Slant/Fin CB-45, CB-90, CB-135, CB-180, CONCEPT 21 CB-180 Installation And Operating Instructions Manual

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Page 1

CONCEPT 21Models CB-45 through CB-180

• Cast-iron • Hot water boilers • Gas Fired • Sealed Combustion

• Direct Vent, Category I, or Category IV Venting Flexibility

INSTALLATION AND OPERATING INSTRUCTIONS

Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Page

Specifications and Dimensions . . . . . . . . . . . . . . . . . . . . . . . .2

Installation Requirements

Boiler Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Boiler Foundation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Minimum Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Approved Venting Applications . . . . . . . . . . . . . . . . . . . . 4

Direct Vent Application Requirements . . . . . . . . . . . . . 4–8

Category IV Venting Requirements . . . . . . . . . . . . . 9–11

Category I Venting Requirements . . . . . . . . . . . . . 12–14

Water Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Electrical Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16–17

Operation Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .18–19

Input Rate Adjustment Specifications . . . . . . . . . . . . . . . . . .20

Testing of System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Sequence of Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-27

Air and Gas Orifices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28–29

Lighting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Boiler Package/Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

IMPORTANT

READ ALL OF THE FOLLOWING WARNINGS

AND STATEMENTS BEFORE READING THE

INSTALLATION INSTRUCTIONS

WARNING

LIQUEFIED PETROLEUM (L.P.)

PROPANE FIRED GAS BOILERS

Installation location ONLY as permitted in paragraph entitled "LIQUEFIED PETROLEUM (L.P.) PROPANE GAS FIRED BOILER LOCATION" on page 3 of this instruction book. The above warning does not apply to NATURAL gas fired boilers.

NOTICE: INSTALLATION AND SERVICE MUST BE PERFORMED BY A TRAINED AND QUALIFIED TECHNICIAN.

The installation must conform to the requirements of the National Fuel Gas Code ANSI Z223.1 or the CSA B149.1-00 for natural gas and propane and the requirements of the authority having jurisdiction as well as the requirements in this instruction manual. In addition, where required by the authority having jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1 or the CSA B149.1-00 for natural gas and propane. If there is any conflict in the above requirements, then the more stringent requirement will apply.

WARNING This boiler, gas piping and accessories must be installed, connected, serviced and repaired by a trained, experienced service technician, familiar with all precautions required for gas fired equipment and licensed or otherwise qualified, in compliance with the authority having jurisdiction.

Printed in Canada

Publication No. CB-40 Rev. C

Part No. 66-1001

This manual must be left with owner, hung on or adjacent to the boiler. Owner should retain manual for future reference.

Heating Contractor

Address

Phone Number

Boiler Model Number

Boiler Serial Number

Installation Date

Page 2

Figure 1. Views — Dimensions — Data

ABCDEFG

mm in mm in mm in mm in mm in mm in mm in

CB-45 743 29.25 508 20 794 31.25 527 20.75 279 11 127 5 356 14 CB-90 743 29.25 584 23 794 31.25 527 20.75 279 11 127 5 432 17 CB-135 743 29.25 660 26 794 31.25 527 20.75 279 11 127 5 508 20 CB-180 743 29.25 737 29 794 31.25 527 20.75 279 11 127 5 584 23

HIJKLMN

mm in mm in mm in mm in mm in mm in mm in

CB-45 127 5 203 8 457 18 413 16.25 273 10.75 95 3.75 660 26 CB-90 165 6.5 203 8 533 21 413 16.25 273 10.75 95 3.75 660 26 CB-135 203 8 203 8 610 24 413 16.25 273 10.75 95 3.75 660 26 CB-180 241 9.5 203 8 686 27 413 16.25 273 10.75 95 3.75 660 26

Boiler Model

DIMENSIONS INCHES

RATINGS AND DIMENSIONS

Boiler No. of Gas Gas Supply Pressure Shipping Boiler

Model Sections Type Max Min Weight Water Vol.

mm in mm in kg lbs l USG

CB-45 1 Natural 229 9 89 3.5

87 192 1.9 0.5

CB-45 1 Propane 356 14 279 11

CB-90 2 Natural 229 9 89 3.5

112 246 3.8 1.0

CB-90 2 Propane 356 14 279 11

CB-135 3 Natural 229 9 89 3.5

142 312 5.7 1.5

CB-135 3 Propane 356 14 279 11

CB-180 4 Natural 229 9 89 3.5

167 368 7.6 2.0

CB-180 4 Propane 356 14 279 11

WATER SUPPLY 32mm (1 1/4") NPT

GAS SUPPLY 13mm (1/2") NPT

76mm (3") VENT DIA. FOR ALL VENTING, ALL MODELS

AIR INTAKE

EXHAUST

WATER RETURN 32mm (1 1/4")

LEFT SIDE VIEW FRONT VIEW RIGHT SIDE VIEW

CIRC. PUMP

Page 3

NOTICE: INSTALLATION AND SERVICE MUST BE PERFORMED BY A QUALIFIED HEATING CONTRACTOR

The installation must conform to the requirements of the National Fuel Gas Code ANSI Z223.1 and CSA B149.1-00 for natural gas and propane for Gas Burning Appliances and Equipment, and the requirements of the authority having jurisdiction as well as the requirements in this instruction manual. In addition, where required by the authority having jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1. If there is any conflict in the above requirements, then the more stringent requirement will apply.

BOILER LOCATION

Structure through which venting will pass must be free and clear for opening (i.e. no hidden conduit, telephone cables or other obstructions).

Boiler location should be such that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, condensate trap, control replacement, etc.).

For a closet installation, ventilation openings must be provided through a door or wall to prevent excessive heat build-up. Two openings, one near the floor and one near the ceiling, should be sized to assure sufficient air circulation in the closet (minimum 64,516mm

[100 sq.

inches] each).

WARNING LIQUEFIED PETROLEUM (L.P.) PROPANE FIRED GAS BOILER LOCATION

REQUIRES SPECIAL ATTENTION Liquefied Petroleum (L.P.) propane gas is heavier than air. Therefore, propane boilers, piping, valves must NOT be installed in locations where propane leaking from defective equipment and piping will "pool" in a basement or other space below the leak. A spark or flame from the boiler or other source may ignite the accumulated propane gas causing an explosion or fire. Provide a level, solid foundation for the boiler. Location should be as near the chimney as possible so that the flue pipe from boiler to the chimney is short and direct.

The UNIFORM MECHANICAL CODE may be in effect in your geographic area.

The following precautions are cited by the 1994 UNIFORM MECHANICAL CODE, section 304.6 or CSA B149.1-00 for natural gas and propane.

“LPG Appliances. Liquefied petroleum gas-burning

appliances shall not be installed in a pit, basement

or similar location where heavier-than-air-gas might collect. Appliances so fueled shall not be installed in an above-grade under-floor space or basement unless such location is provided with an approved

means for removal of unburned gas.” Consult Chapter 5 of the 1994 UNIFORM MECHANICAL CODE for design criteria of the "approved" means for removal of unburned gas.

SAFETY—

KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

BOILER FOUNDATION

A. Provide a solid, level foundation, capable of

supporting the weight of the boiler filled with water,

and extending at least 51mm (2") past the jacket on

all sides. See dimensions of boilers, page 2. B. Boiler can be installed on both combustible and non-

combustible floors, but must NOT be installed on or

above carpeting. C. If boiler is to be located over buried conduit

containing electric wires or telephone cables, consult

local codes or the National Board of Fire Underwriters

for specific requirements.

MINIMUM CLEARANCES

A. Minimum clearances to the exterior surfaces of the

boiler shall be as follows:

MINIMUM ALCOVE AND CLOSET CLEARANCE. B. Provide 457mm (18") on sides used for passage.

For Combustible Recommended

Surface

Construction for Service Front 51mm (2") 457mm (18") Rear 51mm (2") 203mm (8") Left Side 51mm (2") 457mm (18") Right Side 51mm (2") 457mm (18") Top 254mm (10") 254mm (10") Flue Connector 76mm (3") 152mm (6")

C. All minimum clearances shown above must be met.

This may result in increased values of some minimum clearances in order to maintain the minimum clearances of others.

D. Clearance from hot water pipes shall be

25mm (1") **. ** At points where hot water pipes emerge from a

floor, wall or ceiling, the clearance at the opening through the finished floor boards or wall or ceiling boards may not be less than 13mm (1/2"). Each such opening shall be covered with a plate of noncombustible material.

INSTALLATION REQUIREMENTS

Page 4

APPROVED VENTING APPLICATIONS

This Concept 21 boiler is approved to be vented using Direct Vent, Category I, or Category IV applications. These applications are differentiated as follows: Direct Vent — The air for combustion is piped directly to

the air intake of the boiler from outdoors. The vent piping may be run horizontally or vertically to the outdoors, to a common terminal with the combustion air intake or separate from the combustion air intake means. Category I— The air for combustion is taken from the ambient air surrounding the boiler. The vent piping must be upsized and run into a vertical chimney or vent which will insure a non-positive vent pressure. There is only one specified input rate for each model boiler on Category I installations. See chart 2 on page 20. Category IV— The air for combustion is taken from the ambient air surrounding the boiler. The vent piping may be run horizontally or vertically to the outdoors. The vent pressure is typically positive in this application.

The following venting installation requirements are divided into 3 sections, each pertaining to the 3 different applications described above. Once the appropriate venting application has been selected, follow only the requirements specified under that section for venting the boiler. These requirements must be carefully read and followed in order to avoid any hazardous conditions due to improper installation of the flue gas venting system.

DIRECT VENT APPLICATION REQUIREMENTS VENTING LOCATION

Vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1, and CSA B149.1-00 for natural gas and propane, or applicable provisions of local building codes.

Vent termination must meet the following clearances: Minimum of 305mm (12”) above grade and normal snow line to vent terminal bottom; minimum of 305mm (12”) from any building opening; minimum of 914mm (3 feet) above any forced air intake located within 3048mm (10 feet); minimum of 1219mm (4 feet) horizontally from, and in no case above or below, unless 1219mm (4-foot) horizontal distance is maintained, from electric or gas meters, regulators and relief equipment. Vent termination must not be located over any public walkway, in any confined space (i.e. window wells, alcoves, narrow alleys) or under any overhang or deck. Vent termination should not allow flue gas discharge towards neighbor's windows or where personal injury or property damage can occur.

DO NOT install the vent into a common venting system. DO NOT install a vent damper or similar device in vent tubing or on the boiler.

VENT MATERIAL

A. DO NOT use galvanized or plastic vent system

materials. The vent system for Direct Vent Applications must be UL listed 76mm (3”) diameter corrosion resistant stainless steel. The following manufacturer’s systems are approved for use within a specified minimum and maximum equivalent vent length for each model of boiler. Refer to Slant/Fin Parts List, Publication CB 10PL.

B. When joining the various components of the above

listed vent systems, the manufacturers’ instructions should be closely followed to insure proper sealing

. Use GE-RTV106 or Dow-Corning 732 sealant for sealing of pipe and fittings. See Figure 4 for proper application of vent pipe sealant.

C. All vent connections must be liquid and pressure tight.

CB-45 30 100 5 914 3 1524 5 1 CB-90 30 100 5 914 3 1524 5 1 CB-135 24 80 5 914 3 1524 5 1 CB-180 12 40 5 914 3 1524 5 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows

m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

* All lengths specified include mandatory minimum use of 610mm (2

feet) of tubing plus one elbow from boiler to vent termination all models.

Heat Fab Saf-T Vent System

CB-45 30 100 5 1829 6 2438 8 1 CB-90 30 100 5 1829 6 2438 8 1 CB-135 18 60 5 1829 6 2438 8 1 CB-180 9 30 3 1829 6 2438 8 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows* m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

ProTech Fas-N Seal System

CB-45 30 100 5 1829 6 2438 8 1 CB-90 30 100 5 1829 6 2438 8 1 CB-135 21 70 5 1829 6 2438 8 1 CB-180 11 35 4 1829 6 2438 8 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows*

m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

Flex-L Star-34 System

Page 5

Figure 2. General Vent and Air Intake Piping from Boiler

for Direct Venting

All items shown below are REQUIRED. All vent joints must be LIQUID and PRESSURE TIGHT.

Figure 3. Floor and ceiling venting passage

All items shown below are REQUIRED. All vent joints must be LIQUID and PRESSURE TIGHT.

Figure 4. Vent sealing instructions

(Consult vent manufacturer’s instructions.)

DIRECT VENT APPLICATION REQUIREMENTS

AIR INTAKE

A. 76mm (3”) diameter PVC piping materials are

recommended. Sewer and drain type material or PVC schedule 40 piping are best suited for connection to boiler and vent terminal. Use 76mm (3”) PVC fitting provided with vent kit to adapt PVC schedule 40 air intake tubing to air filter box collar. The fitting provided will fit onto the filter box collar and then a schedule 40 76mm (3”) coupling will fit over that.

B. The venting length requirements specified in this

section also apply to the air intake piping.

C. Seal all joints on air intake piping using appropriate

sealants.

VENTING INSTALLATION

A. Follow the vent material manufacturer’s instructions in

conjunction with these instructions for venting system installation.

B. Refer to Figures 2, 3 and 4 which illustrate some of

the requirements for venting in a typical installation.

C. A condensate drain and drain trap MUST be installed

on the flue tubing, see Figure 2. The condensate drain should be installed close to the boiler, as shown, and must be equipped with a trap formed by attaching 10mm (3/8”) I.D. clear plastic tubing to the drain assembly, making a loop approximately 102mm (4") diameter and securing with cord or a tie wrap where the loop crosses over itself. This loop should then be filled with water to form a liquid-filled trap. DO NOT OPERATE THE BOILER WITHOUT INSTALLING THIS TRAP AND FILLING WITH WATER

EXHAUST VENT PIPING 76mm (3”) I.D.

AIR INTAKE PIPING 76mm (3”) I.D.

76mm (3”) PVC FITTING.

152mm (6”) MIN. 610mm (24”) MAX.

CONTINUE WITH PIPING AS SHOWN IN FOLLOWING FIGURES

SLOPE UP 20mm/m (1/4”/FT)

CONDENSATE DRAIN ASSY

FILL TRAP WITH WATER

HEAT EXCHANGER ASSY

TO DRAIN

AIR FILTER BOX ASSY

VENT SEALING INSTRUCTIONS FOR HEAT-FAB 29-4C STAINLESS STEEL VENTING MATERIALS

RING

APPLY ADHESIVE BEAD (6mm [1/4”] DIA. MINIMUM) AROUND OUTSIDE OF MALE END ONLY, BETWEEN 6mm (1/4”) AND 10 mm (3/8”) FROM THE EDGE OF THE MALE END. CARE MUST BE TAKEN TO ASSURE THAT ADHESIVE DOES NOT BLOCK INSIDE OF PIPE

DO NOT APPLY ADHESIVE INSIDE OF FEMALE FITTINGS IN ORDER TO PREVENT BLOCKAGE OF INSIDE OF FITTINGS AND TUBING. IF ANY ADHESIVE SHOULD GET INSIDE, BE SURE TO WIPE IT OUT BEFORE ASSEMBLING

FIRESTOP

EXHAUST VENT TUBING 76mm (3”) I.D.

CLEARANCE: 152mm (6”) MIN. FOR 29-4C STAINLESS STEEL VENTING

FIRESTOP AND SUPPORT

AIR INTAKE TUBING 76mm (3”) I.D.

CLEARANCE: 51mm (2”) MIN. BETWEEN TUBING

76mm (3”) MIN. 610mm (24”) MAX.

TO PREVENT FLUE GAS DISCHARGE INTO SPACE. Periodic inspection should be made of this assembly for deterioration of the tubing and to insure that the trap is filled with water, but not plugged. If it is plugged or appears to have excessive sediment in it, it should be removed from the drain assembly, straightened out to clear the obstruction, reformed, filled with water and reinstalled as before. The drain must extend to a floor drain.

D. The horizontal pipe must be sloped UPWARD from

the boiler, at a pitch of 20mm/m (*1/4” per 1 foot) of run, so that the condensate from the vent system runs to the drain trap. The horizontal portion must also be supported with 19mm (3/4”) pipe strap at intervals no greater than 1829mm (6 feet).

E. The vertical portion of the pipe must be supported in

at least one location for each 9m (30 feet) of vertical run. A firestop is required for each wall, ceiling and floor penetration.

F. Use tabs on vent collar to secure stainless steel vent

tubing to the boiler.

G. Venting is approved for combustible wall passage

through a 102mm (4”) minimum to 305mm (12”) maximum thick wall, providing a thimble is used.

Page 6

Figure 5a. Vent terminal orientation

Figure 5b. Vent terminal installation

VENT TERMINAL INSTALLATION Warning: The vent terminal provided is to be used for

horizontal venting only. DO NOT alter this part in any manner other than shown in these instructions. Only mount on a vertical surface. DO NOT use when vertically venting through a roof or chimney.

1. Wall cutout opening: a) Cut out a rectangular opening 152mm (6”) high and

305mm (12”) wide in the appropriate location of an exterior wall. Be sure that this location will allow for the connection of vent materials that come in fixed lengths, or an adjustable connector will be needed.

b) Boxing in the cutout with wood is allowable, but the

152mm x 305mm (6” x 12”) opening size must be maintained.

c) Plan on the edge of the cutout to be about 76mm (3”)

from the center of the exhaust tube, when installed.

2. Vent terminal orientation: see Figure 5a. a) The open slots for the air intake on the vent terminal

must face downward.

b) The air inlet cover plate must face upward to insure

that rain, debris and flue gases do not enter the air inlet.

3. Vent and air intake tubing orientation: see Figure 5a. a) Air inlet tubing may be located to the left or to the

right of the flue exhaust tubing.

b) If the air inlet tubing is going to be to the left of the

flue exhaust (viewed from outside of building) then the vent terminal should be installed as supplied without alteration.

c) If the air inlet tubing is going to be to the right of t

flue exhaust (viewed from outside building) then t air inlet cover plate must be removed and reinstall over the alternate set of slots. This alteration w

insure that the air inlet slots face down when the ve terminal is installed.

4. Vent terminal installation: see Figure 5b. a) Center the vent terminal over the wall cutout. T

collar on the back of the vent terminal panel shou clear the cutout edges by about 12mm (1/2”).

b) Mark and drill out the location of the four screw hol

in the wall for mounting vent terminal.

c) Seal the vent collar adapter tube 76mm (3”) dia. ma

end stainless) into the collar on the back of the ve terminal box and slide the ring on the tube over t collar tabs, then bend the tabs back over the rin This piece will allow easy connection of the fl exhaust tubing from inside the building.

d) Run a bead of silicone around the perimeter of w

panel and vent collar to prevent water and drafts fro entering building.

e) Orientate the vent terminal on the wall as describ

in Step 2 and secure it to the wall.

5. Interior wall panel installation: a) Cut the wall thimble 127mm (5”) diameter galv. pip

about 12mm (1/2”) shorter than the wall thickness

b) Fit thimble onto the collar on the back of the ve

terminal inside the wall.

c) Hold the interior wall panel up to the wall cutout a

fit the collar on this panel into the thimble. Line up t air inlet holes and secure to wall.

6. Vent and air intake tubing installation to vent terminal: a) Finish tubing connections back to the boil

following

the requirements in the venting installati

instructions

on pages 4 and 5.

b) Exhaust tubing connects to the vent collar adapt

tube. Observe correct flow direction.

c) Air intake tubing should slip into the air inlet openi

in the back of the vent terminal. Make sure the tubi extends into the vent terminal box as far as the tu stop inside the box allows (19mm [3/4”] approx Seal around the air intake tubing where it pass through the outside wall plate.

*Shown with air inlet to the left of exhaust

from outside view.

* Shown from top view.

DIRECT VENTING WITH VENT TERMINAL

All Concept 21 boiler models are certified for horizontal Direct Venting utilizing the vent terminal provided by Slant/Fin only.

This vent terminal must be mounted on a vertical wall outside surface. Terminal CANNOT be mounted on a roof or any horizontal surface.

Vent terminal is designed to deflect flue gases away from outside building wall; properly installed, it will prevent flue gas degradation of normal building materials and reduce the possibility of air intake freeze-up. It is recommended to utilize this vent terminal on Direct Vent applications whenever the installation permits.

Page 7

Figure 7a. Vent and air intake run through a pitched roof

Figure 7b. Vent and air intake run through a flat roof

EXHAUST WITH SCREEN

AIR INTAKE 180° ELBOW WITH SCREEN FACE DOWN

3048mm (10 ft) or less

610mm (2 ft) min.

ROOF FLASHING

54mm (2“) min.

305mm (1 ft) min.

54mm (2“) min.

ROOFLINE

SNOWLINE

EXHAUST WITH SCREEN

3048mm (10 ft) or less

610mm (2 ft) min.

ROOF LINE

SNOW LINE

ROOF FLASHING

54mm (2”) min.

AIR INTAKE 180° ELBOW WITH SCREEN FACE DOWN

305mm (1 ft) min.

914mm

(3 ft) min.

305mm (1 ft) min.

914mm (3 ft) min.

Vertical Venting Configurations

All Concept 21 boiler models are certified for vertical Direct Venting utilizing the following configurations.

1. Vent and air intake piping vertically run up through a roof in close proximity. a. For a pitched roof installation, refer to Figure 7a. For

a flat roof installation, refer to Figure 7b. When floor and ceiling passage is necessary, refer to Figure 3. Adhere to all clearances and materials specified in these illustrations.

b. The stainless exhaust vent pipe must pass through

the roof vertically through a 178mm (7”) min. diameter cutout and appropriate roof flashing. The pipe must exhaust straight up and terminate with a screen terminator.

c. The air intake pipe must pass through the roof

vertically. The cutout does not require any clearance, but must be sealed with a flashing or other means. The air intake opening must face down by using a 180° elbow with a screen positioned at the opening. The air intake opening must be at least 305mm (1 foot) below the vent opening.

DIRECT VENTING WITHOUT VENT TERMINAL

Page 8

Figure 8b. Vent piping vertically run up an existing chimney

and air intake horizontally run out a vertical wall.

Figure 8a. Vent run through a roof and air intake run through

a wall

REFER TO VENT PIPE REQUIREMENTS SHOWN IN PREVIOUS FIGURES FOR VENT AND AIR INTAKE RUN THROUGH A PITCHED OR FLAT ROOF

EXHAUST WITH SCREEN

AIR INTAKE 90° ELBOW WITH SCREEN FACE DOWN

SNOWLINE

305mm (1 ft) min.

GROUNDLINE

CONDENSATE DRAIN ASSY

TO DRAIN

HEAT EXCHANGER ASSY

AIR FILTER BOX ASSY

Slope up 20mm/m (1/4” per ft)

RUN AIR INTAKE PIPE THROUGH THE FOUNDATION OR AN EXTERIOR WALL

REFER TO PREVIOUS FIGURE FOR FLOOR AND CEILING PASSAGE

ROOF LINE

3048mm (10 ft) or less

EXHAUST WITH SCREEN

305mm (1 ft) min.

CHIMNEY TOP PLATE

AIR INTAKE 90° ELBOW WITH SCREEN FACE DOWN

SNOWLINE

305mm (1 ft) min.

GROUNDLINE

CONDENSATE DRAIN ASSY

TO DRAIN

HEAT EXCHANGER ASSY

AIR FILTER BOX ASSY

SLOPE UP 20mm/m (1/4” per ft)

RUN AIR INTAKE PIPE THROUGH THE FOUNDATION OR AN EXTERIOR WALL

SEAL CHIMNEY OPENING WITH MORTAR OR COVER PLATE

610mm (2 ft) min.

Vertical Venting Configurations

2. Vent piping vertically run up through a roof and air intake horizontally run out a vertical wall. a. See Figure 8a for general configuration. For a

pitched roof installation, refer to vent pipe requirements shown in Figure 7a. For a flat roof installation, refer to the vent pipe requirements shown in Figure 7b. When floor and ceiling passage is necessary, refer to Figure 3. Adhere to all clearances and materials specified in these illustrations for installing the vent pipe only. For installing the air intake pipe, refer to the air intake requirements shown in Figure 8a.

b. The stainless exhaust vent pipe must pass through

the roof vertically through a 178mm (7”) min. diameter cutout and appropriate roof flashing. The pipe must exhaust straight up and terminate with a screen terminator.

c. The air intake pipe must pass through a vertical wall

or foundation horizontally. The cutout does not require any clearance, but must be sealed with a flashing or by other means. The air intake opening must face down by using 90° elbow with a screen positioned at the opening.

3. Venting piping vertically run up an existing chimney and air intake horizontally run out a vertical wall. a. Refer to Figure 8b. Adhere to all clearances and

materials specified in this illustration.

b. The stainless exhaust vent pipe must extend the

total length of the chimney. The pipe must exhaust straight up and terminate with a screen terminator. The top of the chimney must be sealed off around the protruding pipe with an appropriate plate or flashing. Other appliances CANNOT be vented into the same chimney or vent pipe within the chimney.

c. The air intake pipe must pass through a vertical wall

or foundation horizontally. The cutout does not require any clearance, but must be sealed with a flashing or by other means. The air intake opening must face down by using a 90° elbow with a screen positioned at the opening.

DIRECT VENTING WITHOUT VENT TERMINAL

Page 9

BOILER ROOM AIR SUPPLY AND VENTILATION

An ample supply of air is required for combustion and ventilation. When buildings are insulated, caulked and weather-stripped, now or later on, direct openings to outside may be required and should be provided. If the boiler is not near an outside wall, air may be ducted to it from outside wall openings.

Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation, of the National Fuel Gas Code, ANSI Z223.1 and

CSA B149.1-00 for natural gas and propane

, or applicable provisions of the local building codes. The following recommendation applies to buildings of energy-saving construction, fully caulked and weather- stripped:

Provide one GRILLED opening near the floor and one near the ceiling on an outside wall near the boiler (or duct from such openings to the boiler), EACH opening to be a minimum of 645mm

(one square inch) per 586w (2000 Btuh)

input to ALL

APPLIANCES in the area. For a total appliance

input of 58 620w

(200,000 Btuh), each opening will be 64 516

(100 square inches). A grilled opening 254mm x 254mm

(10"X10") has 64 516mm

(100 square inches) of area. If fly screen must be used over openings, double the area and inspect and clean the screen frequently.

Openings must never be reduced or closed. If doors or windows are used for air supply, they must be locked open. Protect against closure of openings by snow and debris. Inspect frequently.

No mechanical draft exhaust or supply fans are to be used in or near the boiler area.

The flow of combustion and ventilating air to the boiler must not be obstructed.

The air inlet passage hole located on the top of the boiler jacket should be covered for any installation which does not require combustion air to be piped into the boiler. (i.e. Direct Vent Installation)

VENTING LOCATION REQUIREMENTS

Vent installations shall be in accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223.1 and

CSA B149.1-00 for natural gas and propane, or

applicable provisions of local building codes.

This Concept 21 boiler is approved for pressure venting both horizontally and vertically. The following requirements apply to both types of venting installation.

Vent termination must meet the following clearances: Minimum of 305mm (12”) above grade and normal snow line to vent termination bottom; minimum of 1219mm (4 feet) below or horizontally, or 305mm (1 foot) above any building opening; minimum of 914mm (3 feet) above any forced air intake located within 3048mm (10 feet); minimum of 1219mm (4 feet) horizontally from, and in no case above or below, unless 1219mm (4-foot) horizontal distance is maintained, from electric or gas meters, regulators and relief equipment.

Vent termination must not be located over any public walkway, in any confined space (i.e. window wells, alcoves, narrow alleys) or under any overhang or deck. Vent termination should not allow flue gas discharge towards neighbor's windows or where personal injury or property damage can occur.

DO NOT install the vent into a common venting system. DO NOT install a vent damper or similar device in vent tubing or on the boiler.

VENT MATERIAL REQUIREMENTS

A. DO NOT use galvanized or plastic vent system

materials. The vent system for Category IV applications must be UL listed 76mm (3”) diameter corrosion resistant stainless steel. The following manufacturer’s systems are approved for use within a specified minimum and maximum equivalent vent length for each model of boiler.

Category IV Venting Requirements

CB-45 30 100 5 914 3 1524 5 1 CB-90 30 100 5 914 3 1524 5 1 CB-135 24 80 5 914 3 1524 5 1 CB-180 12 40 5 914 3 1524 5 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows

m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

* All lengths specified include mandatory minimum use of 610mm (2

feet) of tubing plus one elbow from boiler to vent termination all models.

Heat Fab Saf-T Vent System

CB-45 30 100 5 1829 6 2438 8 1 CB-90 30 100 5 1829 6 2438 8 1 CB-135 18 60 5 1829 6 2438 8 1 CB-180 9 30 3 1829 6 2438 8 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows*

m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

ProTech Fas-N Seal System

CB-45 30 100 5 1829 6 2438 8 1 CB-90 30 100 5 1829 6 2438 8 1 CB-135 21 70 5 1829 6 2438 8 1 CB-180 11 35 4 1829 6 2438 8 1

Boiler Model

No.

Maximum

Equivalent

Length

including

Elbows*

m ft

Max.

No. of

Elbows*

Equivalent

Length of

each

Elbow

mm ft

Minimum

Equivalent

Length*

mm ft

Min.

No. of

Elbows*

Flex-L Star-34 System

Page 10

B. When joining the various components of the above

listed vent systems, the manufacturers’ instructions should be closely followed to insure proper sealing. Use GE-RTV106 or Dow-Corning 732 sealant for sealing of pipe and fittings. See Figure 4 for proper application of vent pipe sealant.

C. All vent connections must be liquid and pressure tight.

VENTING INSTALLATION

A. Follow the vent material manufacturer’s instructions in

conjunction with these instructions for venting system installation.

B. Refer to Figures 4 and 9 which illustrate some of the

requirements for venting in a typical installation.

A condensate drain and drain trap MUST be installed on the flue tubing, see Figure 9. The condensate drain should be installed close to the boiler, as shown, and must be equipped with a trap formed by attaching 9mm (3/8") I.D. clear plastic tubing to the drain assembly, making a loop approximately 102mm (4") diameter and securing with cord or a tie wrap where the loop crosses over itself. This loop should then be filled with water to form a liquid-filled trap. DO NOT OPERATE THE BOILER WITHOUT INSTALLING THIS TRAP AND FILLING WITH WATER TO PREVENT FLUE GAS DISCHARGE INTO SPACE. Periodic inspection should be made of this assembly for deterioration of the tubing and to insure that the trap is filled with water, but not plugged. If it is plugged or appears to have excessive sediment in it, it should be removed from the drain assembly, straightened out to clear the obstruction, reformed, filled with water and reinstalled as before. The drain must extend to a floor drain.

D. The horizontal pipe must be sloped UPWARD from the

boiler, at a pitch of 20mm/m (1/4” per 1 foot) of run, so that the condensate from the vent system runs to the drain trap. The horizontal portion must also be supported with 19mm (3/4”) pipe strap at intervals no greater than 1828mm (6 feet).

Category IV Venting Requirements

The vertical portion of the pipe must be supported in at leas one location for each 9m (30 feet) of vertical run. A firestop is required for each wall, ceiling and floor penetration.

F. Use tabs on vent collar to secure stainless steel vent

tubing to the boiler.

G. Venting is approved for combustible wall passage

through a 102mm (4”) minimum to 305mm (12”) maximum thick wall, providing a thimble is used.

HORIZONTAL CATEGORY IV VENTING

All Concept 21 boiler models are certified for horizontal Category IV venting provided the following conditions are met

1. For combustible wall passage of vent piping, a UL and CUL listed thimble must be used, providing the wall thickness is 102mm (4”) minimum to 305mm (12”) maximum.

2. The venting piping must terminate with a screened tee, elbow, or straight termination at the minimum distance from the outside wall shown in Figure 10.

Figure 9. General Vent Piping from Boiler for Category IV Ventin

All items shown below are REQUIRED. All vent joints must be LIQUID and PRESSURE TIGHT.

Figure 4. Vent sealing instructions

(Consult vent manufacturer’s instructions.)

Figure 10. Horizontal Category IV Venting through outside wall

CONTINUE WITH VENT PIPING AS SHOWN IN FOLLOWING FIGURES

EXHAUST VENT PIPING 76MM (3”) I.D.

AIR INLET COVER

203mm (8”) MIN. 610mm (24”) MAX.

AIR FILTER BOX ASSY.

HEAT

EXCHANGER

ASSY.

TO DRAIN

FILL TRAP WITH WATER

CONDENSATE DRAIN ASSY.

SLOPE UP 20mm/m (1/4” PER FT.)

76mm (3”) MIN. 610mm (24”) MAX.

VENT SEALING INSTRUCTIONS FOR HEAT-FAB 29-4C STAINLESS STEEL VENTING MATERIALS

RING

APPLY ADHESIVE BEAD (6mm [1/4”] DIA. MINIMUM) AROUND OUTSIDE OF MALE END ONLY, BETWEEN 6mm (1/4”) AND 9mm (3/8”) FROM THE EDGE OF THE MALE END. CARE MUST BE TAKEN TO ASSURE THAT ADHESIVE DOES NOT BLOCK INSIDE OF PIPE

DO NOT APPLY ADHESIVE INSIDE OF FEMALE FITTINGS IN ORDER TO PREVENT BLOCKAGE OF INSIDE OF FITTINGS AND TUBING. IF ANY ADHESIVE SHOULD GET INSIDE, BE SURE TO WIPE IT OUT BEFORE ASSEMBLING

WALL

THIMBLE

VENT TERMINATION WITH SCREEN

305mm

(1 FT.)

MIN.

OUTSIDE WALL

SNOW LINE

GROUNDLINE

HEAT EXCHANGER

ASSY.

AIR FILTER BOX

ASSY.

AIR INLET COVER

VENT PIPE

SLOPE UP 20mm/m

(1/4” PER FT.)

102mm (4”) MIN.

TO DRAIN

Page 11

Figure 11. Vertical Category IV Venting through a roof Figure 12. Vertical Category IV Venting up an existing

chimney

VERTICAL CATEGORY IV VENTING

All Concept 21 boiler models are certified for vertical Category IV venting through a roof provided the following conditions are met:

1. For roof passage of vent piping, a CUL listed roof flashing must be used.

2. The vent piping must terminate with a screened tee, elbow, straight, or cap termination at the minimum distance from the roof shown in Figure 11.

All Concept 21 boiler models are certified for vertical Category IV venting up an existing chimney provided the following conditions are met:

1. To utilize an existing chimney as a chase, the vent pipe must extend the total length of the chimney. The top of the chimney must be sealed off around the protruding pipe with an appropriate plate or flashing.

2. The vent piping must terminate with a screened tee, elbow, straight or cap termination at the minimum distance from the roof shown in Figure 12.

3. Other appliances CANNOT be vented into the same chimney or vent pipe within the chimney.

VENT TERMINATION WITH SCREEN

305mm (1 FT.) MIN.

SNOWLINE

ROOFLINE

FIRESTOP AND SUPPORT

152mm (6”) MIN. CLEARANCE

CONDENSATE DRAIN ASSY.

TO DRAIN

HEAT EXCHANGER

ASSY.

AIR FILTER BOX

ASSY.

AIR INLET COVER

SLOPE UP 20mm/m (1/4” PER FT.)

FIRE STOP AND

SUPPORT

ROOF FLASHING

610mm (2 FT.) MIN.

3048mm

(10 FT.)

OR LESS

VENT TERMINATION WITH SCREEN

305mm (1 FT.) MIN.

CHIMNEY TOP PLATE

SEAL CHIMNEY OPENING WITH MORTAR OR COVER PLATE

CONDENSATE DRAIN ASSY.

TO DRAIN

HEAT EXCHANGER

ASSY.

AIR FILTER BOX

ASSY.

AIR INLET COVER

SLOPE UP 20mm/m (1/4” PER FT.)

610mm (2 FT.) min.

ROOF LINE

3048mm

(10 FT.)

OR LESS

Page 12

VENTING REQUIREMENTS

If the boiler vent is to be installed into a natural draft masonry chimney or Type “B” venting, it must be in accordance with Part 7, Part 11 and Appendix G,

of the

National Fuel Gas Code, ANSI Z223.1 and

CSA B149.1-00 for

natural gas and propane

For a masonry vitreous tile-lined chimney which is not exposed to the outdoors, use Table 1 in this Slant/Fin manual for venting requirements. DO NOT install this system into an unlined masonry chimney.

If a masonry chimney is exposed to the outdoors on one or more sides below the roof line (exposed chimney), it must be re-lined with a UL listed metallic liner system. See Table 2 in this Slant/Fin manual for venting requirements of metallic re-lined chimneys.

If a Type “B” vent system is used, it must NOT be exposed to the outdoors below the roof line. See Table 2 in this Slant/Fin manual for venting requirements. Vent connectors serving appliances vented by natural draft shall NOT be connected into any portion of mechanical draft systems operating under positive pressure. Single or multiple appliance venting is shown in Figures 13 and 14.

The 76mm to 127mm (3” to 5”) vent adapter MUST be used on the vent collar of ALL models of the Concept boiler for these installations. In some cases, the vent connector diameter must be upsized further to 152mm or 178mm (6” or 7”). Refer to Table 1 and 2 for installations requiring this increased size.

Standard vent connector materials such as galvanized or stainless steel are allowed for these installations. NO types of plastic material can be used as a part of the venting system in any installation.

All Concept boilers require a condensate drain and drain trap. Vent connectors must be liquid tight.

The condensate drain should be installed as close to the boiler as possible and must be equipped with a trap formed by attaching 9mm (3/8") I.D. clear plastic tubing to the drain assembly, making a loop approximately 102mm (4") diameter and securing with cord or a tie wrap where the loop crosses over itself. This loop should then be filled with water to form a liquid filled trap. DO NOT OPERATE THE BOILER WITHOUT INSTALLING THIS TRAP AND FILLING WITH WATER. Periodic inspection should be made of this assembly for deterioration of the tubing and to insure that the trap is filled with water, but not plugged. If it is plugged or appears to have excessive sediment in it, it should be removed from the drain assembly, straightened out to clear the obstruction, reformed, filled with water and reinstalled as before. The drain should extend to a floor drain or to a plastic container which may require emptying periodically.

Category I Venting Requirements

BOILER ROOM AIR SUPPLY AND VENTILATION

An ample supply of air is required to obtain combustion and ventilation. When buildings are insulated, caulked and weather-stripped, now or later on, direct openings to outside may be required and should be provided. If the boiler is not near an outside wall, air may be ducted to the installation area from outside wall openings.

Provisions for combustion and ventilation air must be made in accordance with section 5.3, Air for Combustion and Ventilation,

of the National Fuel Gas Code, ANSI Z223.1 and

CSA B149.1-00 for natural gas and propane, or applicable provisions of the local building codes. The following recommendation applies to buildings of energy-saving construction, fully caulked and weather stripped:

Provide one GRILLED opening near the floor and one near th ceiling on an outside wall near the boiler (or duct from suc openings to the boiler), EACH opening to be a minimum o 645 mm

(one square inch) per 586w (2000 Btuh) input to AL APPLIANCES in the area. For a total appliance input of 58,620w (200,000 Btuh), each opening will be 64 516mm2 (100 squar inches). A grilled opening 254mm x 254mm (10"X10") ha 64 516mm

(100 square inches) of area. If fly screen must b used over openings, double the area and inspect and clea the screen frequently.

Openings must never be reduced or closed. If doors o windows are used for air supply, they must be locked open Protect against closure of openings by snow and debris Inspect frequently.

No mechanical draft exhaust or supply fans are to be used in or near the boiler area.

The flow of combustion and ventilating air to the boile must not be obstructed.

The air inlet passage hole located on the top of the boile jacket should be left covered with the plate provided, to prevent debris from falling into the air intake.

On all Category I installations, the air pressure switch provided on the boiler must be replaced with the switch provided in ven kit 665194. This switch is set to prevent the boiler from operating below the approved Category I input rate.

Page 13

Natural Draft Chimney and Type “B” Venting Diagrams

Figure 13. Chimney Venting for models specified in Table 1 only.

Minimum vent connectors diameter is 127mm (5 inches). It may have to be upsized to 152mm or 178mm (6 or 7 inches) [see Table 1].

Single or multiple appliance venting into chimney using single wall or type “B” metal connectors. Must be installed in accordance with part 7 or 11 of the National Fuel Gas Code, ANSI Z223.1 and CSA B149.1-00 for natural gas and propane. DO NOT use galvanized risers and connectors in cool boiler rooms. ALL ITEMS SHOWN BELOW ARE REQUIRED. All vent connector joints must be liquid tight.

Figure 14. Venting with “B” vent or metal-lined chimney for models specified in Table 2 only.

Minimum vent connectors diameter is 127mm (5 inches). It may have to be upsized to 152mm or 178mm (6 or 7 inches) [see Table 2].

Single or multiple appliance venting into Type “B” double wall metal vent with single or Type “B” metal connectors. Must be installed in accordance with part 11 of the National Fuel Gas Code, ANSI Z223.1 and CSA B149.1-00 for natural gas and propane. DO NOT use galvanized risers and connectors in cool boiler rooms.

ALL ITEMS SHOWN BELOW ARE REQUIRED EXCEPT WHERE OTHERWISE INDICATED. All vent connector joints must be liquid tight.

TYPE “B” VENT

OTHER GAS

APPLIANCE

ADDITIONAL CONDENSATE DRAIN: A DRAIN AT THE BOTTOM OF THE “B” VENT MAY BE NECESSARY IF OTHER APPLIANCES OR THE VENT IS CONDENSING

TO DRAIN OR

CONTAINER

FILL TRAP WITH

WATER

BOILER CONDENSATE DRAIN ASSEMBLY

TO DRAIN OR CONTAINER

FILL TRAP WITH

WATER

CONCEPT

BOILER

INSTALL 127mm

(5”) VENT ADAPTER

610mm (24”) MIN.

203mm (8”) MAX.

152mm (6”) MIN.

406mm (16”) MAX.

CONNECTORS:

PITCH UP TO CHIMNEY

20mm/m (1/4” PER FT.) MIN.

INSTALL WITH SEAM ON TOP

305mm (12”)

MIN.

CONNECTORS: PITCH UP TO CHIMNEY 20mm/m (1/4” PER FT.) MIN. INSTALL WITH SEAM ON TOP

152mm (6”) MIN.

457mm (18”) MAX.

610mm (24”) MIN.

203mm (8”) MAX.

INSTALL 127mm

(5”) VENT ADAPTER

CONCEPT

BOILER

TO DRAIN OR CONTAINER

FILL TRAP WITH WATER

BOILER CONDENSATE DRAIN ASSEMBLY

305mm (12”) MIN.

CHIMNEY (NOT EXPOSED TO THE OUTDOORS BELOW THE ROOF LINE)

OTHER

GAS

APPLIANCE

Page 14

Natural Draft Chimney and Type “B” Venting Tables

Table 1. Masonry Vitreous Tile-Lined Chimney (not metal lined)

Chimneys not exposed to the outdoors below the roof line. (127mm [5"] dia. vent adapter must be used)

Concept Additional CSA B149.1-00 Boiler Gas Appliance for natural gas Model(s) † in Venting System Connector Requirements* and propane

CB-90 No Type “B” 1.

Connector diameter must be upsized to 178mm (7").

Table 5

CB-135 2.

Chimney height limits: Min. 4.6m (15 ft.), Max. 9.1m (30 ft.)

CB-180 3. Lateral length restriction applies (see Table 11-3)

Internal area of chimney: Min. 32 200mm2 (50 sq. in.), Max. 173 500mm2 (269 sq. in.)

CB-180 No Single-wall 1.

Connector diameter must be upsized to 178mm (7").

Table 6

Chimney height limits: Min. 4.6m (15 ft.), Max. 9.1m (30 ft.)

3. Max. lateral length may not exceed 610mm (2 ft.)

Internal area of chimney: Min. 32 200mm2 (50 sq. in.), Max. 173 500mm2 (269 sq. in.)

CB-90 Yes Type “B” 1. See Table 7 for chimney height and connector Table 7 CB-135 length restrictions. CB-180 2.

Connector may have to be upsized to 152mm (6") diameter to meet requirement of Table 7.

CB-135 Yes Single-wall 1. See Table 8 for chimney height and connector Table 8 CB-180 length restrictions.

Connector may have to be upsized to 152mm (6") diameter to meet requirement of Table 8.

Table 2. Type “B” Venting and Metal-Lined Masonry Chimney

UL LISTED MATERIALS ONLY. (127 mm [5"] dia. vent adapter must be used)

Concept Additional CSA B149.1-00 Boiler Gas Appliance for natural gas Model(s) † in Venting System Connector Requirements* and propane

All Models No Type “B” See Table 1 for minimum and maximum of vent Table 1

height and lateral length restriction.

CB-90 No Single-wall See Table 2 for minimum and maximum of vent Table 2 CB-135 height and lateral length restriction. CB-180

CB-90 Yes Type “B” 1. See Table 3 for vent height and connector Table 3 CB-135 length restrictions. CB-180 2.

Connector and vent diameter may have to be increased to 152mm or 178mm (6" or 7") to meet requirement of Table 3.

CB-90 Yes Single-wall 1. See Table 4 for vent height and connector Table 4 CB-135 length restrictions. CB-180 2.

Connector and vent diameter may have to be

increased

to 152mm (6") to meet requirement of Table 4.

† Only Concept boiler models shown for each application permitted to be installed in that manner specified.

Page 15

FILL AND PURGE HEATING SYSTEM

• Make sure flow direction arrows on components are

facing in direction of flow.

• Place bucket under pressure relief valve discharge.

Baseboard & radiant floor systems

• Close all shutoff valves, drain valves and air vents.

• Open supply shutoff valve and return drain valve on

first zone (or return drain valve on non-zoned system). If zoned with zone valves, manually open zone valve.

• Attach a hose from return drain valve to a drain. Open

fill line shutoff valve. Manually operate fill valve regulator. When water runs out of hose in a steady stream (with no air bubbles), close return drain valve.

• Repeat procedure for additional zones (one at a time).

• On completion, open all return shutoff valves.

Standing iron radiation & systems with manual vents at high points

• Close all shutoff valves, drain valves and air vents.

• Open supply and return shutoff valves. If zoned with

zone valves, manually open all zone valves.

• Open fill line shutoff valve. Manually operate fill valve

regulator. Open pressure relief valve manual operator to fill boiler. When water runs out of discharge pipe in a steady stream (with no air bubbles), close operator.

• Starting with nearest manual air vent, open vent until

water flows out; close vent. Repeat procedure, working your way toward farthest air vent.

When finished

• Place fill valve regulator and all zone valve operators in

automatic position.

• Check that temperature/pressure gage reads minimum

of 82.7 kPa (12 psi) (fill pressure) cold. If piping system rises more than 4877mm (16 ft.) vertically above boiler, higher fill pressures are required.

• Check for and repair any water leaks.

WATER PIPING

Always follow good piping practices. Observe minimum 25mm (1") clearance to combustibles around all uninsulated hot water pipes or when openings around pipes are not protected by non-combustible materials.

On a hot water boiler installed above radiation level, the boiler must be provided with a low water cut off device at the time of installation by the installer.

Boiler must not be used in connection with a refrigeration system. If the boiler supplies hot water to heating coils in air handling units, flow control valves or other devices must be installed to prevent gravity circulation of boiler water in the coils during the cooling cycle.

Expansion T

ank: Install into water outlet manifold as shown in Figure 11. Use appropriate size tank for volume of water in system. Boiler volume on page 2 chart. Relief V

alve Discharge Piping: Use same size or larger piping (iron or copper) than valve outlet. Must terminate 152mm (6") from floor (or local codes) with a plain (no threads) end. Do not hard-pipe to drain piping. Make sure discharge is always visible. Cold W

ater Fill: Pressure reducing (fill) valve and shutoff valve should be installed. Supply & Return

: For tapping sizes, see dimensions on page 2. Recommend shutoff valve in supply (and shutoff and drain valves in return on non-zoned system). Radiant Floor & Standing Iron Radiant Systems

: A boiler by-pass loop (or equivalent) will be required to avoid flue gas condensation on cast iron sections for low temperature application. I.E. radiant floor systems. Zone Piping

: See page 17 for zoning with zone valves

and domestic hot water installation.

Figure 15. Water piping

Note: Orientation of piping drawn for clarity. Observe relative location of components.

Page 16

ELECTRICAL WIRING

Boiler must be electrically grounded in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the Canadian Electric Code - CSA-C22.1, Part 1.

ower supply: A separately fused circuit is recommended. Use a standard 15-amp fuse or breaker and 14-gauge conductors in BX cable or conduit. Thermostat connections

: Wire connections to T1 and T2 terminal block must be from an isolated circuit. DO NOT BRING VOLTAGE FROM AN EXTERNAL SOURCE HERE. Wires should be only run from thermostats, zone valve end switches, or circulator end switches. 3 wire zone valves which do not have isolated end switches cannot be used unless a relay is added with the dry contacts wired to T1 and T2. Thermostat heat anticipator

: For zoned system, set to match amp draw of zone valve or circulator relay. For a non-zoned system, set to .3 amps. Circulator relay on board: Do not exceed 5 amp/120V max. rating. Circulator pump: Wire to BX harness from boiler junction box.

GAS PIPING

A. Local installation codes apply. The pipe joint

compound used on threads must be resistant to the action of liquefied petroleum gases.

The gas supply line to the boiler should be run directly from the meter for natural gas or from the fuel tank for L.P. propane gas. See figure 16 for location of union and manual main shut off valve that may be specified locally. Selecting pipe size for natural gas:

1. Measure or estimate the length of piping from the meter to the installation site.

2. Consult gas supplier for heating value of gas-W/m

(BTU/cu. ft.).

3. Divide boiler rated input by heating value to find gas flow in piping (m

/hr) (cu. ft. per hour).

4. Use table below to select proper pipe size.

Example: Boiler model CB-180 is to be installed. Distance from gas meter to the boiler is 6.1m (20 ft). Heating value of natural gas is 10350 W/m

(1000

BTU/cu. ft.) Select proper pipe size.

At 6.1m (20 ft.) length of pipe, match required capacity from table below (choose higher capacity, in this case is 5.4 m

[190 cu. ft.] per hour). Required pipe size is 19mm (3/4"). Improper gas pipe sizing will result in insufficient heat and other installation difficulties. For more information and also if other appliances are to be attached to the piping system, see Appendix C of National Fuel Gas Code ANSI Z223.1-latest edition, and CSA B149.00

The boiler and its gas connection must be leak tested before placing the boiler in operation. Use liquid soap solution for all gas leak testing. Do not use open flame. This boiler and its individual shutoff valve must be disconnected from the gas supply piping system during any pressure testing of that system at test pressures in excess of 3.5 kPa (1/2 PSIG). This boiler must be isolated from the gas supply

Figure 16. Gas piping components location

13mm (1/2”) 19mm (3/4”) 25mm (1”) 32mm (1-1/4”) 38mm (1-1/2”)

mft

m3/hr cu.ft./ hr. m3/hr cu.ft./ hr. m3/hr cu.ft./ hr. m3/hr cu.ft./ hr. m3/hr cu.ft./ hr.

3.0 10 3.7 132 7.9 278 14.7 520 29.7 1050 45.3 1600

6.1 20 2.6 92 5.4 190 9.9 350 20.7 730 31.1 1100

9.1 30 2.1 73 4.3 152 8.1 285 16.7 590 25.2 890

12.2 40 1.8 63 3.7 130 6.9 245 14.2 500 21.5 760

15.2 50 1.6 56 3.3 115 6.1 215 12.5 440 19.0 670

18.3 60 1.4 50 3.0 105 5.5 195 11.3 400 17.3 610

21.3 70 1.3 46 2.7 96 5.1 180 10.5 370 15.9 560

24.3 80 1.2 43 2.5 90 4.8 170 9.9 350 15.0 530

27.4 90 1.1 40 2.4 84 4.5 160 9.1 320 13.9 490

30.5 100 1.1 38 2.2 79 4.2 150 8.6 305 13.0 460

Length of Pipe

Gas Flow In Piping

Pressure Drop = 8mm (.3”) in water Specific Gravity = 0.60

Iron Pipe Size (Ips)—inches

At pressure drop of 0.3 in. water, specific gravity = 0.60.

piping system by closing its individual manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than

3.5 kPa (1/2 PSIG).

D. All gas piping used should be inspected thoroughly

for cleanliness before makeup. A sediment trap must be provided, as illustrated in figure 16.

E. The minimum and maximum gas supply pressure (at

the inlet of gas valve) are shown on the boiler rating plate for the type of gas used. Gas supply pressure should never be less than minimum or more than maximum pressure when the boiler or any other appliance is turned on or off.

Gas flow = = 5.1 m3/hr

52 760 W/hr

10 350 W/m

INSTALL MANUAL MAIN SHUTOFF VALVE 1524mm (5 FT) ABOVE FLOOR WHEN REQUIRED BY LOCAL CODE

UNION

GAS VALVE

FULL SIZE SEDIMENT TRAP

(Gas flow = = 180 cu. ft. per hour)

180,000 BTU/hour

1000 BTU/cu. ft.

DANGER: BEFORE WIRING, ALWAYS TURN OFF ELECTRIC POWER SUPPLY. OTHERWISE, SHOCK OR DEATH CAN RESULT. WARNING: DO NOT USE BOILER TRANSFORMER TO POWER EXTERNAL ACCESSORIES (I.E. ZONE VALVES, RELAYS). OVERLOADED/BURNED-OUT TRANSFORMER CAN RESULT.

Page 17

Figure 17. Power and thermostat wiring

Power Connections

• Remove electrical junction box cover.

• HOT CONNECTION LEAD IS BLACK.

• NEUTRAL CONNECTION LEAD IS WHITE.

• Connect ground inside box.

DO NOT REVERSE POWER CONNECTIONS: if reversed, ignition control will not detect a flame and will go into safety shutdown.

OPTIONS AVAILABLE

Alarm system:

A remote-type alarm device may be connected the boiler that will be activated if the boiler shuts down due to a malfunction, or if power is turned off. Fault contactor terminals on electronic boiler control board are a dry contact (5 amp 120 V max) that makes on a system fault or power outage. Domestic hot water installation: Connect zone valve end switch to T1 and T2 terminal block on control board mounting panel. Water heater thermostat operates zone valve. DO NOT bring power from an external source to these terminals. Note: 3 wire zone valves which do not have isolated end switches cannot be used unless a relay is added with the dry contacts wired to T1 and T2.

Figure 18. Zone valves (with indirect fired water heater) piping & wiring

Page 18

CONTROL BOARD INDICATOR LIGHTS. See Figure 19. Flame indicator (amber): Steady on means burner is lit and producing sufficient flame current signal. P

ower indicator (green): Steady on means there is electrical power to the control board. Diagnostic fault indicator (red): Steady on or intermittent flashing indicates a system operation problem. See page 24 for codes and following pages for causes and solutions.

CALIBRATION EQUIPMENT:

Pressure measurement fittings:

There are 3 service fittings with caps provided on this boiler for convenient calibration of the air/gas ratio and input in the field. See Figure 20 for the location of each. Pressure measurement gauge

: Magnehelic or Incline differential pressure gauge with 0-25mm/w.c. (0 - 1.0” w.c.) range and 0.5mm (0.02”) increments recommended. Available from Slant/Fin is a calibration gauge kit (part number 665185) that has a gauge mounted on a stand with a “toggling” feature which allows the user to switch between the blower and gas valve calibration without moving the tubing connections. T

ubing and connectors for gauge: Need 2 lengths of

5mm (3/16”) I.D. plastic tubing with female adapters

which mate to the service fittings.

STEP A: CALIBRATE BLOWER AIR FLOW

Note: This step will set the air flow required at the proper air/gas ratio for the specified input rate. Refer to the Input Rate Adjustment Specifications Charts on page 20 for the appropriate air flow differential pressure required to achieve the desired input rate of the boiler.

1. With power off, set differential pressure gauge on a level surface and adjust to zero.

2. Locate blower outlet pressure fitting and burner enclosure pressure fitting. See Figure 20.

3. Remove cap on blower outlet pressure fitting and connect to high side of gauge tubing.

4. Remove cap on burner enclosure pressure fitting and connect to low side of gauge tubing.

5. Turn power on. Raise thermostat to start boiler.

6. Boiler should start after 20 seconds. Amber flame indicator light will come on.

7. While the boiler is running, perform the air flow calibration to set the differential pressure to the required reading for the desired input.

8. Locate knurled adjustment knob on side of air filter box. See Figure 20.

9. Loosen air adjustment locking screw on knob by turning counterclockwise. DO NOT remove.

10. Turn knurled adjustment knob to set pressure. Observe gauge while adjusting. Turn clockwise to decrease reading if over the desired differential pressure. Turn counterclockwise to increase reading if under the desired differential pressure.

11. When reading is set correctly, retighten the air adjustment locking screw finger tight. Hold knurled adjustment knob steady while doing this to maintain setting. Double check gauge reading.

12. Disconnect both sides of gauge tubing from fittings and replace service fitting caps hand tight.

Basic Operation Principle

The gas valve on the Concept 21 boiler is “coupled” to the combustion blower; so that the gas flow is proportional to the air flow, even under the most adverse conditions. This insures a high level of safety and reliability when the following Operation Procedures are carefully followed. Note that the proper input is obtained by adjusting the air damper on the blower for a certain air flow, which will feed back to the gas valve and produce a proportionate gas flow. See Step A. DO NOT adjust the gas valve adjustment screw to set input rate, only use this adjustment to set the differential pressure between the blower outlet and gas valve outlet to zero as shown in Step B.

Figure 19. Control board indicator lights Figure 20 . Location of calibration pressure fittings and

adjustment devices

OPERATION PROCEDURES

BURNER ENCLOSURE PRESSURE FITTING

BLOWER OUTLET PRESSURE FITTING

KNURLED ADJUSTMENT KNOB

GAS VALVE OUTLET PRESSURE FITTING

AIR ADJUSTMENT LOCKING SCREW

GAS VALVE ADJUSTMENT SCREW

Page 19

STEP B: CALIBRATE GAS VALVE

Note: This step will set the air/gas ratio for optimum combustion. The purpose of this step is NOT to set input rate. Follow Step A and/or Step C to adjust input.

1. With power off, set differential pressure gage on a level surface and adjust to zero.

2. Locate blower outlet pressure fitting and gas valve outlet pressure fitting. See figure 20.

3. Remove cap on blower outlet pressure fitting and connect to high side of gage tubing.

4. Remove cap on gas valve outlet pressure fitting and connect to low side of gage tubing.

5. Turn power on. Raise thermostat to start boiler.

6. Boiler should start after 20 seconds.Let run for about 1 minute.

7. Gauge reading should register a differential pressure reading of 0. If so, proceed to line 11.

8. If gage reading is not at 0, re-adjustment is necessary. Locate gas valve adjustment screw cap on top of gas valve.See figure 20.

9. Remove gas valve adjustment screw cap by turning counterclockwise with a screwdriver.

10. Position screwdriver into adjustment screw slot carefully. Observe gage while adjusting and turn screw slowly. Turn adjustment screw clockwise to decrease reading if over 0 set point. Turn adjustment screw counterclockwise to increase reading if under 0 setpoint. Note:

Remember that the gas pressure is on the low side of the gage. Consequently, decreasing the differential reading actually is INCREASING the gas pressure reading, since the blower outlet pressure is on the high side of the gage and not changing.

11. When reading is set correctly to 0, retighten the gas valve adjustment screw cap tightly with screwdriver. Double check gage reading.

12. Turn power off, disconnect both sides of gage from fittings and replace service fitting caps hand tight.

STEP C: CHECK BOILER INPUT RATE

1. Turn power on. Raise thermostat to start boiler. Let boiler run steady about 10 minutes.

2. At meter, observe number of M

(cu. ft.) of gas the boiler uses in 3 minutes. Be sure that only this appliance is running on the gas meter at this time.

3. Consult gas supplier for heating value of gas

- usually 10,350 W/m

(1000 BTU/cu.ft.) for natural gas,

25,875 W/m

(2500 BTU/cu.ft.) for propane.

4. Verify input using following formula: m

in 3 minutes X heating value X 20 = W/hr input

(

Cu.ft. in 3 minutes X heating value X 20 = BTU/hr input)

Example:

0.1274m

X 10,350 W/m3X 20 = 26,400 W/hr input

(4.5 cu.ft. X1000 BTU/cu.ft. X 20 = 90,000 BTU/hr input)

5. If gas flow is not at the specified input rate, it is necessary to adjust the air shutter to attain the correct input rate.

6. Locate the knurled adjustment knob on side of air filter box. See figure 20.

7. Loosen air adjustment locking screw on knob. Do not remove.

8. Turn knurled adjustment knob clockwise to reduce air flow, and consequently, reduce gas flow and input rate Turn adjustment rod counterclockwise to increase air flow, and consequently, increase gas flow and input rate. Note:

Make adjustments in small increments and re-

check input as in line 4.

9. When input is set properly, retighten the air adjustment locking screw finger tight. Hold knurled adjustment knob steady while doing this to maintain setting.

10. Restore operation to any appliance shut off for meter clocking.

Notes on Input Rate:

1. Refer to the Input Rate Adjustment Specifications Charts on page 20 for the appropriate input rate setting on each model boiler for each venting application.

2. The procedure in Step A is adequate for setting the input rate. If a gas meter is available, it can be used to verify the setting or as an alternate method for setting the input.

3. For altitudes above 610m (2,000 ft.), ratings shall be reduced at the rate of 4% for each 305m (1,000 ft.) above sea level.

4. Re-orificing for altitude change IS NOT necessary on this Concept 21 boiler.

5. By maintaining the air flow differential pressure set in Step A, this Concept 21 boiler will derate itself accordingly, due to air and gas density reduction as altitude increases.

Page 20

The input rate for the Concept boiler, on Direct Vent or Category IV installations, may be set up to a maximum of 15% above to 25% below the nominal specified rating plate input of each model. See Chart 1. This allowance is useful in better sizing the boiler’s input rate to each installation site's heat load.

The input rate for the Concept boiler, on Category I installations, must only be set to one specified input rate for each model. See Chart 2. This rate, which is typically higher than the nominal specified rating plate input for each model (except the CB-180), will ensure that a high enough flue temperature is obtained to safeguard against condensation forming in the flue piping and chimney stack. On all Category I installations, the air pressure switch provided on the boiler must be replaced with the switch provided in vent kit 665194. This switch is set to prevent the boiler from operating below the approved Category I input rate.

Input Rate Adjustment Specifications

To set the input rate of the Concept boiler perform the following adjustment procedure: A. Refer to the Operation Procedures on pages 18 and 19

which specify the methods of calibrating the boiler’ components for proper input rate and air/gas ratio.

B. Note that Step A and Step C are followed to set rate only

depending on whether a differential pressure gauge or a gas meter is available. Either method is adequate to se input, or both can be performed as a verification of inpu rate. Use these procedures, in conjunction with the appropriate chart below, to adjust the input rate a specified for that venting application.

C. Note that Step B is followed to set the air/gas ratio only

not to set input rate. Follow Step B precisely as specified in the instruction manual.

CB-45 CB-90 CB-135 CB-180

w BTUH w BTUH w BTUH w BTUH

mm w.c. in.w.c.

9 890 33,750 19 780 67,500 29 670 101,250 39 560 135,000 10.67 .42 Reduced by 25%

10 550 36,000 21 100 72,000 31 650 108,000 42 200 144,000 12.19 .48 Reduced by 20%

11 210 38,250 22 420 76,500 33 630 114,750 44 840 153,000 13.72 .54 Reduced by 15%

11 870 40,500 23 740 81,000 35 610 121,500 47 480 162,000 15.49 .61 Reduced by 10%

12 530 42,750 25 060 85,500 37 590 128,250 50 120 171,000 17.27 .68 Reduced by 5%

13 190 45,000 26 380 90,000 39 570 135,000 52 760 180,000 19.05 .75 Nominal 0%

13 850 47,250 27 700 94,500 41 550 141,750 55 400 189,000 21.08 .83 Increased by 5%

14 510 49,500 29 020 99,000 43 530 148,500 58 040 198,000 23.11 .91 Increased by 10%

15 170 51,750 30 340 103,500 45 510 155,250 60 680 207,000 25.15 .99 Increased by 15%

Boiler Model and Allowable Input *

Air Flow Differential Pressure †

Percent of change

to nominal boiler

input rate

* Follow instruction manual operation procedures, Step C, to set with meter. Ability to attain input rates over the nominal rating plate specifications

may be constrained by installation variables such as vent length, altitude, and calorific value of the gas, particularly on the larger models of boilers.

† Follow instruction manual operation procedures, Step A, to set with gauge.

w BTUH mm w.c. in. w.c.

CB-45 16 120 55,000 25.40 1.00 22%

CB-90 30 480 104,000 21.59 .85 15%

CB-135 42 500 145,000 19.05 .75 7%

CB-180 52 760 180,000 16.51 .65 0%

Boiler Model

Category I Input Rate * Air Flow

Differential Pressure †

Percent of increase over nominal boiler

input rate

Chart 2: This chart must be used for Input Rate Adjustment for Category I Installations

* Follow instruction manual operation procedures, Step C, to set with meter. † Follow instruction manual operation procedures, Step A, to set with gauge. Provisions for combustion and ventilation air must be made in accordance with Section 5.3, air for combustion and ventilation, CSA 149.1-00 for natural gas and propane..

Chart 1: Input Rate Adjustment Specifications for Direct Vent and Category IV Installations

Page 21

NORMAL SYSTEM STARTUP

Follow lighting instructions on page 30. Safe lighting and other performance criteria were met with the gas manifold and control assembly provided on the boiler when the boiler underwent tests specified in ANSI Z21.13, and of the National Fuel Gas Code, ANSI Z223.1 and CSA B149.1-00 for natural gas and propane.

CHECK SYSTEM OPERATION

urge air one final time:

• Let system water reach 710C (160°F). Temperature/pressure gage should be between 83 and 172 kPa (12 and 25 psi.).

• Bleed all air vents until water squirts out; start on lowest floor with first air vent in the line of flow.

Check exhaust and air intake venting:

• Check for and reseal any vent tubing leaks.

• Check for and remove any vent terminal obstructions.

Check gas valve operation (with burner firing): USE CAUTION - LINE VOLTAGE PRESENT.

• Disconnect flame sensor wire lead from flame sensor tab. See Fig. 21 for location. Gas valve should close.

• It is normal for boiler to retry for ignition (3 times) with wire removed from flame sensor, but gas valve should only open for a few seconds during each retry and be closed between trials.

• Replace flame sensor wire lead on flame sensor tab.

• If fault shown after trials complete, cycle thermostat or power off/on to clear.

Check high limit operation: HIGH LIMIT CANNOT BE SET BELOW 82°C (180°F). HIGHEST MAXIMUM ALLOWABLE SETTING IS 104°C (220°F).

• Set thermostat high enough for the water temperature to reach limit switch setting of 82°C (180°F).

• When reached, limit switch should open and gas valve should close.

Testing of System

TEST COMMON VENTING SYSTEM (IF REQUIRED)

If existing boiler was removed from a common venting system, common venting system may be too large for proper venting of appliances remaining connected to it.

At the time of removal of existing boiler, the following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in common venting system.

2. Visually inspect venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

3. 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 building. Turn on clothes dryer and any appliance not connected to common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

5. Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from cigarette, cigar or pipe.

6. After it has been determined that each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas-burning appliances to their previous condition of use.

7. Any improper operation of common venting system should be corrected so installation conforms with National Fuel Gas Code ANSI Z223.1 and CSA B1491-00 for natural gas and propane. When resizing any portion of the common venting system, common venting system should be resized to approach minimum size as determined using appropriate tables in Part II of the National Fuel Gas Code, ANSI Z223.1 and CSA B1491-00 for natural gas and propane.

Page 22

THERMOSTAT CALLS FOR HEAT

CIRCULATOR ON

BLOWER ON

BLOWER PREPURGE 10 SEC.

HOT SURFACE IGNITOR ON

IGNITOR WARM UP 10 SEC.

GAS VALVE OPEN 4 SEC.

IGNITOR OFF

GAS VALVE REMAINS OPEN CIRCULATOR AND BLOWER

CONTINUE TO RUN

THERMOSTAT SATISFIED. GAS VALVE CLOSED. CIRCULATOR OFF. BLOWER

POST PURGE 5 SEC. BLOWER OFF

AIR

PRESSURE

SWITCH

CLOSED?

HIGH LIMIT

CLOSED?

AIR

PRESSURE

SWITCH

OPEN?

IGNITOR

CURRENT

CHECK

OK?

FLAME

DETECTED?

GAS VALVE CLOSES

CIRCULATOR & BLOWER

CONTINUE TO RUN

COMPLETE

3 TRIALS

TO DETECT

FLAME?

WAIT 1 HR.

CLEAR FAULT.

RE-TRY

OPERATION.

WAIT 1 HR.

CLEAR FAULT.

RE-TRY

OPERATION.

CIRCULATOR

CONTINUES TO RUN.

BLOWER OFF

DISPLAY FAULT AND

CLOSE FAULT CONTACTOR.

CIRCULATOR

CONTINUES TO RUN.

BLOWER OFF

DISPLAY FAULT AND

CLOSE FAULT CONTACTOR.

CIRCULATOR

CONTINUES TO RUN.

BLOWER OFF

DISPLAY FAULT AND

CLOSE FAULT CONTACTOR.

WAIT 1 HR.

CLEAR FAULT.

RE-TRY

OPERATION.

CIRCULATOR & BLOWER

CONTINUE TO RUN

CIRCULATOR

CONTINUES TO RUN.

DISPLAY FAULT AND CLOSE FAULT CONTACTOR. WAIT FOR PRESSURE SWITCH TO OPEN.

COMPLETE 3

TRIALS

TO CHECK

PRESSURE?

DISPLAY FAULT

AND CLOSE FAULT

CONTACTS

DISPLAY LED

INDICATION

CIRCULATOR

CONTINUES TO RUN

HIGH LIMIT

OPEN OVER

1 HOUR?

YES

SEQUENCE OF OPERATION

Page 23

WIRING DIAGRAMS

Page 24

Indicator codes and component location

DIAGNOSTIC INDICATOR LIGHT (RED) Carefully note red diagnostic indicator light. When a system failure occurs, indicator light will show a series of quick flashes with a short interval between the series of flashes. Count the number of flashes that occur after the short no-flashing interval. Correct failure code for each number of flashes is shown in box.

If the diagnostic light is off when service technician arrives, set thermostat to call for heat. Boiler will attempt restart. (Boiler also attempts restart each hour during failure mode and after a power interruption.) If the boiler restarts, the diagnostic light will stay off. If the boiler does not restart, the diagnostic light will return to either steady on or the series of flashes.

Additional tools recommended

• Differential pressure gauge: 0-25mm/w.c. (0 - 1.0” w.c.) range with 0.5mm (.02”) increments

• Plastic gauge hookup tubing: 2 lengths of 5mm (3/16”) I.D. tubing with female service fitting adapters.

• Microampmeter: 0-25 microamp range with 1 microamp increments.

Boiler Failure Codes

Indicator

Fault indicated Page Steady ON Control internal failure 26 1 Flash High limit open 25 2 Flashes No ignition 25 3 Flashes Pressure switch problem 26 4 Flashes Ignitor failure 26 5 Flashes Flame signal loss 25 6 Flashes Improper flame signal 26

Figure 21. Boiler components location

TROUBLESHOOTING

Page 25

TROUBLESHOOTING: POSSIBLE CAUSES & SOLUTIONS

DIAGNOSTIC “1 FLASH” - HIGH LIMIT OPEN

Important Note: During normal boiler operation, short periods of high limit open indication are normal provided the

fault contactor remains open. If the high limit remains open for over 1 hour, the fault contactor closes, indicating there is a system problem.

CAUSE

High limit is defective?

Circulator not running?

Zone valves not opening?

Boiler water level too low?

TEST

Set high limit above boiler water temperature (raise limit setting substantially as water temperature may be higher than gauge reading when there is no water flow through boiler). Check for continuity across high limit contacts.

With thermostat calling for heat, check for power to circulator. If no power, check wiring connections to circulator.

With thermostat calling for heat, check for power to each valve. If no power, check wiring connections to valve.

Check temperature/pressure gauge pressure reading. Carefully snap open relief valve handle to determine if boiler is full of water. If not full of water, check for system leaks and check water pressure regulator operation.

SOLUTION

If contacts remain open, replace high limit. Replacement must be same manufacturer and model. DO NOT set above 104°C (220°F).

If power OK, but circulator not running, replace circulator.

If power OK, but valve not opening, replace valve.

Repair any system leaks. Adjust or replace water pressure regulator.

No gas supply to gas valve?

No gas supply to burner?

Electrical connections are loose?

Check that manual gas shut-off is open. Check for gas supply pressure to valve.

Check gas valve knob in ON position. Check wiring and tubing connections to valve. Check valve outlet pressure to determine if valve is opening.

Check power wiring to electronic board (hot wire to L1; neutral to L2) and ground wire in junction box.

If no pressure, check for gas shutoff by utility.

If valve not opening, replace valve. Replacement must be same manufacturer and model. Calibrate new valve as shown in Operation Procedures on page 19.

Tighten all wiring connections.

Air-gas ratio is not proper?

Orifice sizing is not correct?

Flame sensor current is weak?

Flame sensor is defective?

Ground bar is defective?

Check gas valve calibration as shown in Operation Procedures on page 19.

Check gas and air orifice size and gas type. Orifice plate is stamped with model number and gas type. Refer to orifice identification on pages 28 and 29.

Check flame sensor current with microampmeter (see Troubleshooting Procedures on page 27).

Remove flame sensor from boiler (see Troubleshooting Procedures on page 27). Check for cracked, wet ceramic insulator or bent, burned, coated kanthal rod.

Remove ground bar from boiler (see Troubleshooting Procedures on page 27). Check for bent, burned, coated or broken assembly. Also check ground wire connections to assembly.

If pressure reading incorrect, adjust gas valve as shown in Operation Procedures on page 19

If size not correct, contact Slant/Fin Technical Services Dept.

If reading is below 1 microamp, continue with “Flame Loss” troubleshooting.

If defective, replace flame sensor. Replacement must be same manufacturer and model.

If defective, replace ground bar. Replacement must be same manufacturer and model. Be sure ground wire is connected properly.

DIAGNOSTIC “2 FLASHES” - NO IGNITION

DIAGNOSTIC “2 FLASHES” AND/OR “5 FLASHES” — no flame signal or flame signal loss

Refer to Replacement Parts information on

page 31 when parts need to be replaced.

Page 26

CAUSE

Electrical wiring?

Pressure switch is defective?

Blower motor not running?

No or reduced pressure signal to pressure switch?

Pressure switch is out of calibration?

TEST

Check wiring connections to pressure switch. Wires should go to normally open (N.O.) and common (C) terminals on switch.

Check that pressure switch contacts are open (between N.O. and C) when blower is off.

Check for voltage to motor at connector.

Check for loose or blocked tubing connections to pressure switch; loose blower hose connection; loose blower wheel or wires. Check for blocked air filter, vent terminal or vent tubing. Check air flow differential pressure. See Operation Procedures on page 18.

Check pressure switch calibration. See Troubleshooting Procedures on page 27.

SOLUTION

Correct all wiring connections.

Replace switch if not. Replacement must be same manufacturer, model and setting.

If voltage is present at connector, motor does not run, replace blower/motor assembly. Replacement must be same manufacturer and model. Check air flow differential pressure and adjust, if necessary, following Operation Procedures on page 18.

Secure all loose connections. Tighten blower wheel set screw. Remove obstructions. Replace or clean filter. Re-adjust air flow differential pressure as shown in Operation Procedures on page 18.

Replace switch. Replacement must be same manufacturer, model and setting.

Electrical wiring?

Hot surface ignitor tip or ceramic insulator is broken?

Hot surface ignitor is defective?

Check wire connections from ignitor.

Turn power OFF. Carefully remove ignitor from boiler (see Troubleshooting Procedures on page 27). Check for cracks or breakage.

Energize ignitor while outside of boiler. BE CAREFUL OF HOT TIP. Observe glow on ignitor tip. Do NOT allow hot tip to come in contact with your hand or any other objects. Turn off gas valve to prevent gas from exiting ignitor opening and igniting outside of boiler.

Tighten all wiring connections.

If defective, replace ignitor. Replacement

must be same manufacturer, model and length.

If tip does not glow quickly and strongly, replace ignitor. Replacement must be same

manufacturer, model and length.

DIAGNOSTIC “4 FLASHES” - HOT SURFACE IGNITOR FAILURE

TROUBLESHOOTING: POSSIBLE CAUSES AND SOLUTIONS

DIAGNOSTIC “3 FLASHES” - PRESSURE SWITCH PROBLEM

Important Note: Boiler control checks for switch contacts to be open before combustion blower is turned on and

switch contacts to be closed once blower is running and proper air flow is established.

Gas valve defective?

Flame detector shorted?

Turn gas valve knob to “OFF” position and check that valve shuts off gas flow.

Remove flame detector from boiler. Check for coating on rod or material contacting rod inside ceramic or combustion area.

If gas flow continues, replace valve. Replacement must be same manufacturer and model. Calibrate new valve following Operation Procedures on page 19.

Clean or clear any foreign matter. Replace flame detector, if necessary, with same manufacturer, model and length.

DIAGNOSTIC “6 FLASHES” - IMPROPER FLAME SIGNAL Indicates flame signal detected when gas valve should be closed.

DIAGNOSTIC “Steady On” - ELECTRONIC CONTROL FAILURE

Electronic Control Control board cannot be serviced. Replacement must be same manufacturer and model. Is Defective?

Refer to Replacement Parts information on

page 31 when parts need to be replaced.

Page 27

• Disconnect wires to gas valve. May be necessary to disconnect gas supply line to gas valve to move assembly slightly.

• Disconnect air adapter from burner enclosure.

• Remove air filter box cover to access blower mounting studs and nuts. Remove the four nuts and drop blower down to move out of way.

• Remove nuts around perimeter of burner enclosure, drop down off of studs and remove enclosure.

• Allow burner enclosure to drop down low enough to access burner bracket. Remove and clear tubing, if necessary, but mark location of each tube for reassembly.

• While supporting underside of burner bracket to keep from falling, undo knurled nuts at either end of burner.

• Drop burner down off studs gently. Pull down burner gasket with burner without ripping it.

• Ceramic burner is only attached to the burner bracket by the ground wire, unscrew the wire tab to remove.

• Ground bar is held to burner with a weld stud through the burner, remove the nuts and washers from the underside of the burner to disassemble.

• To reassemble, follow this procedure in reverse, carefully relocating all items removed in their proper location at tightness noted in removal.

Pressure switch calibration check

• Turn power OFF.

• Remove wire leads from pressure switch terminals.

• Hookup resistance meter between normally open (N.O.) and common (C) terminals.

• With blower off, the switch should be open, meter reading is infinity. If not, switch is defective.

• If switch is open, check cutout pressure with blower running, as described in following steps.

• Hookup differential pressure gauge in same manner as to set blower air flow - high side to blower outlet, low side to burner enclosure. The switch and gauge both read the same air flow differential pressure.

• Turn on power and raise thermostat.

• Note pressure reading on gauge when blower is running. Reading should be higher than the pressure switch cutout pressure, which is marked on the pressure switch label.

• If the pressure switch terminals are still open with the blower running and the gauge reading is at least

2.54mm (.10”) higher than the pressure switch setting, the switch is defective.

TROUBLESHOOTING PROCEDURES

Note: All of the procedures below require the removal of some of the boiler jacket panels.

Checking flame sensing current

• Turn power OFF and remove lead from flame sensor.

• Connect one microampmeter lead to the flame sensor wire lead; connect other microampmeter lead to the flame sensor. (Meter is in series.)

• Turn power ON. Once the gas valve opens, and ignition occurs at the burner, the microampmeter must read at least 1 microamp to keep the gas valve open. Typically, the reading is between 5 and 10 microamps. (If no reading, polarity may be wrong reverse leads.)

Flame sensor removal

• Turn power OFF and remove lead from flame sensor.

• Remove flame sensor hold-down bracket.

• Carefully pull out flame sensor.

Hot surface ignitor removal

• Turn power OFF and remove ignitor hold-down bracket.

• Carefully pull out ignitor (handle with care, fragile). DO NOT CUT WIRES TO REMOVE IGNITOR.

Ceramic burner/Kanthal ground bar removal

• Turn power and gas supply OFF.

• If burner enclosure not accessible from the rear of the boiler, remove sheet metal tray under blower and leg support brace behind blower.

Figure 22. Ceramic burner/Kanthal ground bar removal

Page 28

Combination Air and Gas Orifice Plate

Air and Gas Orifice Plate Description

1. There are two different plates for each boiler model.

One plate is for Natural Gas, the other is for Propane. The plate for Natural Gas has a slightly larger gas orifice hole stamped into it. The air orifice hole is the same size on each.

2. The plate for Natural Gas used is stamped “N” after

the boiler model number. The plate for Propane used is stamped “P” after the boiler model number. These stampings are visible just below the air/gas adapter and face the front of the boiler.

IMPORTANT: Reorificing for altitude change is NOT necessary on this Concept boiler.

Air and Gas Orifice Plate Conversion

1. Turn off power and gas supply to boiler.

2. Remove boiler jacket front cover by turning the four

slotted fasteners one quarter turn.

3. Remove boiler jacket right side cover by removing the

four sheet metal screws.

4. Locate orifice plate behind air/gas adapter.

5. Remove nuts holding air/gas adapter onto burner enclosure studs and pull air/gas adapter off studs.

6. May be necessary to disconnect gas supply line to gas valve to move assembly slightly.

7. Pull out orifice plate off studs.

8. Replace the orifice plate with the appropriately stamped orifice plate for the gas being utilized on that model boiler.

9. When reassembling, make sure there is a gasket on both sides of the orifice plate. To reassemble, follow this procedure in reverse, carefully relocating all items removed in their proper location at tightness noted in removal.

10. Place the appropriate self-adhesive gas conversion label (supplied in the gas conversion kit) adjacent to the boiler rating plate, if the gas being utilized differs from the gas specified on the rating plate.

11. Power and gas supply can be turned back on to operate boiler.

Figure 23. Combination Air and Gas Orifice Plate Installation

Note: This original design of the air and gas orifice holes stamped into the same plate has been revised on the Concept boiler. Whether this design is implemented on any particular Concept boiler depends on when the boiler was manufactured. Follow these instructions only if the boiler is equipped with the design features shown here.

GAS ORIFICE

GAS TYPE

BOILER MODEL

AIR ORIFICE

BURNER ENCLOSURE

MOUNTING STUDS

AIR AND GAS

ORIFICE PLATE

WITH GASKETS

AIR/GAS ADAPTER

HOSE CLAMP

BOOT

BLOWER

AIR

FILTER

BOX

NUTS

BOTTOM

BOILER

Page 29

utilized. To convert from one type of gas to the other the plate should be rotated 180°. The I.D. tab for the gas being utilized must face outward over the straight flange in the gas manifold so that it is clearly in view.

7. Reposition the four screws through the flanges and orifice plate and tighten the four nuts onto the screws. Make sure the nuts are tightened evenly and with sufficient force to prevent loosening or leakage.

8. Replace boiler jacket covers removed for this procedure.

9. The appropriate self-adhesive gas conversion label supplied with these instructions must be positioned adjacent to the boiler rating plate, if the gas being utilized differs from the gas specified on the rating plate.

10. Power and gas supply can be turned back on to operate boiler.

AIR ORIFICE PLATE

1. The air orifice plate for each boiler model is the same for both natural and propane gas — no conversion is necessary.

2. Each model’s air orifice plate has an I.D. tab which protrudes from the side of the boiler, behind the boiler jacket right side cover. The I.D. tab is stamped for the model of each boiler it is to be installed on.

IMPORTANT: Reorificing for altitude change is NOT necessary on this Concept boiler.

Air and Gas Orifice Plates with Convertible Gas Orifice

Figure 24. Convertible Gas Orifice Installation

Note: This revised design features a gas orifice plate which contains both the natural gas and the propane gas orifice hole. Whether this design is implemented on any particular Concept boiler depends on when the boiler was manufactured. Follow these instructions only if the boiler is equipped with the design features shown here.

GAS TYPE I.D.

BOILER MODEL

NATURAL GAS ORIFICE.

PROPANE ORIFICE

GAS ORIFICE I.D. TAB

BOILER MODEL

AIR ORIFICE ADAPTER

BURNER ENCLOSURE

AIR ORIFICE PLATE WITH GASKETS

GAS VALVE

SCREWS

STRAIGHT FLANGE

O-RING

GAS ORIFICE PLATE

O-RING

STUDS

NUTS

ANGLE FLANGE

NUTS

AIR ORIFICE I.D. TAB (BOILER MODEL)

GAS ORIFICE PLATE ORIENTATION

1. The gas orifice plate contains both the natural gas orifice hole and the propane gas orifice hole, to provide for a fast and simple conversion to either gas use.

2. Each gas orifice hole on the plate has an I.D. tab located adjacent to it. The I.D. tab specifies the boiler model and type of gas for each orifice. The larger hole in the plate is always the natural gas orifice hole, and is adjacent to the I.D. tab that is stamped “NAT”. The smaller hole in the plate is always the propane gas orifice hold, and is adjacent to the I.D. tab that is stamped “PROP”.

3. When installed properly, the I.D. tab that is stamped for the type of gas being utilized must face outward over the straight flange in the gas manifold, so that it is clearly in view.

GAS ORIFICE PLATE CONVERSION

1. Turn off power and gas supply to boiler.

2. Remove boiler jacket front cover by turning the four slotted fasteners one quarter turn.

3. Remove boiler jacket right side cover by removing the four sheet metal screws.

4. Remove the four nuts on the gas manifold angle flange.

5. Pull out the four screws on the gas manifold straight flange far enough to remove the gas orifice plate.

6. Place the gas orifice plate in the position specified in the orientation instructions for the type of gas being

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OPERATING INSTRUCTIONS (Label 65-0640)

• STOP! Read the safety information above on this label.

• Set the thermostat to lowest setting.

• Turn off all electric power to the appliance.

• This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand.

• Remove control access panel.

• Turn gas control knob clockwise to “OFF” position.

• Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow "B" in the safety information above on this label. If you don't smell gas, go to next step.

• Turn gas control knob counterclockwise to “ON” position.

• Replace control access panel.

• Turn on all electric power to the appliance.

• Set thermostat to desired setting.

• If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

• Turn off all electric power to the appliance if service is to be performed.

• Remove control access panel.

• Turn gas control knob clockwise to “OFF” position.

• Replace control access panel.

OPERATING INSTRUCTIONS (Label 65-0645)

• STOP! Read the safety information above on this label.

• Set the thermostat to lowest setting.

• Turn off all electric power to the appliance.

• This appliance is equipped with an ignition device which automatically lights the burner. DO NOT try to light the burner by hand.

• Remove control access panel.

• Depress and move gas control selector arm left to “OFF” position. Note: Arm cannot be turned to “OFF” unless arm is pushed in slightly. DO NOT force.

• Depress and move gas control selector arm right to “ON” position.

• Replace control access panel.

• Turn on all electric power to the appliance.

• Set thermostat to desired setting.

• If the appliance will not operate, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO APPLIANCE

• Set thermostat to lowest setting.

• Turn off all electric power to the appliance if service is to be performed.

• Remove control access panel.

• Depress and move gas control selector arm left to “OFF” position.

• Replace control access panel.

(Reference For Labels 65-0640 & 65-0645)

FOR YOUR SAFETY READ BEFORE OPERATING

A. This appliance does not have a pilot. It is equipped with an

ignition device that automatically lights the burner. DO NOT try to light the burner by hand.

B. BEFORE OPERATING smell all around the appliance area

for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor.

WHAT TO DO IF YOU SMELL GAS

• DO NOT try to light any appliance.

• DO NOT touch any electric switch; DO NOT use any phone in your building.

• Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions.

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

C. Use only your hand to turn the gas control knob or depress

and move the gas control selector arm. NEVER use tools. If the knob will not turn or selector arm will not depress or move by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D. DO NOT use this appliance if any part has been under

water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

Gas Valve 36E65

LIGHTING INSTRUCTIONS

WARNING: If you do not follow these instructions exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

Page 31

This section must be brought to the owner’s attention, so the owner can make necessary arrangements with a qualified heating contractor for periodic maintenance of this boiler. Installer must also inform owner that the lack of proper care and maintenance of this boiler may result in a hazardous condition. Installer should discuss contents of the User’s Information Manual with the owner.

KEEP THE BOILER AREA CLEAR AND FREE FROM COMBUSTIBLE MATERIALS, GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS.

BEFORE EACH HEATING SEASON

A trained and qualified service technician should perform the inspections listed in these instructions at least once a year.

Air filter: Located in sheet metal box in front area of boiler. One quarter turn fasteners hold air filter box cover on. Replace (recommended) or clean filter annually (more often if conditions dictate). Slant/Fin replacement air filter, part number 66-0515 must be used. Can be cleaned with soap and water; after drying, spray with an adhesive-type air filter spray which will attract/hold airborne dust particles.

Vent termination: Check for and remove obstructions.

Closet installations

: Check for and remove ventilation

and/or combustion air opening obstructions.

ent tubing: Check for and repair tubing separation, leaks

or sagging.

ent tubing (externally): Check for corrosion of vent material. If corrosion is present, replace and reseal exhaust tubing assembly. If corrosion is present on galvanized vent material (approved for use on Category I installations only), this material should be replaced with #29-4C stainless steel.

ent and air intake tubing (internally): Check for and remove obstructions. To inspect, remove tubing from boiler. When finished, reseal all removed tubing parts with manufacturer’s specified sealant.

Heat exchanger:

In the unlikely event of boiler flue passage blockage, service to remedy situation must be performed only by an authorized Slant/Fin representative.

Burner: Annual service of the burner is not necessary. Follow the burner removal procedure on page 27 when improper operation of the boiler necessitates inspection of this part.

System water:

Check if full of water and properly pressurized. Check for and correct radiation system air “noise”.

Water piping: Check for and repair any leaks.

Gas piping:

Check for and repair any leaks.

Clear plastic tubing: Located around burner enclosure area. Check for cracked, loose or blocked conditions. Replace if necessary.

Safety shutdown controls:

Check operation as detailed on

page 21 in this manual.

Blower:

This is a sealed component which does not require lubrication. Check convoluted boot on blower outlet for air leakage. Replace if necessary.

Circulator:

Some models require lubrication. S.A.E. #20

oil recommended.

WATER TREATMENT

A good water treatment program will extend the useful life of the boiler and is especially recommended in areas where water quality is a problem. A reputable water treatment company should be consulted for determining the best overall treatment program for this equipment.

FREEZE PROTECTION

If anti-freeze must be used, INHIBITED PROPYLENE GLYCOL is recommended as it is practically non-toxic. Fo useful information on the characteristics and mixing proportions of anti-freeze in heating systems, obtain a copy of Technical Topics No. 2A from Hydronics Institute, 34 Russo Place, Berkeley Heights, NJ 07922.

IF REPLACEMENT PARTS ARE NEEDED

When parts are needed, refer to boiler model and serial number shown on the boiler name/rating plate. Whenever possible refer to the original order by number and date.

Control identification and replacement should not be attempted by unskilled personnel. Only simple, easily identified controls and parts may be obtained locally. All other controls and parts should be identified by and ordered from Slant/Fin. Relief/Safety valves must be ASME rated for the pressure and gross output of the boiler.

This boiler is equipped with an unconventional gas control. If this control is replaced, it must be replaced with an identical gas control and calibrated as specified in the Operation Procedures.

Replacement parts are available from:

SLANT/FIN LTD/LTEE 6450 Northam Drive Mississauga, ON L4V 1H9 Phone: (905) 677-8400 Fax: (905) 677-1829

MAINTENANCE PROCEDURES

WARNING: DO NOT USE ETHYLENE GLYCOL, AN AUTOMOTIVE-TYPE OR UNDILUTED ANTI-FREEZE. SEVERE BOILER DAMAGE CAN RESULT.

Page 32

SLANT/FIN LTD/LTEE, 6450 Northam Drive, Mississauga, Ontario L4V 1H9

• Phone: (905) 677-8400 / FAX: (905) 677-1829 e-mail: slantcan@aol.com

Boiler package includes mounted on boiler:

• Full jacket enclosure

• Water manifold/air scoop

• Relief valve

Unmounted parts

• Circulator pump (optional)

• Secondary water high limit (optional)

Literature included

• Boiler Instruction Manual

• Users Information Manual

• Replacement Parts List

• Lifetime Limited Warranty

enting kit options available:

• Horizontal venting with vent terminal

• Vertical venting with roof termination

• Horizontal venting with separate vent and air intake

• Chimney or “B” vent venting

Boiler Package/Options

Slant/Fin CB-45, CB-90, CB-135, CB-180, CONCEPT 21 CB-180 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual