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Infinity Energy 2

RBI Infinity Energy 2 Installation Instructions Manual

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Page 1
IE2IOM-4
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 quali 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.
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.
Af x these instructions near to the boiler. Instruct the building owner to retain the instructions for future use by a quali ed service
technician, and to follow all guidelines in the User’s Information Manual.
62403588 R03 Feb. 04, 2015
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SAFETY INSTRUCTIONS
WARNING: If the information in these instructions is not followed exactly, a re or explosion may result causing property damage, personal injury or death.
- Do not store or use gasoline or other
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 re department.
- Installation and service must be performed
by a quali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 in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 quali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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WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
SAFETY INSTRUCTIONS
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
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 qualied heating installer. Refer to the User’s Information Manual for your reference.
Maintenance: at least once a
year the user must call a Qualied installer for routine maintenance.
Failure to comply with these
provisions can cause a 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 re or explosion causing property damage, personal injury, or death.
WARNING!!!
Qualied installer: qualied installer is an individual with specic, technical training in space heating systems, domestic hot water systems, fuel gas systems and electrical systems. This individual must have the legally required qualications. Failure to comply with these provisions can cause a re or explosion causing property damage, personal injury, or death.
WARNING!!!
Installation
and Alterations: Only a Qualied installer must carry out the installation and calibration of the heater. Never modify the heater or its 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/ue gas system that has been speci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.
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NOTICE! Local approval of the 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 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 ow.
CAUTION!!!
location: The heater must not be installed on carpeting.
Installation location:
Installation
WARNING!!!
Defects: If you 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 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 Quali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!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
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 re or explosion causing property damage, personal injury, or death.
ATTENTION!!!
de l’entretien des commandes,
étiquetez tous les 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 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 quali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 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
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
2.4 - Accessories included .......................................................................................................................................... 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 - Efciency up to 98% (IB boiler only) ..................................................................................................................29
5 - INSTALLATION - Location ........................................................................................................30
5.1 - Choosing the installation location ....................................................................................................................... 30
5.1.1 - Prevent combustion air contamination ..................................................................................................................... 34
5.1.2 Location of an IB boiler ............................................................................................................................................... 34
5.1.3 Location of an IW water heater................................................................................................................................... 34
5.2 - Residential garage installation ........................................................................................................................... 35
5.3 - Closet and alcove installations ........................................................................................................................... 35
5.4 - Clearances for installation and servicing ............................................................................................................ 35
5.5 - Clearances from combustible material ............................................................................................................... 35
5.6 - Vent and combustion air piping .......................................................................................................................... 35
5.7 - Prevent combustion air contamination ............................................................................................................... 35
6 - INSTALLATION - Mounting the heater .....................................................................................38
6.1 - Transporting the heater ...................................................................................................................................... 38
6.2 - Mounting the heater ........................................................................................................................................... 38
6.3 - Dimensions ........................................................................................................................................................39
7 - INSTALLATION - IB boiler water connection ..........................................................................42
7.1 - IB boiler water connections ................................................................................................................................ 42
7.1.1 Boiler water chemistry ................................................................................................................................................ 42
7.1.2 Testing and maintenance of water quality .................................................................................................................. 42
7.1.3 System ushing, treatment, and cleansing ................................................................................................................. 43
7.1.4 Water Quality Maintenance and Warranty .................................................................................................................. 43
7.1.5 Water Treatment Analysis and Scheduling ................................................................................................................. 43
7.2 - Supply and return piping .................................................................................................................................... 44
7.2.1 - Near boiler heating piping components .................................................................................................................... 45
7.2.2 - Relief valve ............................................................................................................................................................... 46
7.2.3 - Expansion Tank and Makeup Water ......................................................................................................................... 46
7.2.4 - Local boiler pump and CH pump .............................................................................................................................. 47
7.2.5 - Sizing heating system ..............................................................................................................................................47
7.2.6 - Domestic Hot Water system Piping when using an indirect water heater ................................................................ 47
8 - INSTALLATION - IW water connections ..................................................................................50
8.1 - IW Water heaters’ water connections .................................................................................................................50
8.2 - Hot and Cold water piping .................................................................................................................................. 50
8.2.1 - Near water heater piping components .....................................................................................................................50
8.2.2 - Temperature and pressure Relief valve .................................................................................................................... 51
8.2.3 - Expansion Tank ........................................................................................................................................................ 52
8.2.4 - Circulator pump ........................................................................................................................................................ 52
8.2.5 - Sizing water system .................................................................................................................................................52
8.2.6 - Anti-legionella ........................................................................................................................................................... 52
8.3 - Scalding .............................................................................................................................................................52
8.4 - Minimum and maximum water ow .................................................................................................................... 53
9 - INSTALLATION - Condensate disposal ...................................................................................56
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TABLE OF CONTENTS
9.1 - Condensate disposal .......................................................................................................................................... 56
10 - INSTALLATION - Electrical connections ...............................................................................58
10.1 - Electrical connections: overview ...................................................................................................................... 58
10.1.1 - Connecting the power supply cable .......................................................................................................................59
10.1.2 - Room Thermostat wiring (IB Boiler only) ................................................................................................................ 59
10.1.3 - Installing the outdoor temperature sensor (IB Boiler only) ..................................................................................... 59
10.1.4 - Connection to an analog Vcc input......................................................................................................................... 60
10.1.5 - Connection to a MODBUS protocol........................................................................................................................ 60
10.2 - Connecting the IB boiler to an indirect water heater ........................................................................................ 61
10.2.1 Indirect water heater priority selection ...................................................................................................................... 61
10.3 - Connecting the IW water heater to a storage tank ........................................................................................... 61
10.4 - Connecting the heater in cascade .................................................................................................................... 64
11 - INSTALLATION - Removing of an heater from a common venting system .......................66
11.1 - Removing of a heater from a common venting system .................................................................................... 66
12 - INSTALLATION - CATEGORY IV: Vent and combustion air .................................................67
12.1 - CATEGORY IV: Positive pressure condensing ................................................................................................ 67
12.2 - CATEGORY IV: Venting and air piping systems .............................................................................................. 67
12.3 - Minimum / Maximum allowable combustion air and vent piping lengths .......................................................... 69
12.4 - Install vent and combustion air piping .............................................................................................................. 69
12.5 - Air inlet pipe materials: ..................................................................................................................................... 71
12.5.1 - Sealing of PVC, CPVC or ABS air inlet pipe .......................................................................................................... 71
12.6 - PVC/CPVC vent piping materials ..................................................................................................................... 72
12.6.1 - Installing PVC/CPVC vent and air piping ...............................................................................................................72
12.6.2 - PVC/CPVC air intake connection ........................................................................................................................... 73
12.6.3 - PVC/CPVC vent connection ................................................................................................................................... 73
12.7 - Stainless steel vent piping materials ................................................................................................................ 74
12.7.1 - Stainless steel air intake connection ...................................................................................................................... 74
12.7.2 - Stainless steel vent connection .............................................................................................................................. 75
12.8 - Polypropylene vent piping materials ................................................................................................................76
12.8.1 - Polypropylene air intake connection....................................................................................................................... 77
12.8.2 - Polypropylene vent connection ..............................................................................................................................77
12.9 - Single pipe vent (not sealed combustion) ........................................................................................................ 78
12.9.1 - Determine location .................................................................................................................................................79
12.10 - Sidewall termination - Two pipes ....................................................................................................................80
12.10.1 - Vent/air termination .............................................................................................................................................. 80
12.10.2 - Determine location ...............................................................................................................................................80
12.10.3 - Prepare wall penetrations..................................................................................................................................... 82
12.10.4 - Termination and ttings ........................................................................................................................................ 82
12.10.5 - Multiple vent/air terminations................................................................................................................................ 82
12.11 - Sidewall termination – Concentric vent ..........................................................................................................83
12.11.1 - Description and usage .......................................................................................................................................... 83
12.11.2 - Sidewall termination installation ........................................................................................................................... 83
12.11.3 - Multiventing sidewall terminations ........................................................................................................................ 84
12.12 - Vertical termination - Two pipes ..................................................................................................................... 85
12.12.1 - Determine location ...............................................................................................................................................85
12.12.2 - Prepare roof penetrations..................................................................................................................................... 85
12.12.3 - Termination and ttings ........................................................................................................................................ 85
12.12.4 - Multiple vent/air terminations................................................................................................................................ 86
12.13 - Vertical termination – Concentric vent ............................................................................................................ 87
12.13.1 - Description and usage.......................................................................................................................................... 87
12.13.2 - Determine location ...............................................................................................................................................87
12.13.3 - Vertical termination installation ............................................................................................................................. 87
12.13.4 - Multiventing vertical terminations ......................................................................................................................... 88
13 - INSTALLATION - CATEGORY II: Vent and combustion air ..................................................89
13.1 - CAT II: Negative pressure condensing .............................................................................................................89
13.2 - CAT II: Adapter and increaser .......................................................................................................................... 89
13.3 - Condensing vent option: CATEGORY II: .......................................................................................................... 90
14 - INSTALLATION - Gas supply .................................................................................................92
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TABLE OF CONTENTS
14.1 - Gas supply piping ............................................................................................................................................. 92
14.2 - Pipe sizing for natural gas ................................................................................................................................ 93
14.3 - Propane Gas .................................................................................................................................................... 93
14.4 - Check inlet gas supply pressure ...................................................................................................................... 94
14.5 - Operating at high altitudes ............................................................................................................................... 94
14.6 - Convert a heater model 199 from Natural Gas to Propane gas or viceversa ..................................................95
14.7 - Convert a heater model 399, 500, 750 or 1000 from Natural Gas to Propane gas or viceversa ..................... 97
15 - START-UP .................................................................................................................................98
15.1 - Operating .........................................................................................................................................................98
15.1.1 - User instructions..................................................................................................................................................... 98
15.1.2 - Filling the condensate and neutralizing box ........................................................................................................... 98
15.1.3 - Filling the heating system on a IB boiler................................................................................................................. 98
15.2 - General warnings concerning gas supply ........................................................................................................ 98
15.3 - Conrming the heater’s gas type .....................................................................................................................99
15.4 - Gas type conversion ........................................................................................................................................99
15.5 - Start-up ............................................................................................................................................................99
15.5.1 - Start-up of the IB boiler ..........................................................................................................................................99
15.5.2 - Start-up of the IW water heater .............................................................................................................................. 99
15.6 - Ignition control testing ...................................................................................................................................... 99
15.7 - Gas supply pressure checking ....................................................................................................................... 100
15.8 - Checking and adjusting CO2 levels ............................................................................................................... 101
15.8.1 - Checking CO2 level on units model 199 .............................................................................................................. 101
15.8.2 - Checking CO2 level on units model 399 up to 1000 ............................................................................................ 101
15.9 - Check the capacity input ................................................................................................................................ 102
15.10 - Minimum water ow .....................................................................................................................................102
16 - USE .........................................................................................................................................103
16.1 - Check water pressure .................................................................................................................................... 104
16.1.1 - Check water pressure on IB boiler ....................................................................................................................... 104
16.1.2 - Check water pressure on IW water heater ........................................................................................................... 104
16.2 - Overview ........................................................................................................................................................ 104
16.3 - Displays .......................................................................................................................................................... 104
16.4 - Start-up procedure ......................................................................................................................................... 104
16.5 - IW supply water temperature adjustment ....................................................................................................... 104
16.6 - IB boiler - Indirect water heater temperature adjustment ............................................................................... 105
16.7 - IB boiler - Heating temperature adjustment ...................................................................................................105
16.8 - IB boiler - Outdoor reset adjustment .............................................................................................................. 105
16.8.1 - Outdoor reset applications ...................................................................................................................................105
16.8.2 - Outdoor reset: setting parameters........................................................................................................................ 105
16.9 - Delays, alarms and protective actions ...........................................................................................................107
16.10 - Circulator pump protection ........................................................................................................................... 107
16.11 - Heater’s Freeze protection ........................................................................................................................... 107
16.12 - Display in energy saver mode ..................................................................................................................... 107
16.13 - “Users’ menu” ............................................................................................................................................... 108
16.14 - “Installer’s menu” .......................................................................................................................................... 109
16.15 - Diagnostic .................................................................................................................................................... 110
16.16 - Diagnostic: Lockouts “Loc” ............................................................................................................................111
16.17 - Diagnostic: Blocking errors “Err” .................................................................................................................. 113
16.18 - Flue blocked pressure switch ....................................................................................................................... 114
16.19 - Shuts heater down ....................................................................................................................................... 114
16.20 - How to clean the appliance jacket ................................................................................................................ 114
17 - MAINTENANCE ......................................................................................................................115
17.1 - Care and maintenance ................................................................................................................................... 115
17.1.1 - Address reported problems .................................................................................................................................. 116
17.1.2 - Check all piping for gas leaks............................................................................................................................... 116
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TABLE OF CONTENTS
17.1.3 - Verify ue and air lines in good condition and sealed tight; ................................................................................. 116
17.1.4 - Check system water pressure/system piping/expansion tank; ............................................................................. 116
17.1.5 - Check control settings .......................................................................................................................................... 116
17.1.6 - Check ignition and ame sense electrodes .......................................................................................................... 116
17.1.7 - Check wiring and connections.............................................................................................................................. 116
17.1.8 - Perform performance verication. ........................................................................................................................ 116
17.1.9 - Flame inspection .................................................................................................................................................. 117
17.1.10 - Check ame signal ............................................................................................................................................. 117
17.1.11 - Check relief valve ............................................................................................................................................... 117
17.1.12 - Check heater area .............................................................................................................................................. 117
17.1.13 - Check pressure gauge ....................................................................................................................................... 117
17.1.14 - Check vent piping ............................................................................................................................................... 117
17.1.15 - Check air piping.................................................................................................................................................. 117
17.1.16 - Check condensate drain system ........................................................................................................................ 117
17.1.17 - Check heater piping (gas and water) ................................................................................................................. 117
17.1.18 - Shut heater down ............................................................................................................................................... 118
17.1.19 - Test low water cutoff (if installed) ....................................................................................................................... 118
17.1.20 - Reset button (low water cutoff) ........................................................................................................................... 118
17.2 - Removing the casing ...................................................................................................................................... 118
17.3 - Cleaning the burner and primary heat exchanger, ue gas side .................................................................... 119
17.3.1 - Thermal insulations .............................................................................................................................................. 122
17.4 - Correct positioning of the ignition and ame detection electrodes ................................................................ 123
17.5 - Clean the air lter ........................................................................................................................................... 123
17.6 - Condensate trap and neutralizing box maintenance and cleaning ................................................................124
17.7 - Connection of the display to other burners ....................................................................................................125
17.8 - How to move a control board ......................................................................................................................... 126
17.9 - Draining the water from the heater ................................................................................................................. 127
17.10 - Water and ue temperature sensor .............................................................................................................. 127
17.11 - Outdoor temperature sensor .......................................................................................................................127
17.12 - 199 model wiring diagram ............................................................................................................................ 128
17.13 - 399 to 1000 models wiring diagram ............................................................................................................. 130
18 - TECHNICAL DATA .................................................................................................................134
19 - SPARE PARTS .......................................................................................................................136
20 - READ OUT FLOW CHART ....................................................................................................158
21 - FACTORY MENU ....................................................................................................................159
22 - SEQUENCE OF OPERATION for BOILER ............................................................................162
23 - SEQUENCE OF OPERATION for WATER HEATER .............................................................163
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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/NFPA 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 specied in ANSI Z21.13 standard.
NOTICE!
IW Water heater version meets the safety and other performance requirements as speci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.
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Page 13
WARNING!!!
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 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 nished grade, in the area of the venting, including but not limited to decks and porches, the following requirements shall be satis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 gastter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed. In addition, the installing plumber or gas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 quali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 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 certied.
3. SIGNAGE. A metal or plastic identi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.
(c) MANUFACTURER REQUIREMENTS
- 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 ue gases, but identies “special venting systems”, the following requirements shall be satis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.
13
Page 14
2 - GENERAL INFORMATION
WARNING!!!
2.1 - Key to symbols used
WARNING!!!
follow these indications can causing an explosion, re, extensive property damage, severe personal injury or death!
XX XXXX
Failure to
CAUTION!!!
observe this 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
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
2.3 - Description of
Important indication symbol
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).
models:
IB = Tankless fully modulating, gas-red, condensing hot water boiler IW = Tankless fully modulating, gas-red, condensing potable water heater
2.4 - Accessories included
The appliance is equipped with the following accessories:
Quantity No. Description P/N Figure
No. 2
No. 1
No. 1
No. 1
BAYONETTE FUSE 102°C 2P MOLEX 62111042
NAT TO LP GAS CONVERSION KIT 199 TO 1000 62630184
SENSOR 10K D6X45 L=2500 T 62110071
OUTDOOR SENSOR (NOT PRESENT ON WATER HEATER VERSIONS) 62110067
No. 1
No. 4 ADJUSTABLE FOOT 60805006
No. 1 NEUTRALIZING LIMESTONE 10KG 62801022
SPECIAL WRENCH 60440013
14
Page 15
3 - MAIN COMPONENTS
12 13
11
10
9
14
15 16
17
18
8
7
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
6
5
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 ow sensor (par. 1062)
17 - Motorized valve (optional) 18 - Return pipe
134 2
15
Page 16
3 - MAIN COMPONENTS
322433 31
25
020009.01.005_a
26
27 28
29
7
18
020009.01.005
30
25
19 - Burner surface 20 - Burner unit condesate discharge 21 - Detection electrode
22 - Thermal insulation 23 - Sight glass
24 - Raccord fan-burner
25 - Modulating Fan 26 - Return temperature sensor (par. 1007)
24
Figure 3-2 Burner unit main components
2223
2021 19
27 - Left ignition electrode 28 - Right ignition electrode 29 - Motorized valve body (optional)
30 - Gasket 31 - Flapper valve 32 - Flapper magnet 33 - Flapper sensor
16
Page 17
3 - MAIN COMPONENTS
1041 6 12
7
11
9 14
13 15
25
16
17
19
20
40
21
24
020010.01.027
4
5
1 - Leveling feet
2 - Condensate hose that coming from heater’s 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 lter
Figure 3-3 Main components for models 199
3
2
1
12 - Flue exhaust connection 13 - 885IF board (Optional) 14 - Electrical terminals (Junction box) 15 - Control panel cover
16 - Display 17 - Control keys
19 - Front cover 20 - Control board 21 - Bottom front cover
17
Page 18
3 - MAIN COMPONENTS
22
23
24
30
32
28
22 - Top cover 23 - Main electrical switch 24 - Flue blocked pressure switch 25 - Electrical board 28 - Flue gas temperature sensor (Blue color connector) (1006) 29 - High limit ue gas temperature fuse (Red color connector)
30 - Flue gas exhaust manifold
29
31
33
34
020010.01.028
31 - Water Return connection 32 - Flue blocked pressure switch pipe connection 33 - Condensate blocked drain magnetic switch 34 - Flue gas manifold cap 40 - Fan cover 41 - Water Supply connection
Figure 3-4 Main components for models 199
18
Page 19
3 - MAIN COMPONENTS
14
15
13
11
10
9
8
6
7
12
25
24
020010.01.002
16
7
5
4
3
2
17
18
40
19
20
40
21
1
1 - Leveling feet
2 - Condensate hose coming from heater’s 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 lter 12 - Flue exhaust connection
Figure 3-5 Main components for models 399 and 500
13 - 885IF 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
19
Page 20
3 - MAIN COMPONENTS
22
23
24
BURNER 2
BURNER 1 (Master)
28
29
30
31
32
28
29
31
33
22 - Top cover 23 - Main electrical switch 24 - Flue blocked pressure switch 25 - Electrical Board 28 - Flue gas temperature sensor (Blue color connector) (1006) 29 - High limit ue gas temperature fuse (Red color connector)
30 - Flue gas exhaust manifold 31 - Water Return pipe
Figure 3-6 Main components for models 399 and 500
34
020010.01.003
32 - Flue blocked pressure switch pipe 33 - Condensate blocked drain magnetic switch 34 - Flue gas manifold cap
20
Page 21
3 - MAIN COMPONENTS
35
39
41
42
36
37
38
43
41
42
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 (1102) 41 - Safety relief valve (P-T safety relief valve on IW water heater) 42 - Pressure and temperature gauge 43 - Headers (IW water heaters are made in stainless steel. IB
boilers are made in carbon steel, and optionally in stainless
steel.)
Figure 3-7 Main components for models 399 and 500
21
Page 22
3 - MAIN COMPONENTS
12
9
11
6
8
7
4
7
8
7
8
7
10
13
14
15
16
17
18
20
40
40
18
40
24
25
020009.01.002
5
3
1 - Leveling feet
2 - Condensate hose coming from heater’s 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 lter 12 - Flue exhaust connection 13 - 885IF board
Figure 3-8 Main components for models 750 and 1000
2
1
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
22
18
19
21
Page 23
3 - MAIN COMPONENTS
BURNER 2 (Not present on model
750)
020009.01.003
22
23
28
29
31
28
29
BURNER 1 (Master)
BURNER 3
BURNER 4
32
31
28
29
31
30
28
29
31
33
34
22 - Top cover 23 - Main electrical switch 28 - Flue gas temperature sensor (Blue color connector) (1006) 29 - High limit 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 magnetic switch 34 - Flue gas manifold cap
Figure 3-9 Main components for models 750 and 1000
23
Page 24
3 - MAIN COMPONENTS
37
35
39
36
41
42
41
42
43
41
42
41
42
38
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 (1102) 41 - Safety Relief valve (P-T relief valve on IW water heater) 42 - Pressure and temperature gauge 43 - Headers (IW water heaters are made in stainless steel. IB
boilers are made in carbon steel, and optionally in stainless
steel.)
Figure 3-10 Main components for models 750 and 1000
020009.01.017
24
Page 25
4 - FUNCTION OVERVIEW
Key to 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 ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back 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 ue pressure switch 29 - Condensing blocked drain switch 30 - Condensing drain 31 - Condensate Siphon 36 - Condensate neutralizer box 37 - ASME Safety relief valve (Boiler) P-T relief valve (Water Heater) 51 - Pressure/temperature gauge
Figure 4-1 - Hydronic functional schematic for models 199
25
Page 26
4 - FUNCTION OVERVIEW
Key to 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 ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back 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 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 (Boiler) P-T relief valve (Water Heater) 47 - Water Flow meter 48 - Motorized valve (optional) 50 - Drain valve 51 - Pressure/temperature gauge
Figure 4-2 - Hydronic functional schematic for models 399 and 500
26
Page 27
4 - FUNCTION OVERVIEW
Key to 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 ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back 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 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 (Boiler) P-T relief valve (Water Heater) 47 - Flow meter 48 - Motorized valve (optional) 50 - Drain valve 51 - Pressure/temperature gauge
Figure 4-3 - Hydronic functional schematic for model 750
27
Page 28
4 - FUNCTION OVERVIEW
Key to 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 ue gas temperature fuse 12 - Premix burner 13 - Ignition electrodes 14 - ignitor 15 - Return temperature sensor 16 - Modulating PWM fan 17 - Back 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 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 (Boiler) P-T relief valve (Water Heater) 47 - Flow meter 48 - Motorized valve (optional) 50 - Drain valve 51 - Pressure/temperature gauge
Figure 4-4 - Hydronic functional schematic for model 1000
28
Page 29
4 - FUNCTION OVERVIEW
4.1 - Intended use and functions
The boiler is designed to supply the maximum heat output at 180°F with a minimum delta T of 35°F. If you want 180°F supply and lower delta T, you should downrate the capacity using parameter 2002 on each burner. If you don’t downrate the capacity the relative burner will go into Err 60.
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 specic procedure in Section
16.6 for the adjustment of the domestic hot water temperature. 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 180°F (82°C) can be congured. 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 efciency and comfort (see Section 10.1.3). In this con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 16.8.
The boiler must be connected to
an heating system with compatible speci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 specications, performance and power rating.
4.2 - Ef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 works at the maximum efciency (see Section
16.8). 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 ef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 efciency
29
Page 30
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
5 - INSTALLATION - Location
WARNING!!!
5.1 - Choosing the
installation location
WARNING!!!
store any ammable materials or liquids in the immediate vicinity of the heater. A 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). Failure to comply with this provision could result in excessive levels of carbon monoxide or a re, which can result in severe personal injury or death!
WARNING!!!
ventilation of the heater room can lead to high air temperatures. Failure to comply with this provision could result in excessive levels of carbon monoxide or a re, which can result in severe personal injury or death!
WARNING!!!
sure that intake and exhaust openings are suf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
Do not install
Provisions for
Insufcient
Make
WARNING!!!
PETROLEUM (L.P.) PROPANE
GAS-FIRED HEATER LOCATION REQUIRES SPECIAL ATTENTION: 1994 UNIFORM
MECHANICAL CODE, section
304.6: “LPG Appliances. Liqueed petroleum gas-burning appliances shall not be installed in a pit, basement or similar location where heavier-than-air­gas might collect. Appliances so fueled shall not be installed in an abovegrade under-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 oors in the structure.
CAUTION!!!
room with thin 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
Maintain minimum specied clearances for adequate operation. All installations must allow sufcient space for servicing the vent connections, water pipe connections, piping and other auxiliary equipment, as well as the appliance. The clearance labels on each appliance note the same service and combustible clearance requirements as shown on section 5.4 and 5.5.
Multiple appliances may be installed in a modular heater installation.
Consult the venting section of this manual for specic installation instructions for the appropriate type of venting system that you will be using. Direct vent and vent/air venting systems require installation with Category IV ue pipe, sealed air inlet pipe, and air inlet caps, which must meet the manufacturer’s specications.
Combustion and ventilation air requirements for appliances drawing air from the equipment room.
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 end Equipment, or applicable provisions of the local building codes.
30
Page 31
5 - INSTALLATION - Location
The equipment room MUST be provided with properly sized openings to assure adequate combustion air and proper ventilation.
1. If air is taken directly from outside the building with no duct, provide two permanent openings to the equipment room (see Fig. 5-1)
EQUIPMENT ROOM
AIR OPENING
AIR OPENING
Figure 5-1 Combustion Air direct from outside
(a) Combustion air opening, with a
minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12” (30 cm) of the bottom of the enclosure.
(b) Ventilation air opening, with a
minimum free area of one square inch per 4000 Btu/hr input (5.5 cm2 per kW). This opening must be located within 12” (30 cm) of the top of the enclosure.
2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the equipment room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11
cm2 per kW) of input (see Fig. 5-2).
AIR OPENING
AIR OPENING
Figure 5-2 Combustion Air through Ducts
EQUIPMENT ROOM
31
Page 32
5 - INSTALLATION - Location
EQUIPMENT ROOM
AIR OPENING
3. If a single combustion air opening is provided to bring combustion air in directly from the outdoors, the opening must be sized based on a minimum free area of one square inch per 3000 Btu/hr (7 cm2 per kW). This opening must be located within 12” (30cm) of the top of the enclosure (see Fig.5-3).
Figure 5-3 Combustion Air from outside - single opening
32
Page 33
5 - INSTALLATION - Location
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
* Outside Air from
2 openings Directly from
Model Number
Opening, in
Top
Outdoor
2
Opening, in
1 Opening Directly from
Bottom
2
* Outside Air from
Outdoors, in
2
Inside Air from
2 Ducts Delivered from
Outdoors
Top
Opening, in
2
Bottom
Opening, in
2
199
250
399
500
750
1000
* Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above requirements are for the water heater only; additional gas red appliances in the equipment room will require an increase in the net free area to supply adequate combustion air for all appliances.
50
(323 cm2)
63
(407 cm2)
100
(646 cm2)
125
(807 cm
2
188
(1213 cm2)
250
(1613 cm2)
)
(323 cm2)
(407 cm2)
100
(646 cm2)
125
(807 cm2)
188
(1213 cm2)
250
(1613 cm2)
Figure 5-4 Minimum recommended combustion air supply to equipment room
50
63
67
(433 cm2)
84
(542 cm2)
134
(865 cm2)
167
(1078 cm2)
250
(1613 cm2)
334
(2155 cm2)
100
(646 cm2)
125
(807 cm2)
200
(1201 cm2)
250
(1613 cm2)
375
(2420 cm2)
500
(3226 cm2)
Combustion air requirements are based on the latest edition of the National Fuel Gas, ANSI Z223.1; in Canada refer to the latest edition of CGA Standard CAN B142.2. Check all local code requirements for combustion air.
All dimensions based on net free area in square inches. Metal louvers or screens reduce the free area of a combustion air opening a minimum of approximately 25%. Check with louver manufacturers for exact net free area of louvers. Where two openings are provided, one must be within 12” (30 cm) of the ceiling and one must be within 12” (30 cm) of the oor of the equipment room. Each opening must have net free area as specied in the chart on Figure 5-4. Single openings shall commence within 12” (30 cm) of the ceiling.
100
(646 cm2)
125
(807 cm2)
200
(1201 cm2)
250
(1613 cm2)
375
(2420 cm2)
500
(3226 cm2)
33
Page 34
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
5 - INSTALLATION - Location
WARNING!!!
circumstances should the equipment room ever be under negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the unit.
WARNING!!!
FANS: Any fan or equipment which exhaust air from the equipment room may deplete the combustion air supply and/or cause a downdraft in the venting system. spillage of ue products from the venting system into an occupied living space can cause a very hazardous condition that must be immediately corrected. Failure to follow this warning could result in excessive levels of carbon monoxide, wich can cause severe personal injury or death.
WARNING!!!
combustion air supply must be completely free of any ammable vapors that may ignite or chemical fumes wich must be avoided are uorocarbons and other halogenated compounds, most commonly present as refrigerants or solvents, such as Freon, trichlorethylene, perchlorethylene, chlorine, etc. These chemicals, when burned, form acids which quickly attack the heat exchanger tubes, headers, ue collectors, and the vent system.
The result is improper combustion and a non-warrantable, premature appliance failure.
Under no
EXHAUST
The
5.1.1 - Prevent combustion air contamination
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 following contaminants.
Products that may contaminate 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 renishing areas and establishments;
- Remodeling areas;
- Garages with workshops.
Contaminated
5.1.2 Location of an IB
boiler
When locating the boiler the following factors must be considered:
location of the openings for the
ventilation of the boiler room regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside (room air for combustion).;
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 ooding is possible, elevate the
boiler sufciently to prevent water from reaching the boiler.
5.1.3 Location of an IW water heater
When locating the water heater the following factors must be considered:
location of the openings for the
ventilation of the boiler room regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside (room air for combustion).;
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 ooding is possible, elevate the
appliance sufciently to prevent water from reaching the unit.
34
Page 35
5 - INSTALLATION - Location
WARNING!!!
WARNING!!!
WARNING!!!
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.
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 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 re, which can cause severe personal injury or death!
Do not use
5.4 - Clearances
for installation and servicing
Figures 5-6, 5-7 and 5-8 shows the minimum clear a n c e s requ i r e d 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 oor of combustible material. See also Figure 5-5 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 Sections 5.1 and
12.9. Vent and air may be vented vertically through the roof or out a side wall, unless otherwise specied. You may use any of the vent/air piping methods covered in Sections 12 and 13.
WARNING!!!
attempt to install the using any other venting / air intake methods than as explained on Sections 12 and
13.
Failure to follow this warning could result in excessive levels of carbon monoxide or a 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 Sections 12 and 13.
Do not
heater
5.7 - Prevent combustion air contamination
Install air inlet piping for the heater as described in Sections 12 and 13. Do
not terminate vent/air in locations that
can allow contamination of combustion air. Refer to Section 5.1.1, for products and areas which may cause contaminated combustion air.
WARNING!!!
the combustion air will not contain any of the contaminants listed in Section 5.1.1. 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), rst 3 ft from the appliance 1 inch (25 mm)
Split vent (two pipes), after 3 ft from the appliance 1/4 inch (7 mm)
Supply and return piping 1/4 inch (7 mm)
Figure 5-5; Clearances from combustible material
35
Page 36
5 - INSTALLATION - Location
G
Figure 5-6 Recommended minimum clearance distances for proper installation and servicing for model 199 (G = Center of gravity)
G
G
Figure 5-7 Recommended minimum clearance distances for proper installation and servicing for models 399 and 500 (G = Center of gravity)
G
36
Page 37
5 - INSTALLATION - Location
G1
G2
Figure 5-8 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)
G2
G1
37
Page 38
B
WARNING!!!
6 - INSTALLATION - Mounting the heater
6.1 - Transporting
the heater
020010.01.011
A
C
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 provision 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 ue
gas and air intake connections at the top of the heater with plastic lm.
D
020010.01.012
Figure 6-2 Remove heater from wood pallet
38
6.2 - Mounting the heater
1. Remove the outer shipping carton
from the
2. Remove the front door (see Section
17.2) 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 39
6 - INSTALLATION - Mounting the heater
WARNING!!!
A
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
18), 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
B
020012.01.008
WARNING!!!
must be capable of supporting the weight (see Section 18) of the unit or the same unit and building may be damaged causing severe personal injury, death, or substantial property damage.
The oor
6.3 - Dimensions
Figures from 6-6 to 6-8 list all dimensions of each heater model.
Figure 6-4 Correct way to lift the appliance
A
020010.01.013
A
Figure 6-5 Install leveling feet
020010_01_030
B = Blocking nut
B
MIN 0 MAX 0,39 " (10 mm)
39
Page 40
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
40
Page 41
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
41
Page 42
WARNING!!!
WARNING!!!
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.
7.1.1 Boiler water chemistry
CAUTION!!!
damage due to unsuitable heating system water. If the heating water is not with the features required in this section, the system water must be separated from the boiler water by a plate heat exchanger able to resist the corrosion. Unsuitable heating system water promotes lime scale fouling, corrosion and deposits formation. This can result in boiler damage and malfunction.
Scale and Corrosion
Free oxygen can cause the formation of rust (iron oxides), which degrade metallic materials. Magnetite is formed in un-inhibited water if there is electrolytic action in the presence of oxygen. Sludge is formed when calcium compounds, primarily CaCO3, are heated. Rust and magnetite, when combined with sludge, can form a very hard scale, which signicantly reduces system efciency and life expectancy of the heating system. Scale reduces heat exchange due to its low heat conductivity and so may cause very dangerous localized overheating. Waterside corrosion of all heating circuit surfaces is also a major concern.
Make-up or Feed Water Quality
Make-up or feed water is water
added to a closed hydronic system
to replenish water lost through evaporation, maintenance, or leakage. The quality of make-up or feed water, which may contain dissolved oxygen, minerals and other dissolved contaminants, is extremely important. Such introduced water must be
chemically treated or strictly limited
when ensuring neutral chemical conditions in boiler system water. Generally, any closed hydronic heating
Risk of system
system should be restricted from receiving untreated makeup water of no more than 5% of the total volume of system water per year.
Treating Water to Prevent Freezing
When using anti-freeze solutions, their compatibility with the heat exchanger and other components of the heating system must be determined prior to use. If a glycol solution is used as anti-freeze protection, a backow preventer must be installed upstream of the ll/makeup valve. Only virgin glycol should be used for systems requiring freeze protection, and it must be treated with an inhibitor compatible with the particular chemical treatment being used in the system. Note that glycol must be changed from time to time due to its limited useful life. Use only inhibited propylene glycol solutions, formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.
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 speci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.
Water Treatment Certication
When using chemical treatments in hydronic systems, it is necessary to ensure that the chosen treatment is appropriate and certied by the manufacturer for such environments. The manufacturer should also guarantee that the treatment,
Never use
Use only
42
when applied according to the manufacturer’s recommendations, will not cause harm to the boiler, pumps, piping, and other components of the hydronic boiler system.
7.1.2 Testing and
maintenance of water quality
Water in the installation should be checked, monitored, and treated for the following conditions and characteristics:
Hardness – High hardness of the available water is measured in grains of hardness and indicates the quantity of minerals (mostly calcium and magnesium) which are dissolved in the water. Hardness substantially contributes to the formation of scaling, which is highly undesirable. The total hardness must be less than 200 ppm total dissolved solids (TDS).
Articial Softness – Do NOT use articially softened water. Articial softening agents generally use salt, which creates a chloride water chemistry, a major contributor
to the corrosion of the types of
metals used in hydronic systems. Elevated salt levels also contribute to higher conductivity levels, another undesirable characteristic in hydronic systems.
Chloride – Chlorides are salts resulting from the combination of the gas chlorine with a metal and are instrumental in accelerating
corrosion in the types of metals
used in hydronic systems. Chlorides may be introduced into the water naturally. Concentrations of chlorides in system water should be less than 150 ppm.
Conductivity – Dissolved
metals and minerals increase the
conductivity of water and indicate not only the presence of undesired corrosive agents, but also contribute to the transfer and migration of ions and charged particles in the water that contribute to fouling of sensors, valves, and other devices used in the system. Additionally, high conductivity contributes to galvanic corrosion, in which one metal will preferentially corrode when in
Page 43
7 - INSTALLATION - IB boiler water connections
contact with another type of metal, when both are in contact with an electrolyte. Conductivity should be less than 3000 μS.
pH – The pH, a measure of the acidic, neutrality, and alkalinity of the water, must always be between
7.5 and 9.5.
Oxygen – All precautions should be taken to avoid the formation and localization of oxygen in the water of a heating system. Water that is low in minerals (soft water) absorbs oxygen much more readily than mineralized (hard) water. For
this reason it is necessary that in
heating systems using oor radiant heating, the plastic pipes used be impermeable to oxygen.
Scale and Corrosion – The use of an inhibitor is advisable to treat feed and make-up water and to protect heating systems against scale, corrosion and microbiologic growth. To prevent freezing, the use of an anti-freezing agent together with the inhibitor is advisable. Qualied companies can also provide boiler de-scaling.
Water treatment is also advisable in the following cases:
- Very large heating systems
- High quantities of replenished water due to leakages or maintenance work
7.1.3 System ushing,
treatment, and cleansing
Note that prior to cleaning the heating system, the boiler MUST be isolated from the piping to prevent infusion of containments, including sludge, into the boiler.
CAUTION!!!
and inhibitors used must be compatible with heat exchanger material. Corrosion/scale inhibitor will be ineffective if added to a dirty system; therefore, it is very important to clean the system rst.
Cleaning solution
CAUTION!!!
cannot be held responsible for any damage caused by incorrect use of additives in the heating system.
When cleaning, treating, and maintaining, a heating system, consult a qualied professional. The following are tips/guidelines for cleaning a heating system – these do NOT take precedence over detailed instructions from qualied professionals.
Make sure to use an appropriate amount of cleaning solution, carefully following the manufacturer’s instructions. Follow the chemical manufacturer’s recommendations when introducing cleaning agents into the system.
Ensure that the cleaning solution is circulated thoroughly in the system.
Flush the system thoroughly to remove the maximum amount of contaminants. When emptying the system, make sure it is done as quickly as possible using all drain off points and ensuring all low lying pipework is fully drained. Opening all bleed valves ensures the system will be completely emptied.
A reliable test to determine if
a system is clean is if the Total
Dissolved Solids (TDS) of the water being drained is within 10% of the make-up water TDS. This indicates that sufcient contamination has been ushed from the system. If the difference in TDS is more than 10%, it is recommended to repeat the cleaning process until that is achieved. A turbidity test can be used as an alternate way to determine if a system is clean.
For boiler retrot/replacement installation, it will be necessary to repeat the cleaning process until the draining water appears to be clear. Once clear, the above TDS comparison (or a turbidity test) should be performed.
The manufacturer
If a ushing machine is used in the cleaning process, carefully follow the manufacturer’s instructions. If the ushing machine is designed to ush individual zones, the TDS comparison must be made between each zone and the make-up water, or the turbidity test performed for each zone.
Add corrosion and scale inhibitor after the system has been declared clean, using the appropriate amount recommended by the manufacturer. Introduce the protector/scale inhibitor to the system following the chemical treatment manufacturer’s instructions. Adding inhibitor to a dirty system reduces its effectiveness. When relling the system, ensure the boiler is not air-bound by opening the pressure­relief valve. Leave the relief valve open until a steady ow of water is observed. Close the valve and nish lling the system.
7.1.4 Water Quality Maintenance and Warranty
Heat exchanger failures due to
improperly cleaned/treated and poorly
maintained water are not covered under warranty. Scheduled system/ boiler water maintenance is required to maintain the heat exchanger warranty. Boiler manufacturer shall reserve the right to require maintenance records when evaluating warranty claims.
7.1.5 Water Treatment Analysis and Scheduling
The proper mixture of water, chemical treatment, and glycol (if used) should be ascertained based on a sample of the system water and the make­up water. Your local water treatment company, may analyze your sample. Adjust the chemical composition of your system water based on the analysis. After this initial analysis, the chemical composition of your system water should be tested at the beginning of each heating season. For boilers operating year round, this analysis should be made at least twice a year.
43
Page 44
7 - INSTALLATION - IB boiler water connection
WARNING!!!
WARNING!!!
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 (11.2 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!!!
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.
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!!!
to directly heat domestic hot water, swimming pool or spa water.
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.
All heating system
The heating system
This boiler can
Do not use the boiler
This boiler is
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 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 specically formulated for hydronic
Never use
Use only
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.
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.
If glycol is used,
Any additives
Floor radiant heating systems
Setting parameter 3015 (see Section
21), 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!!!
oor panel against over heating you must install a safety device that shuts-off the boiler before it reaches the oor panel’s limit temperature.
CAUTION!!!
damage due to unsuitable heating system water. If oxygen-permeable pipes are used, e.g. for under 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.
To protect the radiant
Risk of system
44
Page 45
7 - INSTALLATION - IB boiler water connections
WARNING!!!
WARNING!!!
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 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 specied ow requirements.
3.
Indirect water heater pump: Field supplied. The pump MUST be sized to meet the specied ow requirements. Consult the indirect water heater operating guide to determine 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 ow rate through the boiler.
5. Check valve: Field supplied. Check
valves are recommended for
installation as shown in Figures 7-4 and 7-5. Failure to install these valves could result in a reverse 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 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 specications (see also Section 7.2.2).
circulating
10. Indirect water heaters: 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 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-congured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming.
CAUTION!!!
installer to ensure the minimum system ow is not less than 4 GPM at any time. If the 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 uid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer uid must be water or other non-toxic 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 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. NOTICE! Filter will be able to stops particles with an equivalent volume of a spheres with diameter of 0.04” (1mm);
It is up to the
The National
Failure to comply with
12. Header temperature sensor relocation:
sensor is factory installed (see
item “39”, Figures 3-7 and 3-10). However, in some piping installations with primary/secondary looping (see Figures 7-4 and 7-5), the header temperature sensor must be relocated in the system loop to better measure the temperature changement. In order to relocate the header sensor, operate as follow:
a. - install a well useful for the header
temperature sensor, in the position shown in Figures 7-4 and 7-5. Be carefully to respect the position illustrated. The header sensor must detect the temperature of the primary ow and of the secondary ow.
b.- remove the header temperature
sensor from its original position and relocate the sensor into the well precedently installed. If the length of the sensor is not enough, you can extend it using a #18 AWG cable.
WARNING!!!
header temperature sensor wires conduct 24 Vac, they must never run through conduits containing 120Vac power wires or an electrical shock hazard will exist.
The header temperature
Since the
45
Page 46
7 - INSTALLATION - IB boiler water connections
WARNING!!!
WARNING!!!
WARNING!!!
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. 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
E
F
L
E
F
F
E
Figure 7-2 Piping the relief valve discharge on models 399 up to 1000
H
G
WARNING!!!
L
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.
H
H
H
G
G
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 ll connection at the same location as the expansion tank connection to the system.
G
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
46
Undersized expansion tanks will cause
Page 47
7 - INSTALLATION - IB boiler water connections
WARNING!!!
7.2.4 - Local boiler pump and CH pump
This boiler must be 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 10-4. A eld supplied pump relay must be installed if the pump current draw is greater than 3 amps. The water resistance to size the local pump to supply 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 ow is not less than 4 GPM at any time. If the 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 eld supplied pump relay must be installed if the pump current draw is greater 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 con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
47
Page 48
7 - INSTALLATION - IB boiler water connections
Alternate position of the header sensor
(Item “39” of gures 3-7 and 3-10)
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 = Check valve
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, congure and design that system and to ensure compliance with building and safety code requirements.
9 = Local boiler pump 12 = Manual gas shut-off valve (Install manual shut-off
valve 5 ft (1.5m) above oor) 13 = Ground joint union 15 = Indirect water heater pump (DHW pump) (if needed) 16 = Heating pump (CH pump)
This is a
Figure 7-4 Piping of IB boilers model 199
48
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7 - INSTALLATION - IB boiler water connections
Alternate position of the header sensor
(Item “39” of gures 3-7 and 3-10)
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 = Check valve
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, congure and design that system and to ensure compliance with building and safety code requirements.
9 = Local boiler pump 12 = Manual Gas shut-off valve (Install manual shut-off
valve 5 ft (1.5m) above 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
49
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8 - INSTALLATION - IW water connections
8.1 - IW Water
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 (11.2 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 ushed to remove sediment, ux, lings and other foreign matter. The heat exchanger can be damaged by build-up or corrosion due to sediment.
All water system
Before connecting
CAUTION!!!
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.
CAUTION!!!
heater to directly heat swimming pool or spa water.
This water heater
Do not use this
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 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 backow preventer (eld supplied) on the cold feed make-up water line.
4. Install a eld supplied pump as shown in Figures 8-5 and 8-6.
5. Install a eld supplied expansion tank on the cold water inlet. Consult the tank manufacturer’s instruction for speci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 specications. Storage tanks may require additional valves depending on local codes.
8. Water heater isolation valves: Field supplied. Install isolation valves as shown on gures 8-5 and 8-6. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ow rate through the water heater.
9. Anti-scald mixing valve: Field supplied. Install an anti-scald mixing valve as shown on 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 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. NOTICE! Filter will be able to stops particles with an equivalent volume of a spheres with diameter of 0.04” (1mm).
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.
50
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WARNING!!!
WARNING!!!
WARNING!!!
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 scalding in the event of a discharge. Pipe the discharge of the safety relief valve like on Figures 8-1 or 8-2. 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
L
G
H
valve outlet.
WARNING!!!
relief valve discharge can result in scalding of individuals and animals.
Failure to properly pipe the
Figure 8-1 Piping of the P-T relief valve discharge on models 199
020009.01.009
E
G
F
L
H
E
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
F
F
E
Figure 8-2 Piping of the P-T relief valve discharge on models 399 up to 1000
H
H
G
G
Key to Figures 8-1 and 8-2 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
51
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WARNING!!!
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 back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 18, 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 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 accordingly. To electrically connect the pump (Local pump) follow Figure 10-5. A eld supplied pump relay must be installed if the pump current draw is greater than 3 amps.
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 ow is not less than 4 GPM at any time. If the ow is lower, the unit automatically stops the burner.
It is up to the
8.2.6 - Anti-legionella
The IW water heater is not protected against the proliferation of the Legionella bacteria. If you don’t install any Anti-legionella external system, you have to keep the water temperature inside the tank, at least at 140°F (60°C). This temperature will prevent the proliferation of the legionella bacteria.
WARNING!!!
hot water system must be protected against legionella bacteria. Failure to comply with this provision can result in severe personal injury or death.
Your domestic
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 washing machines 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 8-3 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.
APPROXIMATE TIME / TEMPERATURE
RELATIONSHIPS IN SCALDS
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
Figure 8-3 Time / temperature scalds
52
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8 - INSTALLATION - IW water connections
8.4 - Minimum and maximum water ow
The water heater pressure drops (see Figure 7-3) is based on potable water with a hardness of 5 to 17.6 grains per gallon and a total dissolved solids (TDS) not exceeding 310 ppm. Consult the manufacturer when heating potable water exceeding these specications.
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.
Water with a
CAUTION!!!
system in a way to respect the minimum water ow in function of the water hardness (See Figure 8-4) to prevent scaling inside the heat exchanger.
Figure 8-4 show an example where you are in possession of a water
heater model 1000 and in presence
of water with hardness of 16 gr/gal. In this case, as showned by the graph, the minimum water ow is 65 GPM.
CAUTION!!!
system in a way to never increases above the maximum water ow expected by Figure 8-4 to prevent erosion inside the copper pipes of the appliance.
Size your water
Size your water
199
399 - 500
750 1000
HARD
WATER
WATER
NORMAL
SOFT
WATER
Figure 8-4 Minimum / maximum Water ow in relation to the water hardness
53
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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 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 = Check valve 13 = Recycling pump (If needed)
Figure 8-5 Piping of a IW water heater model 199
54
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, congure and design that system and to ensure compliance with building and safety code requirements.
This is a concept
Page 55
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, con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 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 = Check valve 13 = Recycling pump (If needed)
55
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WARNING!!!
WARNING!!!
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 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 gure 9-1, item “B”) will neutralize the condensate products.
The
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 certied PVC or CPVC pipe, 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 over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
56
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9 - INSTALLATION - Condensate disposal
C ADB EC ADB E
020010.01.029
A = Pipe connected to the heaters’ ue exhaust system B = Condensate neutralizer box C = Condensate drain pipe D = Cover of the box E = PH test port
Figure 9-1 Condensate neutralizer box (see also Figures 3-3 through 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
57
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10 - INSTALLATION - Electrical connections
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
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.
ATTENTION!!!
de l’entretien des commandes,
étiquetez tous les 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/NFPA 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 18.
Line voltage 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.
58
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10 - INSTALLATION - Electrical connections
WARNING!!!
WARNING!!!
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 17.2 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 17.2 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 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 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 16.14);
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
59
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10 - INSTALLATION - Electrical connections
10.1.4 - Connection to an
analog Vcc input
On appliances model 399, 500, 750 and 1000 it is factory supplied the 885IF board that permit installer to drive the unit via a Vcc input (199 model can be equipped on demand). To do this, you have to connect the Vcc supply between terminals 22 and 23 (see Figures 10-4 and 10-5). Also, the CH mode (parameter 2003 as per Section 16.14) must be set to 4 value. Now the heater can start to receive the analog input Vcc 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
21);
- if the inpult voltage move between 2V and 10V, the supply temperature will change proportionally between the Minimum CH setpoint (parameter 3018, see Section 21) and the
Figure 10-2 Room thermostat location
Maximum CH setpoint (parameter 3017, see Section 21).
Figure 10-3 0-10Vcc analog input algorithm
10.1.5 - Connection to a
MODBUS protocol
On appliances model 399, 500, 750 and 1000 it is factory supplied the 885IF board that has an integrated MODBUS protocol (199 model can be equipped on demand). This 885IF board with the MODBUS protocol can be connected to drive the unit from a building management device. Instructions on how to connect the MODBUS protocol are supplied on demand.
60
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WARNING!!!
10 - INSTALLATION - Electrical connections
WARNING!!!
10.2 - Connecting
the IB boiler to
an indirect water
heater
This boiler, can be connected to an indirect water heater as follows:
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 eld supplied pump relay must be installed if the pump current draw is greater 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).
4.
Set the boiler so that it detects the indirect water heater sensor, as follows:
a. Gain access to the Factory menu
(see Section 21);
b. Set parameter 3012 to 1.
Follow Section 16.6 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 satis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 16.14).
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 specied in parameter 2063. At the end of that time period, the boiler will switch to heating priority for the length of time speci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
speci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 eld supplied pump relay must be installed if the pump current draw is greater 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 16.5 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
61
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10 - INSTALLATION - Electrical connections
Figure 10-4 Electrical customer connection for IB boilers
62
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10 - INSTALLATION - Electrical connections
Figure 10-5 Electrical customer connection for IW water heaters
63
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10 - INSTALLATION - Electrical connections
10.4 - Connecting
the heater in
cascade
Heaters can be installed in cascade with a conguration like in Figure 10-
7. Many other congurations can be
done (ask to the heater manufacturer for conceptual drawings). The cascade is managed by the 885HC cascade manager command that is supplied on demand.
Operative instructions on how to
connect the heaters in cascade
are supplied together the 885HC command.
For water, gas, ue exhaust and air intake connections, ask for conceptual drawings to the manufacturer.
Check
valve
Dependent
heater #4
up to #8
Local
pump
Check
valve
Dependent
heater #3
Local
pump
Check
valve
Dependent
heater #2
Local
pump
Check
valve
Managing
heater #1
885HC Cascade manager
Hot
Water
Storage
tank
Cascade
general
sensor
Local
pump
Figure 10-6 Cascade (water heaters) conceptual scheme
Cold
Water
64
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10 - INSTALLATION - Electrical connections
Check
valve
Dependent
heater #4
up to #8
Local
pump
Check
Dependent
heater #3
Local
pump
valve
Dependent
heater #2
Local
pump
Check
valve
Managing
heater #1
Local
pump
885HC Cascade manager
Check
valve
Cascade
general
sensor
Low
loss
header
Heating pump
Figure 10-7 Cascade (boilers) conceptual scheme
65
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WARNING!!!
11 - INSTALLATION - Removing of an heater from a common venting system
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 deciencies which could cause an unsafe condition.
(c) Insofar as is practical, close all
building doors and windows and all doors between the space in which the appliances remaining connected to the common venting
system are located and other
spaces of the building. Turn on
clothes dryers and any 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 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 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, 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.
(c) Dans la mesure du possible,
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 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 modiée, le système devrait étré modi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.
66
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12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.1 - CATEGORY
IV: Positive pressure condensing
An appliance that operates with a positive vent static pressure with a vent gas temperature that may cause condensate production in the vent.
12.2 - CATEGORY
IV: 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!
The vent
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 efciency of the heater it may discharge what looks like white smoke especially 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 12.9. Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specied. You may use any of the vent/air piping methods from Figure 12-1 to Figure 12-6. Do not attempt to install this heater using any other means.
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!
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 12.3.
Use of
WARNING!!!
must be mechanically 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 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!
All vent pipes
The exhaust
WARNING!!!
components from different systems. The vent system could fail, causing leakage of ue products into the living space. Use only approved materials listed on Figures 12-7 and 12-8. Improper materials or mixing materials can result in excessive levels of carbon monoxide which can result in severe personal injury or death!
DO NOT mix
67
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12 - INSTALLATION - CATEGORY IV: Vent and combustion air
Figure 12-1 Side wall two pipes (Direct venting).
Figure 12-2 Vertical two pipes (Direct Venting).
Figure 12-3 Side wall air intake, vertical vent (Direct venting).
Figure 12-4 Vertical concentric (Direct venting).
Figure 12-5 Side wall concentric (Direct venting).
68
Figure 12-6 Side wall (or vertical in a roof) one pipe venting, combustion air from room (not Direct venting).
Page 69
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.3 - 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 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).
12.4 - Install vent and combustion air piping
WARNING!!!
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
5.1.1 of this manual. Inspect 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 12-7 and Figure 12-8, failure to properly seal all seams and joints, mixing
This heater
Using vent
of venting materials or failure to follow vent pipe and ttings manufacturer’s instructions can result in personal injury, death or property damage.
WARNING!!!
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 12-7 and Figure 12-8 for vent pipe, and 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 certied to ULC-S636 (see Figure 12-7).
Use of cellular
Use only the
Vent pipe materials and ttings must comply with the following standards
Item Material
PVC schedule 40/80 ANSI/ASTM D2665
Vent pipe
Vent ttings
Pipe cement/primer
WARNING!!! Use of cellular core PVC, CPVC, and Radel for venting system is not allowed
CPVC schedule 40/80 ANSI/ASTM F441
Polypropylene ULC-S636
Stainless steel AL29-4C UL 1738
PVC schedule 40 ANSI/ASTM D2466
PVC schedule 80 ANSI/ASTM D2467
CPVC schedule 80 ANSI/ASTM F439
Polypropylene ULC-S636
Stainless steel AL29-4C UL 1738
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Standard for installation
in USA
Standard for installation
in CANADA
ULC-S636
Figure 12-7 Approved vent materials
69
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12 - INSTALLATION - CATEGORY IV: 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 prole wall termination kit PVC IPEX (System 636) 199 196985
4” Low pro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 (Innoue System) 199 IASPP03
4” (110mm) Bird screen Polypropylene Centrotherm (Innoue System) 399, 500 IASPP04
6” (160mm) Bird screen Polypropylene Centrotherm (Inno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 (Innoue System) 199 ISELL0387UV
Polypropylene Centrotherm (Innoue System) 399, 500 ISELL0487UV
Polypropylene Centrotherm (Innoue System) 750, 1000 ISELL0687UV
Manufacturer/supplier Applicable
to models
Manufactur.
Part
Number
Figure 12-8 Approved vent manufacturers and items
70
Page 71
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.5 - 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 specication of its manufacturer.
- Polypropylene material to be sealed to specication of its manufacturer.
WARNING!!!
intake materials other than those specied, mixing the specied materials, failure to properly seal all seams and joints or failure to follow the manufacturer’s instructions can result in ue gas recirculation, spillage of 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.
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.
NOTICE! Combustion air piping must be supported per guidelines listed in the “National Mechanical code”, section 305, table 305.4 or local codes dictate.
The air
Using air
12.5.1 - 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 MOMENTIVE - RTV 106, 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 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 ue gas recirculation, spillage of ue products and carbon monoxide emissions causing severe personal injury or death.
WARNING!!!
pipes must be glued, properly supported and pitched a minimum of a 1/4 inch per foot out to the heater (to allow drainage of water into the appliance). Failure to follow this warning could result in excessive levels of carbon monoxide or a re, which can result in severe personal injury or death!
Failure to
All air intake
71
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12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.6 - PVC/CPVC
vent piping materials
WARNING!!!
the materials listed in 12-7 and 12-8 and 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!!!
appliance requires a special venting system. The vent pipe must be connected to the heater following Section 12.6.1. Use only the vent materials, primer, and cement specied in this manual to make the vent connections. Failure to follow this warning could result in 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 re, which can cause severe personal injury or death!
WARNING!!!
installation of PVC or CPVC systems may result in excessive levels of carbon monoxide or a re, which can cause severe personal injury or death!
Use only
Figures
for vent pipe,
This
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 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 certied to ULC-S636
(see
Figures 12-7
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
).
12.6.1 - 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 12.3.
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 ttings using a clean dry rag (Moisture will retard curing and dirt or grease will prevent adhesion).
Connection of the the vent or air piping to the heater adapters
5. Dry t vent or air piping to ensure proper t up before assembling pipes to the heater adapters. The pipe should go completely into the adapter to ensure proper sealing after sealant is applied. a. Handle adapters and pipes
carefully to prevent contamination of surfaces.
b. Apply a liberal even coat of
MOMENTIVE - RTV 106 high temperature silicone (or equivalent) to the the pipe end approximately 1/2” beyond the socket depth.
c. While the MOMENTIVE - RTV 106
high temperature silicone is still wet, insert the pipe into the heater adapter. NOTICE! If voids are present, sufcient MOMENTIVE
- RTV 106 was not applied and joint could be defective.
d. Tight the clamp to mechanically
secure the joint
Connection between pipes and /or elbows and/or terminals of the the vent or air piping
6. Dry t vent or air piping to ensure proper t up before assembling any joint. The pipe should go a third to two-thirds into the tting to ensure proper sealing after cement is applied.
7. Priming and Cementing: a. Handle ttings and pipes carefully
to prevent contamination of
surfaces.
b. Apply a liberal even coat of primer
to the 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
tting socket.
e. While primer is still wet, apply an
even coat of approved cement to
the pipe equal to the depth of the tting socket.
f. While primer is still wet, apply an
even coat of approved cement to
the tting socket.
g. Apply a second coat of cement to
the pipe.
h. While the cement is still wet,
insert the pipe into the tting, if possible twist the pipe a 1/4 turn as you insert it. NOTICE! If voids are present, suf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.
72
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12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
CAUTION!!!
even coat of MOMENTIVE ­RTV 106 high temperature silicone (or equivalent) to the internal side of the heater adapter (item “B” and “P” g.12-9)
Combustion air intake
Apply a liberal
N
A
F
P
020010.01.039
Flue exhaust
020010.01.010
12.6.2 - PVC/CPVC air
intake connection
Combustion Air Intake connection (see Figure 12-9 Item “P”).
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 12-9:
1. Prepare the connection between adapter “P” and pipe “N” like described on Section 12.6.1;
2. Insert the air inlet PVC/CPVC pipe, for 3” into the adapter “P”;
3. Tighten the clamp “F” to mechanically secure the adapter “P”
to the pipe.
This connection is used
12.6.3 - PVC/CPVC vent
connection
Vent connection (see Figure 12-9 Item “C”). This connection
is used to provide a passageway for conveying combustion gas to the
G
H
L
A = MOMENTIVE - RTV 106
A
F
B
high temperature silicone (or equivalent) (Field provided)
B = Flue exhaust adapter for
PVC/CPVC pipe F = mechanically secure clamp G = PVC/CPVC exhaust pipe
(Field provided) H = Combustion analization
probe (Field installed) L = cap (Field provided) N = PVC/CPVC air inlet pipe
(Field provided) P = Air intake adapter for PVC/
CPVC pipe
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 12-9:
1. Prepare the connection between adapter “B” and pipe “G” like described on Section 12.6.1;
2. Insert the ue exhaust PVC/CPVC pipe, for 3” into the adapter “B”;
3. Tighten the clamp “F” to mechanically secure the adapter “B”
to the pipe.
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 re, which can result in severe personal injury or death!
Extend the air intake
pipe to
outside building
Do not
Extend the ue exhaust
pipe to
outside building
020010.01.016
Figure 12-9 PVC/CPVC air intake/
vent connection
Figure 12-10 PVC/CPVC
air intake/Vent connection correctly in place
73
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12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.7 - Stainless
steel vent piping materials
WARNING!!!
materials, vent systems, and terminations listed in Figures 12-7 and 12-8. 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 eld provided vent heater adapter (Figure 12-11, item “B”) must be connected to the heater following Section 12.7.2. Failure to follow this warning could result in re, personal injury, or death.
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.
Use only the
This
Improper
Use only
Failure to
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).
NOTICE!
steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.
NOTICE!
specic vent starter adapter at the ue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Figure 12-8 for approved vent adapters.
Installation of a stainless
The installer must use a
12.7.1 - Stainless steel air
intake connection
Combustion Air Intake connection (see Figure 12-11 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 follows while referring to Figure 12-11:
1. Dry t adapter “R” and heater connection “P” to ensure proper t up before assembling the adapter to the heater. The adapter “R” should go completely into the heater connection to ensure proper sealing after sealant is applied. a. Handle adapters “R” and heater
adapter “P” carefully to prevent contamination of surfaces.
b. Apply a liberal even coat of
MOMENTIVE - RTV 106 high temperature silicone (or equivalent) to the adapter “R” approximately 2” beyond the socket depth.
c. While the MOMENTIVE - RTV
106 high temperature silicone is still wet, insert the adapter “R” into the heaterconnection “P”. NOTICE! If voids are present, sufcient MOMENTIVE - RTV 106 was not applied and joint could be defective.
d. Tight the clamp to mechanically
secure the joint
2. Insert air intake pipe “N”, into adapter “R”, following instruction of stainless steel pipe manufacturer.
NOTICE! For installation in Canada, vent pipe system must be certied to ULC-S636 (see Figure 12-7).
74
Page 75
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
CAUTION!!!
Apply a liberal even coat of MOMENTIVE ­RTV 106 high temperature silicone (or equivalent) to the internal side of the heater adapter (item “B” and “P” g.12-11)
020010.01.039
12.7.2 - Stainless steel
vent connection
Vent connection (Figure 12-11 item “C”)
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
follows while referring to Figure 12-11:
1. Dry t adapter “R” to ensure proper t up before assembling adapter to the heater connection “B”. The adapter “R” should go completely into the heater adapter to ensure proper sealing after sealant is applied. a. Handle adapters “R” and heater
connection “B” carefully to prevent contamination of surfaces.
is used to
b. Apply a liberal even coat of
MOMENTIVE - RTV 106 high temperature silicone (or equivalent) to the adapter “R” approximately 2” beyond the socket depth.
c. While the MOMENTIVE - RTV
106 high temperature silicone is still wet, insert the adapter “R” into the heater connection “B”. NOTICE! If voids are present, sufcient MOMENTIVE - RTV 106 was not applied and joint could be defective.
d. Tight the clamp to mechanically
secure the joint
2. Insert vent pipe “G”, into adapter “R”, following instruction of stainless steel pipe manufacturer.
Combustion air intake
N
N
R
R
A
A
F
F
P
P
Flue exhaust
020010.01.038
G
G
A = MOMENTIVE - RTV 106
H
H
L
L
R
R
A
A
F
F
B
B
high temperature silicone (or
equivalent) (Field provided) B = Flue exhaust connection F = Mechanically secure clamp G = Stainless steel exhaust pipe
(Field provided) H = Combustion analization
probe (Field installed) L = Cap (Field provided) N = Stainless steel air inlet pipe
(Field provided) P = Air intake connection R = Stainless steel adapter
(Field provided)
Extend the air intake
pipe to
outside building
Extend the ue exhaust
pipe to
outside building
020010.01.016
Figure 12-11 Stainless steel
air intake/vent connection
Figure 12-12 Stainless steel
air intake/vent connection correctly in place
75
Page 76
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12.8 - Polypropylene vent piping materials
WARNING!!!
the materials listed in 12-7 and 12-8 and 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 eld provided vent ttings must be connected to the heater following Section 12.8.2. Failure to follow this warning could result in 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 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!!!
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!
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 certied to ULC-S636 (see Figure 12-7).
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
76
Page 77
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
CAUTION!!!
Apply a liberal even coat of MOMENTIVE ­RTV 106 high temperature silicone (or equivalent) to the internal side of the heater adapter (item “B” and “P” g.12-13)
Combustion air intake
020010.01.039
Flue exhaust
12.8.1 - Polypropylene air intake connection
Combustion Air Intake connection (see Figure 12-13 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 follows while referring to Figure 12-13:
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.
12.8.2 - Polypropylene vent connection
Vent connection (Figure 12-13 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
follows while referring to Figure 12-13:
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!!!
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 re, which can result in severe personal injury or death!
Do not
N
A
F
P
D
M
Figure 12-13 Polypropylene air intake/vent connection
020010.01.010_PP
G
H
L
E
A = MOMENTIVE - RTV 106
A
F
B
D
high temperature silicone (or equivalent) (Field provided)
B = Flue exhaust adapter for
PVC/CPVC pipe C = Flue exhaust connection D = Gasket E = Fixing screws
C
F = Mechanically secure clamp G = PVC/CPVC exhaust pipe
(Field provided) H = Combustion analization
probe (Field installed) L = Cap (Field provided) N = PVC/CPVC air inlet pipe
(Field provided) P = Air intake adapter for PVC/
CPVC pipe
77
Extend the air intake
pipe to
outside building
Extend the ue exhaust
pipe to
outside building
020010.01.016
Figure 12-14 Polypropylene air intake/vent connection correctly in place
Page 78
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.9 - 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 (see section 5.1).
Failure to follow this warning could result in excessive levels of carbon monoxide, wich can cause sever personal injury or death!
Commercial applications utilizing this
heater may be installed with a single pipe carrying the ue products to the outside while using combustion air from the equipment room. In this case the following conditions and considerations must be followed.
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
12.6, 12.7 and 12.8.
When utilizing
WARNING!!!
the materials, vent systems, and terminations listed in 12-7 and 12-8 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 ammable materials or liquids. Do not store ammable materials and liquids in the immediate vicinity of the heater.
WARNING!!!
must be clear and free from combustible materials, gasoline and other 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 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 cause severe personal injury or death!
NOTICE! For installation in Canada, vent
pipe system must be certied to ULC-S636 (see Table 12-7).
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).
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
78
Page 79
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.9.1 - 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 12.3.
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 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 ue products impinge on building surfaces or plants.
d. Avoid possibility of accidental
contact of 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 nishes.
3. The vent piping must terminate in an elbow pointed outward as shown in Figures 12-15 or 12-16 or in a roof as shown in Figure 12-22.
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!!!
the maximum lengths of the outside vent piping shown in
Figures 12-15, 12-16 or 12-22.
Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential heater shutdown.
4. Maintain clearances as expected by “Venting of Equipment,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Venting Systems
Do not exceed
79
Page 80
WARNING!!!
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.10 - Sidewall
termination - Two pipes
12.10.1 - 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
12.10.2 - 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 12.3.
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 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 ue products impinge on building surfaces or plants.
d. Avoid possibility of accidental
contact of 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 nishes.
80
Page 81
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
3. The air piping must terminate in a down-turned elbow as shown
Air intake
Flue exhaust
in Figures 12-15 and 12-16. This arrangement avoids recirculation of 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 12-15 and 12-16.
Termination template
Bird screen
Grade/Snow level
Figure 12-15 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 12-15 and 12-
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 12-15 and 12-16. 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 12-16 Two pipes sidewall termination of
air and vent (if space permits)
81
Page 82
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.10.3 - Prepare wall penetrations
Air intake
Flue exhaust
Metal thimble
Termination template
Bird screen
Figure 12-17 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 12-17.
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 oors or walls.
5. Seal exterior openings thoroughly with exterior caulk.
12.10.4 - Termination and
ttings
1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in Figures 12-15 and 12-16.
2. Maintain the required dimensions of the nished termination piping as shown in Figures 12-15 and 12-16.
3. Do not extend exposed vent pipe outside of the building more than what is shown in Figures 12-15 and 12-16. 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 12-18 Two pipes multiple heaters vent terminations
82
12.10.5 - Multiple vent/air
terminations
1. When terminating multiple heaters terminate each vent/air connection as shown in Figure 12-18.
WARNING!!!
air inlets must terminate at the same height to avoid possibility of air inlet ue contamination that excessive levels of carbon monoxide which can cause severe personal injury or death!
2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in Figure 12-18 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 classied as a forced air intake with regard to spacing from adjacent heater vents.
All vent pipes and
could result in
Page 83
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.11 - Sidewall termination – Concentric
Overhang or roof
vent
12.11.1 - Description and usage
The termination kit must terminate outside the structure and must be installed as shown in Figure 12-19. The required concentric termination kit as well as combustion air and vent pipe materials are listed in Figures 12-7 and 12-8. The termination ending must be protected from rain, see Figure 12-20.
Vent
Combustion air
intake
Grade / snow line
Figure 12-19 Concentric sidewall termination clearances
12.11.2 - Sidewall termination
installation
1. Determine the best location for the termination kit (see Figures 12-19 and 12-20).
2. The total length of piping for vent or air must not exceed the limits given in Section 12.3.
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 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 ue products impinge on building surfaces or plants.
d. Avoid possibility of accidental contact of 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 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 12-20 Concentric sidewall termination clearances
83
NOTICE! Ensure termination location clearance dimensions are as shown in Figures 12-19 and 12-20.
CAUTION!!!
couplings to extend pipes. Air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 eld-supplied
Page 84
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.11.3 - 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 12-21. It is important that vent terminations be made as shown to avoid recirculation of 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 12-21 Concentric sidewall multiple heaters terminations
84
Page 85
WARNING!!!
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.12 - 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
Follow
Do not
12.12.1 - 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 12.3.
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 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
12.12.2 - 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 12-22 and listed in Section 12.12.1.
4. Follow all local codes for isolation of vent pipe when passing through oors, ceilings, and roofs.
5. Provide ashing and sealing boots sized for the vent pipe and air pipe.
12.12.3 - Termination and
ttings
1. Prepare the vent termination and the air termination elbow (Figure 12-22) by inserting bird screens.
2. The air piping must terminate in a down-turned 180° return bend as shown in Figure 12-22. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of ue products into the combustion air stream.
3. Maintain the required dimensions of the nished termination piping as shown in Figure 12-22.
4. Do not extend exposed vent pipe outside of building more than shown in Figure 12-22. Condensate could freeze and block vent pipe.
Figure 12-22 Two pipes vertical terminations of air and vent
above roof or snow line
85
Page 86
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
WARNING!!!
12.12.4 - 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 12-23 Two pipes Multiple heaters vertical terminations
1. When terminating multiple heaters,
terminate each vent/air connection
as shown in Figures 12-23 and 12-
24.
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.
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 12-23). 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 classied as a forced air intake with regard to spacing from adjacent heater vents.
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 12-24 Alternate vertical terminations with multiple heaters
vertically from
vent outlet to
any air inlet
86
Page 87
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.13 - Vertical termination – Concentric vent
12.13.1 - 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 12-25.
12.13.2 - 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 12.3.
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
12.13.3 - Vertical termination installation
1. Determine the best location for the termination kit (see Figure 12-26).
2. The total length of piping for vent or air must not exceed the limits given in Section 12.3.
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 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 ue products impinge on building surfaces or plants.
d. Avoid possibility of accidental
contact of 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 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 12-25 and 12-26.
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 12-25.
CAUTION!!!
supplied couplings to extend pipes. Air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 eld-
Combustion
Air
Roof boot /
ashing
(eld supplied)
Vent
Combustion
Air
Combustion
Air
Figure 12-25 Concentric vertical terminations
(18” for Canada) Minimum clearance above highest anticipated snow level. Maximum of 24” above roof.
Support (eld supplied)
Vent
Combustion air intake
Minimum clearance above snow level (18” for Canada) Maximum
24” above roof or snow level)
Figure 12-26 Concentric vertical terminations
87
Page 88
WARNING!!!
12 - INSTALLATION - CATEGORY IV: Vent and combustion air
12.13.4 - Multiventing
vertical terminations
When two (2) or more direct vent
appliances are vented near each
other, each appliance must be individually vented (see Figure 12-27).
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 12-27. It is important that vent terminations be made as shown to avoid recirculation of ue gases.
NEVER
Minimum
clearance
above snow
level (18”
for Canada)
Maximum 24”
above roof or
snow level)
Figure 12-27 Concentric multiple heaters vertical terminations
Combustion air intake
88
Page 89
13 - INSTALLATION - CATEGORY II: Vent and combustion air
13.1 - CAT II:
Negative pressure condensing
An appliance that operates with a non-positive vent static pressure with a vent gas temperature that may cause excessive condensate production in the vent.
C
C
13.2 - CAT II:
Adapter and
B
B
increaser
A
A
020010.01.040
Figure 13-1 Adapter and increaser
MODEL
199 3” to 6”
399 500
750
1000
FLUE
SIZE
4” to 8”
6” to 8”
FAMILY OF MATERIAL
Stainless
steel
Stainless
steel
Stainless
steel
MANUFACTURER ADAPTER INCREASER AIR INLET
DURAVENT 810005378
DURAVENT 810005545
DURAVENT 810005231 810005385
A = HEATER B = ADAPTER C = INCREASER
810003136 + 810005375
810005375 + 810005385
FSBS6 + FSELB9006
FSBS8 + FSELB9008
FSBS8 + FSELB9008
VENT ROOF
TERMINAL
FSVL 3606
FSVL 3608
FSVL 3608
89
Page 90
13 - INSTALLATION - CATEGORY II: Vent and combustion air
13.3 - Condensing vent option: CATEGORY II:
Vertical vent with combustion air from equipment room
The ue outlet terminates on the rooftop.
The termination point for the ue products must
EQUIPMENT ROOM
AIR OPENING
AIR OPENING
follow the vertical vent termination clearance requirements on section 12.12. These units can be identied by the CATEGORY II as noted on the unit’s rating plate.
The ue from this category II appliance must have all vent joints and seams sealed gastight. A category II vent system has specic vent material and installation requirements.
The ue products in the vent system may be cooled below their dew point and form condensate in the ue. The materials used for a category II vent must be resistant to any corrosive damage from ue gas condensate.
Figure 13-2 Vertical vent with combustion air from equipment room
EQUIPMENT ROOM
Follow all requirements in section 5.1, 12.2 and 12.9. Follow all requirements for venting ue products to the outdoors with a vertical termination as per section 12.12.
Vertical direct vent installation with rooftop combustion air
inlet
The vertical direct vent system is installed with a Category II ue and a separate combustion air pipe to the outdoors. The ue outlet and combustion air intake must both terminate on the rooftop.
The termination point for the ue products must follow the vertical vent termination clearance requirements on section 12.12. These units can be identied by the Category II as noted on the unit’s rating plate.
Follow all requirements in sections 5.1, 12.2 and 12.9. Follow all requirements for venting ue products to the outdoors with a vertical termination as per section 12.12.
Figure 13-3 Vertical direct vent installation with rooftop combustion air inlet
The vertical direct vent system requires the installation of an additional pipe to supply combustion air from outdoors directly to the appliance. Follow all requirements under the combustion air inlet section 12.5.
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13 - INSTALLATION - CATEGORY II: Vent and combustion air
WARNING!!!
WARNING!!!
Vent/Air vertical installation with sidewall combustion air inlet
The vent/air vertical with a sidewall combustion air vent system terminates the ue at the rooftop and air inlet at the sidewall. The ue outlet and combustion air intake terminate in different pressure zones.
The termination point for the ue products must follow the vertical vent termination clearance requirements on section 12.12. These units can be identied by the Category II as noted on the unit’s rating plate.
Follow all requirements in sections
5.1, 12.2 and 12.9. Follow all requirements for venting ue products to the outdoors with a vertical termination as per section 12.12.
The vent/air vertical system requires
the installation of an additional pipe to
supply combustion air from outdoors directly to the appliance. Follow all requirements under the combustion air inlet section 12.5.
EQUIPMENT ROOM
Common venting
CATEGORY II:
Flues of multiple water heaters may be combined by incorporating a vent increaser to change the category IV appliance to a category II vent system which can be common vented using an engineered vent system. The increaser kit must be provided by the manufacturer and the combined engineered vent system must be designed to ensure that ue products will be properly exhausted from the building at all times.
WARNING!!!
the correct vent increaser or a properly sized vent system may result in excessive levels of carbon monoxide which can cause severe personal injury or death!
Failure to use
Consult a vent designer to determine
the diameter of the common vent
pipe required for combined vent installation. It is recommended that all vent joints and seams are sealed gasthigt. This vent system has specic vent material and installation requirements. The negative draft in a conventional vent installation must be within the range of 0.02 to 0.08 inches w.c. to ensure proper operation. Make all draft readings while the unit is in stable operation (approximately 10 minutes).
WARNING!!!
venting can result in excessive levels of carbon monoxide which can cause severe personal injury or death!
1. INSTALL A CARBON MONOXIDE DETECTOR. At the time of installation of the common vented gas fueled equipment, the installing plumber or gastter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the oor level where the gas equipment is to be installed. It shall be the responsibility of the property owner to secure the services of qualied licensed
professionals for the installation of hard
wired carbon monoxide detectors.
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 certied.
Improper
Figure 13-4 Vertical vent/air installation with sidewall combustion air inlet
91
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WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
14.1 - 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 re or explosion causing extensive property damage, severe personal injury or death!
Connecting gas supply piping:
1. Refer to Figure 14-1 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 identied by the installer.
2. Install sediment trap / drip leg. (see Figure 14-1).
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 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 ow.
WARNING!!!
apply pipe sealing compound can result in severe personal injury, death, or substantial property damage.
WARNING!!!
typically shipped ready to 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 14.6 or 14.7. 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 14-1 Gas supply piping
TO HEATER
92
WARNING!!!
shutoff valve, must be identied by the installer. Failure to comply could result in re or explosion that can cause severe personal injury, death, or substantial property
damage.
Manual main
Page 93
WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
14.2 - Pipe sizing for natural gas
Refer to Figure 14-2 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 ow
(lockup) or with heater off.
• Minimum 3”W.C. with gas owing
(verify during high 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.
14.3 - Propane Gas
WARNING!!!
are typically shipped ready to 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 14.6 or
14.7. 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 ow
(lockup) or with heater off.
• Minimum 3”W.C. with gas owing
(verify during high 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 specic gravity gas at a pressure of 0.5 PSIG and a
0.3”WC pressure drop
Figure 14-2 Gas pipe capacity for natural gas
93
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WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
14.4 - 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 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 speci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 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 15.7 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, quali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 14-6, clockwise until snug and check for any gas leaks.
DO NOT
CAUTION!!!
pressure connection screw or the gas valve will be damaged!
WARNING!!!
open ame to check for gas leaks, or a re or an explosion could result causing severe personal injury or death!
Never force the
Never use an
14.5 - Operating at high altitudes
For installations in the United
States:
the heater is rated for operation at
altitudes up to 10,000 ft (3078 m). For altitude above 2,000 ft (610 m) check and adjust the CO2 level following Section 15.8. This will result in an authomatic input downrate of 3% each 1,000 ft (305 m) altitude.
For installation in Canada:
the heater is rated for operation at
altitudes up to 4,500 ft (1372 m). For altitude above 2,000 ft (610 m) check and adjust the CO2 level following Section 15.8. This will result in an authomatic input downrate of 3% each 1,000 ft (305 m) altitude.
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WARNING!!!
WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
M
020010.01.020
A
H
Figure 14-3 Dismantle the gas valve
C
L
B
020010.01.021
14.6 - Convert a
heater model 199 from Natural Gas to Propane gas or viceversa
WARNING!!!
conversion shall be performed by a quali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 re or explosion or to prevent property damage, personal injury or death. The quali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 speci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 orice per each burner present on
the unit;
The gas
The
1 - turn off the power to the heater; 2 - close the manual gas shut off valve; 3 - dismantle the jacket of the heater,
follow Section 17.2; 4 - unscrew nut “H” as per Figure 14-3; 5 - with the help of a screwdriver,
remove spring “A” (see gure 14-3); 6 - remove the gas valve from its site
“C” as per Figure 14-4 (take care
attention to o-ring “L” of Figure 14-4); 7 - replace orice “G” of Figure 14-5, for
the correct one for type of gas used.
Verify that the stamping on the orice
matches the Figure 14-7; 8 - reinstall the gas valve, paying close
attention to the o-ring “L” of Figure
14-4 and to the gasket between gas
valve and nut “H” of Figure 14-3; 9 - Insert again the spring “A” of Figure
14-3; 10 - tight nut “H” of Figure 14-3; 11 - open the manual gas shut off valve;
12 - check for any gas leaks on nut “H”
of Figure 14-3;
WARNING!!!
an open ame to check for gas leaks, a re or an explosion could result causing severe personal injury or death!
13 - turn the power on to the heater; 14 - turn completely counter clockwise
the screw “E” of Figure 14-6;
15 - Checking gas supply pressure
following Section 15.7. 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). 16 - Verifying the CO2 rate and its
eventual adjustment following Section
13.8: The heater during its normal
operation, within a maximum altitude
of 2,000 ft, has a CO2 exhaust rate
as shown in Figure 14-7. If not within
range of value shown, malfunctions
will occur.
Never use
Figure 14-4 Lift the gas valve
Installing:
in order to make the gas change follow the instructions below:
95
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WARNING!!!
WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
020010.01.019
G
Figure 14-5 Gas orice
E
F
D
WARNING!!!
(carbon monoxide) level should not exceed values given in Figure 14-7, when combustion is correct. Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.
WARNING!!!
combustion 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.
The CO
All
WARNING!!!
combustion levels are not within the range given in Figure 14-7 for the 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.
17 - check the capacity of the heater
following Section 15.9;
18 - Attach to the front of the heater the
appropriate conversion label, found in
the conversion kit (see Figure 14-8 or
Figure 14-9), stating the new type of
gas adjustment of the heater.
a - Apply the label in Figure 14-8 if
the heater has been converted to LP GAS;
b - Apply the label in Figure 14-9 if
the heater has been converted to NATURAL GAS.
If the
020010.01.022
Figure 14-6 Gas valve
U.M 199 250 399 500 750 1000
Orice stamping for Natural gas mm/100 No orice 930 No orice 930 930 930
Orice stamping for LP gas mm/100 700 700 700 700 700 700
CO2 (Carbon dioxide) for Natural gas at high re % 8.4 to 8.7 8.8 to 9.1 8.4 to 8.7 8.8 to 9.1 8.8 to 9.1 8.8 to 9.1
CO2 (Carbon dioxide) for Natural gas at low re % 8.4 to 8.7 8.8 to 9.1 8.4 to 8.7 8.8 to 9.1 8.8 to 9.1 8.8 to 9.1
CO2 (Carbon dioxide) for LP gas at high re % 9.5 to 10
CO2 (Carbon dioxide) for LP gas at low re % 10.5 to 11.5
O2 (Oxygen) for Natural gas at high re % 5.9 to 5.4 5.2 to 4.7 5.9 to 5.4 5.2 to 4.7 5.2 to 4.7 5.2 to 4.7
O2 (Oxygen) for Natural gas at low re % 5.9 to 5.4 5.2 to 4.7 5.9 to 5.4 5.2 to 4.7 5.2 to 4.7 5.2 to 4.7
O2 (Oxygen) for LP gas at high re % 6.4 to 5.6
O2 (Oxygen) for LP gas at low re % 4.8 to 3.4
CO (Carbon monoxide) for Natural gas at high and low re ppm Less than 150
CO (Carbon monoxide) for LP gas at high and low re ppm Less than 250
Figure 14-7 Settings of the heater for NATURAL GAS and LP GAS
96
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WARNING!!!
WARNING!!!
14 - INSTALLATION - Gas supply
Figure 14-8 Label for LP
gas heater
Figure 14-9 Label for
Natural gas heater
14.7 - 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 performed by a quali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 re or explosion or to prevent property damage, personal injury or death. The quali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 speci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.
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 ori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 “Burner 1 (Master)”;
2. operating on “Burner 1 (Master)”
following exactly Section 14.6 from
point 1. to 16.;
After converting “Burner 1 (Master)” you have to operate on “Burner 2” (See Figure 3-6 and 3-9) and:
3. follow exactly Section 14.6 from
point 1. to 16.;
After converting “Burner 2” you have to operate on “Burner 3”, if present (See Figure 3-6 and 3-9), and:
4. follow exactly Section 14.6 from
point 1. to 16.;
After converting “Burner 3” you have to operate on “Burner 4”, if present, (See Figure 3-6 and 3-9) and:
5. follow exactly Section 14.6 from
point 1. to 16.; After converting all burners:
6. check the inlet gas pressure of the
unit, following Section 15.7;
7. check the capacity input of the unit
following Section 15.9;
8 - 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 14-8 if
the heater has been converted to LP GAS;
b - Apply the label in Figure 14-9 if
the heater has been converted to NATURAL GAS.
97
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WARNING!!!
15 - START-UP
WARNING!!!
WARNING!!!
15.1 - Operating
Before starting the heater, the following must be done.
15.1.1 - 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 modi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 ue gases, and that these must not be modi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 efciency.
15.1.2 - 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 lled with water to prevent the leakage of ue gases from the condensate drainpipe, item “5” in Figures 3-3 through 3-8. To ll and inspect the condensate box proceed follow Section 17.6.
WARNING!!!
off for more than 3 months, repeat the above operation to again 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
15.1.3 - Filling the heating
system on a IB boiler
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 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 ll the heating system, proceed as follows:
1. open any automatic air vent in the heating system;
2. open the ll valve and proceed to ll the heating system and boiler until the pressure gauge, item “M” in Figure 16-1, reads the correct pressure for the heating system size and “Err 59” disappears from the display; (“Err 59” displaing is set at 15PSI. If you want to increase the “Err 59” intervention level, set parameter 3022 to the desired value (See Section 21)
3. check that there is no water leaking from the ttings. If there is, the leaks must be eliminated;
4. close the ll valve;
5. check the pressure gauge during the purging process. If the pressure has dropped, re-open the ll valve to bring the pressure back to the desired value.
Never use
The heating system
The water’s pH must
15.2 - General
warnings concerning gas supply
When starting up the heater for the rst time the following must be checked:
That the heater is supplied with the
type of fuel that it is congured to use. Read Section 14.
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 Sections 12 and 13) 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 re department. Failure to follow the above steps can result in a re or explosion causing property damage, personal injury or loss of life!
To avoid corrosion
98
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WARNING!!!
WARNING!!!
15 - START-UP
15.3 - Con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).
or
LP Gas
Maximum supply pressure = 13 in.W.C. (33.0 mbar). Minimum supply pressure = 3 in.W.C. (7.6 mbar).
15.4 - Gas type conversion
If the gas available at the installation site is not the type the heater is congured to use, the heater must be converted. Special conversion kits are available for this purpose inside the heater. Follow instruction on Sections 14.6 and 14.7.
WARNING!!!
of the heater to use another type of gas must be carried out by a qualied technician. Improper conversion of the heater could result in a re or an explosion causing severe personal injury or death!
Conversion
3. The heater will 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
16.13, 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 16.13, parameter 1004) is lower than “warm weather shut down temperature”, (parameter 2020 into Section 16.14).
4. If the heater is connected to an indirect water heater (See Section
7.2.6) press buttons
domestic hot water temperature.
5. If the display gives a Low water ow error (see Section 16.17), repeat the air purging operations.
to select the desired
to select the desired
and
15.5.2 - Start-up of the IW
water heater
1. Open the manual gas shut off valve (Figure 14-1).
2. Switch the on/off power switch, item “T” in Figure 16-1, to “on”.
3. The heater will re only when the supply temperature settings is higher than the actual supply temperature.
Press buttons select the desired supply temperature.
4. If the display gives a Low water ow error (see Section 16.17), repeat the air purging operations.
or to
3. wait a few minutes for the burner to
light-up as indicated by icon units model 399 and 500, wait until
icons and are present on the
display. On units model 750 wait until
icons  and are displayed.
On units model 1000 wait until icons
. On
 and are displayed.
4. close the manual gas shutoff valve, see Figure 14-1;
5. after 3 minutes, the display must show
Loc 01 and
1000 all burners icons will blinking and
the icon
NOTICE! On unit models 750 and 1000,
because they have 3 and 4 burners, the time to see all burners icons blinking, can arrive at 15 - 20 minutes
6. open the manual gas shutoff valve, see Figure 14-1;
7. verify your gas meter. Gas ow must be zero.
WARNING!!!
occurs, close the manual gas shutoff valve and troubleshoot the system to determine why there is gas ow when the gas valve should be de-energized. Do not operate the heater until the problem is resolved or a re or explosion causing property damage, personal injury or loss of life may occur!
or, on models 399 to
is displayed;
If gas ow
15.5 - Start-up
15.5.1 - Start-up of the IB
boiler
1. Open the manual gas shut off valve (Figure 14-1).
2. Switch the on/off power switch, item “T” in Figure 16-1, to “on”.
15.6 - 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 16-1) to on;
2. follow Section 15.5 to create a call for heat;
99
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WARNING!!!
15 - START-UP
WARNING!!!
15.7 - 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 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 cause severe personal injury or death!
Check the gas supply pressure by following the steps below:
1. close the manual gas shut-off valve, Figure 14-1;
2. follow the steps in Section 17.2 to remove the front cover;
3. turn the screw in pressure port “D” shown in Figure 15-1 three turns counterclockwise;
excessive levels of
DO NOT
The
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 15-1 (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 14-1;
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 maximum setting. Also ensure that the room thermostat is calling for heat and operate downstream the unit to veriy the system is able to dissipate all heat generated.
8. set parameter 2200 to “HIGH” (see section 16.14) (for boiler model 199 use parameter 2010). All burners will now start to run at high re.
9. check the manometer to make sure the gas supply pressure does not
to its
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.
After verifying the correct gas pressures:
1. back to set parameter 2200 to “OFF” (on models 199 back to set parameter 2010 to “OFF”). Now heater will back to work in normal condition;
2. disconnect the manometer;
3. turn the screw in pressure connection “D” in Figure 15-1, clockwise until snug;
4. check pressure port “D” (Figure 15-
1) for any gas leaks;
CAUTION!!!
pressure connection screw or the gas valve will be damaged!
Do not attempt
Never force the
E
F
D
020010.01.022
Figure 15-1 Gas valve
D - Inlet gas pressure
probe E - CO2 adjusting screw F - Factory adjusted
regulator (Should never
be touched)
WARNING!!!
open ame to check for gas leaks, a re or an explosion could result causing severe personal injury or death!
5. close the manual gas shut-off valve, Figure 14-1.
Never use an
100
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