminations and Adapters
ProTech Heat Fab Z Flex
FasNSeal Saf-T Vent Z-Vent
Model
80 - 199
**Boiler
Adapter
300715
(Intake Air)
Flue
Termination
FSBS3
FSRC3(R.C)
Intake
Air
Termination
303889 --
*Boiler
Adapter
Flue
Termination
9392
5300CI
Intake
Air
Termination
9314TERM --
**Boiler
Adapter
Flue
Termination
2SVSTP03
2SVSRCX03
Intake Air
Termination
2SVSTEX0390
*The stainless steel venting option is only available in 3" vent diameters.
20
Page 21
4 Sidewall direct venting
-
FIRE TUBE
Installation & Service Manual
Vent/air termination – sidewall
WARNING
WARNING
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.
2. You must consider the surroundings when terminating
the vent and air:
a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.
Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings
FROM BOILER
VENT PIPE
CONNECTION
Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.
A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.
TO BOILER INTAKE AIR
CONNECTION
BIRD SCREEN
12” MIN
15” MAX
If using the sidewall termination:
3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1A. This arrangement avoids recirculation of flue products into the combustion air stream.
4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1A.
WARNING
Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1A. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.
When venting out a sidewall using PVC, CPVC, or Polypropylene vent materials, an optional sidewall vent termination kit can be ordered (reference Table 4A for kit numbers).
Table 4A Alternate Sidewall Vent Kit
Model
Kit
Number
Air
Size
Vent
Size
Centerline
Width
80 - 150 100157609 2" 2" 5 5/8"
80 - 199 100157610 3" 3" 5 5/8"
Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent
TO BOILER INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
POSSIBLE ORIENTATIONS
VENT / AIR
TERMINATION
GRADE OR
SNOW LINE
12"
MIN
TO OVER HANG
12"
MIN
TERMINATION
PLATE
BIRD SCREEN
GRADE OR
SNOW LINE
12”
MIN
21
Page 22
4 Sidewall direct venting
FIRE TUBE
Installation & Service Manual
Vent/air termination – sidewall
Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings
TO BOILER
INTAKE AIR
CONNECTION
FROM BOILER
VENT PIPE
CONNECTION
BIRD
SCREEN
GRADE OR
SNOW LINE
ALTERNATE VENTING ARRANGEMENT
(IF SPACE PERMITS)
Figure 4-1D Alternate Venting Arrangement - Typical Stainless Steel Sidewall Termination of Air and Vent w/ Field Supplied Fittings
TO BOILER
INTAKE AIR
CONNECTION
FROM
BOILER
VENT PIPE
CONNECTION
BIRD SCREEN
GRADE OR SNOW LINE
5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 21 and 22. Also maintain the following:
a. Vent must terminate:
• At least 6 feet from adjacent walls.
• No closer than 12 inches below roof overhang.
• At least 7 feet above any public walkway.
• At least 3 feet above any forced air intake within 10 feet.
• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches above grade or snow line; at least 12 inches below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches vertically outside the building. c. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.
6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
12" MIN
COUPLING
12” MIN
BIRD SCREEN
12”
MIN
12" MIN
Figure 4-2A Clearance to Gravity Air Inlets w/Field Supplied Fittings
12”
MIN
BIRD
SCREEN
(TYPICAL)
12”
MIN
12”
MIN
Figure 4-2B Clearance to Gravity Air Inlets using an Optional Vent Kit
12"
MIN.
VENT / AIR
TERMINATION
12"
MIN.
12"
MIN.
Figure 4-3A Clearance to Forced Air Inlets using an Optional Vent Kit
VENT / AIR
TERMINATION
7' MIN. ABOVE ANY
PUBLIC WALKWAY
IF LESS
THAN 10’
36"
MIN.
FORCED AIR
INLET
Figure 4-3B Clearance to Forced Air Inlets w/Field Supplied Fittings
IF LESS
THAN 10’
36”
MIN
FORCED AIR
INLET
BIRD
SCREEN
7’ MIN ABOVE ANY PUBLIC WALKWAY
(TYPICAL)
22
Page 23
4 Sidewall direct venting (continued)
FIRE TUBE
Installation & Service Manual
Prepare wall penetrations
1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-4A.
3. Use the sidewall termination plate as a template for
correct location of hole centers.
4. Follow all local codes for isolation of vent pipe when
passing through floors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
Figure 4-4A Sidewall Termination Assembly w/Field Supplied Fittings
ELBOW
AIR PIPING
VENT PIPING
BIRD SCREEN
Figure 4-5A Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1A)
Figure 4-5B Alternate Multiple Vent Terminations (must also comply with Figure 4-1B)
12" MIN. BETWEEN EDGE OF AIR
INLET AND ADJACENT VENT OUTLET
VENT
AIR
GALVANIZED THIMBLE
SIDEWALL TERMINATION PLATE
ELBOW
BIRD SCREEN
Multiple vent/air terminations
1. When terminating multiple boilers terminate each vent/ air connection as described in this manual (FIG. 4-5A).
WARNING
2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.
3. The air inlet of a Noble Fire Tube is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.
All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.
VENT / AIR
TERMINATION
23
Page 24
FIRE TUBE
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Description and usage
The manufacturer offers optional concentric combustion air and vent pipe termination kits (Factory Kit #100140480 - 3" or #100140485 - 2"). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-6.
The required combustion vent pipe and fittings are listed in Table 3B, on page 16 of this manual.
Figure 4-6 Concentric Sidewall Termination
3. Cut one (1) hole (5 inch diameter for #100140480 installations or 4 inch diameter for #100140485 installations) into the structure to install the termination kit.
4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.
a. Cement the Y concentric fitting to the larger kit pipe (FIG. 4-7). b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-7).
Figure 4-7 Kit Contents
Installation & Service Manual
Sidewall termination installation
1. Determine the best location for the termination kit (see FIG. 4-6).
2. Reference the Determine Location Section on page 21 of this manual for general termination considerations.
24
Page 25
FIRE TUBE
Installation & Service Manual
4 Sidewall direct venting (continued)
Sidewall termination – optional concentric vent models
Figure 4-8 Concentric Vent Dimensional Drawing
NOTICE
WARNING
WARNING
Figure 4-9 Rain Cap to Vent Pipe Alternate Assembly
Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9).
When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.
Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.
5. Install the Y concentric fitting and pipe assembly through the structure’s hole.
NOTICE
6. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting.
7. Secure the assembly to the structure as shown in FIG. 4-10 using field-supplied metal strapping or equivalent support material.
NOTICE
NOTICE
NOTICE
Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.
Ensure termination location clearance dimensions are as shown in FIG. 4-6.
If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8).
If assembly needs to be reduced, dimension D can be as short as possible.
25
Page 26
FIRE TUBE
Installation & Service Manual
4 Sidewall direct venting
Sidewall termination – optional concentric vent
Figure 4-10 Concentric Vent Sidewall Attachment
CAUTION
8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-10 for proper pipe attachment.
9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.
DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.
Multiventing sidewall terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-11). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-11. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
26
12" MINIMUM
VENT
COMBUSTION AIR
Figure 4-11 Concentric Vent and Combustion Air Termination
Page 27
5 Vertical direct venting
/
Vent/air termination – vertical
FIRE TUBE
Installation & Service Manual
WARNING
Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.
Determine location
Locate the vent/air terminations using the following guidelines:
1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.
2. Prepare the vent termination and the air termination elbow (FIG. 5-1A) by inserting bird screens.
3. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.
4. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.
5. The vent piping must terminate in an up-turned coupling as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel, above the air intake.
6. Maintain the required dimensions of the finished termination piping as shown in FIG. 5-1A.
7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.
Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” OF VENT PIPE
BIRD SCREEN (TYPICAL)
VENT
COUPLING (FIELD SUPPLIED)
VENT OUTLET 12” MINIMUM ABOVE AIR INLET
COMBUSTION
AIR
6” MINIMUM ABOVE ROOF SNOW LINE
Figure 5-1B Stainless Steel Vertical Termination of Air and Vent
ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” (610 MM) OF VENT PIPE
BIRD SCREEN
(TYPICAL)
6" (152 MM) MINIMUM
ABOVE ROOF /
SNOW LINE
VENT OUTLET
36” (914 MM) MINIMUM
ABOVE AIR INLET
VENT
COMBUSTION AIR
8. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.
WARNING
Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up, reference this section, page 28 and Section 4 - Air Intake Clearances.
27
Page 28
5 Vertical direct venting
Vent/air termination – vertical
FIRE TUBE
Installation & Service Manual
Prepare roof penetrations
1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.
2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:
• 3½ inch hole for 2 inch vent pipe
• 4½ inch hole for 3 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole.
3. Space the air and vent holes to provide the minimum
spacing shown in FIG. 5-1A, page 27.
4. Follow all local codes for isolation of vent pipe when
passing through floors, ceilings, and roofs.
5. Provide flashing and sealing boots sized for the vent pipe
and air pipe.
Figure 5-2 Vertical Terminations with Multiple Boilers
Figure 5-3 Alternate Vertical Terminations with Multiple
Boilers
Multiple vent/air terminations
1. When terminating multiple boilers, terminate each vent/
air connection as described in this manual (FIG. 5-2).
WARNING
2. Place roof penetrations to obtain minimum clearance of
12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.
3. The air inlet of a Noble Fire Tube is part of a direct vent
connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.
Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury, death, or substantial property damage.
28
Page 29
FIRE TUBE
Installation & Service Manual
5 Vertical direct venting (continued)
Vertical termination – optional concentric vent
Description and usage
The manufacturer offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.
Field supplied pipe and fittings are required to complete the installation.
The required combustion air and vent pipe fittings are listed in Table 3B, on page 16 of this manual.
Vertical termination installation
1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).
Figure 5-4 Concentric Vertical Termination
2. Cut one (1) hole (5 inch diameter for #100140480 installations or 4 inch diameter for #100140485 installations) into the structure to install the termination kit.
3. Partially assemble the concentric vent termination kit.
Clean and cement following the cleaning procedures in these instructions.
a. Cement the Y concentric fitting to the larger
diameter kit pipe (see FIG. 4-7, page 24).
b. Cement rain cap to the smaller diameter kit pipe (see
FIG. 4-7, page 24).
NOTICE
WARNING
Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9, page
25). When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.
Figure 5-5 Do Not Install U-Bend to Rain Cap
29
Page 30
FIRE TUBE
Installation & Service Manual
5 Vertical direct venting
Vertical termination – optional concentric vent
WARNING
Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.
4. Install the Y concentric fitting pipe assembly through the structure’s hole and field supplied roof boot/flashing.
NOTICE
Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.
5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.
Figure 5-6 Concentric Vent Roof Installation
CAUTION
DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.
6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting.
7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.
8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.
Multi-venting vertical terminations
When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of flue gases.
Figure 5-7 Concentric Vent and Combustion Air Vertical Termination
NOTICE
NOTICE
Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4, page 29.
If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8, page
25).
12” (18” FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24” ABOVE ROOF.
12”
MINIMUM
COMBUSTION AIR (TYPICAL)
30
Page 31
5 Vertical direct venting (continued)
A
Alternate vertical concentric venting
This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion
air routing.
Concentric Venting Arrangement
The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.
The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below.
The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.
Approved venting materials must be used as specified in Table 3D on page 18.
Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.
The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.
If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A on page 10 for a list of corrosive contaminants and sources.
Figure 5-8 Concentric Vent Example 1
AIR INLET
*For concept illustration only. Individual installations may vary
Figure 5-9 Concentric Vent Example 2
IR INLET
WITH SCREEN
FIRE TUBE
SEALED
Installation & Service Manual
12”
MIN
CAP
due to job site specific equipment.
FLUE EXHAUST
SEAL
COMBUSTION AIR
EXISTING
SEAL
DIR #2000534607 00
FLUE EXHAUST
SEAL
COMBUSTION AIR
EXISTING
SEAL
Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in FIG.’s 5-8 and 5-9.
SEALED CAP
Table 5A Alternate Vertical Concentric Vent / Chase Sizes
Model
80 - 150 2" 4"
Vent / Air
Inlet Size
Minimum Existing
Vent / Chase Size
DIR #2000534609 00
*For concept illustration only. Individual installations may vary
due to job site specific equipment.
80 - 199 3" 5"
31
Page 32
A
5 Vertical direct venting
Existing vent as a chase
Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.
Figure 5-10 Existing Vent as a Chase
FLUE EXHAUST
IR INLET
WITH SCREEN
SEALED CAP
SEAL
EXISTING
SEAL
FIRE TUBE
Installation & Service Manual
DIR #2000534613 00
*For concept illustration only. Individual installations
may vary due to job site specific equipment.
32
Page 33
6A Hydronic piping
FIRE TUBE
Installation & Service Manual
System water piping methods
The Noble Fire Tube is designed to function in a closed loop pressurized system not less than 12 psi (Non-metallic system piping must have an oxygen barrier to be considered a closed loop). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.
For boiler only models, it is important to note that the boiler has a minimal amount of pressure drop and must be figured in when sizing circulators.
Each installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.
Observe a minimum of a 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.
Low water cutoff device
On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.
Chilled water system
If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.
Freeze protection
Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.
WARNING
Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
Heating fluid and Domestic Hot Water (DHW) piping (Combi only)
The diameter of the heating fluid (hot boiler water) and for combi models only, DHW piping will depend on the model number and size of the water heater being installed.
General piping information
IMPORTANT
Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-2 through 6-10), which will guide you through the installation of the Noble Fire Tube.
1. Connect the system return marked “Boiler Inlet”.
2. Connect the system supply marked “Boiler Outlet”.
3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.
4. Install a backflow preventer on the cold feed make-up water line.
5. Install a pressure reducing valve on the cold feed make­up water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.
For boiler models only, install a circulator as shown in the
piping diagrams on the following pages in this section. Make sure the circulator is properly sized for the system and friction loss.
6. Install a system pump if necessary as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.
7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.
8. Install an air elimination device on the system supply.
9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.
10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.
11. Install a field supplied strainer to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre-existing system, a strainer/ filter capable of removing debris left in the system is recommended.
See the *piping illustrations included in this section, FIG.’s 6-2 through 6-10 for suggested guidelines in piping the Noble Fire Tube with either zone valves or circulator pumps.
NOTICE
All boiler piping must contain an oxygen barrier. This will help prevent any excess oxygen from entering the system.
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
33
Page 34
6A Hydronic piping
FIRE TUBE
Installation & Service Manual
Near boiler piping components
1. Boiler system piping:
Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance.
2. Boiler circulating pump:
On Combi units only, an integral boiler circulating pump is supplied by the factory. System piping must be sized to meet the minimum requirements in Table 6A on page 35.
For boiler only models, a field supplied boiler circulating pump must be installed. This circulator must be sized to meet the specified minimum flow requirements listed in Table 6B on page 40.
3. Boiler isolation valves:
Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
4. Check valves:
Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-2 through 6-4 and 6-7 through 6-9. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.
5. Unions:
Field supplied. Recommended for unit serviceability.
6. Temperature and pressure gauge:
Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.
7. Pressure relief valve:
Factory supplied. The pressure relief valve is sized to ASME specifications. Install the 3/4" NPT fitting on the top right side of the boiler (images in this manual show relief valve installed).
8. Boiler purge valve:
Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.
9. System temperature sensor (optional):
Factory supplied with the unit. The manufacturer offers a system temperature sensor (100157718). The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.
WARNING
10. Water Meter:
Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.
11. Indirect water heater (Boiler Only):
The Noble Fire Tube may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium.
The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.
The indirect water heater is connected to the boiler supply/return piping. A pump controlled by the Noble Fire Tube’s control will regulate the flow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the Noble boiler’s control or through a field supplied Aquastat.
The Noble Fire Tube is pre-configured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming. The DHW programming is designed to control and balance the space heating demand by switching between DHW and space heating.
Lochinvar offers the Squire which is a series of indirect water heaters. The Squire features a stainless steel vessel with a single wall stainless steel heat exchanger.
12. Y-Strainer:
Field supplied. A Y-strainer or equivalent multipurpose strainer is recommended at the inlet of the heat exchanger to remove system particles from older hydronic systems and protect newer systems.
The National Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products,
th
5
Edition.
34
Page 35
6A Hydronic piping (continued)
Figure 6-1 Pressure Drop vs. Flow_COMBI ONLY
FIRE TUBE
Installation & Service Manual
Table 6A Temperature Rise Applications_Combi Only
NKC110
Delta T GPM FT/HD Eq Ft of 1" Pipe
19.1°F 10.6 4.0 53
20°F 10.1 6.0 85 25°F 8.1 13.4 287 30°F 6.7 17.4 523 35°F 5.8 19.9 789 40°F 5.1 21.4 1085 45°F 4.5 22.5 1410
NKC199
Delta T GPM FT/HD Eq Ft of 1" Pipe
34.7°F 10.6 4.0 53
40°F 9.2 9.6 162 45°F 8.2 13.1 277
NKC150
Delta T GPM FT/HD Eq Ft of 1" Pipe
26.0°F 10.6 4.0 53
30°F 9.2 9.6 162 35°F 7.9 14.1 317 40°F 6.9 17.0 490 45°F 6.1 19.0 679
Assumed Equivalent Lengths (1" Pipe)
Fitting / Component Eq Ft
90° Elbow 2.5 45° Elbow 1.0
Tee (straight run) 0.5
Tee (side port) 4.5
Ball Valve 4.3
Swing Check 4.5
Flow Check Valve (typical) 54.0
Y-Strainer 4.5
NOTICE
NOTICE
NOTICE
All equivalent pipe lengths are based on the minimum pipe size of one inch.
The data provided takes into account the boiler and integral pump. Flow determination is based solely on piping external to the boiler.
In Primary/Secondary, only the boiler loop is considered when determining flow. In full flow applications, all piping and equipment must be considered.
35
Page 36
FIRE TUBE
6A Hydronic piping
Figure 6-2 Single Boiler - Primary / Secondary Piping_COMBI ONLY
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE GAUGE
Installation & Service Manual
MAKE UP WATER
SYSTEM SUPPLY
TO
SYSTEM
BALL VALVE
(TYPICAL)
BOILER
SENSOR
(OPTIONAL)
SYSTEM
CIRCULATOR
EXPANSION
TANK
DRAIN POINT
(TYPICAL)
AIR SEPARATOR
MAY SUBSTITUTE LOW LOSS HEADER
FROM SYSTEM
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
Y-STRAINER (RECOMMENDED)
CHECK VALVE
NOTICE
CAUTION
NOTICE
36
UNION
(TYPICAL)
TEMPERATURE /
PRESSURE GAUGE
DRAIN
DIR #2000529680
DHW piping omitted for clarity.
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Page 37
FIRE TUBE
6A Hydronic piping (continued)
Figure 6-3 Single Temperature Zoned with Circulators_COMBI ONLY
ZONE #1
Installation & Service Manual
BOILER
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP WATER
AIR SEPARATOR
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
PRESSURE
GAUGE
SYSTEM SUPPLY
SENSOR
(OPTIONAL)
ZONE #2
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
Y-STRAINER (RECOMMENDED)
CHECK VALVE
ZONE #3
ZONE #4
FLOW CHECK
VALVE
(TYPICAL)
ZONE CIRCULATORS
(TYPICAL)
NOTICE
CAUTION
NOTICE
TEMPERATURE / PRESSURE GAUGE
UNION (TYPICAL)
DIR #2000533824
DRAIN
DHW piping omitted for clarity.
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
37
Page 38
FIRE TUBE
Installation & Service Manual
6A Hydronic piping
Figure 6-4 Multiple Boilers - Single Temperature Zoned with Circulators_COMBI ONLY
Number of Units
Model
110 1 1/2" 2" 2" 2 1/2" 2 1/2" 3" 3" 150 2" 2" 2 1/2" 3" 3" 3 1/2" 3 1/2" 199 2" 2 1/2" 3" 3" 3 1/2" 4" 4"
2345678
Required Pipe Sizes
ZONE #1
BOILER 2
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP
WATER
SYSTEM SUPPLY
SENSOR
AIR SEPARATOR
BALL VALVE
(TYPICAL)
(OPTIONAL)
DRAIN POINT
(TYPICAL)
BOILER 1
TEMPERATURE / PRESSURE GAUGE
EXPANSION
TANK
ZONE #2 ZONE #3 ZONE #4
FLOW CHECK
(TYPICAL)
ZONE CIRCULATORS
MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DI A OR MAX. OF 12" APART
Y-STRAINER (RECOMMENDED) (TYPICAL)
NOTICE:
CASCADE IS FOR
SPACE HEAT ONLY.
VALVE
(TYPICAL)
NOTICE
CAUTION
NOTICE
38
TEMPERATURE / PRESSURE GAUGE
UNION (TYPICAL)
DIR #2000529699
DHW piping omitted for clarity.
Mixing valves are required for the protection of low temperature loops.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Page 39
FIRE TUBE
6A Hydronic piping (continued)
Figure 6-5 Single Temperature Piped with Air Handler_COMBI ONLY
AIR SEPARATOR
BALL VALVE
(TYPICAL)
Installation & Service Manual
HANDLER
AIR
BOILER
DRAIN POINT
(TYPICAL)
TEMPERATURE / PRESSURE GAUGE
UNION (TYPICAL)
Y-STRAINER (RECOMMENDED)
PRESSURE
REDUCING VALVE
PRESSURE
GAUGE
EXPANSION
TANK
MAKE UP WATER
PREVENTER
DIR #2000530076 00
BACKFLOW
NOTICE
NOTICE
DHW piping omitted for clarity.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
39
Page 40
6A Hydronic piping
0.000
5.000
10.000
15.000
20.000
25.000
30.000
35.000
0 2 4 6 8 10 12 14 16 18 20 22
NK080
0.000
5.000
10.000
15.000
20.000
25.000
30.000
0 2 4 6 8 10 12 14 16 18 20 22
NK110
0.000
5.000
10.000
15.000
20.000
25.000
30.000
0 2 4 6 8 10 12 14 16 18 20 22
NK150
Figure 6-6 Pressure Drop vs. Flow_BOILER ONLY
FIRE TUBE
Installation & Service Manual
Table 6B Circulator Recommendations for Temperature Rise Applications_20°, 25°, 30, and 35°_Boiler Only
Model
Minimum
Pipe Ø
20°F 25°F 30°F 35°F Maximum Flow
80 1" 7.6 gpm 4.8 ft/hd 6.1 gpm 3.3 ft/hd 5.1 gpm 2.5 ft/hd 4.3 gpm 2.0 ft/hd 17.0 gpm 21.4 ft/hd 3.0 gpm 1.0 gpm
110 1" 10.5 gpm 8.2 ft/hd 8.4 gpm 5.6 ft/hd 7.0 gpm 4.1 ft/hd 6.0 gpm 3.2 ft/hd 17.0 gpm 19.1 ft/hd 4.2 gpm 1.0 gpm
150 1" 14.3 gpm 13.2 ft/hd 11.4 gpm 8.9 ft/hd 9.5 gpm 6.5 ft/hd 8.2 gpm 5.0 ft/hd 17.0 gpm 18.3 ft/hd 5.7 gpm 1.0 gpm
Model Grunfos Speed Taco Bell & Gossett Armstrong
High 005F, 007F, 008F, 0010F-IFC,00R-MSF1-IFC NRF-22, LR-20WR Astro 30, Astro 50-3
80, 110 UPS 15-58 FC
Medium
Low 005F-(IFC), 006F-(IFC), 00R-MSF1-IFC -- Astro 20
High 0013(B)-IFC NRF-36 Sp-2,NRF-45 Sp-2 E7(B)
150 UPS 26-99 FC
NOTICE
NOTICE
40
Medium 0011(F,B)-(IFC), 0014(F,B)-(IFC)
Low -- LR-15BWR Astro 30(B)
Pump sizing and flow requirements are based on 20 feet of piping, 4 - 90° elbows, and 2 - fully ported ball valves.
The temperature rise provided by a pump/model combination will decrease by 3% per 1000 feet of elevation.
005F-(IFC), 007F-(IFC), 008F-(IFC),
0010F-IFC, 00R-IFC, 00R-MSF1-IFC
Minimum Flow
High Fire Low Fire
NRF9F/LW Astro 25, Astro 30-3
Series 100, PL-30, NRF-36
Sp-1,NRF-45 Sp-1, PR
Astro 50(B), H41
Page 41
FIRE TUBE
6A Hydronic piping (continued)
Figure 6-7 Single Boiler - Primary / Secondary Piping_BOILER ONLY
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
PRESSURE GAUGE
Installation & Service Manual
MAKE UP WATER
SYSTEM SUPPLY
TO
SYSTEM
BALL VALVE
(TYPICAL)
BOILER
SENSOR
(OPTIONAL)
SYSTEM
CIRCULATOR
EXPANSION
TANK
DRAIN POINT
(TYPICAL)
AIR SEPARATOR
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
Y-STRAINER (RECOMMENDED)
CHECK VALVE
BOILER CIRCULATOR
DOMESTIC HOT WATER
CIRCULATOR
ANTI-SCALD VALVE
FROM SYSTEM
WATER
HOT OUT
M
HC
COLD
WATER
IN
NOTICE
INDIRECT
DHW TANK
UNION
(TYPICAL)
TEMPERATURE / PRESSURE GAUGE
DRAIN
DIR #2000537249 00
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
41
Page 42
FIRE TUBE
6A Hydronic piping
Figure 6-8 Single Temperature Zoned with Circulators_BOILER ONLY
ZONE #1
Installation & Service Manual
BOILER
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP WATER
AIR SEPARATOR
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
PRESSURE
GAUGE
SYSTEM SUPPLY
SENSOR
(OPTIONAL)
ZONE #2
EXPANSION
TANK
MAY SUBSTITUTE LOW LOSS HEADER
Y-STRAINER (RECOMMENDED)
CHECK VALVE
BOILER CIRCULATOR
DOMESTIC HOT WATER
CIRCULATOR
ZONE #3
ANTI-SCALD VALVE
ZONE #4
WATER
HOT OUT
M
HC
FLOW CHECK
VALVE
(TYPICAL)
ZONE CIRCULATORS
(TYPICAL)
COLD
WATER
IN
NOTICE
CAUTION
42
TEMPERATURE / PRESSURE GAUGE
DRAIN
UNION (TYPICAL)
INDIRECT
DHW TANK
DIR #2000537254 00
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Mixing valves are required for the protection of low temperature loops.
Page 43
FIRE TUBE
Installation & Service Manual
6A Hydronic piping (continued)
Figure 6-9 Multiple Boilers - Single Temperature Zoned with Circulators_BOILER ONLY
Number of Units
Model
80 1 1/4" 1 1/2" 2" 2" 2 1/2" 2 1/2" 2 1/2" 110 1 1/2" 2" 2" 2 1/2" 2 1/2" 3" 3" 150 2" 2" 2 1/2" 3" 3" 3 1/2" 3 1/2"
2345678
Required Pipe Sizes
ZONE #1
BOILER 2
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP
WATER
SYSTEM SUPPLY
SENSOR
AIR SEPARATOR
BALL VALVE
(TYPICAL)
(OPTIONAL)
DRAIN POINT
(TYPICAL)
BOILER 1
TEMPERATURE / PRESSURE GAUGE
EXPANSION
TANK
ZONE #2 ZONE #3 ZONE #4
FLOW CHECK
ZONE CIRCULATORS
MAY SUBSTITUTE LOW LOSS HEADER
NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART
Y-STRAINER (RECOMMENDED) (TYPICAL)
BOILER CIRCULATOR
DOMESTIC HOT WATER
CIRCULATOR
ANTI-SCALD VALVE
WATER
HOT OUT
M
HC
VALVE
(TYPICAL)
(TYPICAL)
WATER
COLD
IN
NOTICE
CAUTION
INDIRECT
DHW TANK
TEMPERATURE / PRESSURE GAUGE
UNION
(TYPICAL)
DIR #2000537257 00
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Mixing valves are required for the protection of low temperature loops.
43
Page 44
6A Hydronic piping
Figure 6-10 Single Temperature Piped Full Flow_BOILER ONLY
FIRE TUBE
Installation & Service Manual
BOILER
PRESSURE
REDUCING VALVE
BACKFLOW
PREVENTER
MAKE UP WATER
AIR SEPARATOR
BALL VALVE
(TYPICAL)
DRAIN POINT
(TYPICAL)
PRESSURE
GAUGE
EXPANSION
TANK
Y-STRAINER (RECOMMENDED)
BOILER CIRCULATOR
DOMESTIC HOT WATER
CIRCULATOR
ANTI-SCALD VALVE
WATER
HOT OUT
M
HC
AIR
HANDLER
COLD
WATER
IN
NOTICE
NOTICE
44
TEMPERATURE / PRESSURE GAUGE
INDIRECT
DHW TANK
UNION (TYPICAL)
DIR #2000537261 00
Air handler shown for illustration purposes only, other heat emitters can be used.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
Page 45
FIRE TUBE
Installation & Service Manual
6B Domestic water piping (Combi Only)
Scalding
This combi heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this combi heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you MUST install an ASSE 1070 anti-scald mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.
WARNING
An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.
Water chemistry
Any damage or failure resulting from improper water chemistry, or heating anything other than potable water. DEFINITION OF POTABLE WATER - Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in Table 6D - Potable Water.
Table 6D Potable Water
Potable Water Levels
Contaminant Level
Total Hardness 200 mg/l (12 grains/gallon)
Aluminum 0.05 to 0.2 mg/l
Chloride 250 mg/l
Color 15 color units
Copper 1.0 mg/l
Corrosivity Non-corrosive
Fluoride 2.0 mg/l
Foaming Agents 0.5 mg/l
Iron 0.3 mg/l
Manganese 0.05 mg/l
Odor 3 threshold odor number
pH 6.5 - 8.5
Silver 0.1 mg/l
Sulfate 250 mg/l
Total Dissolved Solids (TDS) 500 mg/l
Zinc 5 mg/l
The following table (Table 6C) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.
Table 6C Approximate Time / Temperature Scald Chart
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
120°F More than 5 minutes
125°F 1 1/2 to 2 minutes 130°F About 30 seconds
135°F About 10 seconds 140°F Less than 5 seconds
145°F Less than 3 seconds 150°F About 1 1/2 seconds 155°F About 1 second
Near heater piping components
1. Recirculation pump (optional):
Field supplied. The recirculation pump shuts off flow at the desired DHW set point.
2. Check valves:
Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-6 through 6-8. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.
3. Domestic hot water isolation valves:
Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.
4. Anti-scald mixing valve:
Field supplied. For use when utilizing the DHW option. An ASSE 1070 anti-scald mixing valve is required.
5. Unions:
Field supplied. Recommended for unit serviceability.
6. Temperature and pressure gauge:
Field supplied. It is the responsibility of the contractor to provide and install the temperature and pressure gauge on the boiler water outlet.
7. Pressure relief valve:
Field supplied. The pressure relief valve is sized to ASME specifications.
45
Page 46
FIRE TUBE
Installation & Service Manual
6B Domestic water piping (Combi Only)
Table 6E DHW Pressure Drop Chart
DHW PRESSURE DROP
Combi Sequence of operation
 e cold domestic water enters the plate heat exchanger through the DHW inlet connection,  ow switch, and strainer. Cold water  ows through the plate heat exchanger, where it is heated by hot boiler water, and then discharged through the Domestic Hot Water (DHW) outlet connection.
Heated boiler water is supplied from the primary combustion heat exchanger through the diverter valve into the plate heat exchanger.  e boiler water heats the colder domestic water, and is then returned to the primary heat exchanger through the pump.
While operating in DHW Mode, the diverter valve prevents water from  owing through the boiler outlet connection to the heating system. Boiler water is circulated inside the unit between the plate heat exchanger and the primary combustion heat exchanger.
 e diverter valve is normally in the DHW position when the unit is in Standby, thus isolating boiler water from  owing to the heating system. When there is a space heating call, the diverter valve will move to the space heat position allowing boiler water to  ow from the primary combustion heat exchanger through the boiler outlet connection to the heating system, bypassing the plate heat exchanger.  e internal pump is used to circulate water in both Space Heating and DHW Modes.
46
Page 47
FIRE TUBE
Installation & Service Manual
6B Domestic water piping (Combi Only) (continued)
Figure 6-11 Combi DHW Piping
BOILER
EXPANSION TANK
PRESSURE
RELIEF VALVE
(REQUIRED,
FIELD SUPPLIED)
ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)
UNION
(TYPICAL)
TEMPERATURE / PRESSURE GUAGE
FLOW
CONTROL
VALVE
HOT
WATER
SUPPLY
HC
M
FLOW
CHECK
COLD
WATER
SUPPLY
NOTICE
NOTICE
WARNING
DIR #2000534676 00
Hydronic piping omitted for clarity.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.
47
Page 48
A
FIRE TUBE
Installation & Service Manual
6B Domestic water piping (Combi Only)
Figure 6-12 DHW Recirculation w/Dedicated Return
BOILER
Note: Aquastat for DHW recirculation pump or thermostatic shut off valve must be used to stop recirculation water fl ow once the desired temperature has been reached.
For best performance, Pre-Heat Mode should be enabled when using DHW recirculation.
EXPANSION TANK
QUASTAT
PRESSURE
RELIEF VALVE
(REQUIRED,
FIELD SUPPLIED)
ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)
HOT WATER
FIXTURES
UNION
(TYPICAL)
TEMPERATURE / PRESSURE GAUGE
FLOW
CONTROL
VALVE
HC
M
FLOW
CHECK
COLD
WATER
SUPPLY
RECIRCULATION
NOTICE
PUMP
Hydronic piping omitted for clarity.
DIR #2000534677 00
To prevent scalding from DHW recirculation temperature creep, a suitable method to stop recirculation
WARNING
flow once water in the loop has reached the desired temperature must be used. Failure to stop water flow once the desired DHW temperature has been reached can result in serious injury or death due to scalding.
NOTICE
WARNING
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.
48
Page 49
FIRE TUBE
Installation & Service Manual
6B Domestic water piping (Combi Only) (continued)
Figure 6-13 DHW Piping w/Recirculation Return Through Cold Line
Note: Aquastat for DHW recirculation pump or thermostatic shut off valve must be used to stop recirculation water fl ow once the desired temperature has been reached.
For best performance, Pre-Heat Mode should be enabled when using DHW recirculation.
PRESSURE
RELIEF VALVE
(REQUIRED,
FIELD SUPPLIED)
BOILER
UNION
(TYPICAL)
ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)
HC
M
EXPANSION TANK
FLOW
CHECK
NOTICE
WARNING
NOTICE
WARNING
TEMPERATURE / PRESSURE GAUGE
HOT WATER
FIXTURES
AQUASTAT
RECIRCULATION
PUMP
COLD
WATER
SUPPLY
FLOW
CONTROL
VALVE
HOT
WATER
SUPPLY
DIR #2000534675 00
Hydronic piping omitted for clarity.
To prevent scalding from DHW recirculation temperature creep, a suitable method to stop recirculation flow once water in the loop has reached the desired temperature must be used. Failure to stop water flow once the desired DHW temperature has been reached can result in serious injury or death due to scalding.
Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.
An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.
49
Page 50
7 Gas connections
Connecting gas supply piping
FIRE TUBE
Installation & Service Manual
1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler.
a. Install a field supplied sediment trap / drip leg
upstream of the boiler gas controls.
Figure 7-1 Gas Supply Piping
MANUAL SHUTOFF VALVE
UNION
GAS SUPPLY
DRIP LEG
DIR #2000528364 00
2. Support piping with hangers, not by the boiler or its accessories.
WARNING
The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.
3. Purge all air from the gas supply piping.
4. Before placing the boiler in operation, check the boiler and its gas connection for leaks.
a. Close manual main shutoff valve during any
pressure testing at more than 14 inches w.c.
b. Disconnect the boiler and gas valve from the gas
supply piping during any pressure testing greater than 14 inches w.c.
WARNING
Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.
5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.
50
Page 51
7 Gas connections (continued)
FIRE TUBE
Installation & Service Manual
WARNING
Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.
WARNING
Noble Fire Tubes are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi (see page 12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.
WARNING
Use two wrenches when tightening gas piping at boiler (FIG. 7-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.
Figure 7-2 Inlet Pipe with Backup Wrench
Natural gas:
Pipe sizing for natural gas
1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).
a. Table 7A is only for natural gas with specific gravity
0.60 inches, with a pressure drop through the gas piping of 0.3 inches w.c.
b. For additional gas pipe sizing information, refer to
ANSI Z223.1 (or B149.1 for Canadian installations).
Natural gas supply pressure requirements
1. Pressure required at the gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with boiler on.
• Minimum 4 inches w.c. with gas flowing (verify during boiler startup).
2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum.
Propane Gas:
NOTICE
USE BACK UP WRENCH
TO PREVENT PIPE FROM
ROTATING
DIR #2000528388 00
Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.
WARNING
Noble Fire Tubes are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi (see page
12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.
Pipe sizing for propane gas
1. Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.
Propane Supply Pressure Requirements
1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.
2. Pressure required at gas valve inlet pressure port:
• Maximum 14 inches w.c. with no flow (lockup) or with boiler on.
• Minimum 8 inches w.c. with gas flowing (verify during boiler startup).
WARNING
Ensure that the high gas pressure regulator is at least 6 - 10 feet upstream of the appliance.
51
Page 52
7 Gas connections
Table 7A Natural Gas Pipe Size Chart
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)
FIRE TUBE
Installation & Service Manual
Pipe
Size
(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
NOTICE
WARNING
10 20 30 40 50 60 70 80 90 100 125 150 175 200
For more details and additional sizing charts, reference the National Fuel Gas Code.
Noble Fire Tubes are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi (see page 12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.
Check inlet gas supply
NOTICE
WARNING
The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.
If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:
1. Shut OFF power at source.
CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.
DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.
Length of Pipe in Straight Feet
2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.
3. Loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG. 7-3.
4. Slowly turn on the gas supply at the field installed manual gas valve.
5. Turn ON power at source.
6. Press and hold the RIGHT and DOWN buttons simultaneously for five (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will fire at ignition speed and will then modulate up to full fire.
7. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.
8. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.
9. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 10.
10. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.
11. Exit Service Mode.
12. Turn OFF power at source.
52
Page 53
7 Gas connections (continued)
FIRE TUBE
Installation & Service Manual
13. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.
14. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap.
WARNING
When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.
Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.
15. Turn on the gas supply at the manual gas valve.
16. Turn ON power at source.
17. Adjust the temperature set point on the control panel of the boiler control module to the desired water temperature so the appliance will call for heat.
18. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.
Figure 7-3 Inlet Gas Supply Check
DETAIL A
Gas Pressure
The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Noble Fire Tube. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.
The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.
Gas valve replacement
The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances.
WARNING
WARNING
Failure to follow all precautions could result in fire, explosion, or death!
DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.
LOOSEN SET SCREW ONE (1) FULL TURN THEN PLACE TUBING
A
DIR #2000529636 00
OVER PRESSURE TAP
53
Page 54
8 Field wiring
NOTICE
WARNING
NOTICE
CAUTION
Figure 8-1 Remove Metal Junction Box Cover
HIGH VOLTAGE JUNCTION BOX
Figure 8-2A Line Voltage Field Wiring Connections_Boiler Only
Note: Boiler pump is not optional on boiler models.
For field wiring on Combi units, reference the Combi Installation and Service Manual provided with the unit.
ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.
Wiring must be N.E.C. Class 1.
If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.
Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.
DIR #2000529321 00
JUNCTION
BOX
OR
BR
PR
W
BK
G
BOX DEPICTS OPTONAL ITEMS
G
G
L GND
N
DHW PUMP
BOILER PUMP
SYSTEM PUMP
120V
SUPPLY
FIRE TUBE
Installation & Service Manual
Installation must comply with:
1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.
2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.
Line voltage connections
1. Remove the cover of the metal junction box as shown in FIG. 8-1.
2. Connect 120 vac power wiring using wire nuts (field supplied) to the labeled line voltage terminal wires in the junction box.
3. Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code.
4. Boiler Only: Wire the boiler pump as shown in FIG. 8-2A.
When connecting a Domestic Hot Water (DHW) pump,
connect the wiring as shown in FIG. 8-2A.
5. To activate a system pump, wire as shown in FIG.'s 8-2A and 8-2B. If the motor is larger than 2 amps, you must isolate with a relay.
Low voltage connections
1. Route all low voltage wires through the holes in the bottom front right side, just under the control panel, as shown in FIG. 8-3.
2. Connect low voltage wiring to low voltage connection board as shown in FIG.'s 8-4 and 8-5 on pages 56 and 57 of this manual and the boiler wiring diagram.
NOTICE
Figure 8-3 Routing Field Wiring
Do not run low voltage wires next to high voltage wires in the same conduit.
LOW VOLTAGE CONNECTION BOARD
Figure 8-2B Line Voltage Field Wiring Connections_ Combi Only
FROM
UNIT
JUNCTION
BOX
FIELD
WIRING
SYSTEM PUMP
(OPTIONAL)
DIR #2000536085 00
54
LOW VOLTAGE WIRING HOLES
DIR #2000529643 00
Page 55
8 Field wiring (continued)
FIRE TUBE
Installation & Service Manual
Thermostat (field supplied)
1. Connect the room thermostat or end switch (isolated contact only) to the room thermostat as shown in FIG.'s 8-4 and 8-5.
2. Install the thermostat on the inside wall, away from influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sunlight or fireplaces.
3. Thermostat anticipator (if applicable):
a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to match
total electrical power requirements of connected devices. See device manufacturers’ specifications and thermostat instructions for details.
Outdoor temperature sensor
In accordance with the United States Energy Policy and Conservation Act, this boiler is equipped with outdoor air reset, a feature that saves energy by reducing boiler water temperature as heating load decreases. To use this feature, the outdoor air sensor provided with the boiler must be properly installed.
1. Mount the sensor on an exterior wall, shielded from direct sunlight or flow of heat or cooling from other sources.
2. Route sensor wires through a designated wiring hole in the bottom front right side of the boiler (see FIG. 8-3).
3. Connect outdoor temperature sensor (FIG.'S 8-4 and 8-5) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Noble Fire Tube.
System supply sensor
1. By installing the system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The boiler control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point.
CAUTION
2. The 100170581 sensor provided with the boiler must be used for the system sensor.
3. Connect the system supply sensor to these terminals (FIG.'s 8-4 and 8-5).
Do not install the system supply sensor into the system return.
Wiring of the cascade
When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members.
Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop. The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG.'s 8-4 and 8-5). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.
Auxiliary limit switch
A field supplied auxiliary limit switch can be used for the gas pressure switch. When installing the auxiliary limit switch, please follow the kit instructions provided with the switch and then proceed as follows:
1. If the auxiliary switch is mounted to the exterior of the boiler, run the wires through a knockout in the bottom front right side of the boiler. If the auxiliary limit switch is mounted on the interior of the boiler, route the wires to the connection board.
2. Once the wires are inside the boiler and near the connection board, connect the wires to the auxiliary limit switch terminals.
Air handler contacts (Combi Only)
A set of un-powered contacts are available on the low voltage connection board (FIG. 8-5) that can be used to turn off the fan on an air handler when the diverter valve is in the DHW position and therefore not providing hot water to the space heating system. These contacts are normally open and will close when the diverter valve is in the space heat position.
55
Page 56
FIRE TUBE
8 Field wiring
Figure 8-4 Low Voltage Field Wiring Connections_BOILER ONLY
CUT OFF
(OPTIONAL)
LOW WATER
OUTDOOR SENSOR
SYSTEM SUPPLY SENSOR
Installation & Service Manual
FLOW SWITCH
(FIELD SUPPLIED)
COM
NO
AUXILIARY LIMIT
(FIELD SUPPLIED)
(FIELD SUPPLIED)
ROOM THERMOSTAT
56
DIR #2000537237 00
Page 57
8 Field wiring (continued)
Figure 8-5 Low Voltage Field Wiring Connections_COMBI ONLY
CUT OFF
(OPTIONAL)
LOW WATER
OUTDOOR SENSOR
SYSTEM SUPPLY SENSOR
FIRE TUBE
Installation & Service Manual
AUXILIARY LIMIT
(FIELD SUPPLIED)
(FIELD SUPPLIED)
ROOM THERMOSTAT
DIR #2000561794 00
57
Page 58
9 Condensate disposal
FIRE TUBE
Installation & Service Manual
Condensate drain
1. This boiler is a high efficiency appliance that produces condensate.
2. The bottom of the boiler has a 3/4 inch pipe for connection of a 3/4 inch PVC pipe (FIG. 9-1).
3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Noble Fire Tube will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.
A Neutralizer Kit is available from the factory.
4. Do not expose condensate line to freezing temperatures.
5. Use only plastic tubing or piping as a condensate drain line (FIG. 9-1).
NOTICE
NOTICE
6. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage.
Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.
To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.
The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.
Figure 9-1 Condensate Disposal
Note: The Noble Combi condensate trap is factory installed whereas the Noble Boiler condensate trap is factory supplied, but field installed.
58
Page 59
10 Start-up
FIRE TUBE
Installation & Service Manual
Pre-Commissioning Cleaning
1. Prior to fill and start-up, flush the entire heating system.
2. Clean the entire heating system with an approved pre­commissioning cleaner (comparable to Sentinel X300 or Fernox F3) in accordance with the manufacturer’s recommendation to remove debris and prolong the life of the heat exchanger.
3. Clean all water filtering devices in the system.
4. Flush the cleaning solution out of the entire system and refill.
Fill water
Check/control fill water chemistry
IMPORTANT
The manufacturer recommends the following for properly filling your boiler with the appropriate water chemistry for closed loop boilers. Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and corrosion in closed loop systems.
Hardness between 5 and 12 grains per gallon
1. Consult local water treatment companies for hard water areas (above 12 grains per gallon hardness).
2. Hardness levels that are above 12 grains/gallon can lead to lime scale buildup throughout the boiler system. If the fill water is below 5 grains/gallons, usually due to use of a water softener, it is recommended to mix in some potable water at the inlet to increase the hardness of the water to above 5 grains/gallons.
pH between 6.5 and 8.5
1. pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale buildup.
Total Dissolved Solids (TDS) less than 350 ppm
1. Total dissolved solids are all minerals, salts, metals, and charged particles that are dissolved in water.
2. The greater the amounts of TDS present, the higher the corrosion potential due to increased conductivity in the water.
Chlorine concentration less than 150 ppm
1. Do not fill boiler or operate with water containing chlorine in excess of 150 ppm.
2. Filling with fresh drinking water should be acceptable.
Conduct water quality testing prior to installing the appliance. Various solutions are available to adjust water quality.
Boiler water
Do not use petroleum based cleaning or
CAUTION
CAUTION
Table 10A Boiler Water Chemistry
sealing compounds in the boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.
DO NOT use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel, and/or property may result.
BOILER WATER CHEMISTRY
Speci cation Range
Dissolved Solids < 2000 ppm
pH Level 6.5 to 9.5
Chloride < 150 ppm
• Monitoring pH, chlorides, TDS, and hardness levels can prolong the life of the appliance by reducing lime scale buildup, corrosion, and erosion. Check for leaks to ensure that fresh water is not entering the system.
Continual fresh makeup water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.
The addition of oxygen carried in by makeup water can cause internal corrosion in system components.
• Leaks in the boiler or piping must be repaired at once to prevent excessive makeup water. For this purpose, it is recommended to install a water meter to easily check the amount of makeup water entering the system. Makeup water volume should not exceed 5% of the total system volume per year. NOTE: When makeup water is added, make sure the chemical additives are added to maintain the correct level.
• An approved multi-metal corrosion inhibitor (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner recommended by the manufacturer.
Freeze protection
WARNING
Ethylene glycol is toxic, DO NOT use as your freeze protection. Ethylene glycol has a sweet aroma which children and pets could mistake as food and ingest; leading to death.
3. Do not use the boiler to directly heat swimming pool or spa water.
59
Page 60
10 Start-up
FIRE TUBE
Installation & Service Manual
1. Use glycol only if needed for freeze protection.
2. Propylene glycol is the recommended freeze protection.
3. Make sure to flush the boiler system before adding glycol.
4. Determine the freeze protection fluid quantity using system water content, following the fluid manufacturer's instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.
5. Local codes may require a backflow preventer or actual
disconnect from city water supply.
6. When using freeze protection fluid with automatic fill, it is
suggested to install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing the concentration to drop, which reduces the freeze protection level.
7. The freeze protection set points may be lowered when freeze
protection fluid is used (see the Noble Service Manual).
8. Consult the glycol manufacturer for details on the suggested
mix of glycol and water for the desired freeze protection level and the de-rate effect it will have on the boiler output.
Test / replace freeze protection fluid
1. For systems using freeze protection fluids, follow the fluid
manufacturer's instructions.
2. Freeze protection fluid must be replaced periodically due to
degradation of inhibitors over time.
3. It is recommended to test the glycol concentration annually
and adjust within the desired set points.
Oxygen prevention
CAUTION
Dissolved oxygen can have a negative effect on the boiler system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion on non-stainless steel parts of the system. A low pH level combined with oxygen further enhances its corrosive effects. After boiler installation, check for air leaks in the following areas:
• Suction gasket
Pump
• Air valve
• O-ring gaskets
Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.
Fill and test water system
1. Fill system only after ensuring the water meets the requirements of this manual.
2. Close automatic and manual air vents and boiler drain valve.
3. Fill to correct system pressure. Correct pressure will vary with each application.
a. The minimum cold water fill pressure for a system is
12 psi.
b. Pressure will rise when the boiler is turned ON and
system water temperature increases.
4. At initial fill and during boiler startup and testing, check the system thoroughly for any leaks. Repair all leaks before proceeding further.
Purge air from water system
1. Purge air from system:
a. Connect a hose to the purge valve. Route the hose to
an area where water can drain and be seen.
b. Close the boiler or system isolation valve between the
purge valve and fill connection to the system.
c. Close zone isolation valves. d. Open the quick-fill valve on the cold water makeup
line.
e. Open purge valve. f. Open the isolation valves one zone at a time. Allow
water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.
g. Close the quick-fill water valve and purge valve and
remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.
h. After the system has operated for a while, eliminate
any residual air by using the manual air vents located throughout the system.
i. If purge valves are not installed in the system, open the
manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.
2. Open the automatic air vent (diaphragm-type or bladder type expansion tank systems only) one turn.
3. Open other vents:
a. Starting on the lowest floor, open air vents one at a
time until water squirts out.
b. Repeat with remaining vents.
4. Refill to correct pressure.
Precautions include installing a water meter to evaluate the fresh water volume entering the system (should be no more than 5% system volume). Additional volumes of fresh water could indicate that a leak is present.
60
Page 61
10 Start-up (continued)
FIRE TUBE
Installation & Service Manual
Check for gas leaks
WARNING
WARNING
WARNING
Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.
DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.
Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.
Check thermostat circuit(s)
1. Disconnect the external wire connected to the room thermostat terminal on the connection board.
2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.
3. There should NEVER be a voltage reading.
4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)
5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board.
Inspect condensate system
Inspect/check condensate lines and fittings
Inspect the condensate drain line, condensate PVC fittings and
condensate trap (FIG. 10-1).
Clean/Inspect Trap Assembly
Remove the clean out cap on the bottom of the trap. Let the
condensate and any debris drain out.
Figure 10-1 Condensate Trap
HOSE BARB
MOUNTING NUT
FLOAT BALL
CONDENSATE DRAIN
REMOVABLE CAP TO CLEAN OUT TRAP
DIR #2000529332 00
Note: Combi version shown for illustration purposes only.  e Noble Combi condensate trap is factory installed whereas the Noble Boiler condensate trap is factory supplied, but  eld installed.
61
Page 62
10 Start-up
FIRE TUBE
Installation & Service Manual
Final checks before starting the boiler
Read this manual to familiarize yourself with boiler
control module operation. Reference page 63 for proper steps to start boiler.
Verify the boiler and system are full of water and all
system components are correctly set for operation.
Verify the preparation procedures of Section 10, pages
59 - 61 have been completed.
Verify electrical connections are correct and securely
attached.
Inspect vent piping and air piping for signs of deterioration
from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.
Start the boiler
1. Read and follow the Operating instructions in FIG. 10-2, page 63.
If boiler does not start correctly
1. Check for loose connections, blown fuse or service switch off?
2. Is boiler water temperature above 200°F?
3. Is thermostat set below room temperature?
4. Is gas turned on at meter or boiler?
5. Is incoming gas pressure less than 4 inches w.c.?
If none of the above corrects the problem, refer to the Troubleshooting Section.
Check system and boiler
Check water piping
1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on page 61 (startup) regarding failure to repair leaks.)
2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.
Check gas piping
1. Check around the boiler for gas odor following the procedure on page 63 of this manual.
WARNING
Propane boilers – verify conversion
1. Verify propane conversion has been completed per the Propane Conversion instructions.
WARNING
WARNING
If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.
DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.
Noble Fire Tubes are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi (see page 12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.
Check vent piping and air piping
1. Check for gastight seal at every connection, seam of air piping, and vent piping.
WARNING
Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.
62
Page 63
10 Start-up (continued)
Figure 10-2 Operating Instructions
FIRE TUBE
Installation & Service Manual
Move switch to the “OFF” position.
63
Page 64
FIRE TUBE
Installation & Service Manual
10 Start-up
Noble Fire Tube control module
Use the control panel (FIG. 10-3) to set temperatures, operating conditions, and monitor boiler operation.
Figure 10-3 Control Panel
RESET BUTTON
DISPLAY
WINDOW
2
RIGHT BUTTONLEFT BUTTON
UP BUTTON
DOWN BUTTON
- Indicates that the unit has a Space Heating demand.
- Indicates that the unit has a DHW demand. Note: This icon will flash if the unit has a Pre-heat demand (if enabled). (Combi Only)
- Indicates that the boiler pump is running. The pump is integral on Combi and external on the Boiler.
- Indicates the burner is firing and a flame signal is detected.
- Indicates that the DHW pump contacts are being powered.
2
(Boiler Only)
- Indicates that the system pump contacts are being powered.
- Indicates that the unit is running in Service Mode.
- Indicates that Freeze Protection is active.
Home screen
 e Home Screen can be used to view the current operating information of the Noble Fire Tube.  e and buttons can be used to page through the screen sequence, displaying various operating statistics.
Figure 10-4 Screen Sequence
64
Page 65
10 Start-up (continued)
Setup wizard
 e Noble Fire Tube control has a Setup Wizard feature that can be used to help with the initial start-up of the unit.  is Setup Wizard will walk an installer through the most commonly required parameters.
 e Setup Wizard is automatically accessed the  rst time the unit is powered up from the factory and will allow setting of certain parameters without the need to enter the installer password. Once the Setup Wizard is completed or canceled, it can only be accessed again by going through the Installer Menu.
Figure 10-5 Installer Menu
FIRE TUBE
MAX SH SETPT
-
Installation & Service Manual
•  e MAX SH SETPT should be set to the highest space
heating water set point that can be used for the speci c space heating system.  is parameter is the upper limit of what the user can adjust the SH SETPT (COLD DAY) parameter to.  is parameter also serves as a limit of space heat set point that can be generated by the outdoor reset curve in the event that outdoor temperature falls
below the coldest day outdoor temperature setting.
• Range: 60°F – 190°F
Default: 185°F
- OUTDOOR TEMP COLDEST DAY
• When outdoor reset is used, this is the outdoor temperature used on the reset curve corresponding to the SPACE HEAT SETPT (COLDEST DAY).  is parameter should be set to the outdoor temperature used in the heat load calculation for the cold design day.
• Range: -40°F – 75°F
• Default: 10°F
Button functions in the setup wizard
/ - Change value of current parameter - Move to the next parameter or finish Setup
Wizard on last parameter - Save changes and exit the Setup Wizard. This will bypass the remaining parameters in the Wizard.
To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.
Parameters in the setup wizard
- TIME/DATE
- SPACE HEAT SETPT (COLDEST DAY)
• This is the space heating water temperature set point that will be used in Space Heating Mode. If outdoor reset is used, this parameter represents the water temperature on the reset curve corresponding to the coldest day outdoor temperature. When outdoor reset is in use, if outdoor temperature falls below the OUTDOOR TEMP COLDEST DAY parameter, space heating set point can go higher than this setting.
• Range: 68°F – MAX SH SETPT (185°F by default)
Default: 125°F
- OUTDOOR TEMP – WARM WEATHER
SHUTDOWN
• When the outdoor temperature rises above this point, the control will block all space heating demands (DHW demands will still be active). Space heating operation will resume when outdoor temperature falls 10°F below this point.
• Range: 32°F – 104°F
• Default: 70°F
- AUTO RESET HI LIMIT
• When the outlet temperature exceeds the Automatic Reset High Limit setting, automatic high limit action occurs.  e boiler shuts down until the outlet water temperature cools below 10°F under this setting and a 60 second timer has elapsed. Note that this setting applies to both SH and DHW Modes.
• Range: 32°F – 200°F
• Default: 200°F
- MAN. RESET HI LIMIT
• If the outlet temperature continues to increase a er automatic reset high limit action, the Manual Reset High Limit action occurs when the outlet water temperature exceeds this setting.  is will require a manual reset before operation can resume. Note that this setting applies to both SH and DHW Modes.
• Range: 32°F – 210°F
• Default: 210°F
65
Page 66
10 Start-up
FIRE TUBE
Installation & Service Manual
- DHW SETPT
•  is is the desired set point temperature of Domestic Hot Water (DHW) generated by the unit. Note that the required anti-scald mixing valve will likely require a setting greater than the desired DHW temperature.
• Range: 60°F – MAX DHW SETPT
• Default: 120°F
- DOMESTIC HOT WATER BOILER WATER TEMP (BOILER ONLY)
•  is is the desired temperature of the boiler water going to the indirect tank.
Range: 68°F – 190°F
• Default: 180°F
- SPACE HEAT RATE LIMITING (COMBI ONLY)
 is feature is used when the maximum space heating load is less than the maximum input rating of the unit.  is setting will limit the maximum input rate of the unit for a space heating demand only (DHW demands will not be limited).
Range: 10% – 100%
Default: 100%
 e Noble Fire Tube includes a Service Mode feature that can be used to force the unit to run at a particular  ring rate.  is feature can be used by quali ed service technicians for adjusting combustion or troubleshooting the unit.
Service Mode can be accessed by holding and buttons simultaneously for 5 seconds.
Combi Models Only: In Service Mode, the unit will operate with the diverter valve in the space heating position; therefore, zone(s) in the heating system must be actively running in order to reject the heat generated.
Figure 10-6 Service Menu
Button functions in Service Mode
- COMBI PRE-HEAT (COMBI ONLY)
 e Combi Pre-Heat function can be used to improve DHW performance and comfort by maintaining boiler water at an elevated temperature to be able to immediately serve a DHW demand. In certain applications, the Pre­ Heat function can also reduce water usage compared to not using Pre-Heat. Enabling Pre-Heat, however, can increase fuel usage as the unit will periodically  re to maintain heated water.
• Settings: ENABLED/DISABLED
• Default: ENABLED
Service mode
WARNING
Entering Service Mode will immediately cause the boiler to fire. Failure to ensure that the unit is fully assembled and installed and in safe working condition; including having properly installed venting, all air purged from the heat exchanger, and with proper water supply and flow, can result in serious injury, death, significant property damage, or destruction of the heater.
/ - Change the target fan speed in increments of 100 rpm. - Toggle between operating at high  re and low  re. - Exit Service Mode and return to the Home Screen.
Check flame and combustion
1. Turn the main power off to the boiler.
2. Remove the flue plug from the vent pipe adapter. Note: Combustion measurements will be made at this point.
Figure 10-7 Flue Plug Removal
REMOVE THE FLUE PLUG FROM THE VENT PIPE ADAPTER
DIR #2000534695 00
66
Page 67
10 Start-up (continued)
FIRE TUBE
Installation & Service Manual
3. Press the ► and ▼ buttons (simultaneously) for 5
seconds to enter Service Mode.
4. Insert the probe from a combustion analyzer into the hole on the vent adapter.
5. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference Section 13 - Troubleshooting for possible causes and corrective actions.
Table 10A Flue Products Chart
Natural Gas Propane
Goal
CO
2
Range 8.5% - 10.5% 2.3% - 5.7% 10.0% - 11% 4.1% - 5.6%
Target 9.0% 4.9% 10.5% 4.9%
O
2
CO
2
O
2
6. Once the combustion analysis is complete, exit Service Mode.
7. Turn the main power off to the boiler and replace the plug into the vent adapter.
8. Place the boiler back into normal operation.
WARNING
You must replace the flue gas plug on the universal adapter to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.
Set space heating operation
Determine controlling sensor
For space heating systems, the temperature control can be based on the outlet or if installed, the system supply sensor (factory supplied). The control will automatically switch to the system supply sensor once it is connected.
Set domestic hot water (DHW) operation
Verify DHW operation (Combi Only)
The DHW Heating Mode controls the boiler pump and the diverter valve. When the boiler control receives a DHW call for heat from the DHW flow switch, it turns on the boiler pump and puts the diverter valve in the DHW position to route boiler water through the brazed plate heat exchanger. During the call, the boiler control will modulate to maintain the DHW outlet temperature to the DHW set point.
After the DHW call for heat ends, the boiler pump continues to run for a short period of time. This pump delay is factory set to 30 seconds.
Verify DHW mode (Boiler Only)
There are two (2) modes of operation for DHW. In Normal Mode, when a DHW demand begins, the control will start the DHW pump, turn off the boiler pump (if running), and modulate to bring the outlet temperature to the DHW boiler set point. The maximum firing rate may be limited in this mode if desired.
In Zone Mode it is assumed that the indirect DHW tank is piped as a zone on the primary loop. When a DHW demand begins, the control will turn on the DHW pump output, and raise the system temperature set point to the DHW boiler set point (if higher). The boiler pump will be turned on. The system pump may be forced on, forced off, or not changed, depending on the System Pump Mode selected. In this mode, any low temperature zones (such as radiant heating) may need additional controls to limit the water temperature sent to those zones.
Set DHW boiler target temperature (Boiler Only)
When in the DHW Mode, the control will modulate to maintain the boiler outlet temperature or system supply temperature to a set point. This set point is set at the factory to 180°F. If a different set point is desired, the appropriate parameter in the control must be changed.
Verify space heat circulator operation
Note: Diverter valve used on Combi models only.
The Space Heating Mode controls the boiler pump and the diverter valve. When the boiler control receives a space heating call for heat and the boiler is not heating a DHW (Domestic Hot Water) call, and the set point is not met, it turns on the boiler pump and places the diverter valve in the space heating position. After the space heating call for heat ends, the boiler pump continues to run for a short period of time. This pump delay is factory set to 30 seconds. After this pump delay, the pump is turned off and the diverter valve is placed into the DHW position.
67
Page 68
11 Operating information
FIRE TUBE
Installation & Service Manual
General
How the boiler operates
The Noble Fire Tube uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate. The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow.
How the control module operates
The boiler control module receives inputs from boiler sensors and external devices. The control module activates and controls the blower and gas valve to regulate heat input. Switches the boiler pump on and off and controls the diverter valve as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature or system supply temperature.
Menus
CAUTION
NOTICE
Set points menu (user access)
The Set Points Menu can be accessed by pressing the button.
Figure 11-1 Set Point Menu
Before changing parameters, note the settings so that the unit can be returned to its original operating parameters.
Parameters will be automatically saved after menu timeout.
Parameters in the set points menu:
- SH SETPT (COLD DAY)
• Space heating water set point temperature, or the space heating water set point temperature when outdoor temperature is at the cold day setting if outdoor reset is used.
Range: 68°F – MAX SH SETPT
Default: 125°F
- DHW SETPT
• This is the desired set point temperature of domestic hot water generated by the unit. Note that the required anti-scald mixing valve will likely require a setting greater than the desired domestic hot water temperature.
• Range: 60°F – MAX DHW SETPT
Default: 120°F
- TEMPERATURE UNITS
• This parameter can be used to select temperature units to be displayed on the screen (°F/°C)
- AUTO RESET HI LIMIT
• When the outlet temperature exceeds the Automatic Reset High Limit setting, automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 10°F under this setting and a 60 second timer has elapsed. Note that this setting applies to both SH and DHW Modes.
• Range: 32°F – 200°F
Default: 200°F
- MAN. RESET HI LIMIT
• If the outlet temperature continues to increase after automatic reset high limit action, the Manual Reset High Limit action occurs when the outlet water temperature exceeds this setting. This will require a manual reset before operation can resume. Note that this setting applies to both SH and DHW Modes.
• Range: 32°F – 210°F
Default: 210°F
Button functions in the set points menu
/ - Change value of current parameter. - Move to the next parameter. - Save changes and exit the menu.
To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.
68
Installer menu (installer only access)
 e Installer Menu can be accessed by pressing the button and then entering the installer password.
Figure 11-2 Installer Menu
Page 69
FIRE TUBE
11 Operating information (continued)
Installation & Service Manual
Enter the installer password
To enter the installer password, use the and ▼ buttons to change the value of the  rst digit to 5, then press to move to the next digit. Repeat this process to  ll in the remaining digits and enter the password 5-3-0-9. Once the  nal digit has been entered, press the button to access the installer menu.
Entering the installer password will allow future access to the installer menu without requiring the password for up to an hour a er the last button is pressed.
Installer main menu
 e Installer Menu is arranged in a menu/sub-menu structure to help with navigation to the desired settings.  e installer
main menu gives a list of available sub-menus.
Figure 11-3 Installer Main Menu
Button functions in the installer main menu
/ - Move the cursor through the list of available sub- menus. - Access the currently selected sub-menu.
- Save changes and exit the menu.
To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.
Button functions in the installer sub-menus
/ - Change value of current parameter. - Move to next parameter or return to main menu on last parameter in the sub-menu. - Return to Main Menu or save all changes and return to Home Screen on the last parameter in the sub­ menu.
To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.
Note: Certain settings in the Installer Menu can be accessed in multiple sub-menus for ease of navigation.  e Installer Menu also contains settings that can also be found in the Set Points Menu to allow full programming of the boiler within the Installer Menu.
Parameters in the installer menu:
- GENERAL Submenu
• MAX SH SETPT – also found in OUTDOOR RESET Sub-menu
• MAX DHW SETPT
• AUTO RESET HI LIMIT – also found in Set Points Menu
• MAN. RESET HI LIMIT – also found in Set Points Menu
• SH MAX RATE LIMITING
• SH/DHW SW TIME (Boiler Only)
• DHW/SH SW TIME (Boiler Only)
• DHW BLR WATER TEMP OUTDOOR RESET Sub-menu
• SH SETPT (COLD DAY) – also found in Set Points Menu
• MAX SH SETPT – also found in GENERAL Sub-menu
• OUTDOOR TEMP COLDEST
• WARM WEATHER SHUTDOWN
SHIFT RESET
• OUTDOOR TEMP – WARM
• SH SETPT (WARM DAY)
- TIME/DATE Sub-menu
- FAULT LOG
- SETPOINTS Sub-menu – Set Points Menu duplicate
• SH SETPT (COLD DAY)
DHW SETPT
TEMPERATURE UNITS
- CASCADE Sub-menu
CASCADE ADDRESS
• CASCADE TYPE – only available if address is 0
• Boiler size settings – only available if address is 0
- ADVANCED COMBI Sub-menu (Combi Only)
• DHW RESPOND TIME (Combi Only)
• PRE-HEAT – (ENABLED/DISABLED) (Combi Only)
- DHW Submenu
• DHW BLR WATER TEMP
• DHW OPERATING MODE
- SET-UP WIZARD – Access Set-up Wizard after it has been completed.
Control inputs and outputs
Room thermostat
The room thermostat input tells the boiler to provide heat for space heating.
DHW Priority (Combi)
If a DHW call for heat is received while a Space Heating call is in progress, the control will start operating in DHW Mode to move the diverter valve to the DHW position. The control will not resume Space Heating operation until the DHW call has ended.
69
Page 70
11 Operating information
FIRE TUBE
Installation & Service Manual
DHW Priority (Boiler)
The Smart System control allows the connection of a DHW thermostat or tank sensor to the low voltage board. When a tank sensor is connected, the DHW thermostat input is ignored. The control will attempt to satisfy a DHW call before a concurrent space heating call; however, the unit will switch between SH and DHW calls according to the settings SH/DHW SW Time and DHW/SH SW Time.
Anti-cycling
After the burner turns off, the control will delay the next burner cycle for a set time period. The time delay will be bypassed if the inlet water temperature drops too far during the delay. On Combi only models, the anti-cycling delay does not apply to DHW calls for heat.
Modulation
The Noble Fire Tube is capable of modulating its firing rate from a minimum of 10% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, and various other temperature limitations.
Boiler outlet temperature sensor
The Noble Fire Tube is factory equipped with a boiler outlet temperature sensor which is also used as the limit sensor for the heater. During a space heat call for heat, the outlet temperature sensor is used to control modulation of the boiler unless a system supply sensor is field installed.
System supply temperature sensor
A factory supplied, but field installed system supply temperature sensor may be used with the Noble Fire Tube. When installed, this sensor is used to control modulation of the boiler during a space heat call for heating.
Boiler inlet temperature sensor
The Noble Fire Tube is factory equipped with a boiler inlet temperature sensor.
Combi diverter valve (Combi Only)
The Noble Fire Tube is factory equipped with a diverter valve used to route boiler water to the heating system when in the Space Heating Mode or through the brazed plate heat exchanger when in DHW Mode. This diverter valve is normally in the DHW position, thus isolating the boiler from flow in the heating system.
Boiler pump control (Combi Only)
The Noble Fire Tube is factory shipped with an internal boiler pump used to generate flow for both space heating and DHW operation. The boiler pump will run whenever the burner is firing. The boiler pump will also run during Combi Pre-Heat Mode. The boiler pump will continue to run for a short time after the burner turns off, or the Combi Pre-Heat Mode ends.
System pump control (Combi Only)
The Noble Fire Tube is capable of controlling a field supplied and installed space heating system pump. The system pump will run whenever there is a space heating call for heat. The system pump will continue to run for a short time after the end of the heat demand.
Boiler and system pump control (Boiler Only)
The boiler pump will run whenever the burner is firing, unless the DHW is programmed for Normal Mode and the boiler is heating the DHW tank. It will continue to run for a short time after the burner turns off.
The system pump will run whenever there is a space heating call for heat demand. It may be programmed to run during a DHW call for heat when the DHW is programmed for Zone Mode. It will continue to run for a short time after the end of the heat demand. The system pump can be programmed to run continuously if desired, except during outdoor shutdown and/ or a DHW call for heat.
A boiler pump is NOT supplied on boiler only models. On boiler only models the boiler pump generates flow only for space heating.
Combi DHW outlet temperature sensor (Combi Only)
The Noble Fire Tube is factory equipped with a combi DHW outlet temperature sensor. This sensor is used to control modulation of the boiler during a DHW call for heat. When this sensor is missing, limited operation in DHW Mode is possible by controlling the boiler outlet temperature to the DHW set point.
DHW flow switch (Combi Only)
The Noble Fire Tube is factory equipped with a DHW flow switch connected to the control that detects the presence of DHW water flow rates greater than 0.32 gpm. This input tells the boiler to provide heat for DHW heating.
70
Gradient limiting
If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the firing rate to its lowest setting.
SH rate limiting
The Noble Fire Tube includes an SH Rate Limiting feature that limits the maximum modulation during a space heating call.
Page 71
11 Operating information (continued)
FIRE TUBE
Installation & Service Manual
Outdoor air reset
The Noble Fire Tube uses an advanced non-linear outdoor reset curve to improve system efficiency by reducing the boiler water set point as the outdoor temperature warms up. The installer can set the reset curve by setting both the SH SETPT (COLD DAY) parameter to the water temperature required for the coldest design day outdoor temperature and the COLDEST OUTDOOR TEMP parameter to the coldest design day outdoor temperature. The installer should limit the maximum set point for the system using the MAX SH SETPT parameter. The user can adjust the SH SETPT (COLD DAY) parameter up to the MAX SH SETPT as needed to modify the reset curve. For advanced configuration, the installer can also adjust the warm day point on the curve using the installer menu, however because of the non-linear curve, these settings typically do not need to be adjusted.
With the outdoor air sensor connected, the control module will calculate the space heating demand water set point based on the programmed reset curve to automatically match the required heat load. For advanced configuration, the installer can also adjust the warm day point from the Installer Menu.
Outdoor Air Shutdown
Outdoor air shutdown speci es the outdoor air temperature at which the Space Heating demand is blocked. DHW demands will still be active. Space heating operation will resume once the outdoor temperature falls below 10°F less than the Outdoor Air Shutdown setting.
Space Heat Rate Limiting
Space Heat Rate Limiting can be used when the maximum required space heating load is lower than the maximum input rate of the unit.  is feature limits the maximum input rate during a space heating demand to help keep the unit running at lower input rates. Space Heat Rate Limiting does not a ect DHW operation.
Flame current support
To prevent nuisance shutdowns when the boiler is firing at low rates, the control will increase the firing rate when the flame signal drops too low.
Figure 11-4 Outdoor Reset Curve
MAX SH SETPT
(DEFAULT = 185°F)
CURVE MAY BE LIMITED TO A
LOWER SET POINT
SH SETPT (COLD DAY)
(DEFAULT = 125°F)
USER ADJUSTABLE
SH SETPT (WARM DAY)
(DEFAULT = 75°F)
NOT TYPICALLY ADJUSTED
TEMPERATURE
SET POINT
OUTDOOR RESET CURVE
WILL BE AUTOMATICALLY LIMITED
AT 15°F BELOW COLD DAY OUTDOOR TEMPERATURE
Combi Pre-Heat (Combi Only)
 e Noble Fire Tube includes an optional Pre-Heat feature which is intended to maintain the boiler water temperature within a pre-de ned range to improve the time it takes for the unit to supply heated DHW water.  e Pre-Heat feature can also be used to satisfy low  ow DHW demands or for heating water during DHW recirculation where  ows through the unit may be less than the setting of the  ow switch.  e Pre­Heat feature will  rst try to satisfy these demands using the integral boiler pump before  ring. Pre-heat operation will be indicated on the display by a  ashing DHW icon. When the unit  res for a Pre-Heat demand, it will immediately ramp to low  re. Pre-Heat demands will only occur when no other heating demand is present.
WATER
OUTDOOR TEMP (COLDEST) (DEFAULT = 10°F)
WARM WEATHER
SHUTDOWN
(DEFAULT = 70°F)
OUTDOOR TEMP -
WARM
(DEFAULT = 75°F)
NOT TYPICALLY ADJUSTED
DHW Respond (Combi Only)
 e Noble Fire Tube includes a DHW respond feature to help eliminate cold water sandwich issues associated with repeated DHW demands. A er any DHW demand, the unit will go into pre-purge for a pre-determined time a er post-purge has ended. If a new demand occurs during this DHW respond time, the unit will be able to immediately enter ignition, reducing the time it takes for the unit to respond to the subsequent demand. DHW respond time can be set by the installer for a duration of 0 minutes (disabled) up to 15 minutes.
71
Page 72
11 Operating information
Cascade
When multiple Noble Fire Tubes are installed, they can be wired together in a Cascade sequence. A maximum of eight (8) boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/ Lag or Efficiency Optimization control methods. Noble Fire Tubes can only control Space Heating demands in Cascade. A Noble Fire Tube in a Cascade must have its own DHW circuit, as DHW will be controlled individually.
Once the Leader receives a call for heat from a room thermostat, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve of the Leader. If the water temperature at the system supply sensor is less than the set point – 10°F, then the control will initiate a call for heat on the Cascade.
When a Noble Fire Tube in a Cascade receives a DHW call for heat, it will be taken out of the Cascade to satisfy its own DHW demand. Once its DHW demand has ended, it will be put back into the Cascade.
To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals.
Protection features
Outlet temperature, flue temperature, and temperature rise limiting
The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds 185°F, the unit will reduce the maximum fan speed. If the outlet water temperature exceeds 195°F the control will shut the unit down until it cools off.
The control module monitors the flue temperature by a sensor located in the flue exhaust. If the flue temperature exceeds 215°F the control will reduce the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.
The control module monitors the change in the temperature after the burner fires to ensure that the flue sensor is properly installed. In the event that the control module does not detect the required change in the temperature, modulation will be limited to 50% or less. Once the required flue temperature change is observed, the boiler will be allowed to modulate
above 50% on the next call for heat or after the (RESET) button is pressed.
FIRE TUBE
The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F and the minimum off time has expired.
Freeze protection
DO NOT install the boiler in a room likely to freeze.
The following integral feature of the boiler control module provides some protection for the boiler only -- not for the system.
The boiler control module provides freeze-up protection as follows:
Below an inlet temperature of 45°F, the boiler pump operates constantly.
Below an inlet temperature of 37°F, the burner fires.
• Boiler and pumps turn off if boiler water inlet temperature rises above 45°F.
NOTICE
CAUTION
CAUTION
Low voltage blocking
The blower and gas valve require a minimum amount of voltage in order to operate properly. If an ignition attempt is made when the line voltage is temporarily low (such as during a brownout), the control could enter a manual reset lockout. To prevent this, the control monitors the voltage and blocks any heat demands until the voltage returns to an acceptable level.
Monitor external limits
Connections are provided on the connection board for external limits such as a low water cutoff and AUX limit. The boiler control will shut off the burner and inhibit relighting whenever any of these external limits open.
Error logging
The control will hold the last 10 lockouts in memory. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences will be held in memory.
Installation & Service Manual
When system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust.
This feature of the boiler control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.
The Freeze Protection feature will not work if the appliance is locked out or in Shutdown Mode.
72
Page 73
FIRE TUBE
11 Operating information (continued)
Space heat temperature regulation
Operating temperature (target)
The boiler control module senses water temperature and regulates boiler firing rate to achieve a target temperature. The target temperature is calculated as described in this section under "Outdoor Reset Operation" when the outdoor sensor is connected. The maximum target temperature can be limited by the installer using the MAX SH SETPT. This temperature can be set between 32°F and 190°F. If the outdoor sensor is shorted or not properly installed, the target temperature is fixed at the SH SETPT (Cold Day).
High limit operations
The Noble Fire Tube is equipped with an adjustable automatic reset high limit and a manual reset high limit. The automatic reset high limit has a maximum set point of 200°F and the manual reset high limit has a maximum set point of 210°F.
Low water cutoff protection
1. The boiler control module uses temperature sensing of both supply and return ports of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low flow conditions.
2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available from the factory (100208652).
Installation & Service Manual
73
Page 74
11 Operating information
Sequence of operation
OPERATION DISPLAY
1. Upon a call for heat, the control turns on the appropriate pumps. The LWCO must close.
2. Once the LWCO has closed, the auxiliary limit switch must close.
FIRE TUBE
Installation & Service Manual
3. The control starts the pre-purge cycle by initiating the blower.
4. The control starts the trial for ignition by firing the spark electrode and opening the gas valve.
5. If flame is not detected after the sparking ends, the control will perform a postpurge, then start another prepurge cycle and try to light the burner again. The control will perform a total of 4 attempts before locking out.
74
Page 75
11 Operating information (continued)
Sequence of operation (continued)
OPERATION DISPLAY
6. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command.
7. Combi Models Only: If the space heating call for heat is active and the DHW flow switch starts a DHW call for heat, the diverter valve will move to the DHW position and the boiler will switch to the DHW Mode. This will divert the boiler's outlet water from the heating system to the brazed plate heat exchanger. The control will then modulate to maintain the DHW outlet temperature at the DHW set point.
Boiler Models Only: If the space heating call for heat is active,
and the tank thermostat or sensor starts a DHW call for heat, the boiler will switch to the DHW mode. If programmed for normal DHW operation (not as a zone), the DHW pump will turn on first, then the boiler pump will turn off (boiler and DHW pump operation briefly overlap to ensure flow is maintained through the unit). This will divert the boiler’s outlet water from the heating system and send it to the tank coil instead. The control will then modulate to maintain the outlet temperature to the DHW boiler set point.
FIRE TUBE
Installation & Service Manual
8. Once all calls for heat are satisfied, the control will turn off the burner. The blower will continue to run during the postpurge period.
9. Any pumps that are running will continue to run for their respective pump delay times before turning off. A 60 second anti-cycle period will start, which will delay any new space heating call for heat until it times out.
10. In Standby, ready to start a new cycle.
75
Page 76
12 Maintenance
Maintenance and annual startup
Table 12A Service and Maintenance Schedules
FIRE TUBE
Installation & Service Manual
Service technician
(see the following pages for instructions)
General:
• Address reported problems
• Inspect interior; clean and vacuum if necessary;
• Clean condensate trap
Check for leaks (water, gas, flue, condensate)
• Verify flue and air lines in good condition and sealed tight
Check system water pressure/system piping/expansion tank
• Check fill water meter
• Test boiler water. When test indicates, clean system water with approved system restorer following manufacturer’s information.
• Check control settings
Check ignition electrodes (sand off any
ANNUAL START-UP
deposits; clean and reposition)
• Check wiring and connections
Perform start-up checkout and performance verification per Section 10 of this manual.
• Flame inspection (stable, uniform)
Owner maintenance
(see the Noble Fire Tube User’s Information Manual
for instructions)
• Check boiler area
Daily
Monthly
Periodically
Check pressure/temperature gauge
• Check vent piping
• Check air piping
• Check air and vent termination screens
• Check relief valve
• Check condensate drain system
Check air vents
• Test low water cutoff (if used)
• Reset button (low water cutoff)
Flame signal (at least 10 microamps at high fire)
Clean the heat exchanger if flue temperature is more than 54°F above return water temperature.
• Inspect and clean the DHW flow switch filter and sanitary bypass filter in the Combi waterset.
If combustion or performance indicate need:
• Clean heat exchanger
Remove and clean burner using compressed air only
76
Every
6 months
End
of season
months
Check boiler piping (gas and water) for leaks
• Operate relief valve
Shut boiler down (unless boiler used for domestic hot water)
Page 77
12 Maintenance (continued)
FIRE TUBE
Installation & Service Manual
WARNING
Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.
WARNING
The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.
WARNING
Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.
Address reported problems
1. Inspect any problems reported by the owner and correct before proceeding.
Inspect boiler area
1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.
2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual.
Inspect boiler interior
1. Remove the front access cover and inspect the interior of the boiler.
2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.
Clean condensate trap
1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.
2. Replace the clean out cap and resume operation.
Figure 12-1 Condensate Trap
HOSE BARB
MOUNTING NUT
FLOAT BALL
CONDENSATE DRAIN
REMOVABLE CAP TO CLEAN OUT TRAP
DIR #2000529332 00
Note: Combi version shown for illustration purposes only.
Check all piping for leaks
WARNING
1. Inspect all water and gas piping and verify to be leak free.
2. Look for signs of leaking lines and correct any problems found.
3. Check gas line using the procedure found in Section 7 - Gas Connections.
Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in tubes, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.
Flue vent system and air piping
1. Visually inspect the entire flue gas venting system and air
piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.
2. Verify that boiler vent discharge and air intake are clean
and free of obstructions.
WARNING
Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.
Check water system
1. Verify all system components are correctly installed and operational.
2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi).
3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.
4. Inspect air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.
Check expansion tank
1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks and air eliminators.
77
Page 78
12 Maintenance
Check fill water meter
1. Check fill water meter for water usage. If the amount exceeds 5% of your system volume, you could have a leak. Have the system checked for leaks and fixed by a qualified service technician.
Test boiler water
1. Test boiler water. Reference the Noble Installation and Service Manual for guidelines. When test indicates, clean system water with approved system restorer following the manufacturer’s information.
Check boiler relief valve
1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6A - Hydronic Piping before proceeding further.
WARNING
WARNING
78
Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.
Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.
FIRE TUBE
2. After following the warning directions in this manual, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.
Installation & Service Manual
Inspect ignition / flame sense electrodes
1. Remove the ignition / flame sense electrode from the boiler heat exchanger access cover.
2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrode cannot be cleaned satisfactorily, replace the ignition/flame sense electrode with a new one.
3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.
Check ignition ground wiring
1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.
2. Verify all wiring is in good condition and securely attached.
3. Check ground continuity of wiring using continuity meter.
4. Replace ground wires if ground continuity is not satisfactory.
Check all boiler wiring
1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.
Check control settings
1. Set the boiler control module display to Parameter Mode and check all settings. Adjust settings if necessary. See Section 11 - Operating Information for adjustment procedures.
2. Check settings of external limit controls (if any) and adjust if necessary.
Perform start-up and checks
1. Start boiler and perform checks and tests specified in
Section 10 - Start-up.
2. Verify cold fill pressure is correct and that operating
pressure does not go too high.
Check burner flame
1. Inspect flame through observation window.
2. If the flame is unsatisfactory at either high fire or low fire,
turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.
3. Remove the burner, reference FIG. 12-2 (page 79).
4. When replacing the burner, ensure gasket is in good
condition and positioned correctly (FIG. 12-2).
Page 79
12 Maintenance (continued)
FIRE TUBE
Installation & Service Manual
Figure 12-2 Burner Assembly
TOP PLATE
GASKET
BURNER
DIR #2000534736 00
Check flame signal
1. At high fire the flame signal shown on the display should be at least 10 microamps.
2. A lower flame signal may indicate a fouled or damaged ignition / flame sense electrode. If cleaning the ignition/ flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the ignition / flame sense electrode.
3. See Section 13 - Troubleshooting for other procedures to deal with low flame signal.
Review with owner
1. Review the Noble Fire Tube User’s Information Manual with the owner.
2. Emphasize the need to perform the maintenance schedule specified in the Noble Fire Tube User’s Information Manual (and in this manual as well).
3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.
Handling ceramic fiber materials
REMOVAL OF COMBUSTION CHAMBER LINING
WARNING
to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite.
The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines.
Avoid breathing dust and contact with skin and eyes.
• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.
Apply enough water to the combustion chamber lining to prevent airborne dust.
Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.
Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.
NIOSH stated First Aid.
Eye: Irrigate immediately. Breathing: Fresh air.
The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted
4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.
79
Page 80
12 Maintenance
FIRE TUBE
Installation & Service Manual
Cleaning the boiler heat exchanger
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Lochinvar Combi Boiler Installation and Operation Manual.
• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.
2. Allow time for the boiler to cool to room temperature if it has been firing.
3. Remove the front access panel.
4. Disconnect the wiring and reference hose from the gas valve.
5. Disconnect the wiring from the fan assembly.
6. Disconnect the ignition cable and ground wire from the igniter.
7. Using a 3 mm Allen wrench, remove the four (4) screws securing the gas valve flange to the gas valve assembly.
8. Using a 5/16" nut driver, loosen the ratchet clamp connecting the air intake to the venturi.
9. Using a 10 mm wrench, remove the six (6) nuts securing the heat exchanger top plate to the heat exchanger.
10. Remove the heat exchanger top plate, gas valve, fan and venturi as one assembly and set aside.
WARNING
11. Remove the condensate trap from the bottom of the heat exchanger. Place a bucket underneath the condensate fitting attached to the heat exchanger for drainage.
12. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.
13. Using a clean cloth dampened with warm water, wipe out the combustion chamber. Do NOT use a metal bristled brush.
14. Rinse out debris with a low pressure water supply.
15. Allow the heat exchanger to thoroughly dry.
16. Reassemble the unit in reverse order of component removal and reinstall the condensate trap.
CAUTION
17. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 Startup of this
manual.
18. Resume operation.
The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 79. Failure to comply could result in severe personal injury.
Damaged gaskets and seals in the system can result in substantial property damage. Ensure that damaged or torn gaskets are replaced.
Cleaning the combi boiler brazed plate heat exchanger (Combi Only)
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Lochinvar Combi Boiler Installation and Operation Manual.
• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.
2. Shut off domestic water supply.
3. Isolate/disconnect the domestic water piping leading to the domestic water inlet and outlet.
4. Flush the brazed plate heat exchanger.
5. Follow the above steps in reverse order to place the boiler back into service.
6. Resume operation.
DHW flow switch filter cleaning (Combi Only)
1. Shut down boiler:
• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Lochinvar Combi Boiler Installation and Operation Manual.
2. Allow time for the boiler to cool to room temperature if it has been firing.
3. Remove the front access panel.
4. Locate the flow sensor on the DHW flow switch (as shown in FIG. 12-3 on page 81). Slide the flow sensor off the DHW flow switch.
5. Using an adjustable wrench, remove the DHW flow switch
assembly from the unit (FIG. 12-3).
6. Remove the filter from the DHW flow switch and clean
by either blowing water or air into the open end of the filter as shown in FIG. 12-4.
7. Reinstall the filter to the DHW flow switch. Reinstall the
DHW flow switch back into the unit and place the flow sensor back onto the DHW flow switch.
8. If cleaning is unsuccessful, replace the DHW flow switch
assembly.
9. Reinstall the front access panel removed in Step 3 and
resume operation.
80
Page 81
12 Maintenance (continued)
A
FIRE TUBE
Installation & Service Manual
Figure 12-3 Remove flow sensor and DHW flow switch assembly
DHW FLOW
SWITCH
ASSEMBLY
DIR #2000536540 00
REMOVE FLOW SENSOR
Figure 12-4 Clean DHW flow switch filter
5. When the unit stabilizes, begin to slowly shut off the isolation valve on the outlet piping of the boiler (see FIG. 12-5). This will begin to restrict the flow and simulate a low flow condition.
6. While slowly shutting off the isolation valve, refer to the Status Screen to watch the behavior of the boiler. This screen allows you to monitor the inlet temperature, outlet temperature, and T.
7. When the  T reaches 55˚F, the control will attempt to modulate the firing rate down to protect it from low flow conditions.
8. When the T reaches 60°F, the control module will turn off the burner. If the control module shuts down, the test was successful.
9. Completely open the isolation valve on the outlet piping of the boiler.
10. Resume operation.
Figure 12-5 Adjust outlet isolation valve
BLOW AIR OR WATER INTO THE OPEN END OF THE DHW FLOW SWITCH FILTER
DIR #2000536591 00
Test low water flow conditions
NOTICE
Test procedure
1. Place the boiler into the active position by pressing the UP button for five (5) seconds (see page 64).
2. Hold the ► button plus the ▼ button for five (5)
seconds to enter Service Mode, allowing the unit to fire up to 100% modulation.
3. Allow the unit to progress through its normal diagnostics and pre-purge programming.
4. Allow the unit to fire and operate until the temperatures stabilize. This occurs when the inlet and outlet temperatures are rising together and the Delta T ( T) is maintained.
This test is to be carried out once the Noble Fire Tube is completely piped in with adequate gas and water flow. Once the test is completed, ensure that the isolation valve is opened up to allow full water flow.
DJUST OUTLET
ISOLATION VALVE ONLY
DIR #2000528875 00
81
Page 82
13 Troubleshooting
FIRE TUBE
Installation & Service Manual
WARNING
Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage.
WARNING
Never jumper (bypass) any device except for momentary testing as outlined in the Troubleshooting chart. Severe personal injury, death, or substantial property damage can result.
Before troubleshooting:
1. Have the following items: a. Voltmeter that can check 120 vac, 24 vac, and 12 vdc. b. Continuity checker. c. Contact thermometer.
2. Check for 120 vac (minimum 102 vac to maximum
132 vac) to boiler.
3. Make sure thermostat is calling for heat and contacts
(including appropriate zone controls) are closed. Check for 24 vac between thermostat wire nuts and ground.
4. Make sure all external limit controls are installed
and operating.
Check the following:
1. Wire connectors to control module are securely
plugged in at the module and originating control.
2. Gas pressures:
• Maximum: 14 inches w.c. (natural and LP) with no flow (lockup) or with boiler on
• Minimum: 4 inches w.c. (natural), 8 inches w.c. (LP) with gas flowing (verify during boiler startup)
Check control module fuses
NOTICE
1. Turn OFF the power to the boiler at the external line switch.
2. Remove front door/cover.
3. Remove the control module cover.
4. Inspect fuses F1, F2, and F3, see FIG 13-1 below.
Figure 13-1 Control Module Fuses
F3 - 0.8 AMP FUSE
24V DC POWER SUPPLY
F1 - 6.3 AMP FUSE
F2 - 3.15 AMP FUSE
5. The boiler is shipped with three (3) spare fuses in a plastic bag provided with the unit.
6. If necessary, replace open fuse (F3 is .80 amps, F2 is 3.15 amps, and F1 is 6.3 amps).
Note: Fuses F1, F2 and F3 are all slow blow fuses.
WARNING
7. Install control module cover and front door/cover after fuse inspection.
8. Restore power to the boiler at the external line switch and verify boiler operation (Section 10 - Start-up) after completing boiler service.
ALWAYS check control module fuses before replacing control module or any major components (blower, etc.). If one of these fuses is blown, it can prevent the control module or other components from operating.
PUMPS
BLOWER
IMG00260
Do not jumper fuse or replace with any fuse except as specified. Failure to comply could result in severe personal injury, death, or substantial property damage.
82
Page 83
FIRE TUBE
Installation & Service Manual
13 Troubleshooting (continued)
Checking temperature sensors
The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor
It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing. These devices are designated as S1a/S1b, outlet sensor and S3a/S3b, flue sensor. Please reference the wiring diagram in Section 14 of this manual for correct terminal location.
Table 13-1A - Inlet Water/System / DHW Sensor (Combi Only) Resistance vs. Temperature
Temperature Resistance Temperature Resistance
50 18,780 158 1,990
68 12,263 176 1,458
86 8,194 194 1,084
104 5,592 212 817
122 3,893
140 2,760
Table 13-1C - Outlet Water Sensor Resistance vs. Temperature
S1a
(Wire Color - R/BK and Y)
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
50 19,553 158 2,004 50 40,030 158 3,478
68 12,690 176 1,464 68 25,030 176 2,492
86 8,406 194 1,084 86 16,090 194 1,816 104 5,715 212 816 104 10,610 212 1,344 122 3,958 122 7,166 140 2,786 140 4,943
Table 13-1B - Outdoor Air Sensor Resistance vs. Temperature
Temperature Resistance Temperature Resistance
-50 490,813 20 46,218
-40 336,606 30 34,558
-30 234,196 40 26,099
-20 165,180 50 19,900
-10 118,018 60 15,311 0 85,362 70 11,883
10 62,465 80 9,299
S1b
(Wire Color - G and Y)
Table 13-1D - Flue Sensor Resistance vs. Temperature
S3a
(Wire Color - W/B and Y)
Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance
50 40,030 158 3,478 50 258,500 158 16,870
68 25,030 176 2,492 68 125,500 176 12,000
86 16,090 194 1,816 86 80,220 194 8,674 104 10,610 212 1,344 104 52,590 212 6,369 122 7,166 122 35,270 140 4,943 140 24,160
(Wire Color - PR and Y)
S3b
83
Page 84
FIRE TUBE
Installation & Service Manual
13 Troubleshooting
Table 13-2 Troubleshooting Chart - Noisy System
FAULT CAUSE CORRECTIVE ACTION
NOISY
OPERATION
NO PUMP
OPERATION -
BOILER / DHW
PUMP
Supply gas problem. Natural gas pressures should be between 4 inches w.c. and 14 inches w.c. LP gas pressures should be between 8 inches w.c. and 14 inches w.c.
Gas/air mixture problem.
Dirty/damaged burner. • Refer to page 79 in this manual for the burner removal
Low water flow through the heat exchanger. • Refer to Section 6A - Hydronic Piping for minimum
Air in the piping system. • Properly purge all air from the piping system.
Low system water pressure. • Verify system pressure is a minimum of 12 psi.
Blown fuse.
• Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.
• Refer to the Gas Valve Adjustment Procedure on page 93 of this manual for the proper gas valve setting. Verify that the vent/air intake lengths do not exceed the maximum listed in Section 3 - General Venting.
and inspection procedure. Clean or replace the burner door assembly as necessary.
flow rates. Verify that the boiler and system pump are running on a call for heat.
• Replace fuse F1 on the control board, see page 82 of this manual.
Note: Make sure pump amperage does not exceed
1.8 amps.
RELIEF VALVE
OPENING
84
Faulty pump.
Internal fault on control board.
-System pressure exceeds relief valve setting.
• Replace pump.
• Replace main control board.
• Lower the system pressure below the 30 psi rating of the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger.
• Improperly sized expansion tank.
Page 85
FIRE TUBE
Installation & Service Manual
13 Troubleshooting (continued)
Table 13-3 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT DESCRIPTION CORRECTIVE ACTION
MEMORY
ERROR
FAN SPEED
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
LWCO
(will require a manual
reset once condition has
been corrected. Press
the RESET button on the
SMART SYSTEM display
to reset.)
The control module has detected parameter settings that are corrupted.
The actual fan RPM is outside of the tolerance of the fan speed RPM target.
Blown fuse.
The low water cutoff (LWCO) is not making.
Blown fuse.
• Replace control module.
• Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting for proper lengths.
• Check for obstruction or blockage in the vent/air intake pipes or at terminations.
• Check the wiring connections at the fan and at the main control board.
• Replace the fan.
• Replace the main control board.
• Replace fuse F2 on the control board, see page 82 of this manual.
• Check boiler pump operation on a call for heat.
• Check for closed valves or obstructions in the boiler piping.
• Verify system is full of water and all air has been purged from the system.
• Check for a loose or misplaced jumper across terminals 11 and 12.
• Replace LWCO.
• Replace fuse F3 on the control board, see page 82 of this manual.
FLAME SEQUENCE
(will require a manual
reset once the condition
has been corrected. Press
the RESET button on the
display to reset.)
The flame detector circuit is seeing a flame signal when the gas valve is OFF.
• Verify flame is not present. If present, turn off gas supply and replace gas valve.
• Check supply voltage for proper polarity.
• Check external wiring for voltage feedback.
• Check the flame rod and make sure it is clean.
• Check the internal wiring for bad connections.
• Replace main control board.
85
Page 86
FIRE TUBE
Installation & Service Manual
13 Troubleshooting
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT DESCRIPTION CORRECTIVE ACTION
• Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference Section 11 - Operating Information for adjusting procedures.
• Verify that the system is full of water and that all air has been properly purged from the system.
• Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping for the proper piping methods for the Lochinvar Combi Boiler.
• Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.
• Replace the main control board if necessary.
• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.
• If operating on something other than an outlet sensor, check temperature setting of the main control board.
• If the optional manual reset high limit has tripped, check setting of the device.
• Check resistance of water sensors and compare to Table 13-1A on page 83 of this manual. Replace sensor if necessary.
• Check operation of diverter valve motor. Replace if necessary.
OUTLET ARHL
The outlet water temperature has exceeded the setting of the automatic reset high limit.
AIR PRESSURE
SWITCH
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
AUX LIMIT FAULT
86
Air pressure switch contacts are open.
Aux limit device open.
• Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals.
• Air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting for proper lengths.
• Check for obstruction or blockage in the air intake pipes or at terminations.
• Check reference hoses connected to the air pressure switch for blockage or obstruction.
• Inspect the burner. Reference page 79 of this manual for removal and cleaning procedures. Replace if necessary.
• Inspect the heat exchanger. Reference page 80 of this manual for removal and cleaning procedures.
• Faulty air pressure switch. Replace switch.
• Check wiring to aux limit device.
• Check aux limit device.
Page 87
FIRE TUBE
Installation & Service Manual
13 Troubleshooting (continued)
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT DESCRIPTION CORRECTIVE ACTION
• Inspect spark electrode and associated wiring for damage and connection. Reference page 78 of this manual for removal and cleaning procedures. Replace if necessary.
• Check for proper electrical grounding of the unit.
FLAME FAIL:
RUNNING
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
FLAME FAIL:
IGNITION
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
The unit has lost flame signal four (4) times during a call for heat.
The unit has failed to prove main burner ignition after several attempts.
• Check incoming supply gas pressure. Natural gas pressures should be between 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.
• Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged.
• Verify that the vent/air intake pipes are correctly installed and that there are no obstructions.
• Check for 24 vac to the gas valve at the 2-pin connection on the side of the main control board during the ignition attempt. If no voltage is present, replace the main control board.
• If 24 vac is present at the main control board, check the wiring between the main control board and the gas valve. Replace the wiring if necessary. Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point. The main control board can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail fault.
• If 24 vac is present, check the outlet of the valve to ensure the valve is flowing gas. With a manometer connected to the outlet tap of the gas valve, when the unit is in the prepurge period, there should be a negative pressure present. When the valve is energized a change in pressure should occur. If the pressure change does not occur, the gas valve is not opening. Replace the gas valve.
• Inspect flame sensor and associated wiring. Reference page 78 of this manual for removal and cleaning procedures. Replace if necessary.
• Inspect and clean the heat exchanger as necessary. Reference page 80 of this manual for cleaning procedures.
• Inspect the burner. Reference page 79 of this manual for removal and cleaning procedures. Replace if necessary.
• Replace the main control board.
87
Page 88
FIRE TUBE
Installation & Service Manual
13 Troubleshooting
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT DESCRIPTION CORRECTIVE ACTION
FLUE TEMP LIMIT
FLUE TEMP HIGH
OUTLET MRHL
(will require a manual
reset once the condition
has been corrected.
Press the RESET button on the
display to reset.)
OUTLET TEMP
HIGH
The stack temperature has exceeded the Flue Temp Limit set parameters.
The stack temperature has exceeded the set parameters for the boiler.
The outlet water temperature has exceeded the setting of the manual reset high limit.
Outlet water temperature has exceeded the maximum outlet water temperature.
• Inspect the heat exchanger. Reference page 80 of this manual for the procedure on how to clean the flue side of the heat exchanger.
• Inspect the flue sensor and associated wiring. Measure the resistance of the flue sensor and compare to Table 13-1D on page 83 of this manual. Replace the sensor if necessary.
• Verify that the vent/air intake pipes are properly installed and that there are no obstructions.
• Replace the main control board.
• Verify that the system is full of water and that all air has been properly purged from the system.
• Verify that the boiler is piped properly into the heating system. Refer to Section 6A - Hydronic Piping for the proper piping methods for the Lochinvar Combi Boiler.
• Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.
• Replace the main control board if necessary.
• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.
• If operating on something other than an outlet sensor, check temperature setting of the main control board.
• Check resistance of water sensors and compare to Table 13-1A on page 83 of this manual. Replace sensor if necessary.
OUTLET TEMP
DIFF
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
FLUE SENSOR
FAULT
(will require a manual
reset once the condition
has been corrected.
Press the RESET button
on the display to reset.)
88
The temperature difference between the two (2) outlet sensors is too high.
One or both of the flue sensors is open or shorted.
• Check operation of diverter valve motor. Replace if necessary.
• Check wiring to sensor. Make sure wiring is connected and not damaged. Reconnect / repair wiring if necessary.
• Measure the resistance of the sensor and compare to the resistance in Table 13-1C on page 83 of this manual. Replace sensor if necessary.
• Replace control module.
• Inspect the flue sensor and associated wiring. Measure the resistance of the flue sensor and compare to Table 13-1D on page 83 of this manual. Replace the sensor if necessary.
• Replace the main control board.
Page 89
FIRE TUBE
Installation & Service Manual
13 Troubleshooting (continued)
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT DESCRIPTION CORRECTIVE ACTION
OUTLET SENSOR
FAULT
(will require a manual
reset once the condition
has been corrected.
Press the RESET
button on the display to
reset.)
INLET SENSOR
FAULT
(will require a manual
reset once the condition
has been corrected.
Press the RESET
button on the display to
reset.)
One or both of the outlet sensors has opened or shorted.
The inlet sensor is open.
• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.
• Measure the resistances of the sensors and compare the resistances to the tables on page 83. Replace if necessary.
• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.
SET POINT MET
ANTI-CYCLING
DELTA T HIGH
The temperature has reached the set point + 10°F.
The main control board has received a call for heat too quickly after the previous call for heat has ended.
The temperature rise across the heat exchanger has exceeded the set parameters for the boiler.
The fan speed is being limited due to the temperature rise across the heat exchanger exceeding 55°F.
• None
• The control board will release the call for heat after 60 seconds.
• The control board will release the call for heat if the outlet temperature drops 10°F.
• Verify that the system is full of water and that all air has been properly purged from the system.
• Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping for the proper piping methods for the Lochinvar Combi Boiler.
• Check for 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board. Replace the main control board if necessary.
• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.
• Verify that the boiler pump is set to the proper speed or that the pump is the proper size. Reference Section 6 - Hydronic Piping for boiler pump specifications.
89
Page 90
FIRE TUBE
Installation & Service Manual
13 Troubleshooting
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
ERROR CODE DESCRIPTION CORRECTIVE ACTION
• Check 120 vac supply to the transformer.
• Check wiring connections at the low voltage terminal strip.
• Check the wire size/length to remote devices.
• Replace the transformer.
• Check 24V.
LOW VOLTAGE
120 vac input to the main control board has dropped below 80 vac.
NO FLUE TEMP
CHANGE
COMBI SENSOR FAULT
(COMBI ONLY)
LOCKOUT INLET
SENSOR FAULT
The flue temperature did not change after the burner started firing.
DHW sensor is not connected (combi only).
The inlet sensor has been disconnected.
• Verify that the flue sensor is installed.
• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.
• Check the DHW sensor and its associated wiring. Repair or replace as needed.
• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.
• Measure the resistance of the sensors and compare the resistance to the tables on page 83 of this manual.
• Replace the sensor if necessary.
• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.
OUTDOOR SENSOR
MISSING
90
The inlet sensor has been shorted.
The outdoor sensor has opened or shorted.
• Measure the resistance of the sensors and compare the resistance to the tables on page 83 of this manual.
• Replace the sensor if necessary.
• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.
• Measure the resistance of the sensors and compare the resistance to the tables on page 83 of this manual.
• Replace the sensor if necessary.
Page 91
FIRE TUBE
Installation & Service Manual
13 Troubleshooting (continued)
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT CAUSE CORRECTIVE ACTION
• Verify DHW flow is at least 0.4 gpm.
• Check wiring harness connections between the low voltage connection board connector CN4 and the flow switch sensor.
• Verify that voltage between wires CN4-8 and CN4-3 is 9 - 10 Vdc. If no voltage, replace Low Voltage Connection Board.
• Replace flow switch sensor.
• Check wiring harness connections between the Low Voltage Connection Board and the main control board.
• Replace Low Voltage Connection Board.
• Replace Main Control Board.
NO HOT WATER
AT FAUCETS
(COMBI ONLY)
DHW flow switch is not triggering a DHW demand (red light on flow switch sensor does not turn on during a DHW draw).
DHW flow switch input not received by main control board (red light on flow switch sensor turns on during a DHW draw, but combi boiler does not start a DHW Call for Heat).
DHW WATER
IS NOT HOT
ENOUGH
(COMBI ONLY)
Diverter valve is not in DHW position (heated boiler water is being provided to the space heating system rather than to the combi plate heat exchanger.
DHW set point is too low.
Anti-scald mixing valve set point is too low.
DHW flow rate is too high (combi boiler is firing at 100% in DHW Mode, but DHW temperature on screen is lower than the DHW Setpt on the screen).
• Check wiring harness connections between the Low Voltage Connection Board (CN4) and the combi diverter valve motor.
• Check that diverter valve motor is operating.
• Verify that the voltage between wire CN4-2 and ground is 24 Vac during a DHW demand.
• Replace combi diverter valve motor, Low Voltage Connection Board, or wire harness.
• Set DHW Setpt to the appropriate temperature based on the anti-scald mixing valve set point.
• Verify the anti-scald mixing valve is set to the desired temperature.
• During maximum flow conditions at all fixtures, adjust the field supplied flow control valve at the outlet of the mixing valve (or combi DHW outlet) to reduce the hot water flow until the DHW temperature reaches the DHW set point.
Combi DHW sensor fault (display unit will show "Combi Sensor Fault").
• See Combi Sensor Fault.
91
Page 92
FIRE TUBE
Installation & Service Manual
13 Troubleshooting
Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface
FAULT CAUSE CORRECTIVE ACTION
• Wait until DHW demand has ended, then combi unit should provide heated water to the space heating system. The Noble Fire Tube does not provide heated water during a DHW demand.
• Check wiring harness connections between the Low Voltage Connection Board (CN4) and the combi diverter valve motor.
• Check that diverter valve motor is operating.
• Verify that the voltage between wire CN4-1 and ground is 24 Vac during a space heating demand.
COMBI BOILER
IS RUNNING
BUT DOES NOT
SUPPLY HEATED
WATER TO
SPACE HEATING
SYSTEM
(COMBI ONLY)
A DHW demand is present.
Diverter valve is not in DHW position (heated boiler water is being provided to the combi plate heat exchanger rather than to the space heating system).
SPACE
HEATING
SYSTEM HEAT
EMITTERS GET
HOT DURING
A DHW
DRAW AND
THE COMBI
BOILER DOES
NOT PROVIDE
HOT ENOUGH
DOMESTIC HOT
WATER
(COMBI ONLY)
Diverter valve not operating correctly.
• Replace combi diverter valve motor, Low Voltage Connection Board, or wire harness.
• Verify diverter valve motor operation. If combi diverter valve motor is operating correctly, replace the flow group on the combi water set.
• Verify wiring harness connections between the Low Voltage Connection Board, and the diverter valve motor, and between the main control board and the Low Voltage Connection Board.
• Verify that voltage between CN4-2 and ground is 24 Vac and that voltage between CN4-1 and ground is 0 Vac. If voltages are incorrect, replace the Low Voltage Connection Board, wire harness, or main control board.
• If voltages are correct and diverter valve motor is not operating correctly, replace the combi diverter valve motor.
92
Page 93
13 Troubleshooting (continued)
FIRE TUBE
Installation & Service Manual
Combustion Analysis Procedure
1. Turn the main power off to the boiler.
2. Hold the plus the button for five (5) seconds to
enter Service Mode.
3. Once the boiler has modulated up to full fire, measure the combustion. Place the analyzer probe in the fitting on the flue adapter. The values should be in the range listed in Table 13-4. The CO levels should be less than 150 ppm for a properly installed unit.
If the combustion is not within the specified range,
reference Table 13-5 for possible causes and corrective actions.
Table 13-4 Flue Products
Natural Gas Propane
Goal
CO
2
Range 8.5% - 10.5% 2.3% - 5.7% 10.0% - 11% 4.1% - 5.6%
Target 9.0% 4.9% 10.5% 4.9%
4. Once the combustion analysis is complete, test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm. Turn the manual gas valve to the ON position and reset the control.
5. Turn the main power off to the boiler and replace the cap on the sample port.
6. Place the boiler back into normal operation.
O
2
CO
2
O
2
WARNING
You must replace the cap on the vent adapter to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.
Gas valve adjustment procedure
If adjustment of the gas valve is deemed necessary, use the following procedure:
CAUTION
Locate the throttle adjustment screw on the top of the gas valve, see FIG.'s 13-2 and 13-3 on page 94. Using a 2.5 mm Allen wrench, turn the screw 1/8 turn counterclockwise to increase CO2 levels or 1/8 turn clockwise to decrease CO2 levels. After one adjustment on the valve, follow the Combustion Analysis to measure the combustion.
If combustion is still not within the specified range, repeat the procedure. This procedure SHOULD NOT be performed more than four (4) times. If after four (4) adjustments and the combustion is still not within the specified range, revisit the possible causes in Table 13-5 (this page) or replace the gas valve.
Under normal operating conditions this valve should not need adjusting.
Table 13-5 Troubleshooting Chart - Combustion Levels
POSSIBLE CAUSE CORRECTIVE ACTION
Vent/Air Intake Length
or Obstruction
Gas Supply Pressure
Dirty/Damaged Burner
Gas Valve Adjustment
• Refer to Section 3 - General Venting for the proper venting and air intake methods for the Noble Fire Tube.
• Check for obstructions at the vent/air intake terminals.
• Refer to Section 7 - Gas Connections for the proper gas supply for the Lochinvar Fire Tube.
• Refer to page 79 of this manual for burner removal.
• Replace burner if necessary.
• Refer to this page of the manual for the gas valve adjustment procedure.
93
Page 94
13 Troubleshooting
A
Figure 13-2 Gas Valve Adjustment_Layout 1
FIRE TUBE
Installation & Service Manual
DIR #2000534505 00
Figure 13-3 Gas Valve Adjustment_Layout 2
THROTTLE
DJUSTMENT
SCREW
THROTTLE
ADJUSTMENT
SCREW
DIR #2000539041 00
94
Page 95
14 Diagrams
Figure 14-1 Combi Models Only: Ladder Diagram (Standard)
120VAC NEUTRAL GROUND
120V SUPPLY "L"
INTEGRATED CONTROL
VALVE RELAY
SYSTEM PUMP
RELAY
F1
6.3A
BOILER PUMP
RELAY
F2
3.15A
F3
24VDC
0.8A SUPPLY
120 VAC
CONNECTION BOARD
24 VAC
11
13
UNUSED
15
AUX SWITCH
17
CN4-1
DIV
CN4-2
SUPPLY
HEAT/LOOP
DEMAND
COMBI
DIVERTER
VALVE
CN4-3
DHW FLOW
-9V SWITCH
CN4-8
X1-6
X5-9
X4-3
CN3.2
DISPLAY
INLET
SENSOR S2
OPERATING
SENSOR S1a
HIGH LIMIT
SENSOR S1b
FLUE
SENSOR S3a
FLUE
SENSOR S3b
-T
-T
-T
-T
-T
CN4-4
X5-6
X5-4
X5-12
X5-5
X5-13
X5-14
X1-2
X1-4
X1-1
X5-1
VALVE RELAY
DIV
JUNCTION BOX
1
BLOWER
X1-8
X1-5
12
CN6-1
14
16
18
CN4-7
19
20
INTEGRATED
CONTROL
X7
SYSTEM PUMP "L"
3
FIRE TUBE
2
LWCO
24 VAC
AIR HANDLER
ENABLE
120V SUPPLY "N"
SYSTEM
PUMP
BOILER
PUMP
BLOWER
SPARK ROD
Installation & Service Manual
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
CONTROL
CN3-5 X4-8
4-6NC3-6NC
CN3-8
CN6-2
DIV VALVE RELAY
COIL
AIR PRESSURE
SWITCH
GASVALVE
X4-12
CN3-7 X4-10
CN3-3 X4-4
CN3-1 X4-1
CN3-6 X4-9
CN3-4 X4-5
X5-2
X5-10
X5-11
X2-2
X2-1
1
X5-7
2
X5-16
4
X5-8
X5-15
5
TR2
GAS VALVE
RELAYS
HIGH VOLTAGE SPARK LEADCAUTION
CONNECTION BOARD
SHIELD
A
CASCADE
B
SHIELD
UNUSED
SYSTEM SENSOR
OUTDOOR
SENSOR
COMBI DHW
SENSOR
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components block locations when using diagrams to troubleshoot unit.
1
CN5
2 3 4 5 6
7 8 9
10
CN4-5
CN4-6
X6
X6
CN5
X6
CN5
X6
CN5
X6
CN5
X6
CN5
X6
CN5
the appliance must be replaced, it must be replaced
LOW VOLTAGE
120 VAC
HIGH VOLTAGE
with wir e having same
for proper connector
LABEL,LADDER,COMBI
100274889 REV C
95
Page 96
14 Diagrams
Figure 14-2 Combi Models Only: Wiring Diagram (Standard)
DISPLAY
FIRE TUBE
Installation & Service Manual
LOW VOLTAGE 120 VAC
HIGH VOLTAGE
CASCADE
SYSTEM SENSOR
OUTDOOR
SENSOR
SHIELD
SHIELD
WATER
CUT OFF
A
B
LOW
24 VAC
COM
CONNECTION BOARD
CN1
1 2 3 4 5 6 7 8 9
10
CN6-1 CN6-2 CN6-3 CN6-4
INTEGRATED
CONTROL
X1-3
X-7
X1-2
PR
CN5
X6
X1-6
BK
X1-5
W
X1-8
G
X1-4
BR
X1-1
R
RW
1 2G3
JUNCTION
BOX
TRANSFORMER
BOX DEPICTS OPTONAL ITEMS
SYSTEM PUMP
G
L
120V
GND
SUPPLY
N
G
BOILER
PUMP
BLOWER
1 2 3 4 5
96
CN4-5
SENSOR
CN3
BK
CN3-8 CN3-7 CN3-6 CN3-5 CN3-4 CN3-3 CN3-2 CN3-1
FLOW SWITCH CIRCUIT
CN4-8
CN4-3
CN4-4
CN4-6
DHW FLOW
SWITCH
X4-12
BK
X4-10
BK
X4-9
BK
X4-8
BK
X4-5
BK
X4-4
BK
X4-3
BK
X4-1
R
X5-7
T
X5-16
X5-8
W
BK
X5-15
Y
X5-9
BL
X5-1
O
X5-2
P
X5-10
X5-11
O/BK
R/BK
X5-4
X5-12
GY
X5-6
P/BK
X5-5
W/BK
PR
X5-13
X5-14
Y
BK
X2-2
Y
X2-1
X1-7
W/R
TR2
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
ements per either N.E.C. in USA or C.S.A. in Canada
AIR PRESSURE SWITCH
-T
OPERATING SENSOR S1a
-T
HIGH LIMIT SENSOR S1b
-T
INLET SENSOR S2
-T
FLUE SENSOR S3a
-T
FLUE SENSOR S3b
GAS VALVE @24VAC
FLAME SENSOR SPARK
ROD
HIGH VOLTAGE SPARK LEADCAUTION
G
.
d from the factory. Use of a non-approved spar k le
CN2
11 12 13 14
AUX LIM
HEAT/LOOP
DEMAND
AIR HANDLER
CONTACTS
COMBI DIVERTER
VALVE
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requir
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchase or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locatio ns when using diagrams to troubleshoot unit.
15 16 17 18 19 20
K1
NC COM NO
CN4-1
CN4-2
CN4-7
COMBI DHW
ad
LABEL,WIRING,COMBI
100273313 REV B
Page 97
14 Diagrams (continued)
Figure 14-3 Boiler Models Only: Ladder Diagram (Standard)
120VAC
X4-3
CN3-2
120V SUPPLY "L"
INTEGRATED CONTROL
X1-6
BOILER PUMP
RELAY
X5-9
11
13
F1
6.3A
F2
3.15A
F3
0.8A
120 VAC
24 VAC
SYSTEM PUMP RELAY
DHW PUMP
BOILER PUMP RELAY
24VDC
SUPPLY
CONNECTION BOARD
TANK
THERMOSTAT
X1-2
X1-3
X1-4
X1-1
X1-8
X5-1
JUNCTION BOX
BOILER PUMP "L"
1
BLOWER
X1-5
12
CN6-1
14
SYSTEM PUMP "L"
PUMP "L"
3
DHW
2
LWCO
24 VAC
FIRE TUBE
120V SUPPLY "N"
SYSTEM PUMP
DHW PUMP
BOILER PUMP
CN6-2
Installation & Service Manual
NEUTRAL GROUND
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS
DUAL SENSOR
SINGLE HOUSING
INTEGRATED
CONTROL
CN3-5 X4-8
4-6NC3-6NC
CN3-8
X4-12
CN3-7 X4-10
DISPLAY
SENSOR S2
OPERATING
SENSOR S1a
SENSOR S1b
SENSOR S3a
SENSOR S3b
INLET
HIGH LIMIT
FLUE
FLUE
X5-6
X5-4
X5-12
X5-5
X5-13
X5-14
16
1817
19
20
INTEGRATED
CONTROL
X7
UNUSED
SPARK ROD
15
AUX SWITCH
HEATLOOP
DEMAND
-T
-T
-T
-T
-T
AIR PRESSURE
SWITCH
GASVALVE
BLOWER
CN3-3 X4-4
CN3-1 X4-1
CN3-4 X4-5
X5-2
X5-10
X5-11
X2-2
X2-1
1
X5-7
2
X5-16
4
X5-8
X5-15
5
TR2
GAS VALVE
RELAYS
HIGH VOLTAGE SPARK LEADCAUTION
CONNECTION BOARD
SHIELD
A
CASCADE
B
SHIELD
TANK
SENSOR
SYSTEM SENSOR
OUTDOOR
SENSOR
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.
2. If any original equipment wire as supplied with wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components block locations when using diagrams to troubleshoot unit.
1
CN5
2 3 4 5 6
7 8 9
10
X6
X6
CN5
X6
CN5
X6
CN5
X6
CN5
X6
CN5
X6
CN5
the appliance must be replaced, it must be replaced
LOW VOLTAGE 120 VAC
HIGH VOLTAGE
with wire having same
for proper connector
LABEL, LADDER,NKB
100273312 REV C
97
Page 98
FIRE TUBE
14 Diagrams
Figure 14-4 Boiler Models Only: Wiring Diagram (Standard)
DISPLAY
Installation & Service Manual
LOW VOLTAGE 120 VAC
HIGH VOLTAGE
CASCADE
TANK
SENSOR
SYSTEM SENSOR
OUTDOOR
SENSOR
SHIELD
SHIELD
WATER
CUT OFF
A
B
LOW
24 VAC
COM
10
1 2 3 4 5 6 7 8 9
CN6-1 CN6-2 CN6-3 CN6-4
CN1
CONNECTION BOARD
JUNCTION
R
1 2
W
G
3
BOX
TRANSFORMER
X1-3
X-7
CN5
X6
OR
BR
X1-4
X1-2
PR
X1-6
BK
X1-5
W
X1-8
G
X1-1
R
BOX DEPICTS OPTONAL ITEMS
DHW
G
PUMP
BOILER
G
PUMP
SYSTEM
G
PUMP
L
120V
GND
SUPPLY
N
G
BLOWER
1 2 3 4 5
98
R
CN2
11
TANK
THERMOSTAT
AUX LIM
HEAT/LOOP
DEMAND
Notes:
1. All wiring must be installed in accordance with: local, state, provincial and national code requir
2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchase or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.
3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locatio ns when using diagrams to troubleshoot unit.
12 13 14 15 16 17 18
CN3
BK
CN3-8
BK
CN3-7
BK
CN3-6
BK
CN3-5
BK
CN3-4
BK
CN3-3
BK
CN3-2
BK
CN3-1
ements per either N.E.C. in USA or C.S.A. in Canada
X5-7
T
X5-16
X4-12
X5-8
X5-15
X5-9
X5-1
X5-2
X5-10
X5-11
X5-4
X5-12
X5-6
X5-5
X5-13
X5-14
X2-2
X2-1
X1-7
TR2
BOX DEPICTS
OPTIONAL ITEMS
BOX DEPICTS DUAL SENSOR
SINGLE HOUSING
BK
BL
O
O/BK
R/BK
GY
P/BK
W/BK
W/R
W
Y
P
-T
-T
-T
-T
-T
PR
Y
BK
GAS VALVE @24VAC
Y
FLAME SENSOR SPARK
ROD
X4-10 X4-9 X4-8 X4-5 X4-4 X4-3 X4-1
d from the factory. Use of a non-approved spar k le
AIR PRESSURE SWITCH
OPERATING SENSOR S1a
HIGH LIMIT SENSOR S1b
INLET SENSOR S2
FLUE SENSOR S3a
FLUE SENSOR S3b
HIGH VOLTAGE SPARK LEADCAUTION
.
G
ad
LABEL,WIRING,NKB
100274861 REV B
Page 99
Notes
FIRE TUBE
Installation & Service Manual
99
Page 100
Revision A (PCP #3000004508 / CN #500004666) initial release.
Revision B (PCP #3000005203 / CN #500005353) reflects the addition of the DHW flow switch filter cleaning section and the Noble logo.
Revision C (PCP #3000005203 / CN #500005353) reflects updates made to the mixing valve statements.
Revision D (PCP# 3000006133 / CN# 500007549) reflects the addition of PVC-DWV vent fitting in Table 3D on page 18.
Revision E (PCP #3000008325 / CN # 500008312) reflects the addition of parameter values and cleaning instructions for the sanitary bypass filter in the Combi waterset, along with edits made to pages 18, 39, and 58.
Revision F (PCP #3000010352 / CN# 500010041) reflects the removal of the flow switch information on pages 49, 50, and 79.
Revision G (PCP# 3000009959 / CN# 500009745) reflects changes made to water chemistry information on pages 3, 7, 33-34, 36-39, 41-43, 52-53, 69, and 71.
Revision H (PCP #3000010423 / CN #500010150) reflects an update to the neutralizer information on page 51.
Revision J (PCP #3000010561 / CN #500010149) reflects an update to the vent increase notice on page 16 and the bird screen information on page 27.
Revision K (PCP #3000010778_ 3000021144 / CN #500010568) reflects updates made to high altitude on page 6, number 6 along with edits to pages 41 - 43.
Revision L (PCP #3000022821 / CN #500012930) reflects updates made to Table 3F on page 19.
Revision M (PCP #3000023992 / CN #500013886) reflects an update to material numbers on pages 12 and 66.
Revision N (PCP #3000024821 / CN #500000000) reflects the addition of the Noble Boiler.
Revision P (PCP #3000026706 / CN #500016345) reflects an update to the low voltage field wiring connections images on pages 56 and 57.
Revision R (PCP #3000027055 / CN #500016866) reflects the removal of references to an external flow switch.
Revision T (PCP #3000027325 / CN #500017083) reflects the removal of Table 2A on page 12.
Revision U (PCP #3000028215 / CN #500017754) reflects the removal of references to wire colors.
Revision V (PCP #3000029099 / CN #500018651) reflects an update to the ladder diagrams.
MM #100275091_DIR #2000533998_Rev V
11/18
Loading...