RBI Boiler, infinite energy 2 Installation And Operation Instructions Manual

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IE2-IOM-1

82-0147

Condensing, High Efﬁ ciency Water Heaters (IW) and Boilers (IB)

Boiler Manual

Installation and Operation Instructions

This manual is intended only for use by a qualiﬁ ed heating installer/technician. Read and follow this manual, all supplements and

related instructional information provided with the boiler. Install, start and service the boiler only in the sequence and methods given in these instructions. Failure to do so can result in severe personal injury, death or substantial property damage.

Do not use the boiler during construction. Construction dust and particulate, particularly drywall dust, will cause contamination

of the burner, resulting in possible severe personal injury, death or substantial property damage. The boiler can only be operated with a dust-free air supply. Follow the instruction manual procedures to duct air to the boiler air intake. If the boiler has been contaminated by operation with contaminated air, follow the instruction manual guidelines to clean, repair or replace the boiler if necessary.

Afﬁ x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a qualiﬁ ed service

technician, and to follow all guidelines in the User’s Information Manual.

62403588 R00 Feb. 18, 2014

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SAFETY INSTRUCTIONS

WARNING: If the information in these instructions is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

- Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier from

a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the ﬁ re department.

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

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SAFETY INSTRUCTIONS

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SAFETY INSTRUCTIONS

AVERTISSMENT: Assurez vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort

- Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inﬂ ammables à proximité de cette appareil ou de tout autre appareil.

- QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer l’appareil.

• Ne touchez à aucun interrupteur, ne

pas vous servir des téléphones se trouvant dans le bâtiment

• Appelez immédiatement votre

fournisseur de gas de puis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le

fournisseur, appelez le service des incendies

- L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualiﬁ é ou par le fournisseur de gaz.

Un temperature de l’eau au dessus de 125°F (52°C), peut causer de graves brulures instantanément, ou la mort par échaudure.

Les enfants, les personnes handicapées ou âgées sont plus à risque d’être

échaudées

Voir le manuel d’instruction avant de

Chaude

régler la température de l’eau sanitaire

Sentir la temperature de l’eau sanitaire avant un bain ou une douche

Limiteurs de temperature sont disponible, voir le manuel

121110m0_d

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SAFETY INSTRUCTIONS

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SAFETY INSTRUCTIONS

WARNING!!!

Installer: Read all instructions,

including this manual, before installing. Perform steps in the order given.

User: This manual is for use only

by a qualiﬁ ed heating installer. Refer to the User’s Information Manual for your reference.

Maintenance: at least once a

year the user must call a Qualiﬁ ed installer for routine maintenance.

Failure to comply with these

provisions can cause a ﬁ re or explosion causing property damage, personal injury , or death.

WARNING!!!

If the information in this manual is not followed exactly , can result in a ﬁ re or explosion causing property damage, personal injury , or death.

WARNING!!!

Qualiﬁ ed installer: qualiﬁ ed installer is an individual with speciﬁ c, technical training in space heating systems, domestic hot water systems, fuel gas systems and electrical systems. This individual must have the legally required qualiﬁ cations. Failure to comply with these provisions can cause a ﬁ re or explosion causing property damage, personal injury , or death.

WARNING!!!

Installation and Alterations: Only a Qualiﬁ ed installer must carry out the installation and calibration of the heater. Never modify the heater or its ﬂ ue gas carrying components in any way . This heater must be properly vented. Failure to follow these instructions could result in personal injury or death!

WARNING!!!

Flue gas/air intake: You are only permitted to operate this appliance with the combustion air/ﬂ ue gas system that has been speciﬁ cally designed and approved. Failure to follow these instructions could result in excessive levels of carbon monoxide which can cause severe personal injury or death!

WARNING!!!

Flue gas/air intake: Do not obstruct the air intake or vent pipe terminals. Failure to take proper precautions can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

WARNING!!!

Flue gas/ air intake: If heater installation is provided as replacement heater, DO NOT connect new heater venting to an existing vent system, if it is shared with other appliances. Failure to follow these instructions could result in excessive levels of carbon monoxide which can cause severe personal injury or death!

WARNING!!!

Flue gas/air intake terminals: Do not restrict or seal any air intake or outlet openings (terminals). Failure to follow these instructions could result in excessive levels of carbon monoxide which can cause severe personal injury or death!

WARNING!!!

Hazards and Your Safety - Hot Water Can Scald! Water temperature over 125°F (51°C) can cause severe burns instantly, or death from scalds. Children, the disabled, and the elderly are at highest risk of being scalded; see instruction manual before setting temperature at heater! Feel water before bathing or showering.

NOTICE! Local approval of the ﬂ ue

system and the condensate connection to the public sewer system may be required.

NOTICE! The local building regulations

stipulating the installation rules at the time of installation.

CAUTION!!!

The heater must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the heater or to lower ﬂ oors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the heater. The pan must not restrict combustion air ﬂ ow.

CAUTION!!!

location: The heater must not be installed on carpeting.

Installation location:

Installation

WARNING!!!

Defects: If you ﬁ nd any defects, you must inform the owner of the system of the defect and the associated hazard in writing. Failure to follow these instructions could result in excessive levels of carbon monoxide a ﬁ re or explosion which can cause severe personal injury or death!

CAUTION!!!

breakdown and/or malfunction of the heater, turn off the unit and do not make any attempt to repair it. The heater must be serviced exclusively by a Qualiﬁ ed installer using original spare parts. Failure to comply with this requirement may compromise the safety of the unit.

In the event of a

WARNING!!!

When servicing heater, to avoid electric shock, disconnect electrical supply before performing maintenance. Failure to do so can cause severe personal injury or death.

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SAFETY INSTRUCTIONS

WARNING!!!

When servicing heater, to avoid severe burns, allow heater to cool before performing maintenance. Failure to do so can cause severe personal injury or death.

WARNING!!!

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Failure to follow these instructions can cause cause a ﬁ re or explosion causing property damage, personal injury , or death.

ATTENTION!!!

de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

Au moment

WARNING!!!

Correct Use: This heater must only be used for the purpose for which it has been expressly designed: heating of water for closed circuit systems for central heating. Failure to follow these instructions could result in severe personal injury or death!

WARNING!!!

Should overheating occur or the gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, turn off the manual gas shut-off valve external to the appliance. Failure to follow these instructions could result in ﬁ re or explosion which can cause severe personal injury or death!

ATTENTION!!!

surchauffe ou si l’alimentation de gaz ne peut être coupée, ne pas couper ni débranch l’alimentation électrique de la pompe. Fermer plutôt le robinet d’admission de gaz à l’extérieur de l’appareil

En cas de

WARNING!!!

Do not use this appliance if any part has been under water. Immediately call a licensed authorized technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water. Failure to do so can cause severe personal injury or death.

ATTENTION!!!

cet appareil s’il a été plongé dans l’eau, même partiellement. Faites inspecter l’appareil par un tecnicien qualiﬁ é et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

N’utilisez pas

WARNING!!!

Ensure the heater and its controls are protected from dripping or spraying water during normal operation or service. Failure to do so can cause severe personal injury or death.

NOTICE! When calling or writing about

the heater – Please have the heater model and serial number from the heater rating plate.

NOTICE! Any claims for damage or

shortage in shipment must be ﬁ led immediately against the transportation company by the consignee.

WARNING!!!

Only use the heater in the combinations and with the accessories and spares listed in this manual. Failure to do so can cause severe personal injury or death.

WARNING!!!

For safety and environmental reasons, the packing materials must be properly disposed of. Any replaced part or packaging should never be left within the reach of children. Failure to follow these instructions could result in severe personal injury or death!

CAUTION!!!

“homemade cures” or “heater patent medicines”. Serious damage to the heater, personnel, and/or property may result.

CAUTION!!!

petroleum-based cleaning or sealing compounds in the heater system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

NOTICE! The manufacturer declines

all liability, contractual or otherwise (warranty included), for any damage to people, animals property or this same appliance, caused by:

a) - incorrect installation; b) - failure to comply with this or any

other instruction provided by the manufacturer;

c) - failure to comply with the applicable

local and/or national regulations in force;

d) - incorrect use of this appliance e) - inadequate or incorrect service f) - inadequate or incorrect

maintenance.

Do not use

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TABLE OF CONTENTS

SAFETY INSTRUCTIONS .................................................................................................................2

TABLE OF CONTENTS .....................................................................................................................8

1 - CODE REQUIREMENTS ............................................................................................................12

1.1 - Regulations and guidelines ................................................................................................................................ 12

2 - GENERAL INFORMATION .........................................................................................................14

2.1 - Key to symbols used .......................................................................................................................................... 14

2.2 - Manufactured by ................................................................................................................................................14

2.3 - Description of models: ........................................................................................................................................ 14

3 - MAIN COMPONENTS ................................................................................................................15

4 - FUNCTION OVERVIEW .............................................................................................................25

4.1 - Intended use and functions ................................................................................................................................ 29

4.1.1 Intended use and functions of the IB boiler ................................................................................................................ 29

4.1.2 Intended use and functions of the IW water heater .................................................................................................... 29

4.2 - Efﬁ ciency up to 98% (IB boiler only) .................................................................................................................. 29

5 - INSTALLATION - Location ........................................................................................................30

5.1 - Choosing the installation location .......................................................................................................................30

5.1.1 Location of an IB boiler ............................................................................................................................................... 30

5.1.2 Location of a IW water heater..................................................................................................................................... 30

5.2 - Residential garage installation ........................................................................................................................... 30

5.3 - Closet and alcove installations ........................................................................................................................... 31

5.4 - Clearances for installation and servicing ............................................................................................................31

5.5 - Clearances from combustible material ............................................................................................................... 31

5.6 - Vent and combustion air piping .......................................................................................................................... 31

5.7 - Prevent combustion air contamination ............................................................................................................... 31

6 - INSTALLATION - Mounting the heater .....................................................................................34

6.1 - Transporting the heater ...................................................................................................................................... 34

6.2 - Mounting the heater ........................................................................................................................................... 34

6.3 - Dimensions ........................................................................................................................................................35

7 - INSTALLATION - IB boiler water connection ..........................................................................38

7.1 - IB boiler water connections ................................................................................................................................ 38

7.2 - Supply and return piping .................................................................................................................................... 38

7.2.1 - Near boiler heating piping components .................................................................................................................... 39

7.2.2 - Relief valve ............................................................................................................................................................... 40

7.2.3 - Expansion Tank and Makeup Water .........................................................................................................................40

7.2.4 - Local boiler pump and CH pump .............................................................................................................................. 41

7.2.5 - Sizing heating system .............................................................................................................................................. 41

7.2.6 - Domestic Hot Water system Piping when using an indirect water heater ................................................................ 41

8 - INSTALLATION - IW water connections ..................................................................................44

8.1 - IW Water heaters’ water connections ................................................................................................................. 44

8.2 - Hot and Cold water piping .................................................................................................................................. 44

8.2.1 - Near water heater piping components ..................................................................................................................... 44

8.2.2 - Temperature and pressure Relief valve .................................................................................................................... 45

8.2.3 - Expansion Tank ........................................................................................................................................................ 46

8.2.4 - Circulator pump ........................................................................................................................................................ 46

8.2.5 - Sizing water system .................................................................................................................................................46

8.2.6 - Sizing storage tank ................................................................................................................................................... 46

8.3 - Scalding .............................................................................................................................................................46

8.4 - Water chemistry ................................................................................................................................................. 47

9 - INSTALLATION - Condensate disposal ...................................................................................50

9.1 - Condensate disposal .......................................................................................................................................... 50

10 - INSTALLATION - Electrical connections ...............................................................................52

10.1 - Electrical connections: overview ...................................................................................................................... 52

10.1.1 - Connecting the power supply cable ....................................................................................................................... 53

10.1.2 - Room Thermostat wiring (IB Boiler only) ................................................................................................................ 53

10.1.3 - Installing the outdoor temperature sensor (IB Boiler only) ..................................................................................... 53

10.1.4 - Connection to an analogic 0-10Vcc input ............................................................................................................... 54

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TABLE OF CONTENTS

10.1.5 - Connection to the MODBUS interface.................................................................................................................... 54

10.2 - Connecting the IB boiler to an indirect water heater ........................................................................................ 55

10.2.1 Indirect water heater priority selection ...................................................................................................................... 55

10.3 - Connecting the IW water heater to a storage tank ........................................................................................... 55

10.4 - Connecting the heater in cascade ....................................................................................................................59

11 - INSTALLATION - Vent and combustion air ............................................................................60

11.1 - Removing of a heater from a common venting system .................................................................................... 60

11.2 - Prevent combustion air contamination .............................................................................................................61

11.3 - Venting and air piping systems ......................................................................................................................... 61

11.4 - Minimum / Maximum allowable combustion air and vent piping lengths .......................................................... 63

11.5 - Install vent and combustion air piping ..............................................................................................................63

11.6 - Air inlet pipe materials: ..................................................................................................................................... 65

11.6.1 - Sealing of PVC, CPVC or ABS air inlet pipe ........................................................................................................... 65

11.7 - PVC/CPVC vent piping materials ..................................................................................................................... 66

11.7.1 - Installing PVC/CPVC vent and air piping ................................................................................................................ 66

11.7.2 - PVC/CPVC air intake connection ...........................................................................................................................67

11.7.3 - PVC/CPVC vent connection ................................................................................................................................... 67

11.8 - Stainless steel vent piping materials ................................................................................................................68

11.8.1 - Stainless steel air intake connection ...................................................................................................................... 69

11.8.2 - Stainless steel vent connection ..............................................................................................................................69

11.9 - Polypropylene vent piping materials ................................................................................................................. 70

11.9.1 - Polypropylene air intake connection ....................................................................................................................... 71

11.9.2 - Polypropylene vent connection ............................................................................................................................... 71

11.10 - Single pipe vent (not sealed combustion) ...................................................................................................... 72

11.10.1 - Combustion Air and Ventilation openings ............................................................................................................. 72

11.10.2 - Determine location ................................................................................................................................................ 73

11.11 - Sidewall termination - Two pipes .................................................................................................................... 74

11.11.1 - Vent/air termination ............................................................................................................................................... 74

11.11.2 - Determine location ................................................................................................................................................ 74

11.11.3 - Prepare wall penetrations ..................................................................................................................................... 76

11.11.4 - Termination and ﬁ ttings ......................................................................................................................................... 76

11.11.5 - Multiple vent/air terminations ................................................................................................................................ 76

11.12 - Sidewall termination – Concentric vent ..........................................................................................................77

11.12.1 - Description and usage .......................................................................................................................................... 77

11.12.2 - Sidewall termination installation ........................................................................................................................... 77

11.12.3 - Multiventing sidewall terminations ........................................................................................................................ 78

11.13 - Vertical termination - Two pipes ......................................................................................................................79

11.13.1 - Determine location ................................................................................................................................................ 79

11.13.2 - Prepare roof penetrations ..................................................................................................................................... 79

11.13.3 - Termination and ﬁ ttings ......................................................................................................................................... 79

11.13.4 - Multiple vent/air terminations ................................................................................................................................ 80

11.14 - Vertical termination – Concentric vent ............................................................................................................ 81

11.14.1 - Description and usage .......................................................................................................................................... 81

11.14.2 - Determine location ................................................................................................................................................ 81

11.14.3 - Vertical termination installation ............................................................................................................................. 81

11.14.4 - Multiventing vertical terminations ......................................................................................................................... 82

12 - INSTALLATION - Gas supply .................................................................................................83

12.1 - Gas supply piping ............................................................................................................................................. 83

12.2 - Pipe sizing for natural gas ................................................................................................................................ 84

12.3 - Propane Gas .................................................................................................................................................... 84

12.4 - Check inlet gas supply pressure ...................................................................................................................... 85

12.5 - Operating at high altitudes ............................................................................................................................... 85

12.6 - Convert a heater model 199 from Natural Gas to Propane gas or viceversa ..................................................86

12.7 - Convert a heater model 399, 500, 750 or 1000 from Natural Gas to Propane gas or viceversa ..................... 88

13 - START-UP .................................................................................................................................90

13.1 - Operating .........................................................................................................................................................90

13.1.1 - User instructions..................................................................................................................................................... 90

13.1.2 - Filling the condensate and neutralizing box ........................................................................................................... 90

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TABLE OF CONTENTS

13.1.3 - Filling the heating system ....................................................................................................................................... 90

13.2 - General warnings concerning gas supply ........................................................................................................ 90

13.3 - Conﬁ rming the heater’s gas type ..................................................................................................................... 91

13.4 - Gas type conversion ........................................................................................................................................91

13.5 - Start-up ............................................................................................................................................................91

13.5.1 - Start-up of the IB boiler .......................................................................................................................................... 91

13.5.1 - Start-up of the IW water heater .............................................................................................................................. 91

13.6 - Ignition control testing ...................................................................................................................................... 91

13.7 - Gas supply pressure checking ......................................................................................................................... 92

13.8 - Checking and adjusting CO2 levels ................................................................................................................. 93

13.8.1 - Checking CO2 level on units model 199 ................................................................................................................ 93

13.8.2 - Checking CO2 level on units model 399 up to 1000 .............................................................................................. 93

13.9 - Check the capacity input .................................................................................................................................. 94

13.10 - Minimum water ﬂ ow .......................................................................................................................................94

14 - USE ...........................................................................................................................................95

14.1 - Check water pressure ...................................................................................................................................... 96

14.1.1 - Check water pressure on IB boiler ......................................................................................................................... 96

14.1.2 - Check water pressure on IW water heater ............................................................................................................. 96

14.2 - Overview .......................................................................................................................................................... 96

14.3 - Displays ............................................................................................................................................................96

14.4 - Start-up procedure ........................................................................................................................................... 96

14.5 - IW supply water temperature adjustment .........................................................................................................96

14.6 - IB boiler - Indirect water heater temperature adjustment ................................................................................. 97

14.7 - IB boiler - Heating temperature adjustment .....................................................................................................97

14.8 - IB boiler - Outdoor reset adjustment ................................................................................................................ 97

14.8.1 - Outdoor reset applications ..................................................................................................................................... 97

14.8.2 - Outdoor reset: setting parameters.......................................................................................................................... 97

14.9 - Delays, alarms and protective actions .............................................................................................................99

14.10 - Circulator pump protection ............................................................................................................................. 99

14.11 - Heater’s Freeze protection ............................................................................................................................. 99

14.12 - Display in energy saver mode ....................................................................................................................... 99

14.13 - “Users’ menu” ...............................................................................................................................................100

14.14 - “Installer’s menu” .......................................................................................................................................... 101

14.15 - Diagnostic ....................................................................................................................................................102

14.16 - Diagnostic: Lockouts “Loc” ........................................................................................................................... 103

14.17 - Diagnostic: Blocking errors “Err” .................................................................................................................. 105

14.18 - Flue blocked pressure switch ....................................................................................................................... 106

14.19 - Shuts heater down ....................................................................................................................................... 106

14.20 - How to clean the appliance jacket ................................................................................................................106

15 - MAINTENANCE ......................................................................................................................107

15.1 - Care and maintenance ................................................................................................................................... 107

15.1.1 - Address reported problems .................................................................................................................................. 108

15.1.2 - Check all piping for gas leaks............................................................................................................................... 108

15.1.3 - Verify ﬂ ue and air lines in good condition and sealed tight; ................................................................................. 108

15.1.4 - Check system water pressure/system piping/expansion tank; ............................................................................. 108

15.1.5 - Check control settings .......................................................................................................................................... 108

15.1.6 - Check ignition and ﬂ ame sense electrodes ..........................................................................................................108

15.1.7 - Check wiring and connections.............................................................................................................................. 108

15.1.8 - Perform performance veriﬁ cation. ........................................................................................................................ 108

15.1.9 - Flame inspection .................................................................................................................................................. 108

15.1.10 - Check ﬂ ame signal ............................................................................................................................................. 109

15.1.11 - Check relief valve ...............................................................................................................................................109

15.1.12 - Check heater area .............................................................................................................................................. 109

15.1.13 - Check pressure gauge ....................................................................................................................................... 109

15.1.14 - Check vent piping ............................................................................................................................................... 109

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TABLE OF CONTENTS

15.1.15 - Check air piping.................................................................................................................................................. 109

15.1.16 - Check condensate drain system ........................................................................................................................ 109

15.1.17 - Check heater piping (gas and water) ................................................................................................................. 109

15.1.18 - Shut heater down ............................................................................................................................................... 110

15.1.19 - Test low water cutoff (if installed) ....................................................................................................................... 110

15.1.20 - Reset button (low water cutoff) ........................................................................................................................... 110

15.2 - Removing the casing ...................................................................................................................................... 110

15.3 - Cleaning the burner and primary heat exchanger, ﬂ ue gas side .....................................................................111

15.4 - Correct positioning of the ignition and ﬂ ame detection electrodes ................................................................ 113

15.5 - Clean the air ﬁ lter ........................................................................................................................................... 113

15.6 - Condensate trap and neutralizing box maintenance and cleaning ................................................................ 114

15.7 - Connection of the display to other burners .................................................................................................... 115

15.8 - How to move a control board ......................................................................................................................... 116

15.9 - Draining the water from the heater ................................................................................................................. 117

15.10 - Water and ﬂ ue temperature sensor .............................................................................................................. 117

15.11 - Outdoor temperature sensor ....................................................................................................................... 117

15.12 - 199 model wiring diagram ............................................................................................................................ 118

15.13 - 399 to 1000 models wiring diagram ............................................................................................................. 120

16 - TECHNICAL DATA .................................................................................................................124

17 - SPARE PARTS .......................................................................................................................126

18 - READ OUT FLOW CHART ....................................................................................................148

19 - FACTORY MENU ....................................................................................................................149

20 - SEQUENCE OF OPERATION for BOILER ............................................................................152

21 - SEQUENCE OF OPERATION for WATER HEATER .............................................................153

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1 - CODE REQUIREMENTS

1.1 - Regulations and guidelines

- The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to:

- the latest edition of the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 and or CAN/ CSA B149.1, Natural Gas and Propane Installation Code;

- the latest edition of the National Electric Code ANSI/NFP A 70 and or Canadian Electrical Code Part 1 CSA C22.1.

- Where required by the authority having jurisdiction, the installation must conform

to the Standard for Controls and Safety

Devices for Automatically Fired Boilers, ANSI/ASME CSD-1

NOTICE!

Install CO detectors per local regulations.

NOTICE!

IB Boiler version meets the safety and other performance requirements as speciﬁ ed in ANSI Z21.13 standard.

NOTICE!

IW Water heater version meets the safety and other performance requirements as speciﬁ ed in ANSI Z21.10.3 standard.

NOTICE!

IB boiler version: per DOE mandate, the operator control incorporates an automatic means (outdoor reset) of adjusting the boiler water temperature fot hot water heating. The boiler must not operate without the automatic

means enabled.

NOTICE!

IB boiler version: in accordance with Section 325 (f)(3) of the energy policy and conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature has the heating load decreases.

Page 13

1 - CODE REQUIREMENTS

1.2- Commonwealth of Massachusetts Installation Requirements

In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas ﬁ tter.

WARNING!!!

venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

(a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁ nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁ ed:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁ tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂ oor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equip-ment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed licensed professionals for the installation of hard wired carbon monoxide detectors. a. In the event that the side wall

horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level.

b. In the event that the requirements of

this subdivision can not be met at the time of completion of installation, the

Improper

owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁ ed.

3. SIGNAGE. A metal or plastic identiﬁ cation plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2)

inch in size, “GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) Exemptions The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

- GAS EQUIPMENT - VENTING SYSTEM

PROVIDED.

When the manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT - VENTING SYSTEM NOT PROVIDED.

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems”, the following requirements shall be satisﬁ ed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/ or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

Page 14

2 - GENERAL INFORMATION

2.1 - Key to symbols used

WARNING!!!

these indications can causing an explosion, ﬁ re, extensive property damage, severe personal injury or death!

CAUTION!!!

indication may compromise the smooth running of the appliance or cause serious damage to individuals, animals or property.

NOTICE! Indicates special instructions on

installation, operation, or maintenance that are important but not related to personal injury or property damage.

Failure to follow

Failure to observe this

Important indication symbol

2.2 - Manufactured by

RBI WATER HEATER

7555 Tranmere Drive Mississauga, Ontario L5S 1L4 Canada Phone: (905) 670-5888 Fax: (905) 670-5782 www.rbiwaterheaters.com

XX XXXX

2.3 - Description of models:

199 = maximum power input 199,000 Btu/hr (57,5 kW) and minimum 50,000 Btu/hr (14,7 kW). 399 = maximum power input 399,000 Btu/hr (117 kW) and minimum 50,000 Btu/hr (14,7 kW). 500 = maximum power input 500,000 Btu/hr (146,5 kW) and minimum 50,000 Btu/hr (14,7 kW). 750 = maximum power input 750,000 Btu/hr (220 kW) and minimum 50,000 Btu/hr (14,7 kW). 1000 = maximum power input 999,000 Btu/hr (292,8 kW) and minimum 50,000 Btu/hr (14,7

kW).

IB = Tankless fully modulating, gas-ﬁ red, condensing hot water boiler IW = Tankless fully modulating, gas-ﬁ red, condensing potable water heater

Page 15

3 - MAIN COMPONENTS

12 13

15 16

1 - Air / gas mixing device 2 - Gas valve 3 - Air intake silencer 4 - High limit temperature safety switch (UL 353 listed) 5 - Burner unit supply temperature sensor (par. 1001) 6 - Burner unit supply connection 7 - Burner unit supply pipe 8 - Gasket 9 - Unit heat exchanger

Figure 3-1 Burner unit main components

020009.01.004

10 - Burner unit return connection 11 - Support arrangement 12 - Plug (present on BURNER 2, 3 and 4 if any) 13 - Water pressure sensor (present on Burner 1 only) 14 - Spark generator 15 - Ignitors covers 16 - Water ﬂ ow sensor (par. 1062) 17 - Motorized valve (optional) 18 - Return pipe

134 2

Page 16

3 - MAIN COMPONENTS

27 28

020009.01.005

19 - Burner surface 20 - Burner unit condesate discharge 21 - Detection electrode 22 - Thermal insulation 23 - Sight glass 24 - Raccord fan-burner (inside this ﬁ tting ther’is a ﬂ apper valve and

a magnetic control switch)

25 - Modulating Fan

2223

Figure 3-2 Burner unit main components

2021 19

26 - Return temperature sensor (par. 1007) 27 - Left ignition electrode 28 - Right ignition electrode 29 - Motorized valve body (optional) 30 - Gasket

Page 17

3 - MAIN COMPONENTS

1041 6 12

9 14

13 15

020010.01.027

1 - Levelling feet 2 - Condensate hose that coming from heater’s ﬂ ue exhaust 3 - Condensate neutralizer box 4 - Heat exchanger 5 - Condensate discharge hose 6 - Gas inlet pipe 7 - Supply pipe 9 - Air inlet connection 10 - Electrical cable passages 11 - Air ﬁ lter

12 - Flue exhaust connection 13 - Modbus, 0-10Vcc, and cascade communication board

(Optional) 14 - Electrical terminals (Junction box) 15 - Control panel cover 16 - Display 17 - Control keys 19 - Front cover 20 - “Burner 1” (Master) power control board 21 - Bottom front cover

Figure 3-3 Main components for models 199

Page 18

3 - MAIN COMPONENTS

22 - Top cover 23 - Main electrical switch 24 - Flue blocked pressure switch 25 - Electrical board 28 - Flue gas temperature sensor (Blue color connector) 29 - High limit ﬂ ue gas temperature fuse (Red color connector) 30 - Flue gas exhaust manifold

020010.01.028

31 - Water Return connection 32 - Flue blocked pressure switch pipe connection 33 - Condensate blocked drain magnectic switch 34 - Flue gas manifold cap 40 - Fan cover 41 - Water Supply connection

Figure 3-4 Main components for models 199

Page 19

3 - MAIN COMPONENTS

020010.01.002

1 - Levelling feet 2 - Condensate hose that coming from heater’s ﬂ ue exhaust 3 - Condensate neutralizer box 4 - Heat exchanger 5 - Condensate discharge hose 6 - Gas inlet pipe 7 - Water Supply pipe 8 - Heat exchanger 9 - Air inlet connection 10 - Electrical cable passages 11 - Air ﬁ lter 12 - Flue exhaust connection

13 - Modbus, 0-10Vcc, and cascade communication board 14 - Electrical terminals 15 - Control panel cover 16 - Display 17 - Control keys 18 - “Burner 2” power control board 19 - Front cover 20 - “Burner 1” (Master) power control board 21 - Bottom front cover

Figure 3-5 Main components for models 399 and 500

Page 20

3 - MAIN COMPONENTS

BURNER 2

BURNER 1 (Master)

22 - Top cover 23 - Main electrical switch 24 - Flue blocked pressure switch 25 - Electrical Board 28 - Burner unit ﬂ ue gas temperature sensor (Blue color connector) 29 - Burner unit high limit ﬂ ue gas temperature fuse (Red color

connector)

30 - Flue gas exhaust manifold

Figure 3-6 Main components for models 399 and 500

020010.01.003

31 - Water Return pipe 32 - Flue blocked pressure switch pipe 33 - Condensate blocked drain magnetic switch 34 - Flue gas manifold cap

Page 21

3 - MAIN COMPONENTS

020010.01.026

35 - Automatic air vent (not present on IW water heater version) 36 - Water Supply connection 37 - Water Return connection 38 - Draining valves 39 - Header temperature sensor 41 - Safety relief valve (P-T safety relief valve on IW water heater) 42 - Pressure and temperature gauge 43 - Headers (For IW water heaters they are always made in

stainless steel. For IB boiler they can optionally made of carbon steel or stainless steel)

Figure 3-7 Main components for models 399 and 500

Page 22

3 - MAIN COMPONENTS

020009.01.002

1 - Levelling feet 2 - Condensate hose that coming from heater’s ﬂ ue exhaust 3 - Condensate neutralizer box 4 - Heat exchanger of the “Burner 1” (Master) 5 - Condensate discharge hose 6 - Gas inlet pipe 7 - Water Supply pipes 8 - Heat exchangers (the highest heat exchanger is not present on

model 750) 9 - Air inlet connection 10 - Electrical cable passages 11 - Air ﬁ lter 12 - Flue exhaust connection 13 - Modbus, 0-10Vcc and cascade communication board

Figure 3-8 Main components for models 750 and 1000

14 - Electrical terminals 15 - Control panel cover 16 - Display 17 - Control keys 18 - Power control boards (the highest power control board is not

present on model 750) 19 - Front cover 20 - “Burner 1” (Master) power control board 21 - Bottom front cover 24 - Flue blocked pressure switch 25 - Electrical control board 40 - Fan cover

Page 23

3 - MAIN COMPONENTS

BURNER 2 (Not present on model

750)

020009.01.003

BURNER 1 (Master)

BURNER 3

BURNER 4

22 - Top cover 23 - Main electrical switch 28 - Burner unit ﬂ ue gas temperature sensor (Blue color connector) 29 - Burner unit high limit ﬂ ue gas temperature fuse (Red color

connector) 30 - Flue gas exhaust manifold 31 - Water Return connection 32 - Flue blocked pressure switch pipe connection 33 - Condensate blocked drain magnectic switch

Figure 3-9 Main components for models 750 and 1000

34 - Flue gas manifold cap

Page 24

3 - MAIN COMPONENTS

35 - Automatic air vent (not present on IW water heater version) 36 - Water supply connection 37 - Water return connection 38 - Drain valves 39 - Header temperature sensor 41 - Safety Relief valve (P-T relief valve on IW water heater) 42 - Pressure and temperature gauge 43 - Headers (For IW water heaters they are always made in

stainless steel. For IB boiler they can optionally made of carbon steel or stainless steel)

Figure 3-10 Main components for models 750 and 1000

020009.01.017

Page 25

4 - FUNCTION OVERVIEW

Key to ﬁ gures 4-1: 1 - Air inlet 2 - Flue exhaust 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit ﬂ ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back ﬂ ue preventer 20 - Gas valve 22 - Detection electrode 24 - CRV Stainless steel heat exchanger 25 - Water supply 26 - Water return 27 - Gas inlet 28 - Blocked ﬂ ue pressure switch 29 - Condensing blocked drain switch 30 - Condensing drain 31 - Condensate Siphon 36 - Condensate neutralizer box 37 - ASME Safety relief valve (ASME Safety P-T relief valve when is water heater)

Figure 4-1 - Hydronic functional schematic for models 199

Page 26

4 - FUNCTION OVERVIEW

Key to ﬁ gures 4-2: 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit ﬂ ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back ﬂ ue preventer 20 - Gas valve 22 - Detection electrode 23 - Supply and return manifolds 24 - CRV Stainless steel heat exchanger 25 - Water supply 26 - Water return 27 - Gas inlet 28 - Blocked ﬂ ue pressure switch 29 - Condensing blocked drain switch 30 - Condensing drain 31 - Condensate Siphon 33 - Header temperature sensor 36 - Condensate neutralizer box 37 - ASME Safety relief valve (ASME Safety P-T relief valve when is water heater) 47 - Water Flow meter 48 - Motorized valve (optional) 50 - Drain valve

Figure 4-2 - Hydronic functional schematic for models 399 and 500

Page 27

4 - FUNCTION OVERVIEW

Key to ﬁ gures 4-3 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent (Boiler only) 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit ﬂ ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back ﬂ ue preventer 20 - Gas valve 22 - Detection electrode 23 - Supply and return headers 24 - CRV Stainless steel heat exchanger 25 - Water supply 26 - Water return 27 - Gas inlet 28 - Blocked ﬂ ue pressure switch 29 - Condensing blocked drain switch 30 - Condensing drain 31 - Condensate Siphon 33 - Header temperature sensor 36 - Condensate neutralizer box 37 - ASME Safety relief valve (ASME Safety P-T relief valve when is water heater) 47 - Flow meter 48 - Motorized valve (optional) 50 - Drain valve

Figure 4-3 - Hydronic functional schematic for model 750

Page 28

4 - FUNCTION OVERVIEW

Key to ﬁ gures 4-4: 1 - Air inlet 2 - Flue exhaust 3 - Automatic air vent (boiler only) 4 - Sealing chamber 6 - High limit supply temperature switch 7 - Supply temperature sensor 8 - Water pressure sensor 9 - Flue gas temperature sensor 10 - High limit ﬂ ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back ﬂ ue preventer 20 - Gas valve 22 - Detection electrode 23 - Supply and return headers 24 - CRV Stainless steel heat exchanger 25 - Water supply 26 - Water return 27 - Gas inlet 28 - Blocked ﬂ ue pressure switch 29 - Condensing blocked drain switch 30 - Condensing drain 31 - Condensate Siphon 33 - Header temperature sensor 36 - Condensate neutralizer box 37 - ASME Safety relief valve (ASME Safety P-T relief valve when is water heater) 47 - Flow meter 48 - Motorized valve (optional) 50 - Drain valve

Figure 4-4 - Hydronic functional schematic for model 1000

Page 29

4 - FUNCTION OVERVIEW

4.1 - Intended use and functions

4.1.1 Intended use and functions of the IB boiler

The boiler version, is designed to be used for central heating system for civil uses. Any other use is prohibited. The maximum output heat is always guaranteed for the production of domestic hot water since it is given priority over space heating demands. Follow the speciﬁ c procedure in Section

14.6 for the adjustment of the domestic hot water tempera ture. The boiler version can be installed with a Direct Venting system or with a one pipe vent system and getting combustion air from room. The quality of the system water is very important. Poor water quality can damage heating systems and boilers due to scale formation and corrosion. The boiler version can be connected to an indirect storage tank for the production of domestic hot water (Section 7.2.6). Using the boiler version, you can create a system with heating elements functioning at temperature range

between 68°F (20°C) and 187°F (90°C)

can be conﬁ gured. The boiler version can also function directly with a radiant ﬂ oor panel. When connecting the boiler version to

the heating system the installer must consider the head loss of the boiler (see Figure 7-3) and the head loss of the heating system to size adequate pumps. Boiler can be connected to a room thermostat, Section 10.1.2. An outdoor air temperature sensor must also be connected to the boiler for an outdoor reset supply temperature control for maximum fuel efﬁ ciency and comfort (see Section 10.1.3). In this conﬁ guration the room thermostat will compensate by adjusting the room temperature. The room temperature compensation can be of an ON /OFF type. For further information on the outdoor-air reset, refer to Section 14.8.

 The boiler must be connected to

an heating system with compatible speciﬁ cations, performance and power rating.

4.1.2 Intended use and functions of the IW water heater

The water heater version, is designed to warm domestic water (potable) for civil uses. Any other use is prohibited. The water heater can be installed with a Direct Venting system or with a one pipe vent system and getting combustion air from room. The quality of the system water is

very important. Poor water quality can damage the water heater due to scale formation and corrosion. This water heater must be connected to a storage water heater for the production of domestic hot water (Section 8). When connecting the water heater to the storage water heater size the correct circulator pump. The installer must consider:

- the head loss of the water heater (see Figure 7-3);

- the head loss of the piping system;

- the head loss of the storage water heater;

- the water hardness be compatible with the minimum water velocity;

The heater must be connected to a domestic hot water supply with compatible speciﬁ cations, performance and power rating.

4.2 - Efﬁ ciency up to

98% (IB boiler only)

Section applicable to boiler version only. When the outdoor reset is activated (an outside sensor is connected), the boiler always work at the maximum efﬁ ciency (see Section

14.8). It will automatically change the

supply temperature in relation with the outdoor temperature (Outdoor reset). The graph in Figure 4-5 shows an example on how it can work. This graph represents an installation where the supply and return temperatures are 139°F (60°C) and 115°F (46°C) respectively , and the outside temperature is 23°F (-5°C). The outdoor reset drives the boiler, to progressively reduce the supply temperature and thereby optimize the efﬁ ciency. It changes from 87% when outside is -10°F (-23°C), to 94.8% when outside is 23°F (-5°C) and up to 98% when the outside temperature rises up to 67°F (20°C).

Figure 4-5 Outdoor reset control to optimize the efﬁ ciency

Page 30

5 - INSTALLATION - Location

5.1 - Choosing the installation location

WARNING!!!

any ﬂ ammable materials or liquids in the immediate vicinity of the heater. A ﬁ re or explosion can result, causing severe personal injury, death, or substantial property damage.

WARNING!!!

the heater on carpeting. Fire can result, causing severe personal injury, death, or substantial property damage.

WARNING!!!

combustion air and ventilation of the heater room are always required, regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside (room air for combustion). Insufﬁ cient ventilation of the heater room can lead to high air temperatures. Make sure that intake and exhaust openings are sufﬁ ciently sized and no reduction or closure of openings takes place. When the problem is not resolved, do not operate the heater. Please note these restrictions and its dangers to the operator of the heater. Failure to comply with this provisions could result in severe personal injury, death, or substantial property damage.

Do not store

Do not install

Provisions for

WARNING!!!

PETROLEUM (L.P.) PROPANE GAS-FIRED HEATER LOCATION REQUIRES SPECIAL A TTENTION: 1994 UNIFORM MECHANICAL CODE, section 304.6: “LPG Appliances. Liqueﬁ ed petroleum gas-burning appliances shall not be installed in a pit, basement or similar location where heavierthan-air-gas might collect. Appliances so fueled shall not be installed in an abovegrade under-ﬂ oor space or basement unless such location is provided with an approved means for removal of unburned gas.” Failure to comply with this provision could result in and explosion that can cause severe personal injury, death, or substantial property damage.

CAUTION!!!

designed for direct outdoor installation. If installed outside of the structure, it must be sheltered so it is protected from rain, wind, sun and frost. NEVER place this heater in a location that would subject it to temperatures at or near freezing or temperature that exceed 100°F (38°C). Failure to properly locate this heater can result in premature failure.

CAUTION!!!

be installed in a location so that any water leaking from the heater or piping connections or relief valve openings will not cause damage to the area surrounding the unit or any lower ﬂ oors in the structure.

CAUTION!!!

room with thin ﬂ oor, resonating noise may occur. Install noise reducing parts if required.

CAUTION!!!

much dust to collect on the heater.

LIQUEFIED

This heater is not

This heater must

When installed in a

Do not allow too

5.1.1 Location of an IB

boiler

When locating the boiler the following factors must be considered:

 the location of vent/air intake

terminals;

 connection to the gas supply;  connection to the water supply;  connection to the heating system;  connection to the electrical supply;  disposal of the condensation

produced by the boiler;

 connection to the room thermostat

or equivalent device;

 piping of the safety relief valve

discharge;

 connection of the outdoor

temperature sensor;

 possible connection of an indirect

water heater.

 If ﬂ ooding is possible, elevate the

boiler sufﬁ ciently to prevent water from reaching the boiler

5.1.2 Location of a IW

water heater

When locating the water heater the following factors must be considered:

 the location of vent/air intake

terminals;

 connection to the gas supply;  connection to the water supply;  connection to a storage water

heater;

 connection to the electrical supply;  disposal of the condensation

produced by the heater;

 piping of the safety P-T relief valve

discharge;

 If ﬂ ooding is possible, elevate the

appliance sufﬁ ciently to prevent water from reaching the unit

5.2 - Residential

garage installation

Take the following precautions when installing the heater in a residential garage. If the heater 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.

Page 31

5 - INSTALLATION - Location

 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 not less than 18 inches (46 cm) above the ﬂ oor.

 The appliance shall be located or

protected so that it is not subject to physical damage by a moving vehicle.

5.3 - Closet and alcove installations

This heater is approved for the installation in an alcove or in a closet, for which you have to respect all next rules about clearances, ventings, ventilation openings as per this manual and the National Fuel Gas Code, ANSI Z223.1 /NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

WARNING!!!

PVC/CPVC/Polypropylene exhaust pipe material into a closet or alcove. Into closet or alcove, the only exhaust pipe material accepted is stainless steel. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Do not use

5.4 - Clearances for installation and servicing

Figures 5-2, 5-3 and 5-4 shows the minimum clearances required for installation and servicing.

NOTICE! Service clearances are not

mandatory, but are recommended to ensure ease of service should it be required.

5.5 - Clearances from combustible material

This heater may be installed directly onto a ﬂ oor of combustible material. See also Figure 5-1 for other clearances from combustible materials

5.6 - Vent and combustion air piping

This

heater

requires a special vent system, designed for pressurized venting. The

heater

is to be used for either direct vent installation or for installation using room combustion air. When room air is considered, see Section 11.10. Vent and air may be vented vertically through the roof or out a side wall, unless otherwise speciﬁ ed. You may use any of the vent/air piping methods covered in Section 11.

WARNING!!!

attempt to install the using any other venting / air intake methods than that explained on Section 11. to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Be sure to locate the heater 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 Section 11.

Do not

heater

Failure

5.7 - Prevent combustion air contamination

Install air inlet piping for the heater as described in Section 11. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Section 11.2, for products and areas which may cause contaminated combustion air.

WARNING!!!

the combustion air will not contain any of the contaminants listed in Section 11.2. Contaminated combustion air will damage the heater, resulting in possible severe personal injury, death or substantial property damage.

Ensure that

CLEARANCES FROM COMBUSTIBLE MATERIALS

Ceiling 2 inches (51 mm)

Front 2 inches (51 mm)

Rear 2 inches (51 mm)

Sides 2 inches (51 mm)

Floor 0 inches (0 mm)

Concentrinc vent 0 inches (0 mm)

Split vent (two pipes), ﬁ rst 3 ft from the appliance 1 inch (25 mm)

Split vent (two pipes), after 3 ft from the appliance 1/4 inches (7 mm)

Supply and return piping 1/4 inches (7 mm)

Figure 5-1; Clearances from combustible material

Page 32

5 - INSTALLATION - Location

G G

Figure 5-2 Recommended minimum clearance distances for proper installation and servicing for model 199 (G = Center of gravity)

Figure 5-3 Recommended minimum clearance distances for proper installation and servicing for models 399 and 500 (G = Center of gravity)

Page 33

5 - INSTALLATION - Location

G1 G2

Figure 5-4 Recommended minimum clearance distances for proper installation and servicing for models 750 and 1000 (G1 = Center of gravity for 1000 model G2 = Center of gravity for the 750 model)

Page 34

6 - INSTALLATION - Mounting the heater

6.1 - Transporting the heater

020010.01.011

Figure 6-1 Remove heater from wood pallet

WARNING!!!

and carry the heater with a hand truck or special equipment. Failure to comply with this provisions could result in severe personal injury, death or substantial property damage.

CAUTION!!!

damaged when it is improperly secured and transported.

CAUTION!!!

heater may be damaged when not protected against contamination

Always lift

The heater may be

The unpacked

 Only transport the heater using the

right transportation equipment, such as a hand truck with a fastening belt or special equipment for maneuvering steps.

 During transportation the

heater must be secured on the transportation equipment to prevent it from falling off.

 Protect all parts against impacts if

they are to be transported.

 Leave the protective covers on the

connections.

 During transportation, cover the ﬂ ue

gas and air intake connections at the top of the heater with plastic ﬁ lm

020010.01.012

Figure 6-2 Remove heater from wood pallet

6.2 - Mounting the heater

1. Remove the outer shipping carton from the

2. Remove the front door (see Section

15.2) to access the screw “C” (Figure 6-1) in front of the unit

3. Remove the screw “D” in the rear of the unit (Figure 6-2).

heater

Page 35

6 - INSTALLATION - Mounting the heater

020010.01.009

4. take the two factory supplied eyebolts “A” (Figure 6-3) and install them on the upper side of the heater

(see Figure 6-3);

5. Using a proper equipment (check the weight of the unit in Section

16), and lift the unit from the wood pallet and move it to the installation location;

6. Install the leveling feet and plumb the unit accordingly (see Figure 6-5);

Figure 6-3 Install eyebolt to lift the appliance

020012.01.008

WARNING!!!

must be capable of supporting the weight (see Section 16) of the unit or the same unit and building may be damaged causing severe personal injury, death, or substantial property damage.

The ﬂ oor

6.3 - Dimensions

Figures from 6-6 to 6-8 report all dimensions of each heater model.

Figure 6-4 Correct way to lift the appliance

020010.01.013

Figure 6-5 Install leveling feet

Page 36

6 - INSTALLATION - Mounting the heater

1 = Water supply connection (1” 1/2) 2 = Water return connection (1” 1/2) 3 = Air intake connection (3”)

Figure 6-6 Dimensions for models 199

4 = Flue exhaust connection (3”) 5 = Gas connection (1”) 6 = Condensate hose

1 = Water supply connection (2”) 2 = Water return connection (2”) 3 = Air intake connection (4”)

Figure 6-7 Dimensions for models 399 and 500.

4 = Flue exhaust connection (4”) 5 = Gas connection (1”) 6 = Condensate hose

Page 37

6 - INSTALLATION - Mounting the heater

1 = Water supply connection (2” 1/2) 2 = Water return connection (2” 1/2) 3 = Air intake connection (6”)

Figure 6-8 Dimensions for models 750 and 1000

4 = Flue exhaust connection (6”) 5 = Gas connection (1” 1/4) 6 = Condensate hose

Page 38

7 - INSTALLATION - IB boiler water connection

7.1 - IB boiler water connections

The boiler comes with the connections shown in Figures 6-6 or 6-7 and 6.8.

7.2 - Supply and return piping

The boiler is equipped with ASME safety

relief valves set at 50 PSI (3,4 bar).

However, this boiler can be equipped with relief valves set at maximum 160 PSI

(1 1.2 bar) that is the maximum working

pressure.

CAUTION!!!

piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV . All applicable local codes and ordinances must also be followed.

CAUTION!!!

the boiler to the heating system the heating system must be thoroughly ﬂ ushed to remove sediment, ﬂ ux, ﬁ lings and other foreign matter. The heat exchanger can be damaged by build-up or corrosion due to sediment.

CAUTION!!!

inhibitor should be added to the heating system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion.

CAUTION!!!

cannot be held responsible for any damage caused by incorrect use of additives in the heating system.

CAUTION!!!

must be designed so that no piping or radiation elements are higher than the corrispondent maximum pressure of the relief valve or else the hydraulic head of the system will cause the relief valve to open.

All heating system

Before connecting

An approved

The manufacturer

The heating system

CAUTION!!!

make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in boiler or piping must be repaired at once to prevent makeup water entering the boiler.

CAUTION!!!

supply heating water at a temperature up to 203°F (95°C) (setup of the safety high limit thermostat) and pressure of 160PSI (11,2 bar). If the heating system is built with materials not able to resist to this temperature and pressure, contractor must supply and install a device that will shut-off the boiler before the system material’s maximum operating temperature and pressure are met.

CAUTION!!!

damage due to unsuitable heating system water. If oxygenpermeable pipes are used, e.g. for under ﬂ oor heating systems, the systems must be separated from one another by plate heat exchangers able to resist the corrosion. Unsuitable heating system water promotes sludge and corrosion formation. This can result in boiler damage and malfunction.

CAUTION!!!

to directly heat domestic hot water, swimming pool or spa water.

Continual fresh

This boiler can

Risk of system

Do not use the boiler

System water piping methods

This boiler is designed to function in a closed loop pressurized system no less than 15 psi (1 bar). A pressure gauge is included to monitor system pressure. Each boiler 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.

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. The low water cutoff terminals are present within the line voltage junction box.

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 ﬂ uid 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!!!

non-approved additives or toxic boiler treatment chemicals in the heating system as they can cause serious health problems or possibly death. Any additives introduced into the heating system must be recognized as safe by the United States Food and Drug Administration.

WARNING!!!

inhibited propylene glycol solutions, which are speciﬁ cally formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems. Failure to comply with this provisions could result in severe personal injury, death or substantial property damage.

CAUTION!!!

it must be used in accordance with the instructions supplied with the product.

Never use

Use only

If glycol is used,

Page 39

7 - INSTALLATION - IB boiler water connections

CAUTION!!!

added to the heating system must not be added directly inside the boiler but through the heating system piping to prevent damage to the boiler.

CAUTION!!!

capable of servicing multiple temperature loop systems. It is the responsibility of the installer to protect the loops with lower temperature requirements from higher temperatures that may be required by other loops

Any additives

This boiler is

Floor radiant heating systems

Setting parameter 3015 (see Section

19), the boiler will maintain the maximum supply water temperature at that range temperature. No setting changes made from the control panel will cause the supply water temperature to exceed the maximum stated.

CAUTION!!!

ﬂ oor panel against over heating you must install a safety device that shuts-off the boiler before it reaches the ﬂ oor panel’s limit temperature.

CAUTION!!!

damage due to unsuitable heating system water. If oxygen-permeable pipes are used, e.g. for under ﬂ oor heating systems, the systems must be separated from one another by plate heat exchangers able to resist the corrosion. Unsuitable heating system water promotes sludge and corrosion formation. This can result in boiler damage and malfunction.

T o protect the radiant

Risk of system

7.2.1 - Near boiler heating piping components

1. Boiler system piping: boiler system piping MUST be properly sized. Reducing the pipe size can restrict the ﬂ ow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance.

2. Boiler system pump: Field supplied. The system pump MUST be sized to meet the speciﬁ ed ﬂ ow requirements.

Indirect water heater

pump: Field supplied. The pump MUST be sized to meet the speciﬁ ed ﬂ ow requirements. Consult the indirect water heater operating guide to determine ﬂ ow characteristics for the selected product used.

4. Boiler isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

5. Back ﬂ ow preventer: Field supplied. Back ﬂ ow preventer valves are recommended for installation as shown in Figures 7-4 and 7-5. Failure to install these valves could result in a reverse ﬂ ow condition during pump(s) off cycle.

6. Domestic indirect hot water isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

7. If the boiler is connected to an indirect water heater for domestic hot water, an Anti-scald mixing valve (Field supplied) MUST be installed.

8. Unions: Field supplied. Recommended for unit serviceability.

9. Pressure relief valve: Factory installed. The pressure relief valve is sized to ASME speciﬁ cations (see also Section 7.2.2).

10. Indirect water heaters: ﬁ eld supplied. This boiler may be piped to an indirect water heater to heat domestic hot water with the space heat transfer medium. The indirect water heater is connected to the system supply piping. A pump controlled by the boiler’s control will regulate the ﬂ ow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the boiler’s control. The boiler is pre-conﬁ gured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming.

circulating

CAUTION!!!

installer to ensure the minimum system ﬂ ow is not less than 4 GPM at any time. If the ﬂ ow is lower, the boiler automatically stops the burner.

WARNING!!!

Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer ﬂ uid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer ﬂ uid must be water or other non-toxic ﬂ uid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th Edition. this provisions could result in severe personal injury or death.

11. Filter: Field supplied. A ﬁ lter or equivalent multipurpose strainer is recommended at the return pipe of the boiler to remove system particles from older hydronic systems and protect newer systems.

It is up to the

The National

Failure to comply with

Page 40

7 - INSTALLATION - IB boiler water connections

7.2.2 - Relief valve

This boiler is supplied with a Safety Relief valve installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. Pipe the relief valve discharge like on Figures 7-1 or 7-2 to prevent scalding in the event of a discharge.

010.01.008

Pipe the discharge of the safety relief valve to a suitable drain. Provide piping that is the same size as the safety relief valve outlet.

Figure 7-1 Piping the relief valve discharge on models 199

020009.01.009

Figure 7-2 Piping the relief valve discharge on models 399 up to 1000

WARNING!!!

valve discharge can result in scalding of individuals and animals.

WARNING!!!

between the boiler and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

WARNING!!!

of the safety relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

Failure to properly pipe the relief

Never install any type of valve

Never block or plug the outlet

7.2.3 - Expansion Tank and Makeup Water

Install an expansion tank. Ensure the expansion tank is properly sized for the boiler volume (See Section 16, header “Content of water”) and the system volume, temperature and pressure.

CAUTION!!!

system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler failure can result due to this excessive makeup water addition, compromising the functionality of the unit.

The expansion tank must be located as shown in Figures 7-4 and 7-5 when using a primary/secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details. Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator. Always locate and install the system ﬁ ll connection at the same location as the expansion tank connection to the system.

Key to Figures 7-1 and 7-2 E = Safety relief valve F = Temperature and pressure gauge G = Elbow (Field provided) H = Relief valve discharge piping (Field provided) L = Heating supply connection

Undersized expansion tanks will cause

Page 41

7 - INSTALLATION - IB boiler water connections

7.2.4 - Local boiler pump and CH pump

This boiler must be ﬁ tted with a local pump. To connect the local pump to the boiler see Figures 7-4 and 7-5 and electrically connect the pump on terminals as shown on Figure 8-2. A ﬁ eld supplied pump relay must be installed if the pump current draw is grater than 3 amps. The water resistance to size the local pump to supply ﬂ ow through the heating system at the boiler connections is shown in graph form in Figure 7-3.

CAUTION!!!

installer to ensure the minimum system ﬂ ow is not less than 4 GPM at any time. If the ﬂ ow is lower, the boiler automatically stops the burner.

To connect an heating pump (CH pump) on the secondary loop see Figures 7-4 and 7-5 and electrically connect the pump on terminals as

It is up to the

shown on Figure 10-4. A ﬁ eld supplied pump relay must be installed if the pump current draw is grater than 3 amps.

7.2.5 - Sizing heating system

Size the pump, piping and system components required in the space heating system, using recognized design methods.

7.2.6 - Domestic Hot Water system Piping when using an indirect water heater

See Figures 7-4 and 7-5, for recommended piping to an indirect water heater. This recommended piping conﬁ guration ensures priority is given to the production and recovery of DHW. Refer to Figure 10-4 to wire the indirect water heater pump (DHW pump)

Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is mandatory on the domestic hot water outlet of the indirect water heater

WARNING!!!

scald mixing valve downstream domestic hot water piping. Failure to comply with this provision can result in scalding of individuals and animals causing, severe personal injury or death!

Install an anti

199

500

399

750 1000

Figure 7-3 Water side head loss of the heater

Page 42

7 - INSTALLATION - IB boiler water connections

Heating

system

return

Heating

system

supply

Supply to a

DHW indirect

water heater

(if needed)

Cold

water

make-up

Gas inlet

Return from a

DHW indirect

water heater (if

needed)

CAUTION!!!

concept drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the designer are appropriate, in order to properly size, conﬁ gure and design that system and to ensure compliance with building and safety code requirements.

This is a

1 = IB Boiler 2 = Air separator 3 = Ball valve 4 = Drain valve 5 = Filling valve 6 = Expansion tank 7 = Filter 8 = Back ﬂ ow preventer

Figure 7-4 Piping of IB boilers model 199

9 = Local boiler pump 12 = Manual gas shut-off valve (Install manual shut-off

valve 5 ft (1.5m) above ﬂ oor) 13 = Ground joint union 15 = Indirect water heater pump (DHW pump) (if needed) 16 = Heating pump (CH pump)

Page 43

7 - INSTALLATION - IB boiler water connections

Heating

system

return

Cold

water

make-up

Gas inlet

Heating

system

supply

Supply to a

DHW indirect

water heater

(if needed)

Return from a

DHW indirect

water heater (if

needed)

1 = IB Boiler 2 = Air separator 3 = Ball valve 4 = Drain valve 5 = Filling valve 6 = Expansion tank 7 = Filter 8 = Back ﬂ ow preventer

CAUTION!!!

9 = Local boiler pump 12 = Manual Gas shut-off valve (Install manual shut-off

valve 5 ft (1.5m) above ﬂ oor) 13 = Ground joint union 15 = Indirect water heater pump (DHW pump) (if needed) 16 = Heating pump (CH pump)

This is a

Figure 7-5 Piping of IB boilers model 399, 500, 750 and 1000

Page 44

8 - INSTALLATION - IW water connections

8.1 - IW Water

CAUTION!!!

heaters’ water connections

The water heater comes with the connections shown in Figures 6-6, 6-7 or 6-8.

8.2 - Hot and Cold water piping

The water heater is equipped with ASME

safety P-T relief valves set at 125 PSI (8,6 bar) 210°F (99°C). However, this water

heater can be equipped with P-T relief

valves set at maximum 160 PSI (1 1.2 bar) 210°F (99°C) that is the maximum

working pressure - temperature.

CAUTION!!!

piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV . All applicable local codes and ordinances must also be followed.

CAUTION!!!

the water heater to the system this last must be thoroughly ﬂ ushed to remove sediment, ﬂ ux, ﬁ lings and other foreign matter. The heat exchanger can be damaged by build-up or corrosion due to sediment.

APPROXIMATE TIME / TEMPERATURE

120°F (49°C) More than 5 minutes

125°F (51°C) 1,5 to 2 minutes

130°F (54°C) About 30 seconds

135°F (57°C) About 10 seconds

140°F (60°C) Less than 5 seconds

145°F (63°C) Less than 3 seconds

150°F (65°C) About 1,5 seconds

155°F (68°C) About 1 second

All water system

Before connecting

RELATIONSHIPS IN SCALDS

CAUTION!!!

8.2.1 - Near water heater piping components

Water heater system piping MUST be sized considering the pressure drops of the water heater (see Figure 7-3), pipings and storage tank. Reducing the pipe size can restrict the ﬂ ow rate through the water heater, causing poor system performance. Basic steps are listed below along with illustrations on Figures 8-5 and 8-6, which will guide you through the installation of the water heater.

1. Connect the cold water supply to the inlet side of the water heater.

2. Connect the hot water supply to the outlet side of the water heater.

3. Install a backﬂ ow preventer (ﬁ eld supplied) on the cold feed make-up water line.

This water heater can supply water at a temperature up to 203°F (95°C) (setup of the safety high limit thermostat) and pressure of 160 PSI (11,2 bar) (maximum setup of the relief valve). If the hot water system is built with materials not able to resist to this temperature and pressure, contractor must supply and install a device that will shut-off the appliance before the system material’s maximum operating temperature and pressure are met.

Do not use this heater to directly heat swimming pool or spa water.

4. Install a ﬁ eld supplied pump as shown in Figures 8-5 and 8-6.

5. Install a ﬁ eld supplied expansion tank on the cold water inlet. Consult the tank manufacturer’s instruction for speciﬁ c information relating to tank installation. Size the expansion tank for the required system volume and capacity.

6. Install a drain valve at the lowest point of the system.

7. Pipe the discharge outlet of any Pressure and temperature relief valve following Section 8.2.2. The temperature and pressure relief valve is sized to ASME speciﬁ cations. Storage tanks may require additional valves depending on local codes.

8. Water heater isolation valves: Field supplied. Install isolation valves as shown on ﬁ gures 8-5 and 8-6. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the water heater.

9. Anti-scald mixing valve: Field supplied. Install an anti-scald mixing valve as shown on ﬁ gures 8-5 and 8-6. An Anti scald mixing valve is recommended when storing domestic hot water above 115°F.

10. Unions: Field supplied. Install Unios as shown on Figures 8-5 and 8-6, recommended for unit serviceability.

11. Tank sensor: Factory supplied on water heater. The tank sensor MUST be installed in the lower 25% of the storage tank to achieve proper operation.

12. Filter: Field supplied. Install a ﬁ lter or equivalent multipurpose strainer at the cold water inlet connection of the water heater to remove system particles from older hydronic systems and protect newer systems.

Install the heater so the gas ignition system components are protected from water (dripping, spraying, etc.), during appliance operation for basic service or circulator, valves and other parts replacement.

Figure 8-1 Time / temperature scalds

Page 45

8 - INSTALLATION - IW water connections

8.2.2 - Temperature and pressure Relief valve

This water heater is supplied with a Safety Temperature and Pressure Relief valve which discharge connection must be piped in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, to prevent

010.01.008

scalding in the event of a discharge. Pipe the discharge of the safety relief valve like on Figures 8-2 or 8-3. to a suitable drain 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.

WARNING!!!

relief valve discharge can result in scalding of individuals and animals.

Failure to properly pipe the

Figure 8-2 Piping of the P-T relief valve discharge on models 199

020009.01.009

WARNING!!!

the safety relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

WARNING!!!

between the water heater and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

NOTICE! The separate storage vessel must have a

temperature and pressure relief valve installed. This relief valve shall comply with the Standard for Relief Valves for Hot Water Supply Systems, ANSI Z21.22 • CSA 4.4.

NOTICE! If the relief valve discharges periodically, this

may be due to thermal expansion in a closed water supply system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not plug the relief valve.

Never block the outlet of

Never install any type of valve

Figure 8-3 Piping of the P-T relief valve discharge on models 399 up to 1000

Key to Figures 8-2 and 8-3 E = ASME Safety Temperature and Pressure relief valve F = Temperature and pressure gauge G = Elbow (Field supplied) H = Relief valve discharge piping (Field supplied) L = Hot water outlet

Page 46

8 - INSTALLATION - IW water connections

8.2.3 - Expansion Tank

If a water heater is installed in a closed water supply system, such as one having a backﬂ ow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation. Install an expansion tank. Ensure the expansion tank is properly sized for the water volume (See Section 15, header “Content of water”) and the system volume, temperature and pressure.

CAUTION!!!

expansion tanks will cause system water to be lost through the relief valve

The expansion tank must be located as shown in Figures 8-5 and 8-6 or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details.

Undersized

8.2.4 - Circulator pump

This water heater must be ﬁ tted with a circulator pump for domestic hot water. The water resistance of the water heater is shown in graph form in Figure 7-3. To this resistance installer shall add the system water resistance and the storage tank water resistance to size the circulator pump to supply ﬂ ow through the storage tank. To electrically connect the pump (Local pump) follow Figure 10-5. A ﬁ eld supplied pump relay must be installed if the pump current draw is grater than 3 amps.

8.2.6 - Sizing storage tank

Storage tank can be sized for two DHW mode working:

a) - big storage for high peak tapping ﬂ ow requests.

In this case the storage must be properly sized as per recognized design method. Water heater must be set to work with a big storage as follow:

- Gain access to the Factory menu (see section 19) and set parameter 3012 to 1;

- Connect water heater’s electrical terminals as indicated on Figure 10-6

b) - small storage for instantaneous tapping ﬂ ow request.

In this case the storage must be properly sized as per recognized design method. Water heater must be set to work with a small storage that works like an instantaneous heat exchanger:

- Gain access to the Factory menu (see section 19) and set parameter 3012 to 0;

- Connect water heater’s electrical terminals as indicated on Figure 10-5

8.3 - Scalding

This water 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 water temperature control on this water heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you should install a 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.

Figure 8-1 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.

8.2.5 - Sizing water system

Size the pump, piping and system components required in the water system, using recognized design methods.

CAUTION!!!

installer to ensure the minimum water heater ﬂ ow is not less than 4 GPM at any time. If the ﬂ ow is lower, the unit automatically stops the burner.

It is up to the

Page 47

8 - INSTALLATION - IW water connections

8.4 - Water chemistry

The water heater pressure drops (see Figure 7-3) are based on potable water with a hardness of 5 to 25 grains per gallon and a total dissolved solids (TDS) not exceeding 350 ppm. Consult the manufacturer when heating potable water exceeding these speciﬁ cations. Heating of high hardness and/or high total dissolved solids water increases the pressure drops and may require a larger circulating pump, and a revised temperature rise speciﬁ cation based on the water chemistry of the water to be heated.

CAUTION!!!

hardness of less than 5 grains per gallon will usually have a pH which can be aggressive and corrosive causing damage to the heat exchanger and/or heater piping.

CAUTION!!!

system in a way to respect the minimum water velocity in function of the water hardness to prevent scaling inside the heat exchanger:

a) If the water is 5 to 8 grain per

gallon, this is SOFT water and you have to size the system for a 4 ft/sec minimum water velocity (see Figure 8-4 for corresponding water ﬂ ow);

Water with a

Size your water

b) If the water is 8 to 18 grain

per gallon, this is NORMAL water and you have to size the system for a 4 to 8 ft/sec minimum water velocity (see Figure 8-4 for corresponding water ﬂ ow);

c) If the water is 18 to 23 grain per

gallon, this is HARD water and you have to size the system for a 8 ft/sec minimum water velocity (see Figure 8-4 for corresponding water ﬂ ow);

199 399 - 500 750 1000

HARD WATER 18 gr/

gal (308 ppm) up to

23 gr/gal (394 ppm)

8 to 18 gr/gal

(137 to 308 ppm)

NORMAL WATER

gal (137 ppm)

SOFT WATER

Less than 8 gr/

Figure 8-4 Water velocity / water ﬂ ow graph

Page 48

8 - INSTALLATION - IW water connections

1 = Water heater 2 = Manual gas shut-off valve (Install manual gas shut-off valve 5 ft (1.5m) above ﬂ oor) 3 = Storage tank Pump (Local pump) 4 = Filter 5 = Union 6 = Ball valve 7 = Storage tank 8 = Storage tank T-P relief valve 9 = Expansion tank 10 = Mixing valve 11 = Temperature gauge 12 = Back ﬂ ow preventer 13 = Recycling pump (If needed)

Figure 8-5 Piping of a IW water heater model 199

CAUTION!!!

drawing only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the designer are appropriate, in order to properly size, conﬁ gure and design that system and to ensure compliance with building and safety code requirements.

This is a concept

Page 49

8 - INSTALLATION - IW water connections

CAUTION!!!

only. It is up to the system designer to determine the necessary components, including additional equipment and any safety devices which in the judgement of the designer are appropriate, in order to properly size, conﬁ gure and design that system and to ensure compliance with building and safety code requirements.

This is a concept drawing

1 = Water heater 2 = Manual gas shut-off valve (Install manual gas shut-off valve 5 ft (1.5m) above ﬂ oor) 3 = Storage tank Pump (Local pump) 4 = Filter 5 = Union 6 = Ball valve

Figure 8-6 Piping of an IW water heater model 399, 500, 750 and 1000

7 = Storage tank 8 = Storage tank T-P relief valve 9 = Expansion tank 10 = Mixing valve 11 = Temperature gauge 12 = Back ﬂ ow preventer 13 = Recycling pump (If needed)

Page 50

9 - INSTALLATION - Condensate disposal

9.1 - Condensate disposal

WARNING!!!

condensate trap is the same condensate neutralizer box (see Figure 9-1, item “B”). Condensate neutralizer box MUST be ﬁ lled of water or combustion gases will enter the room. This can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

WARNING!!!

condensate neutralizer box (see Figure 9-1, item “B”) must be kept within the unit, as shown in Figures 3-3 through 3-10. Removing the condensate neutralizer box from its position may result in combustion gases entering the room. This can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

This heater produces water as a byproduct of combustion. The heater is equipped with a condensate neutralizer box, Figure 9-1, item “B”, for the evacuation of condensate and to prevent the leakage of combustion products. The condensate drains through pipe shown in Figure 9-1 item “C” and Figure 9-2 item “A”. Slope condensate tubing down and away from the heater into a drain or drain pan (See Figure 9-2). Condensate from the heater will be slightly acidic (around pH 4). The neutralizing box (see ﬁ gure 9-1, item “B”) is will neutralise the condensate products.

The

CAUTION!!!

discharge line must be of 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 certiﬁ ed PVC or CPVC pipe, ﬁ ttings, and cement.

The condensate

be carried out with a pipe with

an internal diameter equal to or

greater than 3/4 in (19 mm);

be installed in such a way so as to

avoid the freezing of the liquid;

never discharge into gutters or rain

collectors;

be properly pitched towards the

point of discharge avoiding high points, which could place the condensate system under pressure.

CAUTION!!!

drainage system is designed to empty all the condensate produced by one heater only. Each heater must be equipped with its own condensate drainage system or the drainage system may malfunction.

A condensate removal pump is required if the heater is below the drain. When installing a condensate pump, select one approved for use with condensing heaters and furnaces. The pump should have an overﬂ ow switch to prevent property damage from condensate spillage.

COMMONWEALTH OF MASSACHUSETTS SPECIAL REQUIREMENT This heater meet the special requirement of the Commonwealth of Massachusetts, because the neutralization unit is already installed within the heater.

The condensate

Page 51

9 - INSTALLATION - Condensate disposal

020010.01.029

A = Pipe connected to the heaters’ ﬂ ue exhaust system B = Condensate neutralizer box C = Condensate drain pipe D = Cover of the box

Figure 9-1 Condensate neutralizer box (see also Figures 3-3 throgh 3-10, Item 3)

A = Condensate drain pipe B = Floor drain or drain pan (Below this point there must be a trap capable of preventing the return of sewer gas)

Figure 9-2 Condensate pipe and drain

Page 52

10 - INSTALLATION - Electrical connections

10.1 - Electrical connections: overview

WARNING!!!

SHOCK HAZARD 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.

WARNING!!!

wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation, severe personal injury or death. Be sure of a correct functioning after the servicing.

WARNING!!!

ATTENTION!!!

de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonction-nement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien terminé.

WARNING!!!

must be electrically wired to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical Code,

ANSI/NFP A 70 and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code.

ELECTRICAL

Label all

Au moment

The heater

Check that the electrical system is

adequate for the power consumption indicated on the rating plate or in Section 16.

Line voltage ﬁ eld wiring of any

controls or other devices must conform to the temperature limitation

of type T wire at 95 °F (35 °C), above

room temperature. Use copper conductors with a minimum size of #14 AWG. Low voltage wiring must not be less than #18 AWG with a neoprene, thermoplastic or other equivalent insulation having a minimum insulation thickness of 0.012

in, (0.3 mm).

 A properly rated shut-off switch shall

be located nearest to the heater for any maintenance use.

Ensure that the polarity between live

and neutral wires is maintained when connecting the heater.

CAUTION!!!

and water piping is not used as a ground connections for the electric and telephone systems. This piping is completely unsuitable for this purpose and could rapidly lead to serious corrosion damage to the heater, piping and radiators.

CAUTION!!!

provided with any protection against lightening strikes.

Ensure that heating

The heater is not

NOTICE! Wiring must be N.E.C. Class 1. Use only type 105°C wire or equivalent.

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.

Page 53

10 - INSTALLATION - Electrical connections

10.1.1 - Connecting the power supply cable

Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code. To connect the electrical power supply cable, follow the steps below while referring to Figures 101, 10-4 or 10-5:

1. remove the heater casing following the instructions given in Section 15.2 and open the junction box cover;

2. install the power supply wires, “B” and “C” to terminals “101” and “102”. connect the ground wire to the ground terminal;

3. connect the 120 volt hot wire to terminal “101”;

4. connect the 120 volt neutral wire to terminal “102”.

NOTICE! If the 120 volt power wires are

inverted, the heater will block, displaying error code Err 65.

10.1.2 - Room Thermostat

wiring (IB Boiler only)

Install the room thermostat in a part of the house where the temperature is as near to average as possible. Avoid areas subject to sudden temperature changes such as outside windows or doors, above radiation elements, near lamps, etc., (see Figure 10-2).

Connect the room thermostat to the boiler by following the steps below:

1. remove the boiler casing according to

the instructions given in Section 15.2 and open the junction box cover;

2. use a two conductor cable with a minimum cross section of #18 AWG between the boiler and the room thermostat;

3. connect the cable leads to the “10” and “11” terminals as shown in Figure 10-4.

NOTICE! the maximum room thermostat

cable length permitted is 32 ft (10 m). For longer lengths, up to 300ft (100 m) a shielded cable, with the shield connected to the ground, must be used.

WARNING!!!

thermostat wires conduct 24 Vac, they must never run through conduits containing 120Vac power wires or an electrical shock hazard will exist.

Since the room

10.1.3 - Installing the

outdoor temperature sensor (IB Boiler only)

The outdoor temperature sensor is supplied with the boiler. Install the outdoor temperature sensor, on an exterior wall of the building facing NORTH or NORTH-EAST, at a height of between 4 ft (1.2 m) and 6 ft (1.8 m) from the ground level. On multi story buildings, install the sensor near the upper half of the second ﬂ oor. Do not install the sensor above doors, windows

or ventilation outlets nor directly under balconies or gutter pipes. Do not shield the outdoor temperature sensor. Do not install the sensor on walls without overhangs, or not protected from rain. Connect the outdoor temperature sensor to the boiler to terminals “14” and “15” (See ﬁ gure 10-4):

1. use a two conductor cable with a minimum cross section of # 18 AWG between the boiler and the outdoor temperature sensor.

NOTICE! the maximum outdoor

temperature sensor cable length permitted is 32 ft (10 m). For longer lengths, up to 300 ft (100 m) a shielded cable, with the shield connected to the ground, must be used;

WARNING!!!

outdoor temperature sensor wires conduct 24 Vac, they must never run through conduits containing 120 Vac power wires or an electrical shock hazard will exist.

2. connect the outdoor temperature sensor cable leads to the ends of the external temperature sensor.

Set the boiler so that it detects the outdoor temperature sensor, as follows:

1. Gain access to the installers’ menu (see Section 14.14);

2. Set parameter 2003 to 1

Since the

Figure 10-1 Junction box

A = Cable conduit B = Line (Hot) cable C = Neutral cable D = Ground cable

Page 54

10 - INSTALLATION - Electrical connections

10.1.4 - Connection to an

analogic 0-10Vcc input

On appliances model 399, 500, 750 and 1000 it is factory supplied a 0-10Vcc interface (199 model can be equipped on demand). This 0-10Vcc interface give you the opportunity to drive the appliance via a 0-10Vcc analogic input. To do this, you have to connect the 0-10Vcc supply between terminals 22 and 23 (see Figures 10-4 and 10-5). Also, the CH mode (parameter 2003 as per Section 14.14) must be set to 4 value. Now the heater can start to receive the analogic input 0-10Vcc and it will control the supply temperature under the rules as explained in Figure 10-3 where:

- if the input voltage is growing up to

1.5V, the heater stay OFF;

- if the input voltage move between 1.5V and 2.0V the heater start to work and the supply temperature stay at the value set on parameter 3018 (Minimum CH setpoint, see Section

19)

- if the inpult voltage move between 2V and 10V, the supply temperature will

Figure 10-2 Room thermostat location

change proportionally between the Minimum CH setpoint (parameter 3018, see Section 19) and the Maximum CH setpoint (parameter 3017, see Section 19)

Figure 10-3 0-10Vcc analogic input algorithm

10.1.5 - Connection to the

MODBUS interface

On appliances model 399, 500, 750 and 1000 it is factory supplied a MODBUS interface (199 model can be equipped on demand). This MODBUS interface can be connected to drive the unit from a building management device. Instructions on this matter are supplied on demand

Page 55

10 - INSTALLATION - Electrical connections

10.2 - Connecting the IB boiler to an indirect water heater

This boiler, can be connected to an indirect water heater as follow:

1. The water connection must be made per Figures 7-4 or 7-5.

2. The indirect water heater pump (DHW pump) must be connected to terminals “107” and “108” (See Figure 10-4); a ﬁ eld supplied pump relay must be installed if the pump current draw is grater than 3 amps as indicated in Figure 10-4.

3. The indirect water heater temperature sensor (Tank sensor) must be connected to terminals “12” and “13” (See Figure 10-4). The sensor must be placed into the indirect water heater in a way that can detect its water temperature (Follow the indirect water heater instruction).

Set the boiler so that it detects the indirect water heater sensor, as follows:

a. Gain access to the Factory menu

(see Section 19);

b. Set parameter 3012 to 1.

Follow Section 14.6 to set the desired indirect water heater temperature.

WARNING!!!

indirect water heater temperature sensor wires conduct 24 Vac, they must never run through conduits containing 120 Vac power wires or an electrical shock hazard will exist.

Since the

10.2.1 Indirect water heater priority selection

The boiler is factory set for DHW priority. This means that the boiler will stay in DHW mode until the capacity of the indirect water heater reaches temperature. In some cases this will result in the house cooling because the central heating function was stopped by the DHW priority mode. Once the indirect water heater is satisﬁ ed the boiler will automatically return to central heating.

Priority selection is a functionality that toggles between CH and DHW demand when they are both active at the same time. The priority selection is set with the 2067 (DHW Priority) parameter in the “Installers’ menu” (see Section 14.14).

If parameter 2067 is set to “0” and a call for heat and domestic water are present at the same time, the boiler will give priority to the indirect water heater for the time period speciﬁ ed in parameter 2063. At the end of that time period, the boiler will switch to heating priority for the length of time speciﬁ ed in parameter 2063. If a call for domestic operation is still present the boiler will switch back to priority mode for the indirect for the time speciﬁ ed in parameter 2063.

If parameter 2067 is set to “1” the boiler will give priority to heating only.

If parameter 2067 is set to “2” the boiler will give priority to indirect water heater only.

10.3 - Connecting the IW water heater to a storage tank

The water heater must be connected to a storage tank:

1. The water connection must be made per Figures 8-5 or 8-6.

2. The storage tank pump (Local pump) must be connected to terminals “113” and “114” (See Figure 10-5) (a ﬁ eld supplied pump relay must be installed if the pump current draw is grater than 3 amps).

3. Remove header sensor present on terminals “8” and “9” of Figure 10-5;

4. The storage tank temperature sensor must be connected to terminals “8” and “9” (See Figure 10-5). The sensor must be placed into the storage tank in a way that can detect the water temperature (Follow the storage tank instruction).

Follow Section 14.5 to set the desired storage tank temperature.

WARNING!!!

storage tank temperature sensor wires conduct 24 Vac, they must never run through conduits containing 120 Vac power wires or an electrical shock hazard will exist.

Since the

Page 56

10 - INSTALLATION - Electrical connections

Figure 10-4 Electrical customer connection for IB boilers

Page 57

10 - INSTALLATION - Electrical connections

Figure 10-5 Electrical customer connection for IW water heaters connected to small instantaneous storage tank (see section 8.2.6, letter b))

Page 58

10 - INSTALLATION - Electrical connections

Figure 10-6 Electrical customer connection for IW water heaters connected to big storage tank (see section 8.2.6, letter a))

Page 59

10 - INSTALLATION - Electrical connections

10.4 - Connecting

the heater in cascade

To connect the heater in cascade you have to follow the electrical connections as per Figure 10-7. A maximum of 8 heaters can be connected in cascade (Figure 10-7 shows the connection of 4 heaters). When the electrical connection is placed, to activate the BUS communication to the HC command, follow the next steps:

1. - Gain access to internal part of the

heater (see Section 15.2)

2. - Move selector S4 of the Burner 1

(Master) board in the off position (see Figure 15-13 to identify the selector S4 of the Burner 1 (Master) board.

3. - Move selector S4 of the MODBUS

interface (item 13 on Figures 3-3, 3-5, and 3-8), in the ON position (see Figure 10-8).

The HC Command, that is the cascade manager, is supplied on demand.

For water, gas, ﬂ ue exhaust and air intake connections, ask for conceptual drawings to the manufacturer/distributor/agent.

SWITCH S4

020009.01.019

Figure 10-7 Electrical customer connection for Cascade (boilers or water heaters)

ON position

OFF position

Figure 10-8 MODBUS board and “Switch S4”

Page 60

11 - INSTALLATION - Vent and combustion air

11.1 - Removing of a heater from a common venting system

WARNING!!!

connect this heater or any other appliance using a positive pressure, in a common vent system! Failure to comply with this WARNING could result in the accumulation of carbon monoxide gas which can cause severe personal injury or death!

When an existing heater is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing heater, 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 and other deﬁ ciencies which could cause an unsafe condition.

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 ﬁ replace dampers.

DO NOT

(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 ﬂ ame of a match or candle, or smoke from a cigarette, cigar or pipe.

(f) Alter it has been determined

that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gasburning appliance to their previous condition of use.

(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 Annex G of the National Fuel Gas Code, ANSI Z223.1 /NFPA 54 and/or CAN/CSA B149. 1, Natural Gas and Propane Installation Code.

Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation

(a) Sceller toutes les ouvertures non

utilisées du système d’évacuation.

(b) Inspecter de façon visuelle le

système d’évacuation pour déterminer la grosser et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement de fruite, de corrosion et autres défaillances qui pourraient présenter des risques.

fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés du système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinère et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

(d) Mettre l’appareil inspecté en

marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

(e) Faire fonctionner le brûleur

principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la ﬂ amme d’une allunette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

(f) Une fois qu’il a été déterminé,

selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façor adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

(g) Tout mauvais fonctionnement

du systéme d’évacution commun devrait étré corrigé de façon que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CSA-B149.1. Si la grosseur d’une section du système d’ évacuation doit étré modiﬁ ée, le système devrait étré modiﬁ é pour respecter les valeurs minimales des tableaux pertinents de l’appendice G du National Fuel Gas Code, ANSI Z223.1/ NFPA 54 et (ou) des codes d’installation CSA-B149.1.

Page 61

11 - INSTALLATION - Vent and combustion air

11.2 - Prevent combustion air contamination

Install air inlet piping as described in this Section. You must pipe combustion air to the heater air intake. Do not terminate vent/air in locations that can allow contamination of combustion air.

WARNING!!!

combustion air will damage the heater, resulting in possible severe personal injury, death or substantial property damage.

Ensure that the combustion air will not contain any of the follow contaminants.

Products that may contaminated the air combustion:

- 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;

Do not pipe combustion air near sources of products that may contaminate the air combustion, like:

-Dry cleaning/laundry areas and establishments;

- Swimming pools;

- Metal fabrication plants;

- Beauty shops;

- Refrigeration repair shops;

- Photo processing plants;

- Auto body shops;

- Plastic manufacturing plants;

- Furniture reﬁ nishing areas and establishments;

- Remodeling areas;

- Garages with workshops.

Contaminate

11.3 - Venting and air piping systems

WARNING!!!

installation must be in accordance with part Venting of Appliances, of the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or section, Venting Systems and Air Supply for Appliances, of the CAN/CSA B149.1, Natural Gas and Propane Installation code or applicable provisions of the local building codes. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

must be mechanically ﬁ xed. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

vent and the air inlet lines, must be supported to prevent sagging. To do this, use a suitable pipe clamp to support the lines. Pipe clamps shall support the line every 3 ft (1 m). Pipe clamp shall be ﬁ xed in correspondance of a wall stud. Improper supporting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

NOTICE! the exhaust pipe must

be pitched a minimum of a 1/4 inch per foot back to the heater (to allow drainage of condensate).

NOTICE! The vent system shall

be installed so as to prevent the accumulation of condensate.

NOTICE! Due to the high efﬁ ciency

of the heater it may discharge what looks like white smoke especially

The vent

All vent pipes

The exhaust

when the outside air temperature is cold. This is a simply water vapor, a purely natural phenomenon and not a reason for concern.

This heater requires a special vent system, designed for pressurized venting. You must install air piping from outside to the heater air intake. The resultant installation is Direct Vent (sealed combustion). The heater is to be used for either Direct Vent installation or for installation using room combustion air. When room air is considered, see Section 11.10. Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise speciﬁ ed. You may use any of the vent/air piping methods from Figure 11-1 to Figure 11-6. Do not attempt to install this heater using any other means.

WARNING!!!

components from different systems. The vent system could fail, causing leakage of ﬂ ue products into the living space. Use only approved materials listed on Figures 11-7 and 11-8. Improper materials or mixing materials can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

cellular core PVC and CPVC or Radel for venting system is not allowed. Use of improper materials can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

DO NOT mix

Use of

Page 62

11 - INSTALLATION - Vent and combustion air

Figure 11-1 Side wall two pipes (Direct venting).

Figure 11-2 Vertical two pipes (Direct Venting).

Figure 11-3 Side wall air intake, vertical vent (Direct venting).

Figure 11-4 Vertical concentric (Direct venting).

Figure 11-5 Side wall concentric (Direct venting).

Figure 11-6 Side wall (or vertical in a roof) one pipe venting, combustion air from room (not Direct venting).

Page 63

11 - INSTALLATION - Vent and combustion air

11.4 - Minimum /

Maximum allowable combustion air and vent piping lengths

The maximum length of the two pipes vent system is 120 equivalent ft (Air intake plus ﬂ ue exhaust). However, each single pipe can’t be longer than 60 ft.

Each 45° elbow inserted in the venting system, has a loss of pressure equivalent to 3 ft of linear pipe.

Each 90° elbow inserted in the venting system, has a loss of pressure equivalent to 6 ft of linear pipe.

The minimum length of the venting sytem is 1 ft (357 mm).

WARNING!!!

decreasing combustion air or vent piping is not authorized. Failure to comply could result in severe personal injury, death, or substantial property damage.

Increasing or

11.5 - Install vent and combustion air piping

WARNING!!!

heater 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 11.2 of this manual. Inspect ﬁ nished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of all applicable codes. Failure to provide a properly installed vent and air system will cause severe personal injury or death.

WARNING!!!

materials other than those listed in Figure 11-7 and Figure 11-8, failure to properly seal all seams and joints, mixing of venting materials or failure to follow vent pipe and ﬁ ttings manufacturer’s instructions can result in personal injury, death or property damage.

This

Using vent

WARNING!!!

cellular core PVC and CPVC or Radel for venting system is not allowed. Use of improper materials can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

materials listed in Figure 11-7 and Figure 11-8 for vent pipe, and ﬁ ttings. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE! 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 installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636 (see Figure 11-7).

Use of

Use only the

Vent pipe materials and ﬁ ttings must comply with the following standards

Item Material

PVC schedule 40, 80 ANSI/ASTM D1785

Vent pipe and ﬁ ttings

Pipe cement/primer

CPVC schedule 40/80 ANSI/ASTM F441

Polypropylene ULC-S636

Stainless steel AL29-4C UL1738

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

WARNING!!! Use of cellular core PVC, CPVC, and Radel for venting system is not allowed

Figure 11-7 Approved vent materials

Standard for installation

in USA

Standard for installation

in CANADA

ULC-S636

Page 64

11 - INSTALLATION - Vent and combustion air

Approved vent manufacturers and items

Item Family of

the Material

3” Concentric roof or wall terminal PVC IPEX (System 636) 199 196006 4” Concentric roof or wall terminal PVC IPEX (System 636) 399, 500 196021 3” Concentric roof or wall terminal CPVC IPEX (System 636) 199 197009 4” Concentric roof or wall terminal CPVC IPEX (System 636) 399, 500 197021 3” Two (and single) pipes roof or wall terminal (90° elb.) PVC IPEX (System 636) 199 196025 4” Two (and single) pipes roof or wall terminal (90° elb.) PVC IPEX (System 636) 399, 500 196124 3” Two (and single) pipes roof or wall terminal (90° elb.) CPVC IPEX (System 636) 199 197201 4” Two (and single) pipes roof or wall terminal (90° elb.) CPVC IPEX (System 636) 399, 500 197202 3” Wall termination kit PVC IPEX (System 636) 199 081219 3” Low proﬁ le wall termination kit PVC IPEX (System 636) 199 196985 4” Low proﬁ le wall termination kit PVC IPEX (System 636) 399, 500 196986 6” Two (and single) pipes roof or wall terminal (90° elb.) CPVC IPEX (System 636) 750, 1000 197203 3” Bird screen PVC/CPVC IPEX (System 636) 199 196051 4” Bird screen PVC/CPVC IPEX (System 636) 399, 500 196052 6” Bird screen PVC/CPVC IPEX (System 636) 750, 1000 196090 3” (80mm) Two (and single) pipes roof or wall terminal

(90° elb.) 4” (110mm) Two (and single) pipes roof or wall terminal

(90° elb.) 6” (160mm) Two (and single) pipes roof or wall terminal

(90° elb.) 3” (80mm) Heater adapter Polypropylene Cosmogas 199 62617332 4” (110 mm) Heater adapter Polypropylene Cosmogas 399, 500 62617333 6” (160mm) Heater adapter Polypropylene Cosmogas 750, 1000 62617334 3” (80mm) Bird screen Polypropylene Centrotherm (Innoﬂ ue System) 199 IASPP03 4” (110mm) Bird screen Polypropylene Centrotherm (Innoﬂ ue System) 399, 500 IASPP04 6” (160mm) Bird screen Polypropylene Centrotherm (Innoﬂ ue System) 750, 1000 IASSS06 3” Two (and single) pipes roof or wall terminal (90° elb.) Stainless steel Duravent (FasNSeal) 199 FSELB9003 4” Two (and single) pipes roof or wall terminal (90° elb.) Stainless steel Duravent (FasNSeal) 399, 500 FSELB9004 6” Two (and single) pipes roof or wall terminal (90° elb.) Stainless steel Duravent (FasNSeal) 750, 1000 FSELB9006 3” Heater adapter Stainless steel Duravent (FasNSeal) 199 FSA-80MM3 4” Heater adapter Stainless steel Duravent (FasNSeal) 399, 500 FSA-100MM4 6” Heater adapter Stainless steel Duravent (FasNSeal) 750, 1000 FSA-160MM6 3” Bird screen Stainless steel Duravent (FasNSeal) 199 FSBS3 4” Bird screen Stainless steel Duravent (FasNSeal) 399, 500 FSBS4 6” Bird screen Stainless steel Duravent (FasNSeal) 750, 1000 FSBS6

Polypropylene Centrotherm (Innoﬂ ue System) 199 ISELL0387UV

Polypropylene Centrotherm (Innoﬂ ue System) 399, 500 ISELL0487UV

Polypropylene Centrotherm (Innoﬂ ue System) 750, 1000 ISELL0687UV

Manufacturer/supplier Applicable

to models

Manufactur. Part Number

Figure 11-8 Approved vent manufacturers and items

Page 65

11 - INSTALLATION - Vent and combustion air

11.6 - Air inlet pipe materials:

WARNING!!!

inlet pipe(s) must be sealed. Improper sealed can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

Choose acceptable combustion air inlet pipe materials from the following list:

- PVC, CPVC or ABS

- AL29-4C, stainless steel material to be sealed to speciﬁ cation of its manufacturer.

- Polypropylene material to be sealed to speciﬁ cation of its manufacturer.

WARNING!!!

intake materials other than those speciﬁ ed, mixing the speciﬁ ed materials, failure to properly seal all seams and joints or failure to follow the manufacturer’s instructions can result in ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide emissions causing severe personal injury or death.

NOTICE! Polypropylene and stainless

steel pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the air inlet pipe

The air

Using air

11.6.1 - Sealing of PVC, CPVC or ABS air inlet pipe

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 or ABS air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. ABS should use a screw type clamp to seal the pipe 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.

WARNING!!!

properly seal all joints and seams as required in the air inlet piping may result in ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide emissions causing severe personal injury or death.

Failure to

NOTICE! The use of 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.

Page 66

11 - INSTALLATION - Vent and combustion air

11.7 - PVC/CPVC vent piping materials

WARNING!!!

the materials listed in 11-7 and 11-8 and ﬁ ttings. 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.

WARNING!!!

requires a special venting system. The ﬁ eld provided vent ﬁ ttings must be connected to the heater following Section

11.7.1. Use only the vent materials, primer, and cement speciﬁ ed in this manual to make the vent connections. Failure to follow this warning could result in ﬁ re, personal injury, or death.

WARNING!!!

insulate PVC/CPVC exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

WARNING!!!

installation of PVC or CPVC systems may result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Use only

Figures

for vent pipe,

This appliance

Do not

Improper

WARNING!!!

pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the heater (to allow drainage of condensate). Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

NOTICE! 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 installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636 (see

Figures 11-7

NOTICE!

vent system should adhere to the PVC/ CPVC vent manufacturer’s installation instructions supplied with the vent system.

Installation of a PVC/CPVC

All vent

11.7.1 - Installing PVC/ CPVC vent and air piping

NOTICE! Use only cleaners, primers,

and solvents that are approved for the materials which are joined together.

1. Work from the heater to vent or air termination. Do not exceed the lengths given in Section 11.4.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Bevel outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and ﬁ ttings using a clean dry rag (Moisture will retard curing and dirt or grease will prevent adhesion).

5. Dry ﬁ t vent or air piping to ensure proper ﬁ t up before assembling any joint. The pipe should go a third to two-thirds into the ﬁ tting to ensure proper sealing after cement is applied.

6. Priming and Cementing: a. Handle ﬁ ttings and pipes carefully

to prevent contamination of surfaces.

b. Apply a liberal even coat of primer

to the ﬁ tting socket.

c. Apply a liberal even coat of primer

to the pipe end to approximately 1/2” beyond the socket depth.

d. Apply a second primer coat to the

ﬁ tting socket.

e. While primer is still wet, apply an

even coat of approved cement to the pipe equal to the depth of the ﬁ tting socket.

f. While primer is still wet, apply an

even coat of approved cement to the ﬁ tting socket.

g. Apply a second coat of cement to

the pipe.

h. While the cement is still wet,

insert the pipe into the ﬁ tting, if possible twist the pipe a 1/4 turn

as you insert it. NOTICE! If voids

are present, sufﬁ cient cement was not applied and joint could be defective.

i. Wipe excess cement from the joint

removing ring or beads as it will needlessly soften the pipe.

Page 67

11 - INSTALLATION - Vent and combustion air

11.7.2 - PVC/CPVC air intake connection

Combustion Air Intake connection (see Figure 11-9 Item “M”). This connection is used

to provide combustion air directly to the heater from outdoors. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate. To connect a PVC/CPVC pipe to the air intake connection proceed as follow while referring to Figure 11-9:

1. install heater adapter “P” above inlet air opening “M” with gasket “D” and bolts “E”;

2. Prepare the connection between adapter “P” and pipe “N” like described on Section 11.7.1;

3. Insert the air inlet PVC/CPVC pipe, for 3” into the adapter “P”;

4. tight the clamp “F” to mechanically secure the adapter “B” to the pipe.

11.7.3 - PVC/CPVC vent connection

Vent connection (see Figure 11-9 Item “C”). This connection

is used to provide a passageway for conveying combustion gas to the outside. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate. To connect a PVC/CPVC pipe to the vent connection proceed as follow while referring to Figure 11-9:

1. install heater adapter “B” above ﬂ ue exhaust opening “C” with gasket “D” and bolts “E”;

2. Prepare the connection between adapter “B” and pipe “G” like described on Section 11.7.1;

3. Insert the ﬂ ue exhaust PVC/CPVC pipe, for 3” into the adapter “B”;

4. tight the clamp “F” to mechanically secure the adapter “P” to the pipe.

WARNING!!!

Do not insulate PVC/CPVC exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Combustion air intake

Flue exhaust

020010.01.010

A = Glue (Field provided)

B = Flue exhaust adapter for

PVC/CPVC pipe (Factory

supplied) C = Flue exhaust connection D = Gasket E = Fixing screw F = mechanically secure clamp G = PVC/CPVC exhaust pipe

(Field provided) H = Combustion analization

probe (Field installed) L = cap (Field provided) M = Air intake connection N = PVC/CPVC air inlet pipe

(Field provided) P = Air intake adapter for PVC/

CPVC pipe (Factory supplied)

Extend the air intake pipe to outside building

Extend the ﬂ ue exhaust pipe to outside building

020010.01.016

Figure 11-9 PVC/CPVC air intake/ vent connection

Figure 11-10 PVC/CPVC air intake/Vent connection correctly in place

Page 68

11 - INSTALLATION - Vent and combustion air

11.8 - Stainless steel vent piping materials

WARNING!!!

materials, vent systems, and terminations listed in Figures 11-7 and 11-8. 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.

WARNING!!!

appliance requires a special venting system. The ﬁ eld provided vent heater adapter (Figure 11-11, item “B”) must be connected to the heater following Section 11.8.2. Failure to follow this warning could result in ﬁ re, personal injury, or death.

Use only the

This

WARNING!!!

installation of Stainless steel systems may result in injury or death.

WARNING!!!

water-based lubricants on joints. Never use hydrocarbons-based lubricants because they would destroy gaskets. follow this warning could result in excessive levels of carbon monoxide, which can result in severe personal injury or death!

NOTICE! 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.

NOTICE! For installation in Canada,

vent pipe system must be certiﬁ ed to ULC-S636 (see Figure 11-7).

NOTICE! All vent pipes connections

must be secured following manufacturer instruction, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the heater (to allow drainage of condensate).

Improper

Use only

Failure to

NOTICE!

steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

NOTICE!

speciﬁ c vent starter adapter at the ﬂ ue collar connection, supplied by the

vent manufacturer to adapt to its vent system. See Figure 11-8 for approved vent adapters.

Installation of a stainless

The installer must use a

Page 69

11 - INSTALLATION - Vent and combustion air

11.8.1 - Stainless steel air intake connection

Combustion Air Intake connection (see Figure 11-11 Item “M”). This connection is used

to provide combustion air directly to the heater from outdoors. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

To connect a stainless steel pipe to the air intake connection proceed as follow: while referring to Figure 11-11:

1. install heater adapter “P” (Field provided) above exit “M” using gasket “D” and bolts “E”.

2. Insert air intake pipe “N”, into adapter “P”, following instruction of stainless steel pipe manufacturer.

11.8.2 - Stainless steel vent connection

Vent connection (Figure 1111 item “C”) is used to provide

a passageway for conveying combustion gases to the outside. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

To connect a stainless steel pipe to the vent connection proceed as follow: while referring to Figure 11-11:

1. install heater adapter “B” (Field provided) above exit “C” using gasket “D” and bolts “E”.

2. Insert vent pipe “G”, into adapter “B”, following instruction of stainless steel pipe manufacturer.

Combustion air intake

Flue exhaust

020010.01.010

A = pipe connection

B = Flue exhaust adapter for

stainless steel pipe (Field

supplied) C = Flue exhaust connection D = Gasket E = Fixing screw F = mechanically secure clamp G = Stainless steel exhaust pipe

(Field provided) H = Combustion analization

probe (Field installed) L = cap (Field provided) M = Air intake connection N = Stainless steel air inlet pipe

(Field provided) P = Air intake adapter for

stainless steel pipe (Field

supplied)

Extend the air intake pipe to outside building

Extend the ﬂ ue exhaust pipe to outside building

020010.01.016

Figure 11-11 Stainless steel air intake/vent connection

Figure 11-12 Stainless steel air intake/Vent connection correctly in place

Page 70

11 - INSTALLATION - Vent and combustion air

11.9 - Polypropylene vent piping materials

WARNING!!!

the materials listed in 11-7 and 11-8 and ﬁ ttings. systems of different types or manufacturers, unless listed in this manual. could result in severe personal injury, death, or substantial property damage.

WARNING!!!

requires a special venting system. The ﬁ eld provided vent ﬁ ttings must be connected to the heater following Section 11.9.2. Failure to follow this warning could result in ﬁ re, personal injury, or death.

WARNING!!!

insulate polypropylene exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Use only

Figures

for vent pipe,

DO NOT mix vent

Failure to comply

This appliance

Do not

WARNING!!!

installation of Polypropylene systems may result in injury or death.

WARNING!!!

NOTICE!

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 installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636 (see Figure 11-7).

NOTICE!

must be secured following manufacturer instruction, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the heater (to allow drainage of condensate).

NOTICE! Installation of a

Polypropylene vent system should adhere to the polypropylene vent manufacturer’s installation instructions supplied with the vent system.

Installation must comply

All vent pipes connections

Improper

Use only

Failure to

Page 71

11 - INSTALLATION - Vent and combustion air

Combustion air intake

Flue exhaust

11.9.1 - Polypropylene air intake connection

Combustion Air Intake connection (see Figure 11-13 Item “M”) is used to provide combustion air directly to the heater from outdoors. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

To connect a polypropylene pipe to the air intake connection proceed as follow: while referring to Figure 11-13:

1. install heater adapter “P” (Field provided) above exit “M” using gasket “D” and bolts “E”.

2. Insert vent pipe “N”, into adapter “P”, following instruction of polypropylene pipe manufacturer.

11.9.2 - Polypropylene vent connection

Vent connection (Figure 11-13 item “C”) is used to provide a passageway for conveying combustion gases to the outside. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate. To connect a polypropylene pipe to the vent connection proceed as follow: while referring to Figure 11-13:

1. install heater adapter “B” (Field provided) above exit “C” using gasket “D” and bolts “E”.

2. Insert vent pipe “G”, into adapter “B”, following instruction of polypropylene pipe manufacturer.

WARNING!!!

Do not

020010.01.010

Figure 11-13 Polypropylene air intake/vent connection

A = pipe connection

B = Flue exhaust adapter for

polypropylene pipe (Field

supplied) C = Flue exhaust connection D = Gasket E = Fixing screw F = mechanically secure clamp G = Polypropylene exhaust pipe

(Field provided) H = Combustion analization

probe (Field installed) L = cap (Field provided) M = Air intake connection N = Polypropylene air inlet pipe

(Field provided) P = Air intake adapter for

polypropylene pipe (Field

supplied)

Extend the air intake pipe to outside building

Extend the ﬂ ue exhaust pipe to outside building

020010.01.016

Figure 11-14 Polypropylene air intake/Vent connection correctly in place

Page 72

11 - INSTALLATION - Vent and combustion air

11.10 - Single pipe vent (not sealed combustion)

For heaters for connection to gas vents or chimneys, vent installations shall be in accordance with “Venting of Equipment,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances,” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes.

WARNING!!!

the single pipe vent 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.

Commercial applications utilizing this heater may be installed with a single pipe carrying the ﬂ ue products to the outside while using combustion air from the equipment room. In this case the following conditions and considerations must be followed.

WARNING!!!

equipment room MUST be provided with properly sized openings to assure adequate combustion air from outside. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE! There will be a noticeable

increase in the noise level during normal operation from the inlet air opening.

NOTICE! Vent system and terminations

must comply with the venting instructions set forth in Sections

11.1, 11.2, 11.3, 11.4, 11.5, 11.7,

11.8 and 11.9.

When utilizing

The

WARNING!!!

the materials, vent systems, and terminations listed in 11-7 and 11-8 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.

WARNING!!!

due to ﬂ ammable materials or liquids. Do not store ﬂ ammable materials and liquids in the immediate vicinity of the heater.

WARNING!!!

must be clear and free from combustible materials, gasoline and other ﬂ ammable vapors and liquids, and corrosive liquids and vapors. Never use chlorine and hydrocarbon containing chemicals (such as spray chemicals, solution and cleaning agents, paints, glues etc.) in the vicinity of the heater. Do not store and use these chemicals in the heater room. Avoid excessive dust formation and build-up. Failure to comply could result in ﬁ re, severe personal injury, death, or substantial property damage.

WARNING!!!

fans, clothes dryers, and kitchen ventilation systems interfere with the operation of appliances, makeup air shall be provided. Failure to follow this warning could result in excessive levels of carbon monoxide, which can result in severe personal injury or death!

NOTICE! For installation in Canada, vent

pipe system must be certiﬁ ed to ULC-S636 (see Table 10-1).

NOTICE All vent pipes connections

must be secured following manufacturer instruction, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the heater (to allow drainage of condensate).

Use only

Figures

. DO NOT mix vent

Fire danger

Heater

Where exhaust

NOTICE! Vent pipe system shall

be installed in a way accumulation of condensate;

to prevent

11.10.1 - Combustion Air and Ventilation openings

WARNING!!!

combustion air and ventilation openings are sufﬁ ciently sized and no reduction or closure of openings takes place. Please note these restrictions and its dangers to the operator of the heater and to the homeowner.Failure to comply could result in severe personal injury, death, or substantial property damage.

Outdoor combustion air shall be provided through opening(s) to the outdoors.

Two Permanent Openings Method.

Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the room shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

1. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2 each 4000 Btu/hr (550 mm2/kW) of total input rating of all appliances located in the room.

2. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2 each 2000 Btu/hr (1100 mm2/kW) of total input rating of all appliances located in the room.

One Permanent Opening Method. One

permanent opening, commencing within 12 in. (300 mm) of the top of the room, shall be provided. The appliances shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directIy communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of 1 in2 each

Make sure that

Page 73

11 - INSTALLATION - Vent and combustion air

3000 Btu/hr (700 mm2 /kW) of the total input rating of all appliances located in the room

11.10.2 - Determine location

Locate the vent termination using the following guidelines:

1. The total length of piping for vent must not exceed the limits given in the Section 11.4.

2. You must consider the surroundings when terminating the vent: a. Position the vent termination where

vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The ﬂ ue 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 ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals.

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.

f. Do not terminate above any door or

window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

3. The vent piping must terminate in an elbow pointed outward as shown in Figures 11-15 or 11-16.

4. Maintain clearances as expected by “Venting of Equipment,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Venting Systems and Air Supply for Appliances” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of the local building codes. 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 4 feet below or horizontally from any door or window or any other gravity air inlet.

b. 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.Item

unique to CANADA: vent system shall terminate at least 6 ft from electrical and gas meters.

5. Locate termination so it is not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

WARNING!!!

exceed the maximum lengths of the outside vent piping shown in Figures 11-15 or 11-16. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential heater shutdown.

Do not

Page 74

11 - INSTALLATION - Vent and combustion air

11.11 - Sidewall termination - Two pipes

11.11.1 - Vent/air termination

WARNING!!!

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.

WARNING!!!

connect any other appliance to the vent pipe or multiple heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE 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.

A gas vent

Do not

11.11.2 - 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 Section 11.4.

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 ﬂ ue 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 ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals.

e. Do not locate the terminations

f. Do not terminate above any door

or window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

Page 75

11 - INSTALLATION - Vent and combustion air

3. The air piping must terminate in a down-turned elbow as shown

Air intake

Flue exhaust

in Figures 11-15 and 11-16. This arrangement avoids recirculation of ﬂ ue 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 Figures 11-15 and 11-16.

Termination template

Bird screen

Grade/Snow level

Figure 11-15 Two pipes sidewall termination of air and vent

Air intake

Flue exhaust

Bird screen

Grade/Snow level

WARNING!!!

exceed the maximum lengths of the outside vent piping shown in Figures 11-15 and 11-

16. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential heater shutdown.

5. Maintain clearances as shown in Figures 11-15 and 11-16. 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;

c. Do not terminate closer than 6

feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 6 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.

Do not

Figure 11-16 Two pipes sidewall termination of

air and vent (if space permits)

Page 76

11 - INSTALLATION - Vent and combustion air

11.11.3 - Prepare wall penetrations

Air intake

Flue exhaust

Metal thimble

Termination template

Bird screen

Figure 11-17 Two pipes sidewall termination assembly

Vent terminals

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;

b. Insert a galvanized metal thimble in the

vent pipe hole as shown in Figure 11-17.

3. Use a 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 ﬂ oors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

11.11.4 - Termination and

ﬁ ttings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in Figures 11-15 and 11-16.

2. Maintain the required dimensions of the ﬁ nished termination piping as shown in Figures 11-15 and 11-16.

3. Do not extend exposed vent pipe outside of the building more than what is shown in Figures 11-15 and 11-16. Condensate could freeze and block vent pipe.

between edge of each air intake pipe Same distance for vent

Air intake

NOTICE! keep the air intake at min. 12” from grade or

snow line. Provide vent and air intake with bird screen

terminal

Figure 11-18 Two pipes multiple heaters vent terminations

11.11.5 - Multiple vent/air

terminations

1. When terminating multiple heaters terminate each vent/air connection as shown in Figure 11-18.

WARNING!!!

inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in Figure 11-18 for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent heater vents.

All vent pipes and air

Page 77

11 - INSTALLATION - Vent and combustion air

11.12 - Sidewall termination – Concentric

Overhang or roof

vent

11.12.1 - Description and usage

The termination kit must terminate outside the structure and must be installed as shown in Figure 11-19. The required concentric termination kit as well as combustion air and vent pipe materials are listed in Figures 11-7 and 11-8. The termination ending must be protected from rain, see Figure 11-20.

Vent

Combustion air intake

Grade / snow line

Figure 11-19 Concentric sidewall termination clearances

11.12.2 - Sidewall termination installation

1. Determine the best location for the termination kit (see Figures 11-19 and 11-20).

2. The total length of piping for vent or air must not exceed the limits given in Section 11-4.

3. 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 ﬂ ue 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 ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of ﬂ ue

products with people or animals

e. Do not terminate above any door or window.

Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent condensate

damage to exterior ﬁ nishes.

4. Cut one (1) hole 5 inch diameter into the structure to install the termination kit.

5. Install the Concentric vent kit following the concentric kit manufacturer’s instruction.

Figure 11-20 Concentric sidewall termination clearances

NOTICE! Ensure termination location clearance

dimensions are as shown in Figures 11-19 and 11-20.

CAUTION!!!

couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

6. 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 ﬁ eld-supplied

Page 78

11 - INSTALLATION - Vent and combustion air

11.12.3 - Multiventing sidewall terminations

When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 11-21. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gas.

Combustion air intake

WARNING!!!

connect any other appliance to the vent pipe or multiple heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

Vent

Do not

NOTICE! keep the terminals horizontally in the same

line and at min. 12” from grade or snow line.

Figure 11-21 Concentric sidewall multiple heaters terminations

Page 79

11 - INSTALLATION - Vent and combustion air

11.13 - Vertical termination - Two pipes

WARNING!!!

instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

WARNING!!!

connect any oher appliance to the vent pipe or multiple heaters to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

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.

Screen

Vent

above air

inlet and

above roof

or snow

line

Do not

11.13.1 - 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 Section 11.4.

2. 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.

3. 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 ﬂ ue products into the combustion air stream.

4. The vent piping must terminate at least 1 foot above the air intake. 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 apart and with the vent termination at least 1 foot above the air intake.

5. 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.

Alternate air intake location: air intake terminal may be located anywhere within 24” of vent terminal

Combustion air intake

11.13.2 - Prepare roof penetrations

1. Air pipe penetration: 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;

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 Figure 11-22 and listed in Section 11.13.1.

4. Follow all local codes for isolation of vent pipe when passing through ﬂ oors, ceilings, and roofs.

5. Provide ﬂ ashing and sealing boots sized for the vent pipe and air pipe.

11.13.3 - Termination and

ﬁ ttings

1. Prepare the vent termination and the air termination elbow (Figure 11-22) by inserting bird screens.

2. The air piping must terminate in a down-turned 180° return bend as shown in Figure 11-22. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of ﬂ ue products into the combustion air stream.

3. Maintain the required dimensions of the ﬁ nished termination piping as shown in Figure 11-22.

4. Do not extend exposed vent pipe outside of building more than shown in Figure 11-22. Condensate could freeze and block vent pipe.

Figure 11-22 Two pipes vertical terminations of air and vent

above roof or snow line

Page 80

11 - INSTALLATION - Vent and combustion air

11.13.4 - Multiple vent/air

terminations

Air intake

NOTICE! keep the terminals at min. 12” from grade or

snow line. Provide vent and air intake with bird screen.

Vent

Air intake

Vent

vertically from vent outlet to any air inlet

from edge of air intake pipe to adjacent vent pipe from another heater

Figure 11-23 Two pipes Multiple heaters vertical terminations

1. When terminating multiple heaters, terminate each vent/air connection as shown in Figures 11-23 and 11-

24.

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another heater for U.S. installations (see Figure 10-23). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent heater vents.

WARNING!!!

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.

Terminate all

Vent

NOTICE! keep the terminals at min. 12” from grade or

snow line. Provide vent and air intake with bird screen.

Air intake

Vent

Air intake

Figure 11-24 Alternate vertical terminations with multiple heaters

vertically from vent outlet to any air inlet

Page 81

11 - INSTALLATION - Vent and combustion air

11.14 - Vertical termination – Concentric vent

11.14.1 - Description and usage

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 Figure 11-25.

11.14.2 - 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 Section 11.4.

2. The concentric terminal 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.

3. Locate termination so it is not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Vent

11.14.3 - Vertical termination installation

1. Determine the best location for the termination kit (see Figure 11-26).

2. The total length of piping for vent or air must not exceed the limits given in Section 11.4.

3. 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 ﬂ ue 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 ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals

e. Do not terminate above any door

or window. Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

4. Cut one (1) hole into the structure to install the termination kit.

5. Install the Concentric vent kit following the concentric kit manufacturer’s instruction.

NOTICE! Ensure termination location

clearance dimensions are as shown in Figures 11-25 and 11-26.

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 Figure 11-25.

CAUTION!!!

supplied couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

6. 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 ﬁ eld-

Combustion

Air

Roof boot /

ﬂ ashing

(ﬁ eld supplied)

Vent

Combustion Air

Combustion

Air

Figure 11-25 Concentric vertical terminations

(18” for Canada) Minimum clearance above highest anticipated snow level. Maximum of 24” above roof.

Support (ﬁ eld supplied)

Vent

Combustion air intake

Minimum clearance above snow level (18” for Canada) Maximum

24” above roof or snow level)

Figure 11-26 Concentric vertical terminations

Page 82

11 - INSTALLATION - Vent and combustion air

11.14.4 - Multiventing

vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see Figure 11-27).

WARNING!!!

common vent or breach vent this appliance to avoid possibility of severe personal injury, death, or substantial property damage.

When two or more direct vent appliances are vented near each other, two vent terminations may be installed as shown in Figure 11-27. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gases.

NEVER

Minimum

clearance

above snow

level (18”

for Canada)

Maximum 24”

above roof or

snow level)

Figure 11-27 Concentric multiple heaters vertical terminations

Combustion air intake

Page 83

12 - INSTALLATION - Gas supply

12.1 - Gas supply piping

WARNING!!!

the type and the pressure of the gas supplied correspond with those required for the heater as stated on the rating plate. Never use a gas different than that stated on the heater rating plate. Failure to comply with this warning can result in a ﬁ re or explosion causing extensive property damage, severe personal injury or death!

Connecting gas supply piping:

1. Refere to Figure 12-1 to pipe gas to the heater. a. Install ground joint union for

servicing, when required.

b. Install a manual shutoff valve in

the gas supply piping, outside heater jacket

c. Manual main shutoff valves, must

be identiﬁ ed by the installer.

2. Install sediment trap / drip leg. (see Figure 12-1).

3. Support piping with hangers, not by the heater or its accessories.

Check that

WARNING!!!

attempt to support the weight of the piping with the heater or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

4. Purge all air from the gas supply piping.

5. Before placing the heater in operation, check the heater and its gas connection for leaks. a. The appliance must be

disconnected from the gas supply piping system during any pressure testing of that system at a test pressure in excess of 1/2 PSIG (3.5 kPa).

b. The appliance must be isolated

from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas

connection must be leak tested before placing it in operation.

Do not

WARNING!!!

an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this WARNING could result in an explosion!

6. Use pipe sealing compound compatible with propane gas. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas ﬂ ow.

WARNING!!!

apply pipe sealing compound can result in severe personal injury, death, or substantial property damage.

WARNING!!!

typically shipped ready to ﬁ re on natural gas. Check heater rating plate to determine which fuel the heater is set for. If set to natural gas, it may be converted to LP following instruction on Section 12.6 or 12.7. Failure to comply could result in severe personal injury, death, or substantial property

Never use

Failure to

This heater is

damage.

INSTALL MANUAL SHUT-OFF VALVE 5 FT (1.5m) ABOVE FLOOR WHERE REQUIRED BY LOCAL CODES

GROUND JOINT UNION

SEDIMENT TRAP OR DRIP LEG

Figure 12-1 Gas supply piping

TO HEATER

WARNING!!!

shutoff valve, must be identiﬁ ed by the installer. Failure to comply could result in ﬁ re or explosion that can cause severe personal injury, death, or substantial property

damage.

Manual main

Page 84

12 - INSTALLATION - Gas supply

12.2 - Pipe sizing for natural gas

Refer to Figure 12-2 for pipe length and diameter. 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 13”W.C. with no ﬂ ow

(lockup) or with heater off.

• Minimum 3”W.C. with gas ﬂ owing

(verify during high ﬁ re).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 13”W.C. at any time. Adjust lockup regulator for 13”W.C. maximum.

12.3 - Propane Gas

WARNING!!!

are typically shipped ready to ﬁ re on natural gas. Check heater rating plate to determine which fuel the heater is set for. If set to natural gas, it may be converted to LP by following instruction on Section 12.6 or

12.7. Failure to comply could result in severe personal injury, death, or substantial property damage.

Pipe sizing for propane gas

Contact gas supplier to size pipes, tanks, and 100% lockup gas pressure regulator.

These heaters

Propane supply pressure requirements:

1. Adjust propane supply regulator provided by the gas supplier for 13”W.C. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 13”W.C. with no ﬂ ow

(lockup) or with heater off.

• Minimum 3”W.C. with gas ﬂ owing

(verify during high ﬁ re).

WARNING!!!

the high gas pressure regulator is at least 6 - 10 ft upstream of the appliance. Failure to comply could result in severe personal injury, death, or substantial property damage.

Ensure that

Iron Pipe size (in)

Nominal: 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4

Actual ID: 0.824 1.049 1.380 1.610 2.067 2.469 3.068 4.026

Length (ft) Capacity in Cubic Feet of Gas per Hour

10 273 514 1060 1580 3050 4860 8580 17500

20 188 353 726 1090 2090 3340 5900 12000

30 151 284 583 873 1680 2680 4740 9660

40 N/A 243 499 747 1440 2290 4050 8270

50 N/A 215 442 662 1280 2030 3590 7330

60 N/A 195 400 600 1160 1840 3260 6640

70 N/A 179 368 552 1060 1690 3000 6110

80 N/A 167 343 514 989 1580 2790 5680

90 N/A 157 322 482 928 1480 2610 5330

100 N/A 148 304 455 877 1400 2470 5040

125 N/A 131 269 403 777 1240 2190 4460

150 N/A 119 244 366 704 1120 1980 4050

175 N/A N/A 224 336 648 1030 1820 3720

200 N/A N/A 209 313 602 960 1700 3460

250 N/A N/A 185 277 534 851 1500 3070

NOTICE! Maximum pipe capacity is based on a 0.60 speciﬁ c gravity gas at a pressure of 0.5 PSIG and a

0.3”WC pressure drop

Figure 12-2 Gas pipe capacity for natural gas

Page 85

12 - INSTALLATION - Gas supply

12.4 - Check inlet gas supply pressure

WARNING!!!

adjust or attempt to measure 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 ﬁ eld adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing excessive levels of carbon monoxide, which can result in severe personal injury or death!

NOTICE! The maximum inlet gas

pressure must not exceed the value speciﬁ ed by the manufacturer and that the minimum value listed is for the purposes of input adjustment.

The gas piping must be sized for the proper ﬂ ow 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”W.C., the meter, regulator, or gas line is undersized or in need of service.

1. Follow Section 13.7 to check the inlet gas supply pressure.

2. If gas supply pressure is within normal range and no adjustments are needed, proceed on to step 4.

3. If the gas pressure is out of range, contact the gas utility, gas supplier, qualiﬁ ed installer or service agency to determine the necessary steps to provide proper gas pressure to the heater.

4. Turn the power switch to the “OFF” position.

5. Shut off the manual gas shut off valve.

6. After verifying the correct gas pressures disconnect the manometer, turn the screw in pressure connection “D” in Figure 12-6, clockwise until snug and check for any gas leaks.

DO NOT

CAUTION!!!

pressure connection screw or the gas valve will be damaged!

WARNING!!!

open ﬂ ame to check for gas leaks, or a ﬁ re or an explosion could result causing severe personal injury or death!

Never force the

Never use an

12.5 - Operating at high altitudes

The heater is rated for operation at altitudes up to 4500 ft (1371 m).

For altitude between 2000 ft and 4500 ft (1371 m) check and adjust the CO2 level following Section 13.8. This will result in a input downrate of a maximum of 10% at 4,500 ft (1371 m) altitude.

For installations at higher altitudes in the United States, follow local codes or, in the absence of local codes, follow ANSI

Z223.1/NFPA No. 54, The National Fuel Gas Code, and check and adjust the

CO2 level following Section 13.8.

Page 86

12 - INSTALLATION - Gas supply

020010.01.020

Figure 12-3 Dismantle the gas valve

020010.01.021

Figure 12-4 Lift the gas valve

12.6 - Convert a

heater model 199 from Natural Gas to Propane gas or viceversa

WARNING!!!

conversion shall be performed by a qualiﬁ ed service agency in accordance with this instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of ﬁ re or explosion or to prevent property damage, personal injury or death. The qualiﬁ ed service agency is responsible for the proper conversion of the heater. The installation is not proper and complete until the operation of the converted appliance is checked as speciﬁ ed in this instructions.

WARNING!!!

conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdition and in accordance with the requirements of the CAN-B149.1 and CAN1-B149.2 installation

code.

Contents:

The conversion kit (supplied with the heater) is composed of the following elements, which are necessary for the gas change:

- a label rating stating the new gas

setting;

- an instruction sheet;

- an oriﬁ ce per each burner present on

the unit;

Installing:

in order to make the gas change please follow the instructions below:

The gas

The

1 - turn off the power to the heater; 2 - gain access to the Factory Menu

in the follow way: press and hold in the same time buttons RESET and

and then, turn the power on; display will enter the Factory Menu (parameters 3000);

3 - using push buttons

, select the parameter 3002.

4 - Press RESET button once a time,

the value of the 3002 parameter will start to blinking. Now you can

change its value by buttons

and ;

5 - Using Figure 12-7 select the right

parameter 3002 value for the heater you are converting to LP gas or viceversa;

6 - Press RESET button to save the

new value;

7 - turn the power off to the heater; 8 - close the manual gas shut off valve; 9 - dismantle the jacket of the heater,

follow Section 15.2;

10 - unscrew nut “H” as per Figure

12-3;

11 - with the help of a screwdriver,

remove spring “A” (see ﬁ gure 12-3);

12 - remove the gas valve from its site

“C” as per Figure 12-4 (take care attention to o-ring “L” of Figure 12-

4);

13 - replace oriﬁ ce “G” of Figure 12-5,

for the correct one for type of gas used. Verify that the stamping on the oriﬁ ce matches the Figure 12-7;

14 - reistall the gas valve, taking care

attention to the o-ring “L” of Figure 12-4 and to the gasket between gas valve and nut “H” of Figure 12-3;

15 - Insert againt the spring “A” of

Figure 12-3;

16 - tight nut “H” of Figure 12-3; 17 - open the manual gas shut off

valve;

18 - check for any gas leaks on nut “H”

of Figure 12-3;

WARNING!!!

open ﬂ ame to check for gas leaks, a ﬁ re or an explosion could result causing severe personal injury or death!

Never use an

and

Page 87

12 - INSTALLATION - Gas supply

020010.01.019

Figure 12-5 Gas oriﬁ ce

020010.01.022

Figure 12-6 Gas valve

19 - turn the power on to the heater; 20 - turn completely counter clockwise

the screw “E” of Figure 12-6;

Checking gas supply pressure

21 -

following Section 13.7. The minimum

gas supply pressure must not be less than 3”WC (7.6 mbar) and the maximum gas supply pressure must not be higher than 13”WC (33 mbar).

22 - Verifying the CO2 rate and its

eventual adjustment following Section

13.8: The heater during its normal operation, within a maximum altitude of 4500 ft, has a CO2 exhaust rate as shown in Figure 12-7. If not within range of value shown, malfunctions will occur.

WARNING!!!

(carbon monoxide) level should not exceed values given in Figure 12-7, when combustion is correct. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

The CO

WARNING!!!

measurements must be performed with calibrated equipment to ensure proper reading and accuracy. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

WARNING!!!

combustion levels are not within the range given in Figure 12-7 for the ﬁ ring rate, shut the heater down and contact your distributor or the heater manufacturer (see reference in the last cover page). Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

23 - check the capacity of the heater

following Section 13.9

24 - Attach to the front of the heater the

appropriate conversion label, found in the conversion kit (see Figure 12-8 or Figure 12-9), stating the new type of gas adjustment of the heater. a - Apply the label in Figure 12-8 if the

heater has been converted to LP GAS;

b - Apply the label in Figure 12-9 if

the heater has been converted to

NATURAL GAS.

All combustion

If the

Appliance model

199 Natural gas 0 No oriﬁ ce 8.4 to 8.7 8.4 to 8.7 5.9 to 5.4 5.9 to 5.4 less than 150 199 LP gas 1 700 9.5 to 10 10.5 to 11.5 6.4 to 5.6 4.8 to 3.4 less than 250 399 Natural gas 0 No oriﬁ ce 8.4 to 8.7 8.4 to 8.7 5.9 to 5.4 5.9 to 5.4 less than 150 399 LP gas 1 700 9.5 to 10 10.5 to 11.5 6.4 to 5.6 4.8 to 3.4 less than 250 500 Natural gas 2 930 8.8 to 9.1 8.8 to 9.1 5.2 to 4.7 5.2 to 4.7 less than 150 500 LP gas 3 700 9.5 to 10 10.5 to 11.5 6.4 to 5.6 4.8 to 3.4 less than 250 750 Natural gas 2 930 8.8 to 9.1 8.8 to 9.1 5.2 to 4.7 5.2 to 4.7 less than 150 750 LP gas 3 700 9.5 to 10 10.5 to 11.5 6.4 to 5.6 4.8 to 3.4 less than 250 1000 Natural gas 2 930 8.8 to 9.1 8.8 to 9.1 5.2 to 4.7 5.2 to 4.7 less than 150 1000 LP gas 3 700 9.5 to 10 10.5 to 11.5 6.4 to 5.6 4.8 to 3.4 less than 250

Gas Type 3002 par

value

setting

/ / Stamping % % % % ppm

Figure 12-7 Settings of the heater for NATURAL GAS and LP GAS

Oriﬁ ce CO2

content at

high ﬁ re

CO2

content at

low ﬁ re

content at

high ﬁ re

O2 content

at low ﬁ re

CO content at high

and low ﬁ re

Page 88

12 - INSTALLATION - Gas supply

Figure 12-8 Label for LP gas heater

12.7 - Convert a heater model 399, 500, 750 or 1000 from Natural Gas to Propane gas or viceversa

Appliances model 399, 500, 750 or 1000 are multiburner appliances. This means that the gas conversion must be performed on each burner present inside the unit.

WARNING!!!

conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdition and in accordance with the requirements of the

CAN-B149.1 and CAN1-B149.2 installation code.

The gas

The

Contents:

The conversion kit (supplied with the heater) is composed of the following elements, which are necessary for the gas change:

- a label rating stating the new gas setting;

- an instruction sheet;

- an oriﬁ ce per each burner present on the unit;

Installing:

in order to make the gas change please follow the instructions below:

1. operate to convert the “Burner 1 (Master)”. See Figures 3-6 and 3-9 to identify “Burner1 (Master)”;

2. operating on “Burner 1 (Master)” follow exactly Section 12.6 from point 1. to 22..

After converting “Burner 1 (Master)” you have to operate on “Burner 2” (See Figure 3-6 and 3-9) and:

3. turn off the main power to the appliance;

4. disconnect plug “B” from connector “A” (See Figure 12-10);

5. connect plug “B” to connector “C” (see Figure 12-10);

6. follow exactly Section 12.6 from point 1. to 22.;

After converting “Burner 2” you have to operate on “Burner 3”, if present (See Figure 3-6 and 3-9), and:

7. turn off the main power to the appliance;

8. disconnect plug “B” from connector “C” (See Figure 12-10);

9. connect plug “B” to connector “D” (see Figure 12-10);

10. follow exactly Section 12.6 from point 1. to 22.;

After converting “Burner 3” you have to operate on “Burner 4”, if present, (See Figure 3-6 and 3-9) and:

Figure 12-9 Label for Natural gas heater

11. turn off the main power to the appliance;

12. disconnect plug “B” from connector “D” (See Figure 12-10);

13. connect plug “B” to connector “E” (see Figure 12-10);

14. follow exactly Section 12.6 from point 1. to 22.;

Page 89

12 - INSTALLATION - Gas supply

Burner 2

Burner 1 (Master)

After converting all burners:

15. connect plug “B” to plug “A” (See Figure 12-10)

16. check the inlet gas pressure of the unit, following Section 13.7;

17. check the capacity input of the unit following Section 13.9;

18 - Attach to the front of the heater

the appropriate conversion label, found in the conversion kit stating the new type of gas adjustment of the heater as follow: a - Apply the label in Figure 12-8 if

the heater has been converted to

LP GAS;

b - Apply the label in Figure 12-9 if

the heater has been converted to

NATURAL GAS.

Burner 3

Burner 4

A = Connector coming from Burner 1 (Master) B = Connector coming from display C = Connector coming from Burner 2 D = Connector coming from Burner 3 (Present only on models 750 and 1000) E = Connector coming from Burner 4 (Present only on model 1000)

Figure 12-10 Moving display connection

Page 90

13 - START-UP

13.1 - Operating

Before starting the heater, the following must be done.

13.1.1 - User instructions

The user must be correctly instructed by the installer, on how to operate the heater, in particular:

Make sure that the user understands

that combustion air and ventilation openings must not be restricted/ closed/ or mdiﬁ ed in any way.

Make sure that the user is informed

of all the special measures to be taken for combustion air inlet and discharging ﬂ ue gases, and that these must not be modiﬁ ed in any way.

Make sure that the user keeps this

manual and all other documentation included with the heater.

Make sure that the user understands

never to tamper with gas control settings and the risk of CO poisoning should an unauthorized individual do so.

Make sure that the user knows how

to adjust temperatures, controls and the room thermostats for maximum efﬁ ciency.

13.1.2 - Filling the condensate and neutralizing box

The condensate and neutralizing box is positioned inside the heater as shown in Figures 3-3 through 3-8, item “3”. It must be ﬁ lled with water to prevent the leakage of ﬂ ue gases from the condensate drainpipe, item “5” in Figures 3-3 through 3-8. To ﬁ ll and inspect the condensate box proceed follow Section 15.6.

WARNING!!!

off for more than 3 months, repeat the above operation to again ﬁ ll the condensate trap. Failure to follow this warning could result in excessive levels of carbon monoxide, which can result in severe personal injury or death!

If heater stays

13.1.3 - Filling the heating system

WARNING!!!

appliance is used like a direct ﬁ re potable water heater, never use additives or toxic heater treatment chemicals in the water system as they can cause serious health problems or possibly death.

WARNING!!!

non-approved additives or toxic heater treatment chemicals in the heating system as they can cause serious health problems or possibly death. Any additives introduced into the heating system must be recognized as safe by the United States Food and Drug Administration.

CAUTION!!!

must be ﬁ lled with clean water and with maximum hardness of TDS 200 ppm. Contaminated or harder water can damage the heat exchanger.

CAUTION!!!

fall within the following limit:

7.5<pH<9.5 and if the system contains aluminium parts, it must be 7.5<pH<8.5. This pH value must be measured after steady condition and after air purging operations has been done (death water condition). Water out from the above pH values can result in premature heat exchanger damage.

To ﬁ ll the heating system, proceed as follows:

1. open any automatic air vent in the heating system;

2. open the ﬁ ll valve and proceed to ﬁ ll the heating system and boiler until the pressure gauge, item “M” in Figure 14-1, reads the pressure for that the heating system is sized and “FILL” disappears from the display; (“FILL” displaing is set at 15PSI. If you want to increase the “FILL” intervention level, set parameter 3022 to the desired value (See

If this

Never use

The heating system

The water’s pH must

Section 19)

3. check that there is no water leaking from the ﬁ ttings. If there is, the leaks must be eliminated;

4. close the ﬁ ll valve;

5. check the pressure gauge during the purging process. If the pressure has dropped, re-open the ﬁ ll valve to bring the pressure back to the desired value.

13.2 - General

warnings concerning gas supply

When starting up the heater for the ﬁ rst time the following must be checked:

That the heater is supplied with the

type of fuel that it is conﬁ gured to use. Read Section 12.

That the gas supply system is

provided with all the safety devices and controls required under current national and local codes.

That the vent and combustion air

terminals are properly connected (see Section 11) and free from any blockages.

That the condensate drain tube is

properly connected (see Section 9).

CAUTION!!!

inside heat exchanger, gas used should have sulphur rates inside maximum annual peak over a short period of time of 150 mg/ m3 and an annual average of 30 mg/m3.

WARNING!!!

If you smell gas:

 Do not try to light any appliance.  Do not touch any electrical

switch. Do not use any phone in your building.

 Immediately call your gas

supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

 If you cannot reach your gas

supplier, call the ﬁ re depart-ment. Failure to follow the above steps can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

To avoid corrosion

Page 91

13 - START-UP

13.3 - Conﬁ rming the heater’s gas type

The type of gas and the gas supply pressure that the heater is set up for is listed on the rating label.

The heater can operate using one of the following two gases:

NATURAL GAS

Maximum supply pressure = 13 in.W.C.

(33.0 mbar).

Minimum supply pressure = 3 in.W.C.

(7.6 mbar).

LP Gas

Maximum supply pressure = 13 in.W.C.

(33.0 mbar).

Minimum supply pressure = 3 in.W.C.

(7.6 mbar).

13.4 - Gas type conversion

If the gas available at the installation site is not the type the heater is conﬁ gured to use, the heater must be converted. Special conversion kits are available for this purpose inside the heater. Follow instruction on Sections 12.6 and 12.7.

WARNING!!!

of the heater to use another type of gas must be carried out by a qualiﬁ ed technician. Improper conversion of the heater could result in a ﬁ re or an explosion causing severe personal injury or death!

Conversion

13.5 - Start-up

13.5.1 - Start-up of the IB boiler

1. Open the manual gas shut off valve (Figure 12-1).

2. Switch the on/off power switch, item “T” in Figure 14-1, to “on”.

3. The heater will ﬁ re only when the room thermostat calls for heat and the heating temperature settings

is higher than the actual supply

temperature. Press buttons

or heating temperature. If the external temperature sensor is connected (See Section 10.1.3), check that the calculated temperature (See Section

14.13, parameter 1012 or parameter 1107 for heater models 399 to 1000) is higher than the actual heater temperature and that the outdoor temperature (See Section 14.13, parameter 1004) is lower than “warm wheather shut down temperature”, (parameter 2020 into Section 14.14).

4. If the heater is connected to an indirect water heater (See Section

7.2.6) press buttons and

domestic hot water temperature.

5. If the display gives a Low water ﬂ ow error (see Section 14.17), repeat the air purging operations.

to select the desired

4. close the manual gas shutoff valve,

5. after 3 minutes, the display must show

NOTICE! On unit models 750 and 1000,

6. open the manual gas shutoff valve,

7. verify your gas meter. Gas ﬂ ow must

13.5.1 - Start-up of the IW

water heater

1. Open the manual gas shut off valve (Figure 12-1).

2. Switch the on/off power switch, item “T” in Figure 14-1, to “on”.

3. The heater will ﬁ re only when the supply temperature settings is higher than the actual supply temperature.

Press buttons or to select the desired supply temperature.

4. If the display gives a Low water ﬂ ow error (see Section 14.17), repeat the air purging operations.

13.6 - Ignition control

testing

After placing the heater in operation, the ignition control’s safety shutoff function must be tested as follow:

1. turn the power switch (item “T” in Figure 14-1) to on;

2. follow Section 13.5 to create a call for heat;

3. wait a few minutes for the burner to

light-up as indicated by icon . On units model 399 and 500, wait until

 and  are displayed.

icons On units model 1000 wait until icons

 and  are displayed.

see Figure 11-1;

Loc 01 and or, on models 399 to 1000 all burners icons will blinking and

the icon is displayed;

because they have 3 and 4 burners, the time to see all burners icons blinking, can arrive at 15 - 20 minutes

see Figure 12-1;

be zero.

WARNING!!!

occurs, close the manual gas shutoff valve and troubleshoot the system to determine why there is gas ﬂ ow when the gas valve should be deenergized. Do not operate the heater until the problem is resolved or a ﬁ re or explosion causing property damage, personal injury or loss of life may occur!

If gas ﬂ ow

icons  and  are present on the

display. On units model 750 wait until

Page 92

13 - START-UP

13.7 - Gas supply pressure checking

WARNING!!!

adjust or attempt to measure gas valve outlet pressure. gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no ﬁ eld adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the gas valve, causing carbon monoxide, which can result in severe personal injury or death!

Check the gas supply pressure by following the steps below:

1. close the manual gas shut-off valve, Figure 12-1;

excessive levels of

Figure 13-1 Gas valve

DO NOT

The

020010.01.022

2. follow the steps in Section 15.2 to remove the front cover;

3. turn the screw in pressure port “D” shown in Figure 13-1 three turns counterclockwise;

4. connect a manometer with graduations of at least 0.1 in.W.C.

(0.25 mbar) to the inlet gas port

“D” shown in Figure 13-1 (on unit model 399 to 1000, choose the pressure port “D” from any gas valve present).

5. open the manual gas shut off valve, Figure 12-1;

6. check that the gas supply pressure does not exceed 13 in.W.C. If the gas supply pressure is higher than 13 in.W.C. adjust the upstream gas pressure regulator to bring the gas supply pressure between 12”WC and 13”WC;

7. turn the power switch to on and generate a heat demand by

pressing button to its maximum setting. Also ensure that the room thermostat is calling for heat and operate downstream the

WARNING!!!

adjust the screws “E” and/or “F” (Figure 13-1). These screws are factory-set for the correct gas ﬂ ow and outlet pressure. Attempting to alter the gas valve setting could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

DO NOT

D - Inlet gas pressure

probe

E - CO2 adjusting screw F - Factory adjusted

regulator (Should never be touched)

unit to veriﬁ y the system is able to dissipate all heat generated.

8. give 3 minutes to each heat exchanger to reach the maximum capacity. Check parameters 1120 up to 1123 (Section 14.13) to see the modulating level. Must be at 100% per each heat exchanger.

9. check the manometer to make sure the gas supply pressure does not drop below 3 in.W.C. (7.6 mbar). If the gas supply pressure is lower than 3 in.W.C. means that your inlet gas line or your gas pressure regulator are not correctly sized;

CAUTION!!!

to adjust your upstream gas pressure regulator. This was already adjusted for the maximum inlet gas pressure.

WARNING!!!

After verifying the correct gas pressures:

1. push button up to see OFF word on Display to bring the unit into stand-by;

2. close the manual gas shut-off valve, Figure 12-1;

2. disconnect the manometer;

3. turn the screw in pressure connection “D” in Figure 13-1, clockwise until snug;

4 check pressure port “D” (Figure 13-

1) for any gas leaks.

CAUTION!!!

pressure connection screw or the gas valve will be damaged!

WARNING!!!

open ﬂ ame to check for gas leaks, a ﬁ re or an explosion could result causing severe personal injury or death!

Do not attempt

DO NOT

Never force the

Never use an

Page 93

13 - START-UP

13.8 - Checking and adjusting CO2 levels

Figure 12-7 lists the correct CO2 ranges for a heater running at normal operating conditions at an altitude below 4500

ft (1371m). CO2 values outside of the

ranges given in Figure 12-7 may lead to malfunctioning of the heater and cause it to prematurely fail. To check the CO2 value, carry out a combustion analysis follow Section 13.8.1 or 13.8.2.

13.8.1 - Checking CO2 level on units model 199

WARNING!!!

procedure compare also CO (carbon monoxide) reading, with the value given in Figure 12-7. If this is higher, STOP the heater and call the Factory service department (see phone number on the last cover page). Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

1. If it is not already present, create a combustion analisys probe site at 8” after the ﬂ ue gas exhaust connection (see Figures 11-9, 11-11 or 11-13, item “H”). To do so, follow the vent pipe manufacturers’ instruction.

2. generate a call for heat and wait until the heater is ﬁ ring;

3. gain access to the “Installers’ menu” and set parameter 2010 to HIGH (see Section 14.14). The heater will now run for 20 minutes at high ﬁ re input;

4. wait 2 to 3 minutes for the CO2 to stabilize;

5. insert the probe of a calibrated combustion analyzer into the combustion analisys probe “H” of Figures 11-9, 11-11 or 11-13 and take a ﬂ ue gas sample;

During this

2.5mm Allen Wrench to turn the screw (clockwise to reduce the CO2 level, counter-clockwise to increase the CO2 level) in small increments and wait for the CO2 to stabilize to prevent overshooting the desired value;

7. when CO2 level match the value of Figure 12-7, seal screw “E” with red paint or nail polish to discourage tampering.

8. set value of parameter 2010 to LOW. The heater will now run for 20 minutes at low ﬁ re input;

9. wait 2 to 3 minutes for the CO2 to stabilize;

10. compare the CO2 reading with the low ﬁ re range given in Figure 12-7, making sure to use the range for the gas type in use. The CO2 reading must be inside the speciﬁ ed range; If not, STOP the heater and call the Factory service department (see phone number on the last cover page).

11. set parameter 2010 to OFF to return the heater to its normal operating mode.

12. close the combustion analisys probe “H” of Figures 11-9, 11-11 or 11-13 with a suitable cap in accordance with the vent pipe manufacturers’ instruction.

WARNING!!!

cap “L” of Figures or 11-13 the heater at high ﬁ re, check that it is absent from leakage and is mechanically ﬁ xed. Improper cap ﬁ xing can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

is right in place, with

Once the

11-9, 11-11

13.8.2 - Checking CO2 level on units model 399 up to 1000

WARNING!!!

1. If it is not already present, create a combustion analisys probe site at 8” after the ﬂ ue gas exhaust connection (see Figures 11-9, 11-11 or 11-13 item “H”). To do so, follow the vent pipe manufacturers’ instruction.

2. keep the heater in stand-by by removing any call for heat (remove the room thermostat jumper, if present, inside the junction box or set the heating service to off by pushing

on the OFF word

3. gain access to the Installer menu and set parameter 2010 to HIGH (see Section 14.14). Now the “Burner 1 (Master) will run for 20 minutes at high ﬁ re input;

4. wait 2 to 3 minutes for the CO2 to stabilize;

5. insert the probe of a calibrated combustion analyzer into the combustion analisys probe “H” of Figures 11-9, 11-11 or 11-13 and take a ﬂ ue gas sample;

6. compare the CO2 reading with the high ﬁ re range given in Figure 12-7, making sure to use the range for the gas type in use. If the CO2 reading is outside the speciﬁ ed range, it must be adjusted operating on the “E” screw of Figure 13-1 of the gas valve closer to the burner unit in ﬁ re. Use a 2.5mm Allen Wrench to turn the screw (clockwise to reduce the CO2 level, counter-clockwise to increase the CO2 level) in small increments and wait for the CO2 to stabilize to prevent overshooting the desired value;

);

During this

button up to see the

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13 - START-UP

7. when CO2 level match the value of Figure 12-7, seal screw “E” (Figure 13-1) with red paint or nail polish to discourage tampering.

8. set value of parameter 2010 to LOW. The master Burner 1 (Master) will now run for 20 minutes at low ﬁ re input;

9. wait 2 to 3 minutes for the CO2 to stabilize;

11. turn off the main power to the appliance;

12. disconnect plug “B” from connector “A” (See Figure 12-10);

13. connect plug “B” to connector “C” of the “Burner 2”) (see Figure 12-

10);

14. turn on the main power to the appliance;

15. follow steps as described in sections (3 through 10);

16. turn off the main power to the appliance;

17. disconnect plug “B” from connector “C” and connect it to connector “D” of the “Burner 3”, if present (See Figure 12-10);

18. turn on the main power to the appliance;

19. follow steps as described in sections (3 through 10);

20. turn off the main power to the appliance;

21. disconnect plug “B” from connector “D” and connect it to connector “E” of the “Burner 4”, if present (See Figure 12-10);

22. turn on the main power to the appliance;

23. follow steps as described in sections (3 through 10);

24. turn off the main power to the appliance;

25. close the combustion analisys probe “H” of Figures 11-9, 11-11 or 11-13 with a suitable cap in accordance with the vent pipe manufacturers’ instruction.

WARNING!!!

is right in place, with

Once the

11-9, 11-11

13.9 - Check the capacity input

The heater has a factory-set air/gas ratio. The pressure of the gas at the burner is indirectly controlled by the blower. The only way to check the heater capacity input is operating directly on the gas meter. To do so proceed as follow:

1. turn the power switch (item “T” in Figure 14-1 ) to on a call for heat by pressing button

to its highest settings, and operate downstream the unit to veriﬁ y the system is able to dissipate all heat generated.

2. give 3 minutes to each heat exchanger to reach the maximum capacity. Check parameters 1120 up to 1123 to see the modulating level. Must be at 100% per each heat exchanger. 199, gain access to the installer menu (See Section 14.13) and set parameter 2010 to HIGH.

3. measure the capacity input to the gas meter. This must match with the value given in Section 16 header “Maximum heat input” with a tolerance of +/- 10%. (For the calculation of the btu/hr, for Natural gas, multiply the measured ﬂ ow in ft3/hr by 1075. For LP gas multiply the measured ﬂ ow in ft3/hr by

2500).

and perform

On unit model

4. if the capacity input is too low, check: a) that there are no obstructions in

the combustion air and/or vent systems;

b) check that the ﬂ ue and air intake

length match with the rules of Section 11.4.;

c) check that the inlet air ﬁ lter (see

Figure 15-9 item B) is clean;

5. if the capacity input is within

tolerance, press button to see OFF word on the display to bring the unit in stand-by. On unit model 199, to OFF to return the heater to its normal running mode;

6. if the capacity input is higher than the expected value, repeat the procedure as per Section 13.8.

bring parameter 2010

13.10 - Minimum

water ﬂ ow

This unit is self protected against low water ﬂ ow. A water ﬂ ow meter (item “16”, Figure 3-1) monitor continuously the water ﬂ ow to each heat exchanger. If the water ﬂ ow decrease below the minimum stated (4 GPM), the burner automatically shuts Off and after 3 minutes an error is displayed.

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020010.01.023

A - Key to reduce the supply water temperature; B - Multifunctional key: reset any lockouts; access to user and installer menu. C - Key to increase the supply water temperature; D - Flame icon, is present when the ﬂ ame is present; E - Radiator icon. Present when heater is enabled to work. Blinking when heater working; F - Faucet icon. Present when an indirect water heater (coil water heater) is enabled. Blinking when an indirect water heater (coil water heater) is loading; H - Unit of measure of the water system pressure L - Burner unit indicators: Light when burner is burning; blinking when burner is in lockout or in blocking error

 = Burner 1 (master)  = Burner 2  = Burner 3  = Burner 4

M - Water pressure gauge and indicator of the parameters G - Icon indicating access to the installer menu N - Supply water temperature gauge and indicator of the parameters value O - Unit of measure of the temperature P - Icon displayed when the outdoor sensor is active Q - Flame crossed icon: is present when the appliance is in lockout or blocking error condition R - Multifunctional key: increase the indirect water heater (coil water heater) temperature; scroll the parameters; increase the parameters’ value; S - Multifunctional key: decrease the indirect water heater (coil water heater) temperature; scroll the parameters; decrease the parameters’ value; T - On-Off Main power switch

Figure 14-1 Instrument panel and main power switch

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14.1 - Check water pressure

14.1.1 - Check water pressure on IB boiler

If the pressure inside the water circuit falls below the minimum pressure for the system, the appliance switches off and the display “N” as per Figure 14-1, shows Err 59 to indicate that it is necessary to restore the correct pressure. Open the ﬁ lling valve and check the pressure on the pressure gauge “M” of Figure 14-1, the word Err 59 will disappear when the pressure back at the right value. To prevent accidental relief valve openings, ﬁ ll the circuit slowly.

CAUTION!!!

operations, the ﬁ lling valve must always remain in the closed position.

If, with time, the pressure drops, restore the correct value. This operation may have to be repeated several times during the ﬁ rst month of operations to remove any air bubbles present. If after one month the pressure continue to decrease, call a qualiﬁ ed service technician.

CAUTION!!!

14.1.2 - Check water pressure on IW water heater

During normal

Continual fresh

you have to check for the net water pressure or for any pressure reducer upstream yhe water supply circuit. When the pressure is restored the Err 59 will disappear.

14.2 - Overview

The heater is pre-set with standard parameters. However, it is possible to make a number of changes or consult the parameters by means of using the “Users’ Menu” (see Section

14.13) and the “Installers’ Menu” (see Section 14.14). During functioning display “N” of Figure 14-1, displays the supply temperature, and display “M” (see Figure 14-1) shows the pressure of the water. The various operating statuses are shown with other icons as per Figure 14-1.

14.3 - Displays

During normal operations, the display remain permanently off, except appliance go into Lockout, or in Blocking error. In any case, pressing any key, display will light on and will stay light on for 5 minutes from the last pressing key.

14.4 - Start-up procedure

1. Open the manual gas shutoff valve;

2. switch on electric power to the heater;

3. If the display shows code Err 65, it means that the polarity has not been observed (Call service department to restore the situation, do not attempt to repair it);

4. press key or to setup the supply temperature desired, then press RESET key to save the changement.

5. press key and to setup the indirect water heater desired temperature, then press RESET key to save the changement.

The ﬂ ame control appliance will start- up the burner. If the burner fails to ignite within 60 seconds, the heater will automatically attempt ignition another four times, after which if it fails to start-up, it will

shut down and the display will show

Loc 1 together icon

Units models 399 up to 1000, because are multiburner, when the they go into any lockout or blocking

error display will show the icon and the corresponding burner icon in

 or  ) that blink.

fail (

Press the RESET key in order to reset normal operating conditions. On units model 399 up to 1000, to restore the normal operating condition, press RESET key one time, diplay will show the type of lockout, than press again RESET key (to back in normal display mode, press and hold for at least 5 seconds RESET key). The heater will automatically attempt another start-up.

CAUTION!!!

frequently shuts down, contact a qualiﬁ ed technician to restore normal running conditions. Do not attempt to repair it.

If the appliance

14.5 - IW supply water temperature adjustment

The water heater provides hot water at the temperature set by adjusting keys

or as shown in Figure 14-1. When the keys are pressed, the display, item “N” in Figure 14-1, shows the supply water setpoint being selected. The range within which the water can be set is 68°F (20°C) to 176°F (80°C).

WARNING!!!

temperature over 125°F (51°C) can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. Feel water before bathing or showering.

Water

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14.6 - IB boiler

- Indirect water heater temperature adjustment

If the heater is installed to perform double service (heating and domestic hot water by an indirect water heater), to control the indirect water heater temperature you have to use keys

and . When the keys are pressed, the display, item “N” in Figure 14-1, shows the indirect water heater setpoint being selected. The range within which the indirect water heater can be set is 104°F (40°C) to 140°F (60°C).

WARNING!!!

temperature over 125°F (51°C) can cause severe burns instantly or death from scalds. Children, disabled and elderly are at highest risk of being scalded. Feel water before bathing or showering.

Water

14.7 - IB boiler

- Heating temperature adjustment

The boiler supply hot water at the temperature set by adjusting keys

or as shown in Figure 14-1. The room thermostat turns the circulator pumps on in order to satisfy the heat demand of the rooms controlled by the thermostat. To maximize the heaters’ performance, the heating temperature, should be set at a value that is just sufficient to maintain the desired temperature of the rooms. As the weather gets colder, progressively increase the heating water temperature

by key . When the weather gets milder turn the water temperature down.

14.8 - IB boiler

- Outdoor reset adjustment

While in the “Installers’ Menu” (Section

14.14), set the 2003 parameter to

01. In this mode the heating supply temperature, calculated temperature in Figure 14-2, will be adjusted automatically based on the input from the outdoor temperature sensor. The relationship between the outdoor temperature and the supply water temperature, corresponds with the graphs shown in Figure 14-2. In order to change the relationship between the supply water temperature and the outdoor temperature, all the parameters listed in the sections below must be set.

14.8.1 - Outdoor reset applications

Outdoor reset is a sophisticated way to maximize comfort and boiler efﬁ ciency. When making adjustments to change the supply temperature, it is advisable to ﬁ rst set the suggested default values for the desired curve shown in Figure 14-2. If these default values do not produce a satisfactory result, then proceed to make the appropriate adjustments bearing in mind that: A - each parameter must be very

gradually;

B - after each parameter change, wait

at least 24 hours in order to see the result;

C - the closer the adjustment curve

matches the actual load of the building, the greater the comfort and the energy savings will be;

14.8.2 - Outdoor reset: setting parameters

Refer to Section 14.14 and set:

- 2020 = “Warm weather shutdown temperature”. When the outdoor temperature drops this value the heating system is forced to shutdown. Suggested starting value is 72°F (22°C).

- 2022 = “Winter supply temperature”. Is the supply temperature correspondent to the “Winter outdoor temperature” (parameter 2021). Suggested values are 104°F (40°C) for ﬂ oor radiant panels or 158°F (70°C) for radiators heating systems.

- 2023 = “Spring outdoor temperature”. Is the typical spring outdoor temperature you want the heating service to the minimum capacity. Suggested value is 64°F (18°C).

- 2024 = “Spring supply temperature”. Is the supply temperature correspondent to the “Spring outdoor temperature” (parameter 2023). Suggested values are 86°F (30°C) for ﬂ oor radiant panels or 108°F (42°C) for radiators heating systems.

Once selected, reset adjustment is completely automatic and will switch off at the end of the heating season and switch back on at the beginning of the heating season. When the outdoor temperature is higher than parameter 2020 (“Warm weather shutdown temperature”) the heating service switches off. When the outdoor temperature reduce below parameter 2020 (“Warm weather shutdown temperature”), the heating service switches back on. If, for some reason the heating service doesn’t match the load, using parameters 2022 (during cold winter) and 2024 (during spring season), to rise or lower the calculated temperature and match the desired room temperature.

- 2021 = “Winter outdoor temperature”. Is the design winter temperature used for the basic heat load calculation.

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Supply calculated temperature (°F)

Par. 2021

Par. 2023

Par. 2020

Par. 3015 = Maximum supply temperature

Par.

3016 = Minimum supply temperature

Par. 2020 = Warm weather shutdown temperature

Par. 3016

Outdoor temperature (°F)

Par. 2024

Par. 2022

Par. 3015

Par. 2021 = Winter outdoor temperature Par. 2022 = Winter supply temperature

2023 = Spring outdoor temperature

Par.

2024 = Spring supply temperature

Figure 14-2 - Graph of the outdoor reset settings

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14.9 - Delays,

alarms and protective actions

To protect the life of the appliance, improve comfort, and maximize energy savings, the following timings have been incorporated into the control logic: a - Pump delay: each time the room

thermostat is satisﬁ ed, the circulator pump continues to run for 4 minutes;

b - DHW delay: each time the domestic

hot water demand is satisﬁ ed, a 4 minutes delay pass before the end of the service;

c - Time delay in restarting the burner:

in its normal functioning state, every time the burner stops, there is a delay time of 3 minutes before the burner starts again.

14.10 - Circulator

pump protection

During stand by state, circulators pumps run once a day for around 15 seconds to prevent them from seizing.

14.11 - Heater’s

Freeze protection

CAUTION!!!

the antifreeze protection of your house to the heater. Because the heaters’ function depends from the electrical supply and from the gas supply and because a trouble can stops the heaters, if you live your house, it is mandatory install a safety device that alarm the user in a case the house will reach a temperature near 40°F (4°C).

Once the heater has reached a

temperature of 50 °F (10 °C), the

heating pump will automatically comes on. If the temperature falls

below 41 °F (5 °C), the burner will

light to prevent the heater from freezing. If the heater will not be used for long time it should be drained per Section

15.9.

do not demandate

14.12 - Display in energy saver mode

The display, in Figure 14-1, is switched off each time no key is touched for at least 5 minutes, with the exception of when it displays errors or settings.

CAUTION!!!

protection function to work, the heater must remain connected to the electrical and gas supplies with DHW and heating service switched to OFF

CAUTION!!!

protection function is conceived to protect the heater only, not the system.

For the freeze

This freeze

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14.13 - “Users’ menu”

Pressing RESET key for 2 seconds, you will enter the “Users’ menu”. When entering the “Users’ menu”, the display, item “M” in Figure 14-1, will

Parameter Parameter’s description Units

1001 Burner 1 supply temperature °F

1002 Indirect water heater temperature °F

1004 Outdoor sensor temperature °F

1006 Burner 1 Flue gas temperature °F

1007 Burner 1 Return temperature °F

1008 Burner 1 Ionisation current μA (micro ampere)

1009 State of the Local pump (and of the Burner 1 Motorized valve) ON/OFF

1010 State of the CH pump ON/OFF

1011 State of the DHW pump ON/OFF

1012 Calculated CH setpoint (when outdoor sensor is enabled) (only for 199 model;

for 399, 500, 750 and 1000 models see Parameter 1107)

1040 Burner 1 Actual Fan speed rpm/min

1041 Burner 1 Ignition fan speed rpm/min

1042 Burner 1 Low power fan speed rpm/min

1043 Burner 1 High power fan speed rpm/min

1051 Burner 1 Last lockout number \

1052 Burner 1 Last Blocking error \

1053 Burner 1 Number of ﬂ ame failures no

1055 Burner 1 Number of failed ignitions no

1056 Burner 1 Total hours of operation Hr x 10

1057 Burner 1 Total hours of operation or the indirect water heater Hr x 10

1059 **Burner 1 Interval between Lockouts. May be: 1:MIN; 2:HRS; 3:DAY; 4:WK

1060 **Burner 1 Interval between Blocking errors. May be: 1:MIN; 2:HRS; 3:DAY; 4:WK

1062 Burner 1 Water ﬂ ow GPM

1101 MULTIBURNER: number of burners ON n

1102 MULTIBURNER: header temperature °F

1103 MULTIBURNER: any Burner into Lockout /

1104 MULTIBURNER: any Burner into Blocking Error /

1106 MULTIBURNER: system is in emergency mode /

1107 MULTIBURNER: current multiburner setpoint °F

1120 MULTIBURNER: burner 1 modulating level %

1121 MULTIBURNER: burner 2 modulating level %

1122 MULTIBURNER: burner 3 modulating level %

1123 MULTIBURNER: burner 4 modulating level %

** How to read the timer values: Eg: If it shows 1:29, it means 29 minutes; Eg: If it shows 2:12, it means 12 hours; Eg: If it shows 3:15, it means 15 days; Eg: If it shows 4:26, it means 26 weeks;

start showing parameters from 1000.

Press keys scroll all parameters inside this menu. All parameters into this “Users’ menu” are reading only. For unit models 399 up to 1000, parameters adressed to “Burner

and to

1 (Master)” are applicable for that burner only. If you want to see the same parameters for other burners you have to connect the display to the burner you want to see. To do this follow procedure in Section 15.7.

°F

100