Slant-Fin J-390 User Manual

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This manual must be left with owner and should be hung on or adjacent to the boiler for reference.

DIRECT-VENT SEALED COMBUSTION CONDENSING BOILER HOT WATER MODEL J-390

GAS-FIRED BOILER FOR NATURAL GAS

INSTALLATION AND OPERATING INSTRUCTIONS

TABLE OF CONTENTS

Boiler Dimensions and Rating ....................................................2

Identification of Parts..................................................................3

Installation Requirements ...........................................................4

Contamination Prevention...........................................................5

Venting Application .....................................................................5

Boiler Room Air Supply and Ventilation......................................5

Flue gas Venting Requirements..................................................6

Additional Installation Requirements for Massachusetts............6

Vent Material ..............................................................................6

Air Intake Material ......................................................................6

Vent and Air Intake Restrictions .................................................7

Non-Direct Vent Installation ........................................................8

Sidewall Venting, Non-Direct Vent ..............................................8

Vent Termination Location and Clearance ..................................8

Non-Direct Vent Vertical Venting .................................................8

Direct Vent Installation ................................................................8

Sidewall Venting, Direct Vent ......................................................8

Vent/Air Intake Termination Installation.....................................14

Direct Vent, Venting and Air Intake through a Roof ..................15

Venting and Air Intake Regular Inspection ...............................16

Condensate Removal System..................................................16

Gas Piping

Electrical Wiring ........................................................................17

Wiring Diagram.........................................................................18

Single and Multi Zoning

Water Piping .............................................................................24

Operating Instructions...............................................................30

Boiler Control Displa

Boiler Control............................................................................30

Sequence of Operation.............................................................36

Gas Input Rate Adjustment

Safety Check ...........................................................................38

Care and Maintenance .............................................................41

Gener

................................................................................16

............................................................

...............................................................30

......................................................

Troubleshooting Guide ................................................42

IMPORTANT

READ ALL OF THE FOLLOWING

WARNINGS AND STATEMENTS

BEFORE READING

INSTALLATION INSTRUCTIONS

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1-latest edition. The installation must also conform to the additional requirements in this Slant/Fin Instruction Book.

In addition where required by the authority having jurisdiction, the installation must conform to American Society of Mechanical Engineers Safety Code for Controls and Safety Devices for Automatically Fired Boilers, No. CSD-1.

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

ity having jur

author

The venting system of this boiler is under positive pressure. Leakage from this system can be hazardous and if not avoided can result in death or serious injury. In addition to the recommendations within this manual and the

l, the venting system, from the flue collector to the out

Manua door discharge fied service agency.

isdiction.

WARNING

ust be carefully chec

, m

THE

mation

s Infor

User’

ked annually by a quali-

Heating Contractor

dress

Phone Number

.A.

Printed in U

Boiler Model Number

Boiler Serial Number

Installation Date

708 Part No. 83-5736

lication No.

Pub

J-40

REAR VIEW

SIDE VIEW

FRONT VIEW

TOP VIEW

95/8

WATER RETURN

1 1/4" NPT (MALE)

AS PIPE

3/4" NPT

1/8

16 3/8

35/8

55/8

CONDENSATE DRAIN - 3/4" DIA

41/4

4" AIR INTAKE CONNECTION

(

5 3/4)

23 5/8

41/4

25/8

5/8

51/2

37/8

(21 1/8)

" VENT CONNECTION

WATER SUPPLY

1 1/4" NPT (MALE)

46 7/8

13 1/2

(7/8)

Jaguar Model J-390

RATINGS AND DIMENSIONS

Figure 1. Dimensions data

SPECIFICATIONS:

Fuel Rate Input:

Boiler Water Volume:

ater Piping

Connections:

Weight of Boiler

(uncrated):

Gas Piping Connection:

ent Connection:

Air Intake Connection:

No or

*Note:

J-390 Boiler

ifice changes are required for high altitude installations.

390,000 BTUH max

110,000 BTUH min

2.0 gallon (16.5 lbs)

1-1/4” NPT (male)

190 lbs.

emale)

NPT (f

3/4”

4” nominal I.D. pipe (PVC, CPVC or

stainless steel)

4” nominal I.D. pipe (PVC, CPVC or

stainless steel)

Jaguar J-390 Boiler

Jaguar Model J-390

BOILER CONTROL

FIELD WIRING TERMINALS (24V)

FIELD WIRING TERMINALS (120V)

GAS VALVE

TRANFORMER

4" AIR INTAKE CONNECTION

4" VENT CONNECTION

SPARK ELECTRODE (IGNITER)

HEAT EXCHANGER

VENTURI

COMBUSTION BLOWER

WINDOW (SIGHT GLASS)

FLUE PIPE

FLUE SENSOR

GAS SUPPLY VALVE

WATER SUPPLY

WATER RETURN

BOILER CONDENSATE TRAP

WATER RETURN SENSOR

WATER SUPPLY SENSOR AND WATER HIGH LIMIT

FLUE SAMPLE PORT

GAS VALVE

CONTROL BOARD COVER

CONTROL PANEL

FLUE SAMPLE PORT

HEAT EXCHANGER

ENCLOSURE

FRONT COVER

CONTROL PANEL

DOOR

FIELD WIRING BX CONNECTORS

FRONT (INTERIOR)

RIGHT SIDE (INTERIOR)

3" MIN

VENTING CONDENSATE TRAP

SEDIMENT TRAP (REQUIET)

INSTALL MANUAL MAIN SHUTOFF VALVE 5' ABOVE FLOOR, WHEN RQUIRET BY LOCAL CODE

HEAT EXCHANGER ENCLOSURE FRONT COVER LATCH

LOCATION AND IDENTIFICATION OF PARTS

Figure 2. Location and identification of parts

* 2" FOR ENCLOSED

Jaguar Model J-390

INSTALLATION REQUIREMENTS

The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1latest edition.

This installation must also conform to the additional require-

ents in this Slant/Fin Instruction Book.

BOILER LOCATION

Provide a level, solid foundation for the boiler. Location should be as near as possible to chimney or outside wall so that the flue pipe from boiler is short and direct. (See paragraph heading “Vent Termination Location and Clearance” on page 8.) The location should also be such that all boiler components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, control replacement, etc.).

BOILER FOUNDATION

Provide a solid, level foundation, capable of supporting the weight of the boiler filled with water, and extending at least 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 FROM COMBUSTIBLE CONSTRUCTIONS

. Minimum clearances to the exterior surfaces of the boiler

shall be as follows:

INIMUM ALCOVE AND CLOSET CLEARANCE

or Combustible Recommended

Surf

ace Construction for Service

ront 0" 24"

F Rear 0" 6" Left Side 0" 0" Right Side 0" 0"

op 4" 6"

T Flue Connector:

Enclosed — 2" 6" Uninclosed — 1" 6"

B. Provide accessibility clearance of 8" on sides requiring

servicing and 18" on sides used for passage.

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 1 inch**.

t points where hot water pipes emerge from a floor,

** A

the clearance at the opening through the finished floor boards or wall or ceiling boards may be not less than 1/2 inch. Each such opening shall be covered with a plate of uncombustible material.

wall or ceiling,

SAFETY

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

Figure 3. Jaguar boiler min. clearances for combustible construction.

Jaguar Model J-390

CONTAMINATION PREVENTION

The combustion air supply must not be susceptible to contamination sources, whether the combustion air comes from the interior or exterior of the building. Contaminated air can cause

orrosion or other damage to the heat exchanger and compo-

c nents of the boiler, causing failure of these parts or unsafe operation.

Below is a list of products and areas which may cause contaminated combustion air:

PRODUCTS TO AVOID

• Spray cans containing chloro/fluorocarbons

• Permanent wave solutions

• Chlorinated waxes/cleaners

• Chlorine-based swimming pool chemicals

• Calcium chloride used for thawing

• Sodium chloride used for water softening

• Refrigerant leaks

• Paint or varnish removers

• Hydrochloric acid/muriatic acid

• Cements and glues

• Antistatic fabric softeners used in clothes dryers

• Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

• Adhesives used to fasten building products and other similar products

AREAS LIKELY TO HAVE CONTAMINANTS

• Dry cleaning/laundry areas and establishments

• Swimming pools

• Metal fabrication plants

• Beauty shops

• Refrigeration repair shops

• Photo processing plants

• Auto body shops

• Plastic manufacturing plants

• Furniture refinishing areas and establishments

• New building construction

• Remodeling areas

• Garages with workshops

VENTING APPLICATION

The Jaguar J-390 is a sealed combustion type boiler, it may be installed and vented either as a direct vent boiler which all air for combustion is obtained directly from outside or as a nondirect vent boiler which air for combustion is taken from inside

he boiler room.

t The Jaguar J-390 boiler must be vented by 4" diameter

PVC/CPVC schedule 40 pipe, or the proper 4” diameter stain-

ess steel venting system (see “vent material” on page ???)

l through the roof or sidewall.

BOILER ROOM AIR SUPPLY AND VENTILATION

n ample supply of air is required for combustion and ventila-

A tion. When buildings are insulated, caulked and weatherstripped, 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-latest edition, or applicable provisions of the local building codes. The following recommendation applies to buildings of energy-saving construction, fully caulked and weatherstripped.

INSTALLATION IN ENCLOSED BOILER ROOM REQUIRES TWO UNOBSTRUCTED OPENINGS FOR PASSAGE OF AIR INTO THE BOILER ROOM.

A. NON-DIRECT VENT INSTALLATION

1. Air drawn horizontally from outdoors DIRECTLY through an outside wall;

floor and one louvered opening near the ceiling, each opening with a minimum FREE air passage area of

square inch per 4000 Btuh of total appliances’ input. Air drawn horizontally through HORIZONTAL DUCTS;

2. one opening near the floor and one opening near the ceiling, each opening with a minimum FREE air passage area of

1 square inch per 2000 Btuh of total appliances’ input.

Air drawn VERTICALLY from outdoors; one opening at

3. the floor and one opening at the ceiling, each opening with a minimum FREE air passage area of 4000 Btuh of total appliances’

Air drawn from inside the building; one opening near the floor and one opening near the ceiling, each opening with a minimum FREE air passage area of per 1000 Btuh of total appliances’ input.

IF BOILERS ARE INSTALLED ADJACENT TO OTHER FUEL BURNING EQUIPMENT, THE AREA OF FREE OPENINGS MUST BE APPR

TE THE ADDITIONAL LO

B. DIRECT VENT INSTALLATION

Adequate air supply should be provided to prevent overheating of the boiler controls and boiler room. air into the boiler room f

⁄2 of the openings required for the non-direct vent as

least mentioned above.

If additional non-direct v same space and adequate air openings are pro there are no additional air openings required for the Jaguar J-390 boiler.

OPRIATEL

one louvered opening near the

input.

Y INCREASED T

AD.

or direct-v

ent appliances are installed in the

ent installation must be at

1 square inch per

1 square inch

CCOMMO-

O A

Openings for passage of

or them,

vided f

Jaguar Model J-390

For both direct and non-direct installation, the following must be considered:

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

sed in or near the boiler area.

- Boiler area must never be under negative pressure. The flow of combustion and ventilating air to the boiler must not be obstructed.

LUE GAS VENTING REQUIREMENTS

The Jaguar J-390 series boiler is a high efficiency, mechanically forced draft boiler and, therefore, require different venting arrangements than natural draft, lower efficiency boilers.

THE FOLLOWING INSTRUCTIONS MUST BE CAREFULLY READ AND FOLLOWED IN ORDER TO AVOID ANY HAZARDOUS CONDITIONS DUE TO IMPROPER INSTALLATION OF THE AIR INTAKE AND FLUE GAS VENTING SYSTEM.

ent piping installation MUST be in accordance with these

The v instructions and with ANSI Z223.1-latest edition NATIONAL FUEL GAS CODE, Part 7, Venting of Equipment. Other local codes may also apply and must be followed. Where there is a conflict between these requirements, the more stringent case shall apply.

The use of a vent damper is NOT permitted on this boiler series.

ADDITIONAL REQUIREMENTS FOR THE COMMONWEALTH OF MASSA

When the Bobcat is installed and used in the Commonwealth of Massachusetts, the following additional code 248 CMR MUST be met:

(1). Exisiting chimneys shall be permitted to have their use continued when a gas conversion burner is installed, and shall be equipped with a manual reset device that will automatically shut off gas to the burner in the event of a sustained back-draft.

(2)(a). For all side wall horizontally vented gas fueld equipment installed in every dwelling, building or structure used in whole or part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finsihed grade in the area of the venting, including but not limited to dec

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time

of installation of the side wall horizontal vented fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall obser wired carbon mono tional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the proper for the installation of hard wired carbon monoxide detectors.

a. is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level.

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

CHUSETTS

requirements pursuant to Massachusetts

ks and porches

ty o

In the e

In th e

, the following requirements shall be satisfied:

e that a battery operated or hard

xide detector with an alar

wner to secure the ser

ent that the side wall horizontally vented gas fueld equipment

ent that the requirements of this subdivision can not be met at

vices of qualified licensed prof

m is installed on each addi

essionals

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

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

DIRECTLY BELOW, KEEP CLEAR OF ALL OBSTRUCTIONS”.

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

5.08(2)(a)1 through 4.

(b) EXEMPTIONS. The following equipment is exempt from 248 CMR

5.08(2)(a)1 through 4:

The equipment listed in Chapter 10 entitled “Equipment Not

1. Required TO Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

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

t for residential purposes.

“GAS VENT

VENT AND AIR INTAKE MATERIALS

The vent and air intake system for direct or non-direct vent installation must be 4” diameter PVC/CPVC schedule. 40 pipe, or UL listed single wall 4” diameter AL29-4C* stainless steel material. The following manufacturers’ systems are approved for use within a specified minimum and maximum equivalent

vent length in this manual.

Manufacturer Type/System Sealant

Heat-Fab. Inc.

ProTech System,

Inc.

national

x-L Inter

Fle

Inc.

x, Inc.

Z-Fle

, Inc.

Metal-F

N/A

When joining the var

ent systems

, the manufacturers’ instructions should be closely fol-

Saf-T Vent

EZ Seal

FasNSeal Not Required

StaR-34 GE-IS806

ent

Z-V

Corr Guard Not Required

PVC pipe,

Schedule 40

CPVC pipe

Schedule 40

Not Required

TV 106

GE, R

PVC primer

and cement

CPVC pr

imer

and cement

ious components of the listed stainless steel

lowed to insure proper sealing. Use sealant specified by vent system manufacturer for sealing of pipe and fittings, if required. When joining the PVC/CPVC pipe and fittings, follow the instructions pro-

All connections must be liquid and pressure

vided in this man

ual. tight. DO NOT use galvanized flue pipe or any plastic-type materials other than PVC/CPVC Schedule 40.

Jaguar Model J-390

4" PVC OR CPVC

AIR INTAKE PIPE

AIR INTAKE COLLAR

4" PVC OR CPVC VENT PIPE

he vent connector on the boiler is designed to directly accom-

T modate either PVC/CPVC Schedule 40 pipe or the listed stainless steel vent systems by utilizing an adapter. The adapter has a built-in sealing ring, so no additional sealant is required.

ake sure the pipes are round and burr-free, and push down

M fully past the sealing ring, until snug. (See Figure 4). Liquid soap may be used to ease insertion.

he air intake collar on the boiler is designed to directly acco-

T modate PVC/CPVC schedule 40 pipe (See figure 4). A small bead of silicon should be applied between the collar and inside of the air antake pipe, to seal properly.

. For each joint, first apply a coat of primer to the outside

ealing surface of the pipe and the inside sealing surface of

s each fitting. Use only the primer type that is specified for either the PVC or CPVC pipe that is bing utilized.

9. Before the primer dries, apply a coat of cement over it. A

second coat of cement can be applied, if necessary, but must be done quickly and in a manner that avoids unnecessary build-up that would cause obstruction inside the system. Use only the cement type that is specified for

ither the PVC or CPVC pipe that is being utilized.

0. Before the cement dries, insert the pipe into the fitting. A

slight twisting motion while pushing the pipe into the fitting will aid in distributing the cement evenly and ensuring the parts fully engage.

11. Quickly wipe the excess cement from the outside areas of

the joint. Discard any rags used to avoid later getting the cement on hands, clothes and equipment.

VENT AND AIR INTAKE RESTRICTIONS

1. Maximum allowed equivalent vent and air intake length for

all of the approved vent and air intake materials is 100 equivalent feet.

2. Equivalent of vent or air intake length is sum of the

straight pipe lengths and equivalent length of elbows. Each 90˚ elbow is equivalent to 10 ft. of 4" pipe.

Figure 4. Vent & Air Intake Pipe installation into Boiler Adapter.

PVC/CPVC PIPE GENERAL ASSEMBLY METHOD

The following are the recommended methods for cutting, cleaning and connecting PVC and CPVC pipe, for both the vent and air intake piping system:

1. When laying out the piping system, work from the boiler

2. Cut the PVC/CPVC pipe to the required lengths, and

3. Once the pre-assembled PVC/CPVC pipe vent and air

4. De-b

5. Wipe or knock out any debris from inside the PVC or

6. Thoroughly clean the outside ends of each pipe, and the

7. Re-assembly of the PVC or CPVC pipe should be done in

vent and air intake adapter to the point of outside termination.

pre-assemb

le the entire system, bef

ore sealing. Disassembly after sealing, to make any corrections, will not be possible

intake system is verified to be of the proper length pipe and fitting orientation, begin disassembling and preparing the pipes and fittings for the sealing process.This can be done section by section, or the complete vent and air intake system can be disassemb

led. It is recommended to mark the various parts, before complete disassembly, to eliminate the possibility of errors during re-assembly.

y PVC/CPVC pipe, to

urr the inside and outside of e

ensure that the

y engage fully into the fittings, and flow is

not compromised. A small chamfer on the outside of each pipe can particularly aid in the final assembly process.

CPVC pipe, which may have accumulated there from the cutting process or stor

age. Debris can cause operational

problems with the boiler combustion components.

inside of each fitting. sealing agents to w lengths a

way from the cleaned ends, and handle the

ust be dr

The surf

aces m

k properly. Handle the prepared pipe

y for the

cleaned fittings, from the outside, to avoid contamination.

sections, to avoid the primer and cement drying before the parts are engaged.

Figure 5.

3. The vent termination is in addition to the allowed equivalent lengths.

4. Minimum vent length is 2 feet of straight pipe, plus one 90˚ elbow.

5. Vent length restriction is for both direct and non-direct vent installations.

EXAMPLE: The combustion air is provided by air intake piping directly to the boiler (direct-vent installation). The vent piping will be PVC and installation location will require the use of 4 elbows for the vent to run the termination. The air intake piping will also be PVC, and also will require the use of 4 elbows.

Jaguar Model J-390

In this case, the maximum straight pipe vent length that can be utilized with the 4 elbows would be: 100’ - (4’ x 10’) = 60’. Since the air intake pipe also is PVC and requires the use of

elbows, the maximum straight pipe air intake length that

4 can be utilized is also 60 feet.

If the air for combustion were taken from the boiler room (non-direct vent installation), still the maximum straight vent length would be 60 feet.

6. The Jaguar J-390 boiler is equipped with a built-in ondensation drain and trap system. The traps must be

c filled with water. DO NOT operate the boiler without filling the trap with water to prevent flue gas discharge into space. The drain must dispose of possibly large quantities of condensate, which may require a neutralizing system. Refer to the “Condensate Drainage” section of this manual. No additional condensation drain and trap is required on the vent piping system itself.

7. The horizontal vent pipe must be sloped upward from the

boiler at a pitch of at least 1/4” per 1 foot of run, so that the condensate from the vent system runs to the boiler vent adapter pipe, then out the built-in condensation drain and trap.

The horizontal vent and air intake pipes must be supported with pipe straps, at intervals no greater than 5 feet, when PVC/CPVC pipe is utilized. This support spacing applies also to stainless steel vent pipe, unless the manufacturer’s instructions permit otherwise. The vertical vent and air intake pipes also must be supported, wherever the building construction provides allowance for it, such as ceiling or roof passage openings where a firestop and support or braces can be affixed.

9. Minimum clearances of vent pipes from combustible

constructions must be maintained (see Page 4). No clearance is required between the vent and air intake pipes of this boiler.

10. Common venting with other appliances or another Jaguar

boiler is not allowed.

11. DO NOT install a vent damper or similar devices in vent

system or on the boiler.

12. DO NOT insulate venting system.

should be protected from discoloration and degradation.

ENT TERMINATION LOCATION AND CLEARANCES

. The venting system shall terminate at least 3 feet above

any forced air inlet located within 10 feet.

. The venting system shall terminate at least 4 feet below,

4 feet horizontally from, or 1 foot above any door, window or gravity air inlet into any building.The bottom of the vent terminal or air intake terminal shall be at least 12 inches

bove grade or the normal snow level whichever is

a greater.

3. Through the wall vents shall not terminate over public walkways or over areas where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators, relief valves or other equipment. Minimum clearance of 4 feet horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

4. Vent termination must not be located 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 damages can occur.

B. NON-DIRECT VENT - VERTICAL VENTING

Figure 8 shows typical venting through the roof.The vent pipe must pass through the ceiling, floor and the roof vertically through a 8" minimum diameter cutout. A fire stop is required for each ceiling and floor penetration. For roof passage, an appropriate UL listed roof flashing must be used.

An existing chimney (see Figure 9) may be used as a chase for vertical venting. Other appliances CANNOT be vented into the same chimney or vent pipe with in the chimney.

The vertical vent piping must terminate with a screened tee, combination of 45˚ elbow and a 90˚ screened elbo tion or a rain cap termination.

II. Direct Vent Installation

w termina-

VENTING

Only PVC/CPVC and approved stainless steel materials listed on page 6 may be used for the venting system installation. If stainless steel vent systems are used, f

s instructions

er’

I. Non-Direct Vent Installation

The air for comb surrounding the boiler for combustion and ventilation (see page 6.)

DO boiler is contaminated. See page 5 for the list of harmful contaminants and their sources, to avoid.

Figures 6 and 7 show typical horizontal sidewall venting. For combustible wall passage of vent piping, a UL listed thimble or flashing and sealing boot must be used, providing the wall thickness from 3" minimum up to 14" maximum. The vent piping must terminate with a screened tee or elbow termination facing down.

condense

INSTALLATION

actur-

w the man

, in conjunction with these instructions.

ustion is tak

NOT use this installation method if the surrounding of the

ALL VENTING - NON-DIRECT VENT

SIDEW

UTION:Flue gasses e

. Building materials in the area of the vent terminal

en from the ambient air

ore, ample supply of air is required

theref

;

xiting from the v

ollo

ent ter

minal will

Air intake piping from outside to the boiler air intake adapter provides the air for combustion.The boiler surrounding may be contaminated (See page 5). can prev entering the combustion air supply.

A. SIDEWALL DIRECT VENTING

Figures 10 and 11 sho Slant/Fin vent/air intake termination.

CAUTION: Flue gasses existing from the vent terminal will condense. Building materials in the area of the terminal should be protected from discolor requirements of the vent termination location and clearances stated in this manual.

ent contaminants from the boiler surrounding from

Piping the air intak

all direct venting, using a

w typical side

ation and degradation, in addition to the

e to the outside

Jaguar Model J-390

AIR INTAKE (

DO NOT BL0CK)

U/L LISTED FLASHING AND SEALING BOOT MUST BE USED ON COMBUSTIBLE W

ALLS.

IN. DIA.

VC/CVPC PIPE FOR V

ENT

ERMINATION 90 ELBOW

WITH SCREEN

SNOW LINE

(

SEE DEFINITION)

OUTSIDE WALL

SLOPE UP 1/4 IN. P

ER FOOT MIN. FROM BOILER TO V

ENT TERMINATION

0 ELBOW

6" MIN.

0" MAX.

12" MIN

(DO NOT BL0CK)

AIR INTAKE

90 ELBOW

STANDARD

VENT TERMIN ATION

FROM BOILER TO

PER FOOT MIN.

SLOPE UP

1/4 IN.

VENT

MATERIAL FOR

STEEL VENTING

STAINLESS

4 INCH. DIA.

OUTSIDE V ENT TERMINATION ELBOW WITH SCREEN

OUTSIDE WALL

SNOW LINE

(SEE DEFINITION)

6" MIN

10" MAX

12" MIN

WALL THIMBLE MUST BE USED ON COMBUSTIBLE WALLS

JAGUAR J-390 NON-DIRECT VENT, SIDEWALL VENTING

All joints must be liquid and pressure tight. Use 4” dia. PVC/CPVC schedule 40 pipe or U/L listed single wall 4" dia.

AL29-4C S.S.*. venting materials (See page 7).

Figure 6. Non-direct vent, side wall venting - utilizing PVC/CPVC pipe for venting.

Figure 7.

Non-direct vent, side wall venting - utilizing stainless steel vent materials for venting.

** Definition of Sno

w Line:

wledge of local conditions will re

Kno

The height should be used as the SNOW LINE.

AL 29-4C IS A REGISTERED

TRADEMARK OF ALLEGHENY LUDLUM CORP

eal the maxim

um height that repeated sno

alls accumulate to.

SUPPORT

FIRESTOP AND

AIN CAP TERMINATION MAY BE USED

ALTERNATE VERTICAL TERMINATION

LBOW WITH SCREEN

0°TERMINATION

5°ELBOW

PIPE OR STAINLESS STEEL

4 IN. DIA. PVC/CPVC

FIRESTOP AND SUPPORT

VENTING MATERIAL FOR VENT

"MIN

TORM C OLLAR

LASHING AND

4 IN. DIA. PVC/CPVC

VENTING MATERIAL FOR VENT

PIPE OR STAINLESS STEEL

EE WITH SCREEN

VENT TERMINATION

SLOPE UP 1/4 IN.

PER FOOT MIN.

(DO NOT BLOCK)

AIR INTAKE

90°ELBOW

2" MIN

1 FT. MIN

10 FT. MIN

Jaguar Model J-390

JAGUAR J-390 NON-DIRECT VENT, VENTING THROUGH A ROOF

All joints must be liquid and pressure tight. Use 4” dia. PVC/CPVC schedule 40 pipe or U/L listed single wall 4" dia.

AL29-4C S.S.*. venting materials (See page 7).

Figure 8. Jaguar J-390 - non-direct vent, venting through the roof

AL 29-4C IS A REGISTERED TRADEMARK OF ALLEGHENY LUDLUM CORP

Jaguar Model J-390

CHIMNEY T

OP PLATE

VENT TERMINATION T

EE WITH SCREEN

VENT

VENTING MATERIAL FOR

PIPE OR STAINLESS STEEL

4 INCH DIA. PVC/CPVC

SEAL CHIMNEY OPENING

VENT

VENTING MATERIAL FOR

PIPE OR STAINLESS STEEL

4 INCH DIA. PVC/CPVC

WITH MO R TAR OR CO VE R PLATE

45°ELBOW

AIN CAP TERMINATION MAY BE USED

ALTERNATE VERTICAL TERMINATION

LBOW WITH SCREEN

0°TERMINATION

PER FOOT MIN.

SLOPE UP

1/4 IN.

90°ELBOW

(DO NOT BLOCK)

AIR INTAKE

1FT.MIN

10 FT. MIN

JAGUAR J-390 NON - DIRECT VENT, UTILIZING AN EXISTING

All joints must be liquid and pressure tight. Use 4” dia. PVC/CPVC schedule 40 pipe or U/L listed single wall 4" dia.

CHIMNEY AS A CHASE

AL29-4C S.S.*. venting materials (See page 7).

Figure 9. Jaguar J-390 - non-direct vent, utilizing an existing chimney as a chase.

AL 29-4C IS A REGISTERED

TRADEMARK OF ALLEGHENY LUDLUM CORP

SLANT/FIN VENT/AIR INTAKE TERMINATION KIT PART # 83 0802 000

AIR INTAKE LOUVERS

SNOW LINE ** (SEE DEFINITION)

OUTSIDE WALL

4" DIA PVC/CPVC PIPE FOR AIR INTAKE

" - 14" THICK WALL

90°ELBOW

4" DIA PVC/CPVC FLUE PIPE

4" DIA PVC/CPVC COUPLING WITH SCREEN

SLANT/FIN VENT/AIR INTAKE TERMINATION KIT PART # 83 0802 000 TOGETHER WITH SPECIAL KIT FOR STAINLESS STEEL VENT PIPE

AIR INTAKE LOUVERS

4" DIA STRIGHT SCREENED VENT TERMINATION

SNOW LINE ** (SEE DEFINITION)

OUTSIDE WALL

ADAPTOR

4" DIA STAINLESS STEEL PIPE FOR VENT

90°ELBOW

4" DIA PVC/CPVC PIPE FOR AIR INTAKE

3" - 14" THICK WALL

Jaguar Model J-390

JAGUAR J-390 - DIRECT VENT, SIDEWALL VENTING

All joints must be liquid and pressure tight. Use 4” dia. PVC/CPVC schedule 40 pipe or U/L listed single wall 4" dia.

AL29-4C S.S.*. venting materials (See page 7).

Figure 10. Direct vent, sidewall venting illustration; utilizing PVC/CPVC pipe for venting

Figure 11.

** Definition of Sno The height should be used as the SNOW LINE.

Direct vent,

w Line:

AL 29-4C IS A REGISTERED

wall venting illustration;

side

wledge of local conditions will reveal the maximum height that repeated snowfalls accumulate to.

Kno

TRADEMARK OF ALLEGHENY LUDLUM CORP

utilizing stainless steel vent materials f

or venting.

Jaguar Model J-390

4" DIA PVC/CPVC PIPE FOR VENT

" DIA PVC/CPVC PIPE FOR AIR INTAKE

NSIDE TERMINATION P LATE

OUTSIDE TERMINATION P LATE

CREEN

4" DIA PVC/CPVC COUPLING

SCREW

ALL

(3" - 14 " THIC K)

COMBUSTIO N

VENT

GASES

STOP FOR AIR/VENT O

UTSIDE TERMINAL

" DIA PVC/CPVC COUPLING

CREEN

OUVERS

EAL HERE

UTSIDE TERMINATION P LATE

INSIDE TERMINATION

LATE

4" DIA PVC/CPVC PIPE

FOR AIR INTAK E

4" DIA PVC/CPVC PIPE FOR VEN T

WALL (

3" - 14" THICK)

SCREW

4" PVC OR CPVC

IR IN TAKE PIPE

4" PVC OR CPVC VENT PIPE

AIR INTAKE COLLAR

4" DIA PVC/CPVC PIPE FOR AIR I NTAKE

4" DIA STAINLESS STEEL SLIP JOINT PIPE FOR VENT

SCREW

INSIDE TERMINATION PLATE

4" DIA STRAIGHT SCREEN TERMINATION

OUTSIDE TERMINATION PLATE

REDUCER RING FOR SLIP JOINT PIPE

4" DIA STAINLESS STEEL SLIP JOINT PIPE FOR VENT

VENT

GASES

COMBUSTION

AIR

4" DIA PVC/CPVC PIPE

FOR AIR INTAKE

INSIDE TERM INATION

PLATE

SEAL HERE

WALL (3"-14"THICK)

OUTSIDE TERMINATION P LATE

LOUVERS

STOP FOR AIR/VENT OUTSIDE TERMINAL

SCREW

WALL (3"-14"THICK)

4" DIA STRAIGHT SCREEN TERMINATION

SCREW

IR IN TAKE COLLAR

EDUCER RING FOR USE WITH STAINLESS STEEL V

ENT PIPING

4" STAINLESS STEE L V ENT P IPE

4" PVC OR CPVC

AIR INTAKE PIPE

Figure 12a. Vent/Air intake termination; utilizing PVC/CPVC pipe for venting.

Figure 12b. Vent/Air intake termination; utilizing stainless steel venting materials.

Jaguar Model J-390

ENT/AIR INTAKE TERMINATION FOR PVC/CPVC

ENTING INSTALLATION

This termination is designed specifically for 4” diameter PVC or CPVC Schedule 40 pipe to be used as the vent and air intake piping material, only. It can be used on a combustible wall, provided that the wall passage is cut out as specified in step 5.

. Termination must be installed horizontally.

. Refer to Figure 12a for installation details.

3. Wall thickness should be 3” to 14” thick.

4. Follow instruction for “vent termination location and clearances” explained on page 8.

5. Cut a rectangular opening with the following dimensions in the wall. Height: 5 Width: 12

⁄4”

6. From outside of the wall, install outside termination plate using 4 screws. Make sure the louvers are at right side. Seal the plate perimeter with silicon.

7. Apply a bead of silicon around the outer surface of the out side termination plate air intake collar, about 1/2” from the edge. This will seal the air intake pipe to the air intake collar, in step #9.

8. From inside, install the inside termination plate, using 4 screws. Make sure that the holes for the vent and air intake pipe visually line up with the vent passage hole and air intake collar on the outside termination plate.

9. Cut the PVC or CPVC air intake pipe to the proper dimension to fit onto the air intake collar of the terminal. Slide the air intake pipe through the inside termination plate and onto the air intake collar, where the sealant was pre-applied in Step #7.

10. Cut the PVC or CPVC vent pipe so that it will extend out past the outer surface of the outside termination plate by 2”.

11. Cement a 4”

diameter PVC or CPVC coupling onto the PVC or CPVC vent pipe, and install a stainless steel screen into the coupling.

12. From outside the wall, insert the bare end of the PVC or CPVC vent pipe through the outside and inside terminal

, until the coupling is flush with the outside wall plate.

plates

13. From inside, proceed with the air intake and vent pipe

w the proper PVC/CPVC assemb

installation. F

actices specified on page 7, and venting system

pr restr

ictions specified on page 7 of this manual.

ollo

ENT/AIR INTAKE TERMINATION FOR STAINLESS STEEL

ENTING INSTALLATION

This termination is easily modified for Heat-Fab Saf-T vent 4” diameter stainless steel venting system to be used as the vent, by installing the special reducing rings provided in the optional stainless steel flue pipe kit, with 4” diameter PVC or CPVC schedule 40 pipe to be used as the air intake piping material,

nly. It can be used on a combustible wall, provided that the

all passage is cut out as specified in step 5.

1. Termination must be installed horizontally.

2. Refer to Figure 12b for installation details.

3. Wall thickness should be 3” to 14” thick.

4. Follow instruction for “vent termination location and clearances” explained on page 8.

5. Cut a rectangular opening with the following dimensions in the wall. Height: 5 Width: 12

⁄4”

6. Install the reducing rings on the inner facing side of the outside and inside termination plates (see figure 12b).

7. From outside of the wall, install outside termination plate using 4 screws. Make sure the louvers are at right side. Seal the plate perimeter with silicon.

8. Apply a bead of silicon around the outer surface of the outside termination plate air intake collar, about 1/2” from the edge. This will seal the air intake pipe to the air intake collar, in step #10.

9. From inside, install inside termination plate using 4 screws.

10. Cut the PVC or CPVC air intake pipe to the proper dimension to fit onto the air intake collar of the terminal. Slide the air intake pipe through the inside termination plate and onto the air intake collar, where the sealant was pre-applied in Step #8.

11. Assemble and seal straight screened termination to the slip joint connector.

12. From outside of the building, insert vent pipe (slip joint connector and termination assembly) through the 4” holes of the outside and inside termination plate.

From inside, proceed with air intake and vent pipe

13. installation. Follow vent manufacturer’s instructions and restrictions specified on page 7 of this manual.

Jaguar Model J-390

SUPPORT

FIRESTOPAND

PER FOOT MIN.

SLOPE UP

1/4 IN.

PIPE

ITH SCREEN

TORM COLLA R

STRAIGHT TERMINATION

FLASHING AND

180°ELBOW

WITH SC REEN

AIR INTAKE

4" DIA. PVC/CPVC PIPE FOR

SUPPORT

FIRESTOP AND

4" DIA PVC/CPVC OR STAINLESS STEEL MATERIAL FOR VENT

2" MIN.

10FT.MIN.

1FT.MIN.

1FT.MIN

B. DIRECT VENT - VENTING AND AIR INTAKE

THROUGH A ROOF

igure 13 shows typical vertical venting. The vent pipe must

ass through the ceiling, floor and the roof vertically through a

p 8” minimum diameter cutout. A fire stop is required for each ceiling and floor penetration. For roof passage an appropriate UL listed roof flashing must be used.

The vertical vent piping must terminate with a screened straight termination. The air intake termination should be a screened 180˚ elbow facing down.The air intake opening must

e at least 1 foot below the vent opening.

JAGUAR J-390 - DIRECT VENT, VENTING AND AIR INTAKE

THROUGH A ROOF

All joints must be liquid and pressure tight. Use 4” dia. PVC/CPVC schedule 40 pipe or U/L listed single wall 4" dia.

AL29-4C S.S.*. venting materials (See page 7).

or PVC/CPVC pipe, follow the proper assembly practices

pecified on page 7, and venting system restrictions specified

s on page 7 of this manual. For stainless steel venting systems, follow the vent manufacturer’s instructions and the restrictions specified on page 7 of this manual

Figure 13. Direct vent, venting and air intake through a roof.

** Definition of Snow Line: Knowledge of local conditions will reveal the maximum height that repeated snowfalls accumulate to. The height should be used as the SNOW LINE.

AL 29-4C IS A REGISTERED TRADEMARK OF ALLEGHENY LUDLUM CORP

NEUTRALIZING UNIT (IF REQUIRED)

CONDENSATE PUMP (IF REQUIRED)

DRAIN INSIDE BUILDING

PLASTIC TUBING

DRAIN VACUUM BREAKER, LEAVE OPEN

Jaguar Model J-390

VENTING AND AIR INTAKE SYSTEM REGULAR INSPECTION

A. Inspect the system regularly for condensation, corrosion,

sagging and/or physical damage. A qualified professional should service the boiler annually and include such an

nspection at that time. The homeowner should look over the

i system monthly for damage, water stains, any signs of rust, other corrosions or separation of the vent and air intake piping (if direct-vent).

B. Should an inspection turn up signs of condensation,

corrosion, sagging or damage, the boiler should be shut down immediately and the condition should be corrected by a qualified professional.

CONDENSATE REMOVAL SYSTEM

aguar J-390 boiler is equipped with a built-in condensation

The J drain and trap system. This system consists of two traps, one being dedicated to the condensate produced by the boiler, and another being dedicated to the condensate produced within the vent piping. (See page 13 for the location of each of the traps). Both of these traps must be filled with water. This is most easily accomplished by pouring water from a small container into the vent connector at the top of the boiler, before the vent pipe is attached, until the tubing loop trap in the rear of the boiler is visibly filled. DO NOT operate the boiler without filling the trap with water to prevent flue gas discharge into space. Periodic inspection should be made of this assembly for deterioration of the tubing and components, and to insure that the traps are not plugged. If any part is plugged or appears to have excessive sediment within, it should be removed from the drain assembly, have the obstruction cleared, refilled with water and reinstalled as before.

A 3/4” PVC tee assembly, located in the rear of the boiler jacket, is provided to run the condensate liquid from the boiler. Connect the plastic tubing that will be run to the drain to the bottom takeoff of the tee. Leave the top take-off of the tee open, to act as a vacuum breaker. If the building drain is above the bottom portion of the tee, a condensate removal pump will be required.This pump must have an overflow switch, and be compatible with the acidic condensate liquid, as must all fittings and the tubing used in this condensate removal system. (See Figure 14).

No part of the condensate removal system can be exposed to freezing temperatures, or any other conditions that could cause blockage. DO NOT run drain tubing to the outside of the building. In addition, certain jurisdictions or drain pipe materials may require a neutralization unit to be installed in the condensate removal system. Any piping other than plastic types will be subject to corrosion or deter

ioration from the acidic conden

sate, which may have a pH level as low as 3.0. A condensate filter containing lime, marble, or phosphate chips can neutralize the condensate to a pH level above 6.5, which is safe for all drain piping materials. (See Figure 14).The neutralizing filter medium will require periodic changing, to ensure it’s affectiveness. Replacing the medium on an annual basis is recommended, or refer to the manufacturer’s instructions for systems

hat are available for neutralizing condensate.

COMMONWEALTH OF MASSACHUSETTS SPECIAL REQUIREMENT

When the Jaguar J-390 is installed and used in the Commonwealth of Massachusetts, a neutralization unit MUST be installed in the condensate removal system.

GAS PIPING

A. Local installation codes apply.The pipe joint compound

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

he gas supply line to the boiler should run directly from the meter

B. T

A manual gas supply shut-off valve is provided on the boiler’s gas supply pipe. (See Figure 2, on page 3). Local codes may specify a manual main gas supply shut-off valve to be 5’ above the floor, and a disconnection union at the gas piping entrance to the boiler. In this case, the gas supply shut-off valve must be relocated to the specified location. If the gas supply pipe must be upsized for flow considerations, then the same size main gas supply shut-off valve must be used.

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 (Btu/cu. ft.).

3. Divide boiler rated input by heating value to find gas flow in piping (cu. ft. per hour).

4. Use table below to select proper pipe size.

EXAMPLE: Distance from gas meter to the boiler is 30ft. Heating value of natural gas is 1020 Btu/cu. Ft. Select proper pipe size.

Gas flow = 390,000 Btu/hr

= 382 cu. ft. per hour

1020 Btu/cu. ft.

Figure 14. Condensate disposal system

Jaguar Model J-390

t 30 ft. length of pipe, match required capacity from table on

his page (choose higher capacity, in this case is 590 cu. ft. per

t hour). Required pipe size is 1

mproper gas pipe sizing will result in flame outages, insuffi-

⁄4".

cient 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.

C. The boiler and its gas connection must be leak tested

before replacing the boiler in operation. Use liquid soap solution for all gas leak testing. DO NOT use open flame. This boiler and it’s individual shutoff valve must be disconnected from the gas supply piping system during and pressure testing of that system at test pressures in excess

⁄2 PSIG. This boiler must be isolated from the gas supply 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

⁄2 PSIG.

D. All gas piping used should be inspected thoroughly for

cleanliness before makeup. A sediment trap is required, as illustrated on page 3.

E. The minimum and maximum gas supply pressure (at the

inlet of gas valve) are shown on the boiler rating plate. 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.

Length of pipe in Feet

Gas Flow In piping -- cu. ft. per hr.

Iron Pipe Size (IPS) — inches

1/2

/4 11

11/2

10 132 278 520 1050 1600 20 92 190 350 730 1100 30 73 152 285 590 890 40 63 130 245 500 760 50 56 115 215 440 670 60 50 105 195 400 610 70 46 96 180 370 560 80 43 90 170 350 530 90 40 84 160 320 490

100 38 79 150 305 460

vity = 0.6.

At pressure drop of 0.3 in. w

, specific gr

ater

oiler must be electrically grounded in accordance with the

equirements of the authority having jurisdiction, or, in the

r absence of such requirements, with the National Electrical Code, ANSI/NFPA 70-latest edition.

Proper polarity is critical for the power supply connections. Reversed polarity will cause system lockout. Proper grounding is critical for boiler operation, connect the ground wire to the green ground screw next to the line voltage terminal

trip.

2. Circulator(s)

A set of terminals are provided for the boiler (primary loop) circulator. Only wire this circulator to these terminals, additional (secondary loop) circulators for space heating require the use of relays and a separate power source.

For multiple zoning, either zone valves or circulators maybe used.

For zone valve system (See Figure 16a).

For pump zoning system (See Figure 16b and 16c).

DO NOT use boiler transformer to power external accessories like zone valve and relays, overload and/or burned out transformer and boiler malfunction can result. Use separate transformer to power such components.

A second set of terminals are provided for the domestic hot water tank circulator (if used). The primary loop circulator is always de-energized when the DHW tank circulator is energized, for priority.

3. SPACE HEATING THERMOSTAT(S)

Install thermostat on an inside wall and away from any heat sources, sunshine and drafts. A set of terminals are provided for connection of 24 volt style thermostats, relays or zone valve end switches (isolated contacts). (See wiring diagram Figure 15a).

Thermostat heat anticipator: For a non-zoned system set thermostat heat anticipator to 0.1 Amps, for zoned system set to match power requirements of zone valves or relays. Refer to man see instr

uctions with ther

ufacturer’

s instructions and specifications. Also

mostat.

ELECTRICAL WIRING

All field wiring to the boiler is connected to the 2 sets of

minal str

ter

ips, located under the jacket top panel.

(See Figure 2, on page 3)

DANGER: Before wiring always turn off electric power supply. Otherwise, shock or death can result.

1. Power Supply

A separately fused circuit is recommended. Use standard 15 Amp. fuse or breaker and 14 gage conductors in BX

le or conduit.

cab

Provide disconnect means and overload protection as

am (Figure 15a) boiler

required.

See boiler wir

ing diag

control (Figure15b) and ladder diagram (Figure 15c).

4. DOMESTIC HOT WATER TANK THERMOSTAT

A set of terminals are provided for connection of the DHW tank thermostat (if used). (See wiring diagram Figure 15a).

5. OUTDOOR AIR SENSOR

A set of terminals are provided for connection of an outdoor air sensor (if this method is used). (See wir

ing diagr

Figure 15a).

Mount on

The outdoor air sensor m

ust be a 12k ohm type

. an outside wall, shielded from direct sunlight or flow of heat or cooling form other sources. See instructions provided with sensor.

6. LOW WATER CUTOFF

or connection of a LWCO. If

A set of ter this de

minals are pro

vice is used, remove the factory installed jumper from

vided f

these terminals. (See wiring diagram Figure 15a).

WIRE LEGEND:

CAUTION:

678

1 2 3 4 5 6

1 2 3

W W

DISPLAY

ROUND

1 2 3 4 5 6 7

LABEL ALL WIRES PRIOR TO DISCONNECTION WHEN SERVICING CONTROLS. WIRING ERRORS CAN CAUSE IMPROPER AND DANGEROUS OPERATION. "VERIFY PROPER OPERATION AFTER SERVICING".

COMBUSTION

BLOWER

OW WATER

CUT OFF

(

IF USED,REMOVE

-8 JUMPER)

12 Kohm

OUTDOOR

SENSER

(IF USED)

20V

60HZ

HOT

EUTRAL

BOILER

IRCULATOR

OWER

N/OFF

WITCH

FLUE GAS SENSOR

(1/4" TABS)

RETURN WATER SENSOR

(BLUE CONNECTOR)

UPPLY WATER SENSOR

(RED CONNECTOR)

WATER HIGH

LIMIT

(1/4" TABS)

3PIN

CONNECTOR

GAS VALVE

3PIN

CONNECTOR

HW TANK

THERMOSTAT

(

IF USED)

DHW

IRCULATOR

(IF USED)

120V/24V

TRANSFORMER

IELD WIRING

TERMINALS

4V ROOM THERMOSTAT

R ISOLATED CONTACT

J13

PROVIDE DISCONNECT MEANS & OVERLOAD PROTECTION AS REQUIRED. IF ANY OF THE ORIGINAL W IRE AS SUPPLIED WITH THE APPLIIANCE MUST BE REPLACED, IT MUST BE REPLACED WITH TYPE 105°C OR ITS EQUIVALENT.

FACTORY WIRED FIELD WIRED, FIELD SUPPLIED

CALL FOR HEAT"

Jaguar Model J-390

Figure 15a. Schematic wiring diagram.

Jaguar Model J-390

ARGUS VISION CONTROL

NOT

USED

NOT

USED

J12

J13

SPARK

IGNITOR

SPARK

CABLE

GROUND

FUSE

BOILER CONTROL

Figure 15b. Boiler Control.

GND

NEUTRAL

HOT

120V/60HZ

120V

10V

120V

24V

DISPLAY

WATER HIGH

LIMIT

"CALL FOR HEAT"

24V ROOM THERMOSTAT

DHW THERMOSTAT

(IF USED) OR SENSOR

LOW WATER CUT OFF

(IF USED) OR JUMPER

120V SECTION OF CONTROL BOARD

MICRO

PROCESSOR

ON CONTROL

BOARD

OUTDOOR SENSOR

(IF USED)

FLUE GAS

SENSOR

RETURN WATER

SENSOR

SUPPLY WATER

SENSOR

GAS

VALVE

BOILER ON/OFF

SWITCH

COMBUSTION

BLOWER

BOILER

CIRCULATOR

DHW CIRCULATOR

(IF USED)

SPARK

ELECTRODE

DISCONNECT

SWITCH

CHASSIS

GND

OR ISOLATED CONTACT

COMBUSTION

BLOWER

Jaguar Model J-390

Figure 15c. Ladder wiring diagram.

Jaguar Model J-390

END

SWITCH

TH-TR

MOTOR

T T T T T T T T T T T T T T

3 4 5 6

SPACE

HEATING

SYSTEM

CIRCULATOR

END

SWITCH

TH-TR

MOTOR

ZONE 2

THERMOSTAT

V8043E/F

END

SWITCH

TH-TR

MOTOR

ZONE 3

THERMOSTAT

V8043E/F

1 2 3 4 5 6 7 8

FIELD WIRING

TERMINALS

ON BOILER

JUMPER

R845A

RELAY

ZONE 1

THERMOSTAT

120V/24V

TRANSFORMER

POWER SUPPLY, P ROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION

AS REQUIRED.

MULTIZONING OF "JAGUAR" BOILER;

ZONE VA LVE SYSTEM USING V8043E/F ZONE VALVES AND R845A RELAY

DISCONNECT

SWITCH

V8043E/F

Figure 16a. Multizoning of Jaguar boiler; zone valve system.

1 2 3 4 5 6 7 8

FIELD WIRING

TERMINALS

ON BOILER

T T

3 4 5 6

T T T T

DISCONNECT

SWITCH

R845A

RELAY ZONE 3

CIRC.

ZONE 3

R845A

RELAY ZONE 2

CIRC.

ZONE 2

R845A

RELAY ZONE 1

CIRC.

ZONE 1

ZONE 3

THERMOSTAT

ZONE 2

THERMOSTAT

ZONE 1

THERMOSTAT

POWER SUPPLY, PROVIDE DISCONNECT

MEANS AND OVERLOAD PROTECTION

AS REQUIRED.

MULTIZONING OF "JAGUAR" BOILER;

PUMP ZONING SYSTEM USING R845A RELAY

2 3 4 5 6

Jaguar Model J-390

Figure 16b. Multizoning of Bobcat Jaguar; pump zoning system using R845A relay.

Jaguar Model J-390

DISCONNECT

SWITCH

120V/24V

TRANSFORMER

FIELD WIRING

TERMINALS ON BOILER

CIRC.

ZONE 3

THERMOSTAT

POWER SUPPLY, PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

MULTIZONING OF "JAGUAR" BOILER;

PUMP ZONING SYSTEM USING R882A/B RELAYS

CIRC.

ZONE 2

R882A/B

ZONE 2

THERMOSTAT

CIRC.

ZONE 1

R882A/B

ZONE 1

THERMOSTAT

120V/60HZ

1 2 3 4 5 6 7 8

POWER SUPPLY, PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DISCONNECT SWITCH

R845A RELAY

THERMOSTAT

CIRCULATOR

FIELD WIRING TERMINALS ON BOILER

1 2 3 4 5 6 7 8

POWER SUPPLY, PROVIDE DISCONNECT MEANS AND OVERLOAD PROTECTION AS REQUIRED.

DISCONNECT SWITCH

THERMOSTAT

CIRCULATOR

R 882A/B RELAY

120 V / 24 V TRANSFORMER

FIELD WIRING TERMINALS ON BOILER

Figure 16c. Multizoning of Jaguar boiler; pump zoning system using R882A/B relays.

Figure 16d. Single zoning of Jaguar boiler; pump zoning system using R845A relay.

Figure 16e. Single zoning of Jaguar boiler; pump zoning system using R882A/B relay.

Jaguar Model J-390

WATER PIPING

1. Connection of system to boiler:

rimary/secondary piping of the system is recommended, to

nsure the proper flow through the boiler. (See Figures 19

e through 21). The boiler loop piping must be the same diameter as the water outlet (supply) and inlet (return) piping connections provided on the boiler, particularly on longer loops. See page 2 for piping connection size.

2. Circulator Pumps:

The boiler loop piping must utilize the Taco 1400-20 circulator

hat is supplied with the boiler, to ensure the proper flow

hrough the boiler. Refer to Figure 18 for the boiler water side

t pressure drop and Table 2 for the recommended pump models for the domestic hot water system. Install the pumps in the orientation shown in Figures 19 through 21.

3. Relief Valve(supplied with boiler):

Tee the relief valve into the boiler water outlet (supply) piping as close to the water outlet (supply) connection as possible. (See Figure 17). The relief valve’s discharge piping must be the same size or larger than the relief valve’s outlet, and must terminate 6” minimum from floor with a plain (no threads) end. Place a bucket under pressure relief valve discharge. Make sure discharge is always visible. DO NOT hard-pipe to drain piping, or any place where freezing could occur. No shut-off valve is permitted between the relief valve and boiler, or in the discharge line.

4. Air Control System:

An appropriately sized diaphragm-type expansion tank must be used to control the system pressure. See boiler volume data on page 2, and the recommended location in Figures 19 through 21. An air vent is recommended to be installed on an air separator in close proximity to the expansion tank.

5. Cold Water Fill:

A pressure reducing (fill) valve, with a shut-off valve upstream of it, should be installed in close proximity of the expansion tank. (See Figures 19 through 21). Use a back flow check valve in the cold water supply as required by local codes.

Low Water Cutoff:

On a hot water boiler installed abo must be provided with a low water cutoff device at the time of installation by the installer (see Figure 17 for piping arrangement).

ve radiation level, the boiler

7. Water Treatment and Freeze Protection:

A good water treatment program will not only extend the useful life of this boiler but it will also save much of the time

nd expense of repairs made necessary by preventable

ccurrences. A reputable water treatment company should be

o consulted to evaluate and determine the best overall treatment program for your boiler equipment.

The heat exchanger is made of aluminum, so the system water must be maintained between 7.0 and 8.5 PH level.

horoughly flush the system, before connecting the boiler, to

emove any sediment or glycol.

Anti-freeze is sometimes used in hydronic systems to protect against freeze-up in the event of power failure or boiler shut down in the cold winter.

(Propyleneglycol with Pro-Tek 922 inhibitor) by Rhomar Water Management, Inc.

instructions for proper application and proper mixture for

um ambient temperature.

minim

other than that supplied by Slant-Fin or specifically approved and/or recommended for use by Slant-Fin will void this warranty. Never use Ethylene Glycol as it is toxic to humans.

Never use any types of automotive or standard gylcol freeze protection fluids.

8. Piping a heating - cooling system to a water boiler and chiller:

Figure 21 illustrates a method of piping a heating-cooling system to a water boiler and a chiller. Hand valves (shown) or automatic valves must be installed to prevent circulation of chilled water in the boiler or hot water in the chiller.

The air control system and pressure control system must operate with chiller only, or the boiler only, being valved to the piping system. Separate control devices on the boiler and chiller may be used, or a single set of air and pressure controls on the common piping may be preferred.

If the boiler is used to supply hot water to heating coils in air handling units, flow control valves or other devices must be installed to prevent gravity circulation of water in the coils during the cooling cycle.

Follow the manufacturer’s

Use RhoGard

y use of anti-freeze

Jaguar Model J-390

PIPING ORIENTATION FOR REFERENCE ONLY.

WATER OUTLET PIPING TO REST OF THE SYSTEM

PROBE TYPE LOW WATER CUTOFF (IF REQUIRED)

PRESSURE RELIEF VALVE (SUPPLIED WITH BOILER)

1 1/4" x 1 1/4" x 3/4" NPT TEE

3/4" NPT STREET ELBOW

1 1/4" NPT STREET ELBOW

WATER OUTLET (SUPPLY) PIPE 1 1/4" DIAMETER

WATER INLET (RETURN) PIPE 1 1/4" DIAMETER

RELIEF VALVE DISCHARGE PIPING

1 1/4" NPT TEE

INSTALL MANUAL MAIN SHUTOFF VALVE 5' ABOVE FLOOR, WHEN REQUIRED BY LOCAL CODE

GAS SUPPLY VALVE

SEDIMENT TRAP

1 1/4" X 1/4" NPT REDUCER BUSHING

PRESSURE & TEMPERATURE GAUGE *

(SUPPLIED WITH BOILER) LOW WATER CUTOFF MANIFOLD (IF LWCO UTILIZED)

Gauge must face front of boiler, in clear view

Figure 17. Relief v

alve, pressure/temperature gauge and low water cutoff installation.

PRESSURE DROP

Boiler heat los

ORIGINAL

gpm Feet w .c DATA

28 16 14.53

23.4 11.77 11.77

20.04 9 8.77

17.55 7.38 7.38

14.04 5.3 5.3

11.7 4.2 3.46 0

column modif ied

/25/2007

JAGUAR

0 5 10 15 20 25 30

low Rate (GPM)

Head

(feet w.c.)

Figure 18. Boiler water side pressure drop

Jaguar Model J-390

Flow Rate

(gpm)

28.0 25˚ 16 6.5

23.5 30˚ 11.5 6.0

20.0 35˚ 8.5 5.5 9.0 18.0 32.0

17.5* 40˚ 7.0 5.0 11.5 21.5 35.0

able 2. Jaguar boiler recommended pump models for domestic hot water tank piping.

Notes:

*** Refer to the DHW Tank Manufacturer’s water flow rate requirements and associated pressure drop head loss, to select

Available Head Capability for Various Model

Circulators to Overcome DHW Tank Head Loss

(Feet w.c.) ***

(2 in series)

Taco 1400-20 Taco 1400-45 Taco 1400-20

Not Recommended

4.5 9.5

11.5 20.5

Temp

Rise

(˚F)

Boiler

Head

Loss

(Feet w.c.)

Domestic Water

Tank Piping

Head Loss **

(Feet w.c.)

* This is the minimum flow rate recommended for Jaguar boiler.

Domestic w

ater tank piping head is based on 1” inside diameter piping and full port valves.

the appropriate circulator.

▲ If 2 circulators are specified, they must be piped in series in order to provide the head capacity shown. Power to

circulator(s) must be supplied through an appropr

iate relay to protect the boiler control’s fuse.

▲

Jaguar Model J-390

SOLATION

VALVE

OILER LOOP

URGE/

VALVE

RAIN

HE BOILER)

CIRCULATOR (SUPPLIED WITH

SOLATION

ALVE

FLOW CHECK VALVE

igure20.Zoningw ithcirculators.

.592

ISOLATION

VALVE

DONOTEXCEED

12"APAR

FROM REST OF SYSTEM

FLOWCHECK

VALVE

SPACEHEAT

ZONE#

ADDITIONA

ZONES

AIRVENT

ZON

CIRCULATO

BOILERWATER

INLET(RETURN)

VALVE

FLOWCHECK

RELIE

VALVE

BOILERWATER

OUTLET(SUPPLY

)

DHW

CIRCULATO

ISOLATION

VALVE

(DIAPHRAMTYPE

)

EXPANSIONTANK

T+P

VALVE

RELIE

BACKFLO

PREVENTOR

(IFREQUIRED

)

PRESSUR

REDUCIN

VALVE

SHUTOFF

VALVE

HOTWATE

OUTLE

AIRSEPARATO

OREST

OF SYSTEM

MAKEU

WATER

SUPPL

ISOLATION

VALVE

DRAINVALV

COL

WATER

INLET

TAN

HOTWATE

DOMESTI

SHUTOFF

VALVE

Figure 19. Zoning with circulators.

ISOLATION VALVE

OILER LOOP

URGE/

VALVE

DRAIN

THE BOILER)

CIRCULATOR (

SUPPLIED WITH

ISOLAT ION VALVE

FLOW CHECK VALVE

Figure20.Zoningwithcirculators.

8.592

ISOLATION

VALVE

DONOTEXCEED

12"APAR

SPACE HEAT

ZONE #1

DDITIONAL

ZONES

AIRVENT

BOILERWATER

INLET(RETURN)

VALVE

FLOWCHECK

RELIE

VALVE

BOILERWATER

OUTLET(SUPPLY

)

DHW

CIRCULATO

ZON

VALVE

(DIAPHRAMTYPE

)

EXPANSIONTANK

T+P

VALVE

RELIE

BACKFLO

PREVENTOR

(IFREQUIRED

)

PRESSUR

REDUCIN

VALVE

SHUTOFF

VALVE

HOT WATER

OUTLET

AIRSEPARATO

MAKE UP

ATER

SUPPLY

ISOLATION

VALVE

DRAINVALV

COLD

WATER

INLET

TANK

HOT WATER

DOMESTIC

SHUTOFF

VALVE

PRESSURE BYPASS VALVE (IF USED )

DIFFERENTIAL

SYSTEM C

IRCULATOR

Jaguar Model J-390

Figure 20. Zoning with zone v

alves.

Jaguar Model J-390

HILLER

ATER

VALVE

UNIT

STRAINER

INLET (RETURN)

BOILER WATER

CIRCULATOR

BOILER LOOP

VALVE

SOLATION

2" APART

ONOTEXCEED

DRAIN VALVE

URGE/

VALVE

SHUTOFF

VALVE

RELIEF

T+P

VALVE

ISOLATION

DRAIN VALVE

DOMESTIC

HOT WATER

TANK

OUTLET

HOT WATER

DRAIN VALVE

INLET

WATER

COLD

CIRCULATOR

DHW

OUTLET (SUPPLY)

BOILER WATER

THE BOILER)

FLOW CHECK VALVE

(SUPPLIE D WITH

VALVE

ISOLATION

Figure20.Zoningwithcirculators.

8.592

VALVE

RELIEF

VALVE

ISOLATION

VALVE

FLOW CHECK

EXPANSION TANK (DIAPHRAM TYPE)

VALVE

ONES

DDITIONAL

ZONE

SPACE HEAT

ZONE #1

AIR SEPARATOR

VALVE

REDUCING

PRESSURE

(IF REQUIRE D)

PREVENTOR

BACK FLOW

IFFERENTIAL

VALVE (IF US ED)

PRESSURE BYPASS

SUPPLY

WATER

MAKE UP

VALVE

SHUTOFF

ISOLATION

FLOW CHECK

SYSTEM CIRCULATOR

AIR VENT

ALANCING

VALVE

Figure 21. Piping a heating-cooling system to the boiler and a chiller.

OPERATING INSTRUCTIONS

I. FILLING AND VENTING WATER SYSTEMS

Jaguar Model J-390

. While “t” is blinking, DHW tank temperature may be

et to desired temperature (if tank is equipped with

s sensor). The setting range is between 104˚ to 185˚F.

. Fill the system with water. Vent or purge of air.

B. Fire the boiler as soon as possible (see following warning

and instructions) and bring water temperature in the system.

C. Vent air and add water as needed to achieve operating

pressure on boiler gauge. Pressure must be between

pproximately 12 psi (cold water) and 25 psi at water

emperature setting of high limit control, for boilers

t equipped with 30 psi relief valves. Boilers rated for a higher pressure and equipped with a matching relief valve may operate at a higher pressure, but no higher than 5 psi

w the relief valve opening pressure.

belo

D. Check for and repair any leaks before placing system in

service.

BEFORE FIRING BOILER, make these checks:

Before firing boiler, review the “Boiler Control and Display Features” section of this manual. Understanding the features and programming the applicable parameters is essential for setting up the boiler to operate properly on the heating system it is installed on.

1. System is full of water. Air is vented or purged.

2. Relief valve is installed in accordance with ASME Boiler and Pressure Vessel Code, Section IV. Valve opening is not closed or reduced in size.

3. Venting is installed according to instructions under “FLUE GAS VENTING REQUIREMENTS”.

4. View actual boiler supply & return water temperature, domestic hot water tank temperature (if tank equipped with sensor), flue temperature and outside temperature (if outside sensor is used) on “Temperature Display” by selecting 1, 2, 3, 4, or 5 on

Mode Display”.

“

• These numbers are steady on display and are

not settable.

• All sensor inputs to the control must be

connected to a 12k ohm sensor.

Viewing and changing system setting:

A trained, experienced service technician or installer should perform following adjustments. See table 5 for details.

1. Space heating and DHW post pump time may be changed.

2. Space heating and DHW modes may be chosen.

3. Weather compensation slope and set point temperature may be changed (if outside sensor is used). (See Figure 23 for graph).

4. Read actual blower RPM

5. Adjust blower RPM for high and low input adjustment.

6. Read flame current in micro amp.

7. Run boiler on high, low or ignition input steady for 20 minutes for test purposes.

Display and push buttons:

4. All wiring is completed, following applicable wiring diagrams.

5. Using soap solution, check for gas leaks in all gas piping from meter to boiler gas supply pipe flame.

II. BOILER CONTROL AND DISPLAY FEATURES

(See Figure 23)

A. Boiler Operation Status:

“Mode Display” shows status of boiler operation (see table 3).

View and Changing Temperatures:

Setting boiler supply w temperature (see table 4). Press “Select” button for viewing following different modes on “Mode Display”

1. While “c” is blinking, boiler supply water temperature for space heating may be set to desired temperature The setting r

“d”

While

2. for DHW may be set to desired temperature. The setting range is between 104˚ to 185˚F.

ater temperature and water tank

ange is betw

linking, boiler supply w

is b

DO NOT use open

een 90˚ to 185˚F

ater temper

ature

1. Reset - Used to clear a Lock out error (indicated with an

“A” in the “Mode Display”).

Select - Used to scroll through the modes in the “View

2. and Changing Temperatures” and “Viewing and Changing System Setting” men

Enter - Used to store values that are changed in the “View

3. and Changing Temperatures” and “Viewing and Changing System Setting” menus.

Up- Used to increase v Temperatures” and “Viewing and Changing System Setting” menus.

wn -

Changing Temperatures” and “Viewing and Changing System Setting”

Used to decrease v

us.

alues in the “View and Changing

alues in the “View and

men

Jaguar Model J-390

"TEMPERATURE" DISPLAY (3 DIGITS)

"UP" PUSH BUTTON

"DOWN" PUSH BUTTON

"ENTER" PUSH BUTTON

"SELECT" PUSH BUTTON

"BURNER STATUS"

STEADY DOT = BURNER ON

BLINKING DOT = BURNER OFF

"MODE" DISPLAY

"RESET" PUSH BUTTON

Table 3

Table 1

Table 3

Figure 22. Display Board

MODE

DISPLAY

Table 3

JAGUAR BOILER DISPLAY BOARD

“Boiler Operation Status”

DESCRIPTION & TEMPERATURE DISPLAY

Boiler is on stand-by mode.

Temperature display shows supply water Temp.

Space heating mode.

Temperature display shows supply water Temp.

Domestic hot water mode.

Temperature display shows supply water Temp.

emper

Reset button must be pressed to resume normal operation.

Temperature display indicates the error code.

Frost protection mode. **

Lockout (Alarm) condition.

ature Display indicates the lockout code

Error Condition. *

Warning Condition. ***

TE:

Blinking dot on Steady dot indicates b

Error m

The boiler loop circulator is energiz

**:

Error m

***:

the “Reset” button is not required.

“Mode Displa

ust be corrected to resume boiler oper

ust be corrected to resume DHW oper

ner is on.

indicates activ

y”

e heating control, b

Pressing the

ation.

ed, if the boiler w

ater temper

Space heating not aff

ation.

urner off.

“Reset”

ature drops belo

utton is not required.

w 50˚F

Pressing

ected.

able 1

able 3

Table 1

Table 3

able 1

able 3

Table 3

able 3

Table 3

Jaguar Model J-390

Table 4

VIEWING AND CHANGING TEMPERATURES

Press “SELECT” button for viewing different modes on “MODE DISPLAY”

ODE

DISPLAY

Space heating supply water temperature could be changed by

blinking

Domestic hot water supply temperature could be changed by

blinking

DESCRIPTION & TEMPERATURE DISPLAY

pressing “Up/Down” button. Settable from 90˚F to 185˚F

(steps of 1 F). The default value is 176˚F.

Press “Enter” button to store.

(see note 1)

pressing”Up/Down” button. Settable from 104˚F to 185˚F

(steps of 1 F). The default value is 176˚F.

Press “Enter” button to store.

(see note 2)

Domestic hot water tank temperature could be changed by

pressing “Up/Down” button. Settable from 104˚F to 160˚F

(steps of 1 F). The default value is 140˚F.

Press “Enter” button to store.

(see note 3)

NOTE:

Temperature display shows actual supply water temperature.

Temperature display shows actual return water temperature.

Temperature display shows actual DHW tank temperature.

(if the water tank is equipped with sensor).

Temperature display shows actual flue gas temperature.

Temperature display shows actual outside temperature.

(if outdoor sensor is used)

or space heating mode “0”

1- F 2- For DHW mode “2” (storage tank with Aquastat) 3- For DHW mode “1” (storage tank with sensor)

(boilers not utilizing outdoor sensor))

Jaguar Model J-390

Table 3

VIEWING AND CHANGING SYSTEM SETTING - Table 5

“To change system setting or perform system test”

he menu is accessed by pressing and holding “SELECT” and “ENTER” buttons for 10 seconds. To change

WARNING: Only a trained, experienced service technician or installer should use this table.

system setting: Press “UP or DOWN” button, then press “ENTER”

MODE DISPLAY

DESCRIPTION

Changing space heating post pump time. Settable from 10 to 900 seconds.

(steps of 10 seconds). The default value is 30 seconds.

Changing DHW post pump time. Settable from 1 to 255 seconds.

(steps of 1 seconds). The default value is 15 seconds.

hanging space heating control mode

0: Thermostat only (default) - boiler without outdoor sensor

: Outside sensor and Thermostat

Outside sensor only

2: 3: Permanent heat demand (boiler circulator always on)

hanging domestic hot water (DHW) mode

0: No DHW 1: Storage tank with sensor 2: Storage tank with thermostat (default value)

Plate heat e

Changing DHW or space heating priority mode

0: DHW priority (no time limit) 1: Space heating priority (no time limit) 2: DHW priority for limited time (default) 3: Space heating priority for limited time

Changing priority limited time. Settable from 20 to 80 minutes.

Boiler model selection, value is 5 for model J-390

xchanger

The default value is 30 minutes.

(space heating mode 1 or 2). Settab

Changing weather compensation set point (space heating mode 2 only).

Change blower RPM for high input (steps of 30 RPM, limit +/- 480 RPM).

Change blower RPM for low input (steps of 30 RPM, limit +/- 120 RPM).

Boiler model confirmation, value is 5 for model J-390

Weather compensation supply water reference temperature

The def

Changing compensation slope (space heating mode 1 or 2).

Displa

Settable from 0.1 to 5.0 (steps of 0.1).

The default value is 1.0.

Settable from 32˚F to 122˚F (steps of 1˚F).

y sho

System test – Display shows flame current

The default value is 68˚F.

ws blower RPM (mutiply reading by 10 for actual RPM)

Display shows flame current in micro amps

0: System test off L: Steady low input (20 minutes) I: Steady ignition input (20 minutes) H: Steady high input (20 minutes)

le from 16˚F to 122˚F (steps of 1 F).

alue is 86˚F.

ault v

Not Utilized

NOTE: *: Alternating **: Steady

70 60 -20-10 -3001020304050

Outdoor Temp. (°F)

Water

Supply

Target Temp.

(°F)

185 °F

140

150

130

190

180

170

160

120

110

100

(

)

(

)

-40

(

)

ximum water target temp.

Water reference temp.(default of86°F)

Minimum

watertarget

temp.

68°F

Jaguar Model J-390

Figure 23. Space Heating mode with outside sensor water set point graph.

Jaguar Model J-390

AS SUPPLY SHUTOFF VALVE

IN "OPEN" POSITION

AS SUPPLY SHUTOFF VALVE

IN "CLOSED" POSITION

URN 90˚

TO CLOSE

TURN 90˚ T

O OPEN

III. INITIAL START

Safe lighting and other performance criteria were met when testing various gas manifold and control assemblies used on the Jaguar J-390 boiler under the ANSI Z21.13 - latest edition.

Instructions

Follow the lighting instructions in this manual.These instructions are also attached to the boiler.

. Use only your hand to turn the gas supply shut-off valve.

Never use tools. If the supply shut-off valve will not turn 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.

OPERATING INSTRUCTIONS

STOP! Read the safety information above.

2. Set the thermostat to lowest setting.

3. Turn off all electric power to the appliance.

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

Figure 24. Gas supply shutoff valve operation.

SAFETY INFORMATION

For Your Safety Read Before Operating

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

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

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

BEFORE OPERATING smell all around the appliance area

for gas. Be sure to smell next to the floor because some gas

vier than air and will settle on the floor

is hea

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

•

If you cannot reach your gas supplier, call the fire

tment.

depar

5. Open the gas supply shut-off valve, by turning the handle to be parallel to the gas piping (See Figure 24).

6. Wait five (5) minutes (longer for propane) to clear out any gas, then smell for gas, including near the floor. If you then smell gas, STOP! Follow “B” in the safety information above on this page. If you don’t smell gas, go to next step.

7. Turn on all electric power to the appliance.

8. 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

1. Set thermostat to lowest setting.

n off all electric po

ormed.

be perf

er to the appliance if ser

vice is to

3. Close the gas supply shut off valve, by turning the handle to be per

pendicular to the gas piping. (See Figure 24).

Jaguar Model J-390

JAGUAR MODEL J-390 SEQUENCE OF OPERATION

THERMOSTAT CALLS FOR HEAT

CIRCULATOR(S) ON

COMBUSTION BLOWER ON

(AT MEDIUM SPEED)

CONTROL LOCKOUT

DISPLAY SHOWS

ERROR “A 33”

CONTROL LOCKOUT

DISPLAY SHOWS

ERROR “A 03”

BLOWER SPEED CONFIRMED?

YES

5 SECOND PRE-PURGE

TRIAL FOR IGNITION - 6 SECONDS

SPARK IGNITOR ENERGIZED

GAS VALVE OPENS

WATER HIGH LIMIT CLOSED?

YES

GAS VALVE REMAINS OPEN

FOR 4 SECONDS

PERIOD

3 TRIALS FOR

IGNITION

WITH NO FLAME SENSED?

2 TIMES RETRIALS

FOR IGNITION

CONTROL LOCKOUT

DISPLAY SHOWS

ERROR “A 01”

YES

SPARK IGNITOR DE-ENERGIZED

FLAME SIGNAL SENSED?

YES

GAS VALVE REMAINS OPEN. CONTROL

CONTINUOUSLY MONITORS

, HIGH LIMIT, WATER

THERMOST

SENSORS, BLOWER SPEED, FLAME

SIGNAL, AND LWCO (IF USED).

THERMOST

10 SECOND

15 SECOND

CALL FOR HEAT ENDS

CLOSES

GAS

POST PURGE.

WER

BLO

CIRCULATOR POST PURGE.

GAS VALVE CLOSED.

BLOWER POST PURGE

10 SECONDS.

Jaguar Model J-390

INLET PRESSURE TAP

OUTLET PRESSURE TAP

GAS VALVE

VENTURI

COMBUSTION BLOWER

GAS PIPE

OFFSET ADJUSTMENT SCREW (BELOW CAP)

IV. CHECK COMBUSTION AND FUEL INPUT RATE

A. Start and run the burner at the high firing rate, by using the

“System Test” mode in the “View and changing system setting” menu. Refer to Table 5 on page 33.

1. Measure the CO, and CO2of the flue gas. A flue sample port is provided in the vent pipe (See Figure 2 on page 3). The CO should not exceed 100 ppm, when the combustion is correct. The CO2 is not field adjustable, and should be in the range of 8.5% to

9.5% (9.0% is the nominal reading). Record the actu-

l high firing rate CO2, as it will be used as a refer-

nce in setting the low firing rate CO2 (in Step B).

2. Once the correct combustion is confirmed at the high firing rate, check the fuel input rate on the gas meter.

BTUH INPUT = cu. ft. metered in 3 minutes x

* The higher heating value of the gas can vary for

different localities. Consult the gas supplier for this value in BTU/cu.ft.

3. If the fuel input is not at the rate specified on page 2 at the high firing rate, then the blower speed should be adjusted to attain the specified input rate. This can be done by using the “Change blower RPM for high input” mode in the “View and changing System Setting” menu. Refer to Table 5 on page 33. Increasing the blower rpm will increase the fuel input rate, and decreasing the blower rpm will decrease the fuel input rate.

B. In the “System Test” mode in the “View and Changing

System Setting” menu, use the “down” push button to switch to the low firing rate. Refer to Table 5 on page 33.

1. Measure the CO and CO2of the flue gas. The CO should not exceed 30 ppm, when the combustion is correct. The CO high firing rate CO2(recorded in Step A). If this reading is obtained, then proceed to Step 4.

heating value of the gas* x 20

should be 0.2% lower than the

2. If the CO2is not 0.2% at the low firing rate, then the gas valve needs to be accessed for proper adjustment. Remove the boiler jacket top cover, 3 front cover panels, and enclosure front cover (see figure 2 on page 3 for locations.

3. Remove the cap that covers the gas valve offset screw (see figure 25 for location). Adjust the low fire CO2to be 0.2% lower than the recorded high fire CO2. Turn the offset clockwise to increase the CO

alue. Turn the offset counter-clockwise to decrease

he CO

ent is complete.

4. Once the correct combustion is confirmed at the low firing rate, check the fuel input rate of the gas meter. BTUH Input = cu. ft. metered in 3 minutes x heating valve of the gas * x 20.

5. If the fuel input is not at the rate specified on page 2 at the low firing rate, then the blower speed should be adjusted to attain the specified input rate. This can be done by using the “Change blower RPM

or low input” mode in the “View and changing

f System Setting” menu. Refer to Table 5 on page 33. Increasing the blower rpm will increase the fuel input rate, and decreasing the blower rpm will decrease the fuel input rate.

6. Replace the boiler enclosure front cover, 3 jacket front cover panels, and top cover (see figure 2 on page 3 for locations).

C Exit the “System Test” mode, once the combustion and fuel

input rate has been checked and adjusted, if necessary. Refer to Table 5 on page 33.

alue. Replace the offset cap when adjust-

Figure 25. Gas valve adjustment.

Jaguar Model J-390

. SAFETY CHECK

A. Check for gas leaks:

Using soap solution, check for gas leaks from meter to gas valve including all pipes and fittings and gas valve connections. Use liquid soap solution for all gas testing. DO NOT use open flame.

Thermostat Test:

et thermostat setting to low enough to end call for heat.

as valve should close and burner should stop firing.

lower and circulator pump should go into a post purge,

B then shut off.

A. LOCKOUT ERRORS: Indicated by an “A” in the mode display.The reset button must be pressed to clear the error

and retry operation. The temperature display shows the error code.

ontrol Safety Shutdown test:

ith the burner firing, disconnect the spark cable from the

W spark ignitor. Gas valve should close and burner should stop firing. The boiler will try for ignition three times after this, then should lock out with an “A 01” error shown on the display. Reconnect the spark cable to the spark ignitor, and press the “Reset” button to return to normal operation.

I. DIAGNOSTIC ERROR CODES

ARNING:

should perform troubleshooting. Turn off all electric power to the boiler before service.

nly a trained, experienced service technician

ERROR CODE INDICATION REMEDY

Check for steady sparking at electrodes. If spark not steady - check spark gap to be .125”, clean or replace spark ignitor, check power supply voltage and grounding. If spark is steady - check for proper gas supply pressure.

Ignition Failure - 3 unsuccessful

ignition attempts in a row.

Check combustion, if able to ignite, or replace gas valve.

04, 05, 09, 10, 12, 13, 14, 15,

16, 18, 32

19, 20

Flame Failure - 3 losses of flame

signal during one demand.

Water High Limit Open

Control Failure

Flame Detected at

ailure - RPM error

an F

Wrong

Time

Check for proper combustion, at both max. and min. input firing rates. If combustion is within the range specified on page 37, clean or replace spark ignitor, check power supply voltage and grounding.

Check to see if the water outlet temperature reaches 203˚F. If it does, replace the water outlet 12k ohm sensor. If it does not, replace the water high limit switch.

Replace control board. Make sure the proper boiler model selection and confirmation code is entered. See Table 5 on page 33.

If a flame is still observed after a call for heat is stopped,

If the burner seems to be shutting

replace the gas v

alv

down properly, replace the spark ignitor.

Check wire harness connections going to the blower. Replace blower.

Jaguar Model J-390

B. BLOCKING ERRORS: Indicated by an “E” in the mode display. Operation is automatically restored, once the

condition returns to normal or is fixed. The temperature display shows the error code. Pressing the “Reset”

utton is not required.

ERROR CODE INDICATION REMEDY

Check wire harness connections going to the

Water Outlet Sensor Open

Water Inlet Sensor Open

Flue Gas Sensor Open

sensor. Replace the sensor.

Check wire harness connections going to the sensor. Replace the sensor.

11 12 13

19, 42, 45,

46, 47, 48

Water Outlet Sensor Shorted Replace the sensor.

Water Inlet Sensor Shorted Replace the sensor.

Flue Gas Sensor Shorted Replace the sensor.

Replace control board. Make sure the proper

Control Failure

Flame Detected at Wrong Time

Polarity Error Reverse the hot and neutral power supply wires.

Frequency Error

Earth Connection Faulty Check grounding of control and boiler chassis.

boiler model selection and confirmation code is entered. See Table 5 on page 33.

If a flame is still observed after a call for heat is stopped, replace the gas valve, If the burner seems to be shutting down properly, replace the spark ignitor.

Check power supply frequency to be 60 hz, certain power supplies may not provide the proper frequency

contin

ued on pa

e 39

continued from page 38

ERROR CODE INDICATION REMEDY

Check flue gas temperature, at the maximum firing rate and high water temperature. If the flue gas

Excess Flue Temperature

Low Water Cutoff Error

Excess Water Inlet Temperature

temperature reaches 212˚F, check the fuel input rate and combustion. Check the condition of the heat exchanger. If the flue gas temperature does not reach 212˚F, replace the flue sensor.

If a low water cutoff is installed, check the system water pressure and content. Check the condition of the LWCO. If no LWCO is installed, check the jumper is in place at the wiring terminal board. See Figure 15a on page 18.

Check that the wire harnesses to the water inlet and outlet sensors are not reversed.The water inlet sensor harness should have a blue colored connector, the water outlet sensor harness should have a red colored connector. Check that the pumping flow direction is correct.

Jaguar Model J-390

ARNING ERR

C. W

ed, and the warning is displayed intermittently. Operation of the DHW mode is automatically restored, once the condition is fixed. The temperature display shows the error code. Pressing the “reset” button is not required.

ORS:

Indicated b

Domestic Hot Water Tank Sensor Open

Reset Button Error

Boiler Model Selection Error

“H” in the mode display

y an

Domestic Hot Water Tank

Sensor Shorted

Try turning power supply off and on again. If error returns, replace the display board.

Check that the proper boiler model selection and confirmation code is entered in the display. See Table 5 on page 33.

Operation of the space heating mode is not aff

If sensor is utilized, check wire harness connections going to the sensor sor is utilized, check the proper DHW mode is pro-

ammed.

If sensor is utilized, replace the sensor. If no sensor is utiliz grammed. See Table 5 on page 33.

See Table 5 on page 33.

ed, chec

, or replace the sensor

k the proper DHW mode is pro

. If no sen-

ect-

Jaguar Model J-390

CARE AND MAINTENANCE

This section must be brought to the attention of the owner by the installer so that the owner can make the necessary arrangements with a qualified service agency for the periodic care and maintenance of the boiler.The installer must also inform the owner that the lack of proper care and maintenance of this boiler and any fuel burning equipment may result in a hazardous condition. Installer should discuss contents of the User’s Information Manual (Publication J-UIM) with the owner.

A trained and qualified service technician should perform the inspection listed in these instructions before each heating season and at regular intervals.

I. GENERAL MAINTENANCE

A. Safety check, see page 38.

B. Vent and air intake system inspection

1. Check for obstruction, condensation, corrosion and physical damage.

2. Check outside termination. Screen and louvers should be free of any debris and must be cleaned as required.

3. Perform “Venting and Air intake System Regular Inspection”, see page 16.

C. Piping

Check the following:

1. Water piping and accessories for leaks. Slightest leaks should be corrected.

2. System to be full of water and pressure to remain stable at correct setting on gauge.

B. Check venting system. See “Venting and Air Intake System

Regular Inspection” on page 16.

C. Check condensation drain trap to be full of water. Check for

deterioration of the tubing. Check that the trap is not plugged.

. The combustion blower does not require or have provisions

or lubrication.

E. If required, lubricate the circulator as per the manufacturer’s

instruction.

III. CLEANING

A. Heat Exchanger: In the unlikely event of flue passage or

water passage blockage, service to remedy situation must be performed only by an authorized Slant/FIn representative.

Burner: In the unlikely event of blockage or deterioration,

service to remedy situation must be performed only by an authorized Slant/Fin representative.

IF REPLACEMENT PARTS ARE NEEDED

When parts are needed, refer to boiler model and serial number shown on the boiler name/rating plate. Refer to publication number J-10PL replacement parts for part numbers. 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 control and parts should be identified by and ordered form Slant./Fin. Relief/Safety valves must be ASME rated for the pressure and gross output of the boiler.

3. Air-control system. Noise and air binding in radiation should not occur.

4. Low water cutoff for operation (see instruction furnished with unit).

D. Boiler Room Air Supply

Check air vents for continuous positive supply of air as required. installation is non-direct vent method. Air vents must open and free of obstruction.

WARNING: The flow of combustion and ventilating air to the

II. INSPECTION DURING HEATING SEASON

A. Check water pressure regularly and add water slowly to

system when needed. If m necessary indicate either a system leak, or a f a faulty automatic fill valve.

Air needs are greatest in cold weather if boiler

boiler should not be obstructed.

enting ma

Regular loss of w

uch water is added, v

ater from boiler system may

aulty air control system, or

For replacement parts, heating contractors should contact their Slant/Fin boiler distributor.

y be

Jaguar Model J-390

GENERAL TROUBLESHOOTING GUIDE FOR SERVICE PERSONNEL

WARNING: Only a trained, experienced service technician should perform troubleshooting.

Turn off all electrical power to the boiler before servicing.

A. BURNER FAILS TO OPERATE - NO HEAT

USE REMEDY

1. No power, display off, power switch off. Main electric 1. Close switch. Check or replace fuse. switch open. Blown or defective line fuse.

2. Gas supply valve shut off. 2. Open gas supply valve. Check gas pressure.

3. Harnesses plug-in connectors are not securely connected. 3. Check connectors on boiler control.

4. Operational problem, detected by control. 4. Error code on display can be correlated to

specific problems and remedy. Refer to page 38-40 for error codes.

B. NOT ENOUGH HEAT

1. Thermostat setting is too low. 1. Set thermostat at higher setting.

2. Boiler water maintained at too low temperature. 2. Increase space heating set point temperature.

Refer to Table 4 on page 32.

3. Circulator not running. 3. With thermostat calling for heat, check for power

to circulator. If power is O.K. but circulator is not running, replace circulator.

4. Boiler water level too low. 4. Carefully snap open relief valve handle to

determine if boiler is full of water, if not full of

, check for system leaks and check water

ater

w pressure regulator. Repair any system leaks. Adjust or replace water pressure reducing valve.

5. Fuel input rate too low. 5. Check the maximum fuel input firing rate.

Refer to page 37 for the procedure.

C. FUMES AND GAS ODORS

1. Leaks in gas piping or accessories. 1. Locate leaks and repair.

2. Gas leaks in service line or meter connections. 2. Close service supply valve - shut down boiler

and notify utility.

3. Condensation traps are not full of water. 3. Check and fill with water

4. Venting system is physically damaged. 4. Check carefully and repair. Also, see “Venting

System Regular Inspection”.

5. Over - firing or poor combustion. 5. Check the maximum fuel input firing rate and

combustion. Refer to page 37 for procedure.

Jaguar Model J-390

NOTES

SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600

(516) 484-5921

AX:

• Canada:

Slant/Fin

TD/L

TEE

, Mississauga, Ontar

.slantfin.com

www

Slant-Fin J-390 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual