Lochinvar Water Heater 45 User Manual

RSB-i&s-05

INSTALLATION AND SERVICE MANUAL

HYDRONIC HEATING BOILERS and

DOMESTIC WATER HEATERS

45,000 - 500,000 Btu/hr MODELS

IMPORTANT:

ƽ WARNING

This is a gas appliance and should be installed by a

licensed electrician and/or certified gas supplier.

Service must be performed by a qualified service

installer, service agency or the gas supplier.

Improper Installation, Adjustment,

Alteration, Service or Maintenance

can cause injury or property damage.

Refer to this manual. For assistance or

additional information consult a qualified

installer, service agency or the gas supplier.

WARRANTY

CHECKING EQUIPMENT

Installation and service must be performed by a

qualified service installer, service agency or the gas

supplier.

Upon receiving equipment, check for signs of shipping

damage. Pay particular attention to parts accompanying

the appliance which may show signs of being hit or

otherwise being mishandled. Verify total number of

pieces shown on packing slip with those actually

received. In case there is damage or a shortage,

immediately notify carrier.

Factory warranty (shipped with appliance) does not

apply to appliances improperly installed or improperly

operated.

Experience has shown that improper installation or

system design, rather than faulty equipment, is the

cause of most operating problems.

DO NOT Use this appliance if any part has been

under water. The possible damage to a flooded

appliance can be extensive and present numerous

safety hazards. Any appliance that has been under

water must be replaced.

1. Excessive water hardness causing

lime

buildup in the copper tube is not the fault of

the equipment and is not covered under the

manufacturer’s warranty (see Water Treatment

and Water Chemistry).

ƽ WARNING

2. Excessive pitting and erosion on the inside of

the copper tube may be caused by too much

water velocity through the tubes and is not

covered by the manufacturer’s warranty (see

Boiler Flow Rates and Temperature Rise for

flow requirements).

If the information in this manual is not followed

exactly, a fire or explosion may result causing

property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any

location where gasoline or flammable vapors are

likely to be present, unless the installation is such to

eliminate the probable ignition of gasoline or

flammable vapors.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any

phone in your building.

SPECIAL INSTRUCTIONS TO OWNER

Note: Retain this manual for future reference.

This manual supplies information for the installation,

operation and servicing of the appliance. It is strongly

recommended that this manual be reviewed completely

before proceeding with an installation.

• Immediately call your gas supplier from a

neighbors phone. Follow the gas supplier’s

instructions.

• If you cannot reach your gas supplier, call the

fire department.

• Installation and service MUST BE performed by

a qualified installer, service agency or the gas

supplier.

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CODES

The equipment shall be installed in accordance with

installation regulations in force in the local area where

the installation is to be made. These regulations shall

be carefully followed in all cases. Authorities having

jurisdiction shall be consulted before installations are

made. In the absence of such requirements, the instal-

lation shall conform to the latest edition of the National

Fuel Gas Code, ANSI Z223.1. 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 Auto-

matically Fired Boilers, ASME CSD-1. All boilers

conform to the latest edition of the ASME Boiler and

Pressure Vessel Code, Section IV. Where required by

the authority having jurisdiction, the installation must

comply with the Canadian Association Code,

CAN/CGA-B149.1 and/or B149.2 and/or local codes.

This appliance meets the safe lighting performance FIG. 2 Typical Boiler (Rear View) Cabinet Construction

criteria with the gas manifold and control assembly

LOCATION OF UNIT

provided as specified in the ANSI standards for

gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.

1. Locate the appliance so that if water connections

should leak, water damage will not occur. When

such locations cannot be avoided, it is

recommended that a suitable drain pan, adequately

drained, be installed under the appliance. The pan

must not restrict combustion air flow. Under no

circumstances is the manufacturer to be held

responsible for water damage in connection with

this appliance, or any of its components.

INSTALLATION PROCEDURE

2. The appliance must be installed indoors where it is

protected from exposure to wind, rain and weather.

3. The appliance must be installed so that the ignition

system components are protected from water

(dripping, spraying, rain, etc.) during appliance

operation and service (circulator replacement,

control replacement, etc.,).

4. Appliances located in a residential garage and in

adjacent spaces that open to the garage and are not

part of the living space of a dwelling unit must be

installed so that all burners and burner ignition

devices have a minimum clearance of not less than

18" (46cm) above the floor. The appliance must be

located or protected so that it is not subject to

physical damage by a moving vehicle.

FIG. 1 Typical (Front View) Cabinet Construction

5. DO NOT install this appliance in any location

where gasoline or flammable vapors are likely to

be present.

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CLEARANCE FROM

COMBUSTIBLE CONSTRUCTION

Clearances from Combustible Construction:

29"

Right Side - 6"

Rear - 6"

Left Side - 18" (24" suggested for service)

Front - 18" (24" suggested for service)

Top - (measured from the top of the unit)

45,000 - 180,000 Btu/hr Models - 14"

199,999 - 500,000 Btu/hr Models - 29"

All units have been approved for alcove installation (an

ALCOVE is a closet enclosure without a front door).

18"

The boiler must not be installed on carpeting.

18"

All units have been approved for use on combustible

surfaces.

Allow sufficient space for servicing pipe connections,

pump and other auxiliary equipment, as well as the

appliance.

FIG. 4 Clearances Models 199,999 - 500,000 Btu/hr

COMBUSTION AND VENTILATION AIR

REQUIREMENTS FOR

CONVENTIONALLY VENTED

APPLIANCES

Provisions for combustion and ventilation air must be in

accordance with Section 5.3, Air for Combustion and

Ventilation, of the latest edition of the National Fuel

Gas Code, ANSI Z223.1, in Canada, the latest edition of

CGA Standard B149 Installation Code for Gas Burning

Appliances and Equipment, or applicable provisions of

the local building codes.

The room where the appliance is installed MUST be

provided with properly sized openings to assure

adequate combustion air and proper ventilation when

the appliance is installed with conventional venting.

FIG. 3 Clearances Models 45,000 - 180,000 Btu/hr

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FIG. 5 Combustion Air Direct from Outside

FIG. 7 Combustion Air from Interior Space

1. If air is taken directly from outside the building

with no duct, provide two permanent openings:

3. If air is taken from another interior space that is

adequately ventilated, each of the two openings

specified above should have a net free area of one

a. Combustion air opening, with a minimum free

area of one square inch per 4000 Btu/hr input

square inch for each 1000 Btu/hr (22cm per kW)

of input, but not less than 100 square inches

(5.5cm per kW). This opening must be located

(645cm ).

within 12" (30cm) of the floor.

b. Ventilation air opening, with a minimum free

area of one square inch per 4000 Btu/hr input

(5.5cm per kW). This opening must be located

within 12" (30cm) of the ceiling.

FIG. 8 Combustion Air from Outside Single Opening

4. If a single combustion air opening is provided to

bring combustion air in directly from the outdoors,

the opening must be sized based on a minimum free

area of one square inch per 3000 Btu/hr

FIG. 6 Combustion Air Through Ducts

(7cm per kW). This opening must be located

2. If combustion and ventilation air is taken from

the outdoors using a duct to deliver the air

to the room where the appliance is installed, each of

the two openings should be sized based on a

within 12" (30cm) of the ceiling.

minimum free area of one square inch per

2000 Btu/hr (11cm per kW).

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Outside air openings shall directly communicate with

the outdoors. When combustion air is drawn from the

outside through a duct, the net free area of each of the

two openings must have twice (2 times) the free area

required for Outside Air/2 Openings. Table A lists the

requirements for the appliance only, additional gas fired

appliances located in the same room will require an

increase in the net free area to supply adequate

combustion air for all appliances. Combustion air

requirements are based on the latest edition of the

National Fuel Gas Code, ANSI Z223.1, in Canada refer

to National Standard CAN B149.1 or B149.2. Check all

local code requirements for combustion air.

ƽ CAUTION

Under no circumstances should the room where

the appliance is installed ever be under a

negative pressure. Particular care should be

taken where exhaust fans, attic fans, clothes

dryers, compressors, air handling units, etc.,

may take away air from the appliance.

The combustion air supply must be completely free of

any flammable vapors that may ignite or chemical

fumes which may be corrosive to the appliance.

Common corrosive chemical fumes which must be

avoided are fluorocarbons and other halogenated

compounds, most commonly present as refrigerants or

All dimensions are based on net free area in square

inches. Metal louvers or screens reduce the free area of

a combustion air opening a minimum of approximately

25%. Check with louver manufacturers for exact net

free area of louvers. Where two openings are provided,

one must be within 12" (30 cm) of the ceiling and one

must be within 12" (30 cm) of the floor of the room

where the appliance is installed. Each opening must

have a net free area as specified in Table A. Single

openings shall be located within 12" (30 cm) of the

ceiling.

solvents,

such

freon,

tricholorethylene,

perchlorethylene, chlorine, etc. These chemicals, when

burned, form acids which quickly attack the heat

exchanger finned tubes, headers, flue collectors, and the

vent system. The result is improper combustion and a

non-warrantable, premature appliance failure.

TABLE - A

MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY

Combustion Air Source

Input

Btu/hr

Outside Air/2

Openings

Outside Air/1

Opening

Inside Air/2

Openings

45,000

75,000

90,000

12 in²

19 in²

23 in²

34 in²

45 in²

50 in²

55 in²

56 in²

67 in²

68 in²

79 in²

90 in²

100 in²

125 in²

15 in²

25 in²

30 in²

45 in²

60 in²

67 in²

74 in²

75 in²

89 in²

90 in²

105 in²

120 in²

133 in²

167 in²

100 in²

135 in²

180 in²

200 in²

224 in²

225 in²

269 in²

270 in²

315 in²

360 in²

400 in²

500 in²

135,000

180,000

199,999

215,000

225,000

260,000

270,000

315,000

360,000

399,999

500,000

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EXHAUST FANS: Any fan or equipment which ex-

hausts air from the room where the appliance is installed

may deplete the combustion air supply and/or cause a

down draft in the venting system, spilling flue products

into the room. Spillage of flue products from the

venting system into an occupied living space can cause

a very hazardous condition that must be corrected im-

mediately. If a fan is used to supply combustion air to

the room where the appliance is installed, the installer

must make sure that it does not cause drafts which could

lead to nuisance operational problems with the

appliance.

VENTING

FIG. 9 Conventional Negative Draft Vertical Venting

Vent installations for connection to gas vents or

chimneys must be in accordance with Part 7, “Venting

of Equipment,” of the latest edition of the National Fuel

Gas Code, ANSI Z223.1, in Canada, the latest edition of

CGA Standard B149 Installation Code for Gas Burning

Appliances and Equipment or applicable provisions of

the local building codes.

A CONVENTIONAL NEGATIVE DRAFT

VENTING SYSTEM

The negative draft in a conventional vent installation

must be within the range of a negative 0.02 to 0.05

inches water column to ensure proper operation. All

draft readings are made while the appliance is in stable

operation (approximately 2 to 5 minutes).

Adequate combustion and ventilation air must be

supplied to the room where the appliance is installed in

accordance with the latest edition of the National Fuel

Gas Code, ANSI Z223.1, in Canada, the latest edition of

CGA Standard B149 Installation Code for Gas Burning

Appliances and Equipment, or applicable provisions of

the local building codes.

Multiple appliance installations with combined venting

or common venting with other negative draft applianc-

es require that each appliance must have draft within

the proper range. If the draft measured above the

appliance’s built-in draft diverter exceeds the specified

range in a dedicated chimney for a single appliance

installation or in combined venting with other negative

draft appliances, a barometric damper must be installed

to control draft.

The distance of the vent terminal from adjacent

buildings, windows that open and building openings

MUST comply with the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada, the latest

edition of CGA Standard B149 Installation Code for

Gas Burning Appliances and Equipment.

TABLE - B

VENT PIPE SIZES

Input Btu/hr

Flue Size

Vent connection is made directly to the top of the

appliance. This appliance is designed with a built-in

draft diverter. No additional external draft hood is re-

quired. The connection from the appliance vent to the

common vent or chimney must be made as direct as

possible.

45,000

75,000

90,000

10"

135,000

180,000

199,999

215,000

260,000

315,000

360,000

399,999

500,000

10"

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On a conventionally vented, negative draft appliance,

the connection from the vent to the chimney or vent

termination on the outside of the building MUST be

made with listed Type “B” double wall (or equivalent)

vent connectors and must be direct as possible with no

reduction in diameter. Use the National Fuel Gas Code

venting tables for double wall vent to properly size all

vent connectors and stacks. The Type “B” vent and

accessories, such as firestop spacers, thimbles, caps,

etc., MUST be installed in accordance with the

manufacturer’s listing. The vent connector and firestop

must provide correct spacing to combustible surfaces

and seal to the vent connector on the upper and lower

sides of each floor or ceiling through which the vent

connector passes.

(a) Seal any unused opening in the common

venting system.

(b) Visually inspect the venting system for proper

size and horizontal pitch and determine there is

no blockage or restriction, leakage, corrosion

and other deficiencies which could cause an

unsafe condition.

and windows and all doors between the space in

which the appliances remaining connected to

the common venting system are located and

other spaces of the building. Turn on clothes

dryers and any other appliances not connected

to the common venting system. Turn on any

exhaust fans, such as range hoods and

bathroom exhausts, so they will operate at

maximum speed. Do not operate a summer ex-

haust fan. Close fireplace dampers.

Any vent materials used must be listed by a nationally

recognized test agency for use as vent material.

Locate appliance as close as possible to a chimney or

gas vent.

(d) Place in operation the appliance being

inspected. Follow the lighting instructions.

Adjust thermostat so appliance will operate

continuously.

Avoid long horizontal runs of the vent pipe, 90° elbows,

reductions and restrictions. Horizontal portions of the

venting system shall be supported to prevent sagging.

Horizontal runs must slope upwards not less than 1/4

inch per foot (21 mm/m) from the appliance to the vent

terminal. Follow manufacturer’s instructions.

(e) Test for spillage at the draft hood/relief opening

after 5 minutes of main burner operation. Use

the flame of a match or candle, or smoke from

a cigarette, cigar or pipe.

Do not use an existing chimney as a raceway for a flue

pipe if another appliance or fireplace is vented through

the chimney.

(f) After it has been determined that each

appliance remaining connected to the common

venting system properly vents when tested as

outlined above, return doors, windows, exhaust

fans, fireplace dampers and other gas burning

appliances to their previous conditions of use.

The weight of the venting system must not rest on the

appliance. Adequate support of the venting system must

be provided in compliance with local codes and other

applicable codes. All connections should be secured

with rustproof sheet metal screws.

(g) Any improper operation of the common

venting system should be corrected so that the

installation conforms to the latest edition of the

National Fuel Gas Code, ANSI Z223.1. In

Canada, the latest edition of CGA Standard

B149 Installation Code for Gas Burning

Appliances and Equipment. When resizing any

portion of the common venting system, the

common venting system should be resized to

approach the minimum size as determined

using the appropriate tables in Part 11 in the

latest edition of the National Fuel Gas Code,

ANSI Z223.1. In Canada, the latest edition of

CGA Standard B149 Installation Code for Gas

Burning Appliances and Equipment.

Vent connectors serving appliances vented by natural

draft shall not be connected to any portion of a

mechanical draft system operating under positive

pressure. Connection to a positive pressure chimney

may cause flue products to be discharged into the living

space causing serious health injury.

Common venting systems may be too large when an

existing appliance is removed. At the time of removal

of an existing appliance, the following steps shall be

followed with each appliance remaining connected to

the common venting system placed in operation, while

other appliances remaining connected to the common

venting system are not in operation.

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VENTING TERMINATION

FIG. 12 Vent Termination from Flat Roof 10’ or Less from

Parapet Wall

FIG. 10 Vent Termination from Peaked Roof 10’ or Less

from Ridge

10’ OR MORE

MORE THAN 10'

10'

3’

RIDGE

2' MIN

NOTE:

3' MIN

NO HEIGHT ABOVE

PARAPET REQUIRED

WHEN DISTANCE

FROM WALLS OR

WALL OR

PARAPET

PARAPETS IS MORE

CHIMNEY

THAN 10’.

FIG. 13 Vent Termination from Flat Roof More Than 10’ from

Parapet Wall

CHIMNEY

The vent cap should have a minimum clearance of 4

feet (1.22m) horizontally from and in no case above or

below, unless a 4 foot (1.22m) horizontal distance is

maintained from electric meters, gas meters, regulators

and relief equipment.

FIG. 11 Vent Termination from Peaked Roof More Than 10’

from Ridge

The vent terminal should be vertical and exhaust

outside the building at least 2 feet (0.61m) above the

highest point of the roof within a 10 foot (3.05m) radius

of the termination. The vertical termination must be a

minimum of 3 feet (0.91m) above the point of exit.

The venting system shall terminate at least 3 feet (0.9m)

above any forced air inlet within 10 feet (3.05m).

A vertical terminal less than 10 feet (3.05m) from a

parapet wall must be a minimum of 2 feet (0.61m)

higher than the parapet wall.

The venting system shall terminate at least 4 feet (1.2m)

below, 4 feet (1.2m) horizontally from, or 1 foot (30cm)

above any door, window or gravity air inlet into any

building.

Do not terminate the vent in a window well, stairwell,

alcove, courtyard or other recessed area. The vent can

not terminate below grade. The bottom of the vent

terminal shall be located at least 12 inches (30cm)

above grade.

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To avoid a blocked vent condition, keep the vent cap systems (Type “B” double wall or flexible or rigid

clear of snow, ice, leaves, debris, etc.

metallic liners) are recommended. Consult with local

code officials to determine code requirements or the

Flue gases will form a white plume in winter. Plume advisability of using or relining a masonry chimney.

could obstruct window view.

SIDEWALL VENTING

Flue gas condensate can freeze on exterior surfaces or

on the vent cap. Frozen condensate on the vent cap can

result in a blocked vent condition. Flue gas condensate

can cause discoloration of exterior building surfaces.

Adjacent brick or masonry surfaces should be protected

with a rust resistant sheet metal plate.

IMPORTANT

Examine the venting system at least once a year.

Check all joints and vent pipe connections for

tightness.

Also check for corrosion or

deterioration. Immediately correct any problems

observed in the venting system.

MASONRY CHIMNEY

INSTALLATION

FIG. 14 Sidewall Venting with an Induced Draft Fan

This appliance is NOT approved for sidewall venting

with the negative draft venting system as shipped from

the factory. An induced draft fan MUST be used if the

installation requires that the flue gases be vented out a

sidewall. A properly sized and installed induced draft

fan may also be used to vent the flue gases vertically if

required by jobsite restrictions. The induced draft fan

must be listed by a nationally recognized test agency, be

properly sized and installed per the recommendations of

the induced draft fan manufacturer and meet local code

requirements. Use care to ensure that the mechanical-

ly supplied draft does not exceed the range of a

negative 0.02 to 0.05 inches water column to ensure

proper operation. If draft exceeds the specified range,

the fan must be adjusted or the installation of a baro-

metric damper in the flue may be required to properly

control draft. An induced draft fan MUST be

interlocked into the appliance’s control circuit to start

when the appliance calls for heat. The induced draft fan

MUST also be equipped with a proving switch,

properly interlocked into the appliance’s control circuit

to prove fan operation before the main burners are

allowed to fire. A vertical or sidewall vent termination

for an induced draft fan MUST be installed per the

recommendations of the fan manufacturer and provide

proper clearances from any combustion or ventilation

openings, windows, doors or other openings into the

building. All induced draft fan installations must

comply with local code requirements.

A masonry chimney must be properly sized for the

installation of a gas fired appliance. Venting of an

appliance into a cold or oversized masonry chimney can

result in operational and safety problems. Exterior

masonry chimneys, with one or more sides exposed to

cold outdoor temperatures, are more likely to have

venting problems. The temperature of the flue gases

from an appliance may not be able to sufficiently heat

the masonry structure of the chimney to generate proper

draft. This will result in condensing of flue gases,

damage the masonry flue/tile, insufficient draft and

possible spillage of flue gases into an occupied living

space. Carefully inspect all chimney systems before

installation. If there is any doubt about the sizing or

condition of a masonry chimney, it must be relined with

a properly sized and approved chimney liner system.

Inspection of a Masonry Chimney

A masonry chimney must be carefully inspected to

determine its suitability for the venting of flue gases. A

clay tile lined chimney must be structurally sound,

straight and free of misaligned tile, gaps between

liner sections, missing sections of liner or any signs

of condensate drainage at the breaching or clean

out. If there is any doubt about the condition of a

masonry chimney, it must be relined. An unlined

masonry chimney must not be used to vent flue

gases from this appliance. An unlined chimney must be

relined with an approved chimney liner system when a

new appliance is being attached to it. Metallic liner

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The part number for the automatic vent damper

required on this heating boiler is printed on the rating

plate. Vent damper regulations are design certified per

the latest edition of ANSI Z21.66.

AUTOMATIC VENT DAMPER

This heating boiler is design certified for use with the

automatic vent damper (FIG. 15) part number printed on

the boiler’s rating plate. A vent damper must be

installed on all residential heating boilers with inputs of

less than 300,000 Btu/hr to comply with minimum

efficiency requirements. A vent damper is factory

supplied with residential heating boilers with inputs of

45,000 thru 260,000 Btu/hr. A vent damper is optional

on all heating boilers above 260,000 Btu/hr. A vent

damper is available as an option on all water heaters.

The vent damper is a useful tool for saving energy when

installed inside the living space where air can

circulate freely around the appliance. The vent damper

will not save as much, if any, energy if it is installed in

locations such as:

-Unheated garage

-Attic

-Crawlspace

-Mechanical room that is vented outdoors

For installation and maintenance on the vent damper, refer

to the instructions supplied with the vent damper.

FIG. 15 Vent Damper and Vent Damper Terminal Block

ƽ WARNING

Residential heating boilers with inputs of less than

300,000 Btu/hr must have the vent damper properly

installed and the vent damper wire harness plugged into

the terminal block on the side of the control panel to

allow the boiler to function. Larger input heating

boilers and water heaters will have a jumper plug

installed in the terminal block to allow operation

without a damper. Remove the jumper plug from the

terminal block to connect an optional vent damper wire

harness. The jumper plug MUST be in place if an

optional vent damper is not used on water heaters and

larger input heating boilers.

The vent damper must be installed directly on the

flue outlet located on the top of the draft hood (see

Figure 15). Do not alter the wire harness supplied

with the vent damper. Follow the instructions

supplied with the vent damper.

ƽ CAUTION

An appliance which is shut down or will not

operate may experience freezing due to convective

air flow down the flue pipe connected to the unit.

Proper freeze protection must be provided, see

Freeze Protection.

ƽ CAUTION

Do not install the vent damper within 6" (152 mm)

of combustible materials.

Install the vent damper to service only the single

appliance for which it is intended. If improperly

installed, a hazardous condition such as an explosion or

carbon monoxide poisoning could result.

The damper position indicator must be in a visible

location with access for service following installation.

The damper must be in an open position when appliance

main burners are operating.

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GAS PRESSURE TEST

GAS SUPPLY

1. The appliance must be disconnected from the

gas supply piping system during any pressure

testing of that system at a test pressure in

excess of 1/2 PSIG (3.5kPa).

Verify that the appliance is supplied with the type gas

specified on the rating plate. This appliance is orificed

for operation up to 2000 feet altitude. The appliance

will be derated 4% per 1000 feet above 2000 feet eleva-

tion. Consult the factory for installations above 2000

feet elevation. Field conversions for operation at high

altitude must be performed by certified personnel only.

The appliance will be marked to indicate suitability for

high altitude operation.

2. The appliance must be isolated from the gas

supply piping system by closing a manual

shutoff valve during any pressure testing

of the gas supply piping system at test

pressures equal to or less than 1/2 PSIG

(3.5kPa).

GAS SUPPLY PRESSURE: Measured at the inlet

pressure tap located upstream of the combination gas

valve(s) see Figures 20 - 22, page 17.

3. The appliance and its gas connection must

be leak-tested before placing it in operation.

TABLE - C

GAS SUPPLY PRESSURE

GAS CONNECTION

Nat. Gas LP Gas

1. Safe operation of the appliance requires

properly sized gas supply piping. See data

in Table E.

Max. (Inches Water Column) 10.5

Min. (Inches Water Column) *4.5

Min. (Inches Water Column) **5.0

2. Gas pipe size may be larger than appliance

gas connection.

*Models 45,000 - 360,000 Btu/hr Only

**Models 399,999 - 500,000 Btu/hr Only

3. Installation of a union is suggested for ease

of service, see Figure 16 on page 14.

4. Install a manual main gas shutoff valve,

outside of the appliance gas connection and

before the gas valve or manifold connection,

when local codes require.

Maximum inlet gas pressure must not exceed the value

specified. Minimum value listed is for the purposes of

input adjustment.

MANIFOLD PRESSURE: Measured at the pressure

tap on the downstream side of the combination gas

valve(s) (see Figures 20 - 22 on page 17). The gas

regulator settings for single stage and two stage

operation are factory set to supply proper manifold

pressure for normal operation. To check manifold

pressure, see Manifold Adjustment Procedure. Do not

increase manifold pressure beyond specified

pressure settings shown below in Table D.

5. A trap (drip leg) MUST be provided by the

installer in the inlet of the gas connection to the

appliance, see Figure 16 on page 14.

6. The combination gas valve has an integral

vent limiting device and does not require

venting to atmosphere, outside the building.

TABLE - D

MANIFOLD PRESSURE

Single and Two-Stage

Two Stage

Btu/hr

Input Gas

Full or High Fire Settings

Natural Gas L.P. Gas

Low Fire Settings

Natural Gas

L.P. Gas

45,000

75,000

90,000 - 180,000

199,999

215,000 - 399,999

500,000

3.5"

2.4"

3.5"

2.9"

3.5"

10"

7.5"

10"

0.9"

N/A

2.5"

N/A

3.5" 10" (two valves)

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TABLE - E

SUGGESTED GAS PIPE SIZE

SINGLE APPLIANCE INSTALLATIONS

Btu/hr

INPUT

45,000

75,000

90,000

135,000

180,000

199,999

215,000

260,000

315,000

360,000

399,999

500,000

DISTANCE FROM METER (In Feet)

0-50

1/2"

3/4"

51 - 100

101 - 200

201 - 300

301 - 500

1 1/4"

1 1/2"

1/2"

3/4"

1 1/4"

1 1/2"

1 1/4"

1 1/2"

1 1/4"

1 1/2"

1 1/4"

2 1/2"

For each elbow or tee, add equivalent straight pipe from Table F to total length .

TABLE - F

TABLE G

GAS CONNECTIONS

FITTINGS TO EQUIVALENT

STRAIGHT PIPE

45,000 - 135,000

180,000 - 315,000

360,000 - 500,000

1/2"

3/4"

Diameter Pipe (inches)

3/4 1 1/4 1 1/2

Equivalent length of Straight Pipe (feet)

7. Optional gas controls may require routing

of bleeds and vents to the atmosphere,

outside the building when required by local

codes.

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TABLE - H

MULTIPLE APPLIANCE INSTALLATIONS

GAS PIPING SIZE CHART

Nominal

Iron Pipe

Size, Inches

Length of Pipe in Straight Feet

205

384

789

174

328

677

155

292

595

923

141

267

543

830

128

246

502

769

121

226

472

707

90 100

113 106

210 200

441 410

666 636

125

150 175

86 79

200

3/4

369 256

697 477

179

369

564

164 149

333 308

513 472

974 871

138

287

441

820

1 1/4

1 1/2

1,400 974

2,150 1,500 1,210 1,020

4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100

2 1/2

6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300

11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340

23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720

Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 13.5 Inches Water Column

(0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on the calorific value of Natural Gas,

1025 Btu/ft³@ 0.60 Specific Gravity)

GAS PIPING

sufficient capacity. Verify pipe size with your gas

supplier.

2. Use new, properly threaded black iron pipe free

from chips. If tubing is used, make sure the ends

are cut squared, deburred and clean. All tubing

bends must be smooth and without deformation.

Avoid flexible gas connections. Internal diameter

of flexible lines may not provide proper volume of

gas.

3. Run pipe or tubing to the gas valve or manifold

inlet. If tubing is used, obtain a tube to pipe

coupling to connect the tubing to the gas valve

or manifold inlet.

4. Thread pipe the proper amount for insertion into gas

valve or manifold inlet as shown in Table H.

DO NOT OVER TIGHTEN. Over tightening may

result in damage to the gas valves. Valve distortion

or malfunction may result if the pipe is inserted too

deeply into the gas valve.

5. Apply a moderate amount of good quality pipe

compound (DO NOT use Teflon tape) to pipe

only, leaving two end threads bare.

FIG. 16 Gas Line Connection

All gas connections must be made with pipe joint

compound resistant to the action of liquefied petroleum

and natural gas. All piping must comply with local

codes. Tubing installations must comply with approved

standards and practices. Reference Figure 16 for a

typical installation.

6. Remove seal over gas valve or manifold inlet.

7. Connect pipe to gas valve or manifold inlet. Use

wrench to square ends of the gas valve (FIG. 17).

Install Piping to Control

1. The gas line should be a separate line direct

from the meter unless the existing gas line is of

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1. Turn the power “OFF” at the main disconnect

switch.

2. Turn gas valve control knob to “PILOT” position

on standing pilot models. Ensure that the standing

pilot remains on. If the pilot goes out, follow the

“Lighting Instructions” for standing pilot models

to light the pilot. Turn gas valve control knob to

“OFF” position on spark ignition models.

3. Remove the 1/8" hex plug located on the outlet

side of the gas valve and install a fitting suitable to

connect to a manometer or magnahelic gauge. See

Figure 18. Minimum range of scale should be up

to 5" w.c. for Natural gas models and 10" w.c. for

L.P. gas models.

FIG. 17 Wrench

8. For L.P. gas, consult your L.P. gas supplier for

expert installation.

4. The 500,000 Btu/hr model will have two gas

valves with a pressure regulator on each valve.

Repeat the following adjustment procedure to set

the manifold pressure on each gas valve.

IMPORTANT

Upon completion of any piping connections to the

gas system, leak test all gas connections with a soap

solution while system is under pressure.

Immediately repair any leaks found in the gas train

or related components. Do Not operate an

appliance with a leak in the gas train, valves or

related piping.

5. Remove pressure regulator adjustment cap screw

on the gas valve. See Figure 18 for location.

6. Turn the power “ON” at the main disconnect

switch.

7. Turn gas valve control knob to “ON” position.

8. Set the thermostat(s) to call for heat.

GAS MANIFOLD PRESSURE

ADJUSTMENT PROCEDURE

9. Observe gas regulator pressure when all burners

are firing. See Table D, Manifold Pressure for

proper regulator pressure settings.

Pressure Regulator Adjustment

(under cap screw)

10. If adjustment is necessary, turn regulator

adjustment screw clockwise to raise regulator gas

pressure, counterclockwise to lower gas pressure,

to proper setting. Note: Adjustment fitting is

plastic and may require slightly greater turning

force than a metal fitting.

Manometer

11. Turn the power “OFF” at the main disconnect

switch.

NOTE:

Do not increase regulator pressure beyond specified

pressure setting.

3.5"

12. Turn gas valve control knob to “PILOT” position

on standing pilot models. Turn gas valve control

knob to “OFF” position on spark ignition models.

Gas Valve

13. Remove fitting from the gas valve and replace the

1/8" hex plug that was previously removed and

tighten.

FIG. 18 Manifold Pressure Adjustment

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14. Repeat the adjustment procedure for the second 6. Turn on gas supply at the manual valve, turn on

gas valve on the 500,000 Btu/hr model. L.P. gas at tank if required.

15. Turn the gas valve control knob(s) to “ON” 7. Turn the power “ON” at the main disconnect

position. switch.

16. Turn the power “ON” at the main disconnect 8. Turn gas valve control knob to “PILOT”

switch. The appliance is now ready to operate.

position on standing pilot models. Follow the

“Lighting Instructions” for standing pilot models

to light the pilot. Turn gas valve control knob to

the “ON” position when the pilot is established.

Turn gas valve control knob(s) to the “ON”

position on spark ignition models.

If manifold pressure can not be properly adjusted, use

the following procedure to check gas supply pressure

with a manometer connected to the inlet pressure tap on

the gas control.

9. Set the thermostat(s) to call for heat.

CHECKING GAS SUPPLY PRESSURE

Gas Supply Pressure

10. Observe the gas supply pressure with all burners

firing. Ensure inlet pressure is within

specified range. Check gas supply pressure with all

other gas fired appliances in operation to ensure

proper gas volume during periods of peak gas

usage.

Manometer

11. If gas pressure is out of range, contact gas utility,

gas supplier, qualified installer or service agency

to determine necessary steps to provide proper gas

pressure to the control.

12. If the gas supply pressure is within the specified

range, proceed with the following steps to return

the appliance to service.

Gas Valve

13. Turn the power “OFF” at the main disconnect

switch.

FIG. 19 Gas Supply Pressure

14. Turn gas valve control knob to “PILOT” position on

standing pilot models. Turn gas valve control

knob(s) to “OFF” position on spark ignition models.

1. Turn the power “OFF” at the main disconnect

switch.

2. Turn gas valve control knob(s) to the “OFF”

position.

15. Shut off gas supply at the manual valve in the gas

piping to the appliance. If fuel supply is

L.P. Gas, shut off gas supply at the tank.

3. The 500,000 Btu/hr model will have two gas

valves. Turn the gas valve control knob on each

valve to the “OFF” position.

16. Remove the manometer and related fittings from

the “inlet” side of the gas valve, replace 1/8" hex

plug in gas valve.

4. Shut off gas supply at the manual valve in the gas

piping to the appliance. If fuel supply is L.P. gas,

shut off gas supply at the tank.

17. Turn on gas supply at the manual valve, turn on

L.P. Gas at tank if required.

5. Remove the 1/8" hex plug, located on the “inlet”

side of the gas valve and install a fitting suitable to

connect to a manometer or magnahelic gauge. On

two gas valve models, remove the hex plug from

the gas valve closest to the gas supply connection.

Range of scale should be 14" w.c. or greater to

check inlet pressure. See Figures 18 and 19 for

location.

18. Turn the power “ON” at the main disconnect

switch.

19. Turn the gas valve control knob(s) to the “ON”

position. If the pilot is not burning, follow the

“Lighting Instructions” for standing pilot models to

light the pilot. Spark ignition models will automat-

ically light the pilot on a call for heat.

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20. Set the thermostat to call for heat. The appliance

is now ready to operate.

IMPORTANT

Upon completion of any testing on the gas system,

leak test all gas connections with a soap solution

while main burners are operating. Immediately

repair any leak found in the gas train or related

components. Do Not operate an appliance with a

leak in the gas train, valves or related piping.

Check burner performance by cycling the system while

you observe burner response. Burners should ignite

promptly. Flame pattern should be stable, see

“Maintenance-Normal Flame Pattern.” Turn system

off and allow burners to cool, then cycle burners again

to ensure proper ignition and flame characteristics.

FIG. 22 M9 Gas Valve 45,000 - 399,999 Btu/hr Models

Each unit has a combination gas valve(s) to control the

gas supply to the burners. The 500,000 Btu/hr model

has two combination gas valves to supply gas to the

burners. The combination valve consists of a gas

regulator and two valve seats to meet the requirements

for redundant gas valves. The valve has a gas control

knob that must remain in the open position at all times

when the appliance is in service. Each gas valve has

pressure taps located on the inlet and outlet sides.

Manifold pressure is adjusted using the regulator

located on the valve. The manifold pressure is preset at

the factory and adjustment is not usually required. If

the manifold pressure is to be adjusted, follow the “Gas

Manifold Pressure Adjustment Procedure”, page 15 for

proper adjustment.

COMBINATION GAS VALVES

Pressure Regulator

Adjustment (under cap screw)

Outlet Pressure Tap

Inlet

Pressure

Tap

Pilot Outlet

Gas Control

Knob

Red Reset Button

Venting of Combination Gas Valves

The combination gas valve regulator used on all models

is equipped with an integral vent limiting orifice. The

vent limiter ensures that the volume of gas emitted from

the valve does not exceed the maximum safe leakage

rate allowed by agency requirements. Combination gas

valve/regulators equipped with integral vent limiters are

not required to have vent or relief lines piped to the

outdoors. A dust cap is provided at the vent termination

point on the valve to prevent blockage of the vent

limiter by foreign material. The combination gas valve

regulator with an integral vent limiter complies with the

safety code requirements of CSD-1, CF-190(a) as

shipped from the manufacturer without the installation

of additional vent lines.

FIG. 20 F1 Gas Valve 90,000 - 270,000 Btu/hr Models

FIG. 21 F9 Gas Valve 90,000 - 500,000 Btu/hr Models

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WATER FLOW SWITCH (IF EQUIPPED)

RELIEF VALVE

FIG. 24A Water Flow Switch Water Heater - Side Connections

FIG. 23A Relief Valve - Water Heater

FLOW SWITCH

RELIEF

VALVE

FIG. 24B Water Flow Switch Boiler - Top Connections

A water flow switch is available as a factory supplied

option on all heating boilers and water heaters. The

flow switch should be wired between terminals X and

B. Remove the jumper between the X and B terminals

on the terminal strip. This wiring connection installs

the flow switch in the 24 VAC safety circuit to prove

water flow before main burner ignition. A flow switch

installed with the factory supplied minimum adjustment

setting requires a specific minimum flow to make the

switch and start burner operation. The minimum flow

requirement to actuate the switch is specified in Table I.

The flow rate required is a function of the diameter of

pipe and tee used for installation. Ensure that the pump

installed on the boiler or water heater will supply

adequate flow to make the flow switch contacts and

operate the boiler.

FIG. 23B Relief Valve - Boiler

This appliance is supplied with a relief valve(s) sized in

accordance with ASME Boiler and Pressure Vessel

Code, Section IV (“Heating Boilers”). The relief

valve(s) is mounted directly into the heat exchanger

inside the header. To prevent water damage, the dis-

charge from the relief valve shall be piped to a suitable

floor drain for disposal when relief occurs. No reducing

couplings or other restrictions shall be installed in the

discharge line. The discharge line shall allow complete

drainage of the valve and line. Relief valves should be

manually operated at least once a year.

ƽ CAUTION

Avoid contact with hot discharge water.

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A water flow switch meets most code requirements 4. To avoid serious damage, DO NOT energize the

for a low-water cut off device on boilers requiring

forced circulation for operation.

appliance until the system is full of water.

Serious damage may result.

5. Provide the unit with proper overload protection.

TABLE I

6. Install a wall thermostat on the inside wall. DO

NOT install the thermostat in an area affected by

drafts, sunlight, light fixtures, hot or cold water

pipes or near a fireplace. See “Terminal Strip Con-

nection of a Room Thermostat”, page 38 for proper

wiring connection.

MINIMUM FLOW RATE REQUIRED TO

ACTUATE FLOW SWITCH

Pipe Size

GPM Flow Rate

1 1/2"

TABLE J

AMP DRAW DATA

45,000 thru 500,000 Btu/hr Models

LOW WATER CUTOFF (IF EQUIPPED)

MAXIMUM

A hot water boiler installed above radiation level must be

provided with a low water cutoff device either as part of

the unit or installed at the time the boiler is installed. An

electronic low water cutoff is available as a kit on all

units. Low water cutoffs should be inspected every six

months, including flushing of float types.

FIRING

TOTAL AMPS

@ 120 VAC

CONTROLS

F1 Standing Pilot (Single Stage

90,000 - 260,000 Btu/hr)

2.5

F9 Intermittent Pilot (Single Stage

90,000 - 399,999 Btu/hr)

TWO STAGE BURNER

CONTROL SYSTEM

F9 Intermittent Pilot (Single

Stage/2 valves 500,000 Btu/hr)

The 45,000 thru 500,000 Btu/hr boilers (M9) are

equipped with a two stage burner control system. The

45,000 thru 399,999 Btu/hr models will be equipped

with a two stage gas valve to control high/low burner

operation. The 500,000 Btu/hr model achieves two

stage burner firing by staging the operation of the two

combination gas valves.

M9 with Internal Pump

(45,000 - 260,000 Btu/hr)

2.0

M9 Intermittent Pilot (Two Stage

Valve 315,000 - 399,999 Btu/hr)

M9 Intermittent Pilot (Two Stage/2

valves 500,000 Btu/hr)

2.0

Pump Wiring for a Heating Boiler

ELECTRICAL CONNECTIONS

The heating boiler circulating pump must be purchased

locally. The maximum load for the pump switched by

the internal pump relay must not exceed 1 HP. The

current draw for a field installed 120 VAC pump MUST

be added to the boiler’s current draw to determine the

minimum wire size for 120 volt service.

This appliance is wired for 120 VAC service. The

appliance, when installed, must be electrically

grounded in accordance with the requirements of the

authority having jurisdiction or in the absence of such

requirements, with the latest edition of the National

Electrical Code ANSI/NFPA No. 70. When the unit is

installed in Canada, it must conform to the CSA C22.1,

Canadian Electrical Code, Part 1 and/or local Electrical

Codes.

1. All wiring between the appliance and field

installed devices shall be made with type T wire

[63° F(35° C) rise].

2. Line voltage wire exterior to the appliance must be

enclosed in approved conduit or approved metal

clad cable.

3. The pump must run continuously when the

appliance is being fired.

FIG. 25 Standing Pilot System F1 Control Panel

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Temperature Control Settings

There are three setting knobs on the temperature control

unless your unit is specified as a boiler only with an

outdoor air reset option. If your unit is a boiler only with an

outdoor air reset option, there are additional controls for

this option. They are explained under Outdoor Air Reset

Option, page 22.

The three setting knobs on the temperature control are for

Set point, Differential, and High-Fire Offset (see

Figure 28).

FIG. 26 Intermittent Pilot System F9/M9 Control Panel

FIG. 28 Temperature Control

Maximum Set Point Determination

The maximum set point for the control is factory set.

Boilers can be set to 240°F max., water heaters are set to

190°F max., and specialty state and local codes to 200°F.

These maximum set points are established by cutting the

OJ1 and OJ2 jumpers located on the right side of the

temperature controller. The maximum set point is

determined as shown below in TABLE-K.

FIG. 27 Control Panel Assembly 500,000 Btu/hr

TEMPERATURE ADJUSTMENT

Operating Temperature Control

TABLE K

Maximum Set point Determination

NOTE:

Max.

The temperature controller is pre-set at the factory with

test settings. You may need to adjust the settings to meet

your specific needs.

OJ1

OJ2

Set Point

Connected

Cut

Connected

240°F

190°F

Connected

Cut

200°F

160°F

ƽ WARNING

Return water temperatures must not be less than

140°F. If lower return water temperatures are

required, follow the instructions for Low

Temperature Bypass Requirements or Three-Way

Valves, see page 35.

NOTE:

Anytime that OJ1 is the only jumper cut, a new

overlay is required under the Set Point knob on the

temperature controller because the scale has changed

to a maximum of 190°F.

Locating Temperature Control

Remove the control panel door on the front of the unit in

order to locate and access the temperature control.

Anytime the OJ2 jumper is cut (with or without OJ1),

a new overlay is required under the Set Point knob on

the temperature controller because the scale has

changed to a maximum of 200°F.

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Set Point

for water heater applications. Connect this sensor to the

two blue wires in the upper left-hand corner of the control

panel.

The Set Point knob specifies the target outlet water

temperature in degrees, Fahrenheit. After the water

temperature reaches the set point, the temperature control

shuts off the burners.

Outdoor Air Temperature Sensor

The outside air temperature sensor will only be used for

boiler systems. The outside air sensor is optional. This

sensor allows you to tie boiler operation to the outdoor air

temperature. As outside temperatures drop, the control will

increase the temperature setting of the boiler. As outdoor

temperatures rise, the control will decrease the temperature

to the selected set point of the boiler. You can set the

control to shut the boiler off when a desired outdoor air

temperature level is reached.

Differential

The Differential specifies the number of degrees below the

set point that the control will allow the water temperature

to drop before it brings the unit back on again.

High-Fire Offset

The temperature control operates a two-stage firing system.

The two stages are High-Fire and Low-Fire. High-Fire

operates all burners at full rate while Low-Fire operates the

burners at approximately one-half rate.

You must purchase the sensor from the appliance

manufacturer. The sensor comes with a housing that helps

protect the sensor from the elements. Mount the air sensor

housing outdoors, under the eve of the roof. Make sure the

housing is out of direct sunlight. This will ensure that the

sensor will accurately read the true outdoor temperature.

Connect the outdoor air temperature sensor to the terminal

block on the outdoor air reset board. For more information

on wiring the sensor, see Wiring of Remote Sensors, this

page.

The High-Fire Offset knob specifies the number of degrees

below set point that the High-Fire stage shuts down. At that

point, the unit will continue to operate at the Low-Fire

stage until the set point is reached.

The High-Fire Offset knob has settings between 0°F and

20°F. If set at 0°F, the High-Fire Offset is disabled and the

unit will operate the High-Fire stage until the set point is

reached and the temperature control shuts the unit off.

No matter what the High-Fire Offset knob is set to, the unit

will light at Low Fire and operate for approximately 10 to Installation of Remote Sensors

120 seconds before the High-Fire stage actuates.

Make sure to insert the sensor all the way into the bulbwell,

leaving no air pocket between the front surface of the

sensor and the back of the bulbwell. Air pockets are

thermally non-conductive and will cause sensors to read

inaccurately.

Boiler Application

Standard boiler units are shipped with one sensor, the inlet

water temperature sensor. An optional sensor can be

purchased and installed for use as a remote system sensor.

Boilers with the outdoor air reset option also have an

outside air temperature sensor.

System Sensor

The system sensor is used for boiler applications. Install

the sensor in the system supply to the building.

Water Heater Application

Water heater units are shipped with two sensors; the inlet

water temperature sensor and the multi-purpose

temperature sensor to be used as a tank sensor.

Tank Sensor

The tank sensor is used in water heating applications.

Install the sensor in a water storage tank to measure water

temperature. For more information on wiring the sensor,

see Wiring of Remote Sensors below.

Temperature Control Sensors

This is a two-stage temperature control that controls the

burner ignition and pump functions. This temperature

controller can measure up to three different sensor inputs,

depending upon how the unit is set up. They are as follows:

1. Inlet Water Temperature Sensor

2. Multi-Purpose Temperature Sensor

3. Outside Air Temperature Sensor

Wiring of Remote Sensors

To wire remote sensors, follow the guidelines below. Take

care to correctly wire sensors to the unit. Erratic

temperature readings can be caused by poor wiring

practices. Twist the wires between the unit and the remote

sensor. Turn wires at least three or four turns per linear foot

of wiring. This provides protection against some types of

electrical interferences.

Inlet Water Temperature Sensor

1. Do not route temperature sensor wiring with building

power wiring.

This sensor measures the inlet water temperature coming

into the unit.

2. Do not locate temperature sensor wiring next to control

The inlet water temperature sensor is placed into the inlet

bulbwell on the boiler. This sensor is installed by the

factory in new units.

contactors.

3. Do not locate temperature sensor wiring near electric

motors.

Multi-Purpose Temperature Sensor

Depending upon how your unit is set up, this sensor can be

used as a system sensor in a boiler system or a tank sensor

4. Do not locate temperature sensor wiring near welding

equipment.

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5. Make sure good mechanical connections are made to

the sensor, any interconnecting wiring and the

controller.

6. Do not mount sensor with leadwire end pointing up in

an area where condensation can occur.

7. Use shielded wiring to connect the sensor to the control

when the possibility of an electrically noisy

environment exists. Shielded cable is recommended on

all cable runs of more than 25 feet in length.

Ratio

The Ratio knob allows control over the reset ratio to be

used during Outdoor Air Reset. The allowable ratios are as

low as 0.5:1 or as high as 1.5:1.

Selecting the 0.5:1 ratio will increase the set point 0.5° for

every 1.0° drop in outdoor air temperature up to the

maximum set point temperature.

Selecting the 1.5:1 ratio will increase the set point 1.5° for

every 1.0° drop in outdoor air temperature up to the

maximum set point temperature.

NOTE:

If the outdoor design and boiler design temperatures are

known, the Ratio setting can be calculated using the

following formula:

Ground the cable shield at the connection to the boiler

temperature control only. Do not ground the shielded

cable at the sensor end.

Ratio = (boiler design temperature - operator set point)

(O.A. Max. setting - outdoor design temperature)

To maintain temperature accuracy, sensor wires should

be 18 AWG two conductor (18/2). Use shielded wire if

required.

Note that the reset set point cannot exceed the maximum

set point of the boiler thermostat.

OUTDOOR AIR RESET OPTION

Outdoor Air Reset Option

These settings are illustrated graphically in Figure 30.

For boilers ordered with the Outdoor Air Reset option,

there is an additional control (FIG. 29). There are three

setting knobs for Shutdown, Outdoor Air Max., and Ratio.

There is also a switch to turn the outdoor air shutdown

feature On or Off. An O.A. Sensor is also included.

CN1

CN3

CN2

OJ1

CN7

O.A. SENSOR

CN4

CN8

ENABLE

SW1

VR3

DISABLE

CN5

CN6

OJ2

O.A. SHUTDOWN

SHUTDOWN

1.0

0.9

0.8

1.1

1.2

1.3

1.4

1.5

RATIO

0.7

0.6

VR1

VR2

0.5

CN1

O.A. MAX.

CN9

160

200

140

120

HIGH-FIRE

OFFSET

FIG. 30 Outdoor Air Control Example Chart

220

Outdoor Air Shutdown Enable/Disable Switch

The Outdoor Air Shutdown Enable/Disable switch turns

the outdoor air shutdown feature On and Off. Disabling the

Outdoor Air Shutdown feature allows the unit to operate

regardless of the outdoor air temperature. This is needed

for indirect domestic hot water systems for example.

VR2

VR3

(F-)0

240

DIFFERENTIAL

OFF

TST2314

SETPOINT

FIG. 29 Optional Outdoor Air Reset Control

Shutdown

The Shutdown knob specifies the outdoor air lockout

temperature at which the control would prevent the unit

from operating.

ADDITIONAL TEMPERATURE

CONTROLS

High Water Temperature Limit Control

Outdoor Air Max (O.A. Max)

The O.A. Max knob allows a reset up to the maximum

outdoor air temperature specified by this knob setting.

When the outdoor air temperature is above the specified

setting, the unit will not function in the O.A. Reset Mode,

but will continue to run at the selected set point

temperature.

The appliance is supplied with a fixed setting, auto-reset

high water temperature limit control. The setting of this

control limits maximum discharge water temperature. If

water temperature exceeds the setting, the limit will

break the control circuit and shut down the appliance.

The limit control will only be reset after the water tem-

perature has cooled well below the setting of the limit.

The auto-reset high water temperature limit control is

mounted in the outlet side of the front header.

Note that the set point knob will now indicate the

“minimum” boiler temperature. Target temperature is

determined by the ratio and outdoor air temperature below

the O.A. Max setting.

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Manual Reset High Water Temperature Limit

Control (Standard Fixed Settings on Water Heaters and

Optional Adjustable Settings on Boilers and Water Heaters)

Water heaters are supplied with a fixed setting, manual

reset high water temperature limit control. This manual

reset temperature limit control has a fixed limit setting

of 230°F (110°C). If water temperature exceeds this

setting, the limit will break the control circuit and shut

down the unit. The limit control can only be reset after

the water temperature has cooled well below the setting

of the limit. Reset of the limit control is accomplished

by pushing the Red Reset Button (Manual Reset High

Limit) (see Figures 25 - 27 on pages 19 and 20) located

on the front side of the control panel. A label on the

control panel indicates the exact location of the manual

reset high water temperature limit control.

FLAME ROLL-OUT SWITCH /

INTERLOCK SWITCH

BLOCKED VENT AND FLAME

ROLL-OUT/FLAME INTERLOCK SWITCH

FIG. 32 Flame Roll-Out/Flame Interlock Switch Location

All units are equipped with manual reset blocked vent

and flame roll-out / flame interlock switches. These

temperature switches are located in the controls

compartment and in the relief opening of the boiler’s

built-in draft hood. Each switch has a red reset button.

In the event the system has actuated to shut off the main

burner gas supply, wait for the boiler to cool, then press

the red reset to return the boiler to operation. Operation

of a blocked vent and/or flame roll-out / interlock

switch usually indicates a problem with the venting

system, obstruction of the heat exchanger flue gas

passageway and/or a combustion air supply problem.

The cause for operation of the blocked vent and/or

flame roll-out / interlock switch must be determined and

corrected. If the boiler cannot be restored to normal

operation, contact a qualified service installer, service

agency or the gas supplier.

FIG. 31 Blocked Vent Switch Location

INITIAL START-UP

Follow the Lighting Instructions on the label applied to

the appliance.

A. On water heaters and boilers with the system

pump delay option, the operating temperature

control will energize the pump relay which

energizes the pump on a call for heat. The

operating temperature control will de-energize

the pump relay approximately 30 seconds after

the call for heat ends. If either the inlet sensor

or the optional multi-purpose temperature

sensor reads below 40°F, the pump relay will

turn ON. When the temperature rises above

50°F the pump relay will turn OFF.

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On boilers, the pump will operate whenever the

“W” terminal is energized.

LIGHTING INSTRUCTIONS FOR

STANDING PILOT MODELS (F1)

MODELS 90,000 THRU 270,000 Btu/hr

INPUT FOR YOUR SAFETY READ

BEFORE OPERATING

B. Location - The appliance should be located

within a room having a temperature safely

above freezing [32°F(0°C)].

C. Shutdown and Draining - If, for any reason,

the appliance is shut off, the following

precautionary measures must be taken:

ƽ WARNING

If you do not follow these instructions exactly, a

fire or explosion may result causing property

damage, personal injury or loss of life.

1. Shut off gas supply,

2. Shut off water supply.

3. Shut off electrical supply.

A. This appliance has a pilot which must be

ignited by hand. When lighting the pilot,

follow these instructions exactly.

4. Drain the heat exchanger completely. Re-

move one 3/8" NPT plug or bulb well from the

inlet side and one from the outlet side of the

front header of the heat exchanger.

5. Drain the pump. Remove the 3/4" plug in

the bypass loop.

B. BEFORE OPERATING, smell around the

appliance area for gas. Be sure to smell next to

the floor because some gas is heavier than air

and will settle to the floor.

PRE-START CHECKLIST

WHAT TO DO IF YOU SMELL GAS

1. Inspect the burners to be sure they are properly

aligned.

Do not try to light any appliance.

2. Inspect the pilot gas line, thermocouple leads,

ignition leads and wire connections to the gas

valve to be sure none were damaged during

shipment.

Do not touch any electric switch; do not use any

phone in your building.

Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

3. Check to ensure that gas connections have been

made properly and the gas line is purged of air.

If you cannot reach your gas supplier, call the

fire department.

4. Check to ensure that water connections are tight

and the appliance and piping system have been

properly filled.

C. Use only your hand to push in or turn the gas

control knob. Never use tools. If the knob 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.

5. Ensure that discharge from the relief valve has

been piped to a floor drain.

6. Verify that properly sized combustion and

ventilation air openings are provided and not

obstructed in any way.

D. Do not use this appliance if any part has been

under water. Immediately call a qualified

service technician to inspect the appliance. The

possible damage to a flooded appliance can be

extensive and present numerous safety hazards.

Any appliance that has been under water must

be replaced.

7. Check carefully for gas leaks.

8. Read the appliance’s safety warnings, lighting

instructions and check out procedure carefully,

before firing the system.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information.

2. Remove the control panel door.

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3. Set the thermostat to the lowest setting (OFF).

4. Turn off all electrical power to the appliance.

5. Turn the gas control knob on the gas valve

clockwise to the “OFF” position.

FIG. 35 Lighting Wand

NOTE:

The information package shipped with the

appliance contains a wire lighting wand. The loop

end of the wand will hold a match. The wand

extends your reach to the pilot and makes lighting

the pilot easier.

FIG. 33 F1 Gas Valve 90,000 - 270,000 Btu/hr Models

6. Wait five (5) minutes to clear out any gas, then

smell for gas, including near the floor. If you smell

gas, STOP! Follow the steps in the“What To Do If

You Smell Gas” section in the safety information

on page 24. If you do not smell gas go on to the

next step.

10. Use the loop end of the wire lighting wand,

shipped with the instruction package, to hold the

match and reach the pilot. An access slot is

provided in the lower front jacket panel, beside the

burner, to insert the lighting wand and match to the

pilot. Lift the pilot cover (FIG. 35) to access the

pilot. Push down and hold in the red button on the

gas valve. This should start gas flow to the pilot.

Continue to hold the red button in for about one (1)

minute after the pilot is lit. Release the button and

it will pop back up. The pilot should remain lit. If

the pilot goes out, repeat steps 5 through 10.

7. Remove the lower panel door to gain access to the

pilot.

8. Find the pilot - Follow the metal tube from the gas

valve to the pilot. The pilot is located on the right

side of the burner approximately centered in the

burner tray.

If the red button does not pop up when released,

stop and immediately call your gas supplier.

If the pilot will not stay lit after several tries, turn

the gas control to “OFF” and call your

service technician or gas supplier.

11. Turn the gas control knob on the gas valve

counterclockwise to the “ON” position.

12. Turn on all electric power to the appliance.

13. Re-install the lower panel door.

14. Set the thermostat to the desired setting.

15. Re-install the control panel door.

FIG. 34 Pilot Location

9. Turn the control knob on the gas valve

counterclockwise to the “PILOT” position.

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5. After successful completion of test, turn the

control knob on the gas valve clockwise to the

“OFF” position. Do not force.

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the OFF position.

6. Carefully reconnect the thermocouple to the gas

valve.

2. Turn off all electric power to the appliance if

service is to be performed.

7. Follow the Lighting Instructions to relight the pilot

and establish normal operation.

3. Turn the gas control knob on the gas valve

clockwise to the “OFF” position. Do not force.

LIGHTING INSTRUCTIONS FOR SPARK

IGNITION PILOT MODELS (F9/M9)

MODELS 45,000 THRU 500,000 Btu/hr

INPUT FOR YOUR SAFETY READ

BEFORE OPERATING

ƽ WARNING

Should overheating occur or the gas fail to shut

off, turn off the external manual gas valve to the

appliance.

ƽ WARNING

If you do not follow these instructions exactly, a fire

or explosion may result causing property damage,

personal injury or loss of life.

SAFETY SHUTOFF TEST FOR

STANDING PILOT IGNITION SYSTEM

A. This appliance is equipped with an ignition

device which automatically lights the pilot. Do

not try to light the pilot by hand.

B. BEFORE OPERATING, smell around the

appliance area for gas. Be sure to smell next to

the floor because some gas is heavier than air

and will settle to the floor.

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use

any phone in your building.

Immediately call your gas supplier from a

neighbor’s phone. Follow the gas supplier’s

instructions.

FIG. 36 Pilot with Thermocouple and Spark Ignition

1. With the main burners on and firing, unscrew the

thermocouple connection from the gas valve

(FIG 36) and remove from the fitting. See Figure

25 to locate the thermocouple outlet connection on

the gas valve.

If you cannot reach your gas supplier, call the

fire department.

C. Use only your hand to turn the gas control

knob. Never use tools. If the knob 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.

2. The main gas valve should extinguish the burners

immediately after removal of the thermocouple.

3. If burners do not extinguish, immediately follow

D. Do not use this appliance if any part has been

under water. Immediately call a qualified

service technician to inspect the appliance. The

possible damage to a flooded boiler can be

extensive and present numerous safety hazards.

Any appliance that has been under water must

be replaced.

steps in “To Turn Off Gas To Appliance”.

4. Immediately call a qualified serviceman or

installer to repair an ignition system that fails to

operate properly and shut down the burners.

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OPERATING INSTRUCTIONS

TO TURN OFF GAS TO APPLIANCE

1. STOP! Read the safety information first.

2. Remove the control panel door.

1. Set the thermostat to the OFF position.

2. Turn off all electric power to the appliance if

service is to be performed.

3. Set the thermostat to the lowest setting (OFF).

4. Turn off all electrical power to the appliance.

3a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr

models, rotate the gas control knob on the gas

valve clockwise to the “OFF” position. Do not

force.

5. This appliance is equipped with an ignition device

which automatically lights the pilot. DO NOT try

to light the pilot by hand.

3b. 180,000 - 360,000 Btu/hr models, rotate the gas

control knob on the gas valve clockwise to the line

on the collar around the knob. Depress the knob

and continue rotation to the “OFF” position. Do

not force.

6a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr

models, rotate the gas control knob on the gas

valve clockwise to the “OFF” position.

6b. 180,000 - 360,000 Btu/hr models, rotate the gas

control knob on the gas valve clockwise to the line

on the collar around the knob. Depress the knob

and continue rotation to the “OFF” position.

ƽ WARNING

Should overheating occur or the gas fail to shut off,

turn off the external manual gas valve to the

appliance.

7. Wait five (5) minutes to clear out any gas, then

smell for gas, including near the floor. If you smell

gas, STOP! Follow the steps in the “What To Do

If You Smell Gas” section in the safety information

on page 26. If you do not smell gas go on to the

next step.

SAFETY SHUTOFF TEST FOR SPARK

IGNITION PILOT SYSTEM

1. Turn “OFF” gas supply to the appliance.

2. Turn thermostat to highest setting.

3. Turn electric power “ON”.

8a. 45,000 - 135,000 and 399,999 - 500,000 Btu/hr

models, rotate the gas control knob on the gas

valve counterclockwise to the “ON” position.

8b. 180,000 - 360,000 Btu/hr models, rotate the gas

control knob on the gas valve counter-

clockwise to the line on the collar around the knob.

Allow the knob to “pop” up, and continue rotation

to the “ON” position.

4. Pump relay pulls in to start pump.

5. The ignition will begin sparking at the pilot.

6. The ignition module will lock out after the 90

second trial for ignition period on the 45,000 thru

399,999 Btu/hr models and after the 15 second

trial for ignition period on the 500,000 Btu/hr

model.

9. Turn on all electric power to the appliance.

10. Set the thermostat to the desired setting.

11. Re-install the control panel door.

7. Immediately call a qualified serviceman or

installer to repair an ignition system that fails to

lock out and properly shut down burner operation.

12. If the appliance will not operate, follow the

instructions “To Turn Off Gas To Appliance” and

call your service technician or gas supplier.

8. After successful completion of the test, readjust

the thermostat to normal setting.

9. Turn “ON” gas supply.

10. Turn power “OFF” then “ON” to reset ignition

module.

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11. If ignition system fails to operate properly, repair 4. Freeze protection for a heating boiler or hot water

work must be performed by

serviceman or installer.

qualified

supply boiler using an indirect coil can be provided

by using hydronic system antifreeze. Follow the

manufacturers instructions.

DO NOT use

undiluted or automotive type antifreeze.

INTERMITTENT PILOT

SPARK IGNITION SYSTEM (F9/M9)

5. A snow screen should be installed to prevent snow

and ice accumulation around the appliance venting

system in cold climates.

The ignition module is not repairable. Any modification

or repairs will invalidate the warranty and may create

hazardous conditions that result in property damage,

personal injury, fire, explosion and/or toxic gases. A

faulty ignition module must be replaced with a new

module.

6. Shut-down and Draining - If for any reason, the

appliance is to be shut off, the following

precautionary measures must be taken:

(a) Shut off gas supply.

IGNITION and CONTROL TIMINGS

(b) Shut off water supply.

F1 Standing Pilot Models (thermocouple supervised)

Pilot Flame Failure Response Time - 180 Seconds

(d) Drain the unit completely. Remove one

threaded plug or bulb well from the inlet

side of the front header and one from the

outlet side of the front header on the heat

exchanger. Blow all water out of the heat

exchanger.

Maximum

F9/M9 Intermittent Spark Ignition Pilot Models

Pilot Trial for Ignition Period - 90 Seconds

(45,000 thru 399,999 Btu/hr models)

Pilot Trial for Ignition Period - 15 Seconds

(500,000 Btu/hr model)

(e) Drain pump and piping.

Pilot Failure Response Time - 0.8 Seconds at less than

1.0 µA flame current

FREEZE PROTECTION FOR A HEATING

BOILER SYSTEM (If Required)

Pump Delay Timing (Standard on Water Heaters and

Optional on Boilers) - 30 Seconds after burner shut-

down

1. Use only properly diluted inhibited glycol anti-

freeze designed for hydronic systems. Inhibited

propylene glycol is recommended for systems

where incidental contact with drinking water is

possible.

FREEZE PROTECTION

1. For water heaters, and boilers with the pump delay

option, if either the inlet sensor or the optional

multi-purpose temperature sensor reads below

40°F, the pump relay will turn ON. When the

temperature rises above 50°F the pump relay will

turn OFF.

ƽ CAUTION

DO NOT use undiluted or automotive type

antifreeze.

2. A solution of 50% propylene glycol will provide

maximum protection of approximately -30°F.

2. Location - Heating boilers and water heaters must

be located in a room having a temperature safely

above freezing [32°F(0°C)].

3. Follow the instructions from the glycol antifreeze

manufacturer. The quantity of glycol antifreeze

required is based on total system volume including

expansion tank volume.

3. Caution - A room where the appliance is installed

and operating under a negative pressure may

experience a downdraft in the flue of an appliance

which is not firing. The cold outside air pulled

down the flue may freeze a heat exchanger. This

condition must be corrected to provide adequate

freeze protection.

4. Glycol is more dense than water and changes the

viscosity of the system. The addition of glycol

will decrease heat transfer and increase frictional

loss in the heating boiler and related piping. A

larger pump with more capacity may be required to

maintain desired flow rates in a glycol system.

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5. Local codes may require a back flow preventer or

actual disconnect from city water supply when

glycol antifreeze is added to the system.

a. Normal Flame: A normal flame is blue, with

slight yellow tips, with a well defined inner

cone and no flame lifting.

b. Yellow Tip: Yellow tip can be caused by

blockage or partial obstruction of air flow to

the burner(s).

WATER TREATMENT

In hard water areas, water treatment should be used to

reduce the introduction of minerals to the system.

Minerals in the water can collect in the heat exchanger

tubes and cause noise on operation. Excessive build up

of minerals in the heat exchanger can cause a

non-warrantable failure.

c. Yellow Flames: Yellow flames can be caused

by blockage of primary air flow to the

burner(s) or excessive gas input.

This

condition MUST be corrected immediately.

d. Lifting Flames: Lifting flames can be caused

by over firing the burner(s) or excessive

primary air.

MAINTENANCE

Listed below are items that must be checked to ensure

safe reliable operation. Verify proper operation after

servicing.

If improper flame is observed, examine the venting

system, ensure proper gas supply and adequate supply

of combustion and ventilation air.

ƽ CAUTION

3. Combustion Air Adjustment: This appliance uses

an atmospheric combustion process. Combustion

air is provided to the burners by the gas injection

pressure into the venturi of the burners. The

burners do not have an adjustable air shutter.

Adequate combustion air must be supplied to the

room where the appliance is installed to ensure

proper burner operation. Check frequently to be

sure the flow of combustion and ventilation air to

the unit is not obstructed. When the main burners

light, observe the burner flame. Flames should be

light blue in color with slight yellow tips; flames

should be settled on burner head with no lifting

when supplied with correct volume of combustion

air.

Label all wires prior to disconnection when

servicing controls. Wiring errors can cause

improper and dangerous operation.

1. Examine the venting system at least once a year.

Check more often in the first year to determine

inspection interval. Check all joints and pipe

connections for tightness, corrosion or

deterioration. Clean louvers and/or screens in the

combustion air intake system as required. Have

the entire system, including the venting system,

periodically inspected by a qualified service

agency.

2. Visually check main burner flames at each start up

after long shutdown periods or at least every six

months.

4. Flue Gas Passageways Cleaning Procedures: Any

sign of soot around the outer jacket, at the burners

or in the areas between the fins on the copper heat

exchanger indicates a need for cleaning. The

following cleaning procedure must only be

performed by a qualified serviceman or installer.

Proper service is required to maintain safe

ƽ WARNING: The area around the burners is hot and direct contact could result in burns!

operation.

Properly installed and adjusted

appliances seldom need flue cleaning.

All gaskets on disassembled components must be

replaced with new gaskets on reassembly. Gasket kits

are available from your distributor.

FIG. 37 Burner Flames

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e. Disconnect gas valve wiring and remove gas

manifold assembly.

INSPECTION CLEANING PROCEDURE

f. Remove ignition wire leading to the pilot

assembly from the ignition module.

ƽ WARNING

The combustion chamber lining in this appliance

contains ceramic fiber materials. Ceramic fibers can

transform into cristobalite (crystalline silica) when

exposed to temperatures above 2192°F (1200°C)

dependent upon the length of exposure time.*

g. Disconnect the wiring from the flame roll-

out/interlock switch, see Figure 32, page 23.

h. Remove the lower front jacket panel.

i. Remove the control panel mounting screws.

When removing the control panel, lay the

control panel to the side with the wiring intact,

being careful not to damage any of the wiring.

The International Agency for Research on Cancer

(I.A.R.C.) has concluded, "Crystalline silica inhaled in

the form of quartz or cristobalite from occupational

sources is carcinogenic to humans."**

Remove the combustion chamber door. Use

caution to prevent damage to burners,

refractory, pilot or wiring.

Testing has confirmed that the ceramic fibers in this

application do not reach 2192°F (1200°C).

*Reference Dyson, D., Butler, M., Hughes, R., Fisher,

R., and Hicks, G. The Devitrification of Alumino-

silicate Ceramic Fiber Materials - The Kinetics of the

Formation of Different Crystalline Phases, Ann.

Occup. Hyg. Vol. 41, No. 55, 1997.

INSPECTION AND CLEANING

j. Check the heat exchanger surface for sooting.

The external surfaces of the copper tubes

should be free of any soot deposits. (A slight

black smudge is normal with some types of

gases.) If abnormal soot deposits are present,

the heat exchanger must be cleaned and the

cause of the soot problem corrected. Proceed as

follows:

**Reference I.A.R.C. Monograph 68, June 1997.

NOTE:

The ceramic fiber material used in this appliance is an

irritant; when handling or replacing the ceramic materials

it is advisable that the installer follow these safety guides.

k. Remove soot from burners and bottom of the

finned tubes with a stiff bristle brush. Dirt

may also be removed from burner ports by

rinsing the burner thoroughly with water.

Drain and dry burners before re-installing.

Damaged burners must be replaced.

REMOVAL OF COMBUSTION CHAMBER LINING

OR BASE PANELS:

• Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95)

(http://www.cdc.gov/niosh/homepage.html).

• Lightly mist with water (only those areas being handled)

the combustion chamber lining or base insulation to

prevent airborne fibers.

An appliance installed in a dust or dirt contaminated

atmosphere will require cleaning of the burners on a 3

to 6 month schedule or more often, based on severity of

contamination. Contaminants can be drawn in with the

combustion air. Non-combustible particulate matter

such as dust, dirt, concrete dust or dry wall dust can

block burner ports and cause non-warrantable failure.

Use extreme care when operating an appliance for

temporary heat during new construction. The burners

will probably require a thorough cleaning before the

appliance is placed in service.

• Remove combustion chamber lining or base insulation

from the boiler and place it in a plastic bag for disposal.

• Wash potentially contaminated clothes separately from

other clothing. Rinse clothes thoroughly.

• NIOSH stated First Aid:

Eye: Irrigate immediately.

Breathing: Fresh air.

HEAT EXCHANGER/BURNER ACCESS

l. Remove gas manifold as described in steps a.

thru e. in “Heat Exchanger/Burner Access.”

a. Turn “OFF” main power to the appliance.

m. Loosen mounting screws and remove front

control panel.

b. Turn “OFF” external manual gas shutoff valve

to appliance.

n. Loosen screws on the upper front jacket panel

and remove toward front of the appliance. Use

caution to prevent damage to refractory on the

doors inner surface.

c. Remove the control panel door.

d. Remove the outer air deflector (FIG.38A )

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o. Check “V” baffles on top of the heat 6. Keep appliance area clear and free from

exchanger. Remove and clean if necessary.

combustible materials, gasoline and other

flammable vapors and liquids.

p. Remove soot from the heat exchanger with a stiff

bristle brush. Soot may also be removed from the 7. Check frequently to be sure the flow of combus-

heat exchanger by washing thoroughly with

detergent and water. Remove the heat exchanger

before using water for cleaning. Rinse thoroughly

and dry before re-installing. Use a vacuum to

remove loose soot from surfaces and inner

chamber.

tion and ventilation air to the boiler is not

obstructed.

8. Inspection of Heat Exchanger Waterways:

Appliances operated in hard water areas should

have periodic inspections of the tubes to be sure

that no sediment or scale accumulates on the heat

transfer surfaces. Inspection plugs are located at

both ends of the heat exchanger. Inspection plugs

should be removed and tubes inspected at the end

of the first 45 days of operation and again at the

end of 90 days of operation. If no scale

accumulation is observed, inspections can be made

at the end of each six months of operation.

q. Remove the heat exchanger (HEX) filler bracket

(FIG. 38A).

r. The heat exchanger can be removed by sliding

towards the front of the appliance. Once the

heat exchanger is removed from the appliance,

a garden hose can be used to wash the tubes to

ensure that all soot is removed from the heat

exchanger surfaces.

9. Pilot Flame Adjustment Procedure - The pilot

flame should envelop 3/8" to 1/2" (10 to 13mm) of

the tip of the thermocouple (see Figure 38B).

s. Ensure that all burner ports are cleaned to

remove any soot. See Inspection and Cleaning

Procedure, page 30.

t. Carefully re-install the heat exchanger, “V”

baffles, jacket panels, and wires.

u. Reassemble all gas and water piping. Test for

gas leaks.

v. Cycle the appliance and check for proper

operation.

UPPER FRONT

JACKET PANEL

OUTER AIR

DEFLECTOR

FIG. 38B Pilot Flame on Thermocouple

a. Remove pilot adjustment cover screw on gas

valve. See Gas Valve Illustrations in the

Lighting Instructions section for location of

cover screw.

HEX FILLER

BRACKET

b. Turn inner adjustment screw clockwise to

decrease or counterclockwise to increase pilot

flame.

c. If difficulty is experienced in adjusting the

pilot flame, a tee may be installed in the pilot

line from the gas valve to the pilot burner.

FLAME ROLL-OUT SWITCH /

INTERLOCK SWITCH

LOWER FRONT

JACKET PANEL

FIG. 38A Outer Air Deflector and HEX Filler Bracket

5. Water Circulating Pump: Inspect pump every 6

months and oil if required. Use SAE 30

non-detergent oil or lubricant specified by pump

manufacturer.

d. Replace pilot adjustment cover screw on valve.

Tighten firmly after adjustment to prevent gas

leakage.

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expansion tank installed. Typically, an air charged

diaphragm-type expansion tank is used. The expansion

tank must be installed close to the boiler and on the

suction side of the system pump to ensure proper

operation. Caution: This boiler system should not be

operated at less than 12 PSIG. Hot water piping must

be supported by suitable hangers or floor stands, NOT

by the boiler. Copper pipe systems will be subject to

considerable expansion and contraction. Rigid pipe

hangers could allow the pipe to slide in the hanger

resulting in noise transmitted into the system. Padding

is recommended on rigid hangers installed with a

copper system. The boiler pressure relief valve must be

piped to a suitable floor drain. See the relief valve

section in the Installation and Service Manual.

IMPORTANT

Upon completion of any testing on the gas system,

leak test all gas connections with a soap solution

while main burners are operating. Immediately

repair any leak found in the gas train or related

components. Do Not operate an appliance with a

leak in the gas train, valves or related piping.

GAS TRAIN AND CONTROLS

ƽ CAUTION

A leak in a boiler system will cause the system to

intake fresh water constantly, which will cause the

tubes to accumulate a lime/scale build up. This will

cause a NON-WARRANTABLE FAILURE.

WATER CONNECTIONS

HEATING BOILERS ONLY

FIG. 39 Gas Train 45,000 - 399,999 Btu/hr Models

Heating Boilers with inputs of 45,000 - 260,000 Btu/hr

have 1 1/2" NPT inlet and outlet connections. Heating

boilers with inputs of 315,000 - 500,000 Btu/hr have 2"

NPT. All water heaters have 2" NPT. Caution: Field

installed reducing bushings may decrease flow resulting

in boiler noise or flashing to steam.

CIRCULATOR PUMP REQUIREMENTS

This is a low mass, high efficiency hot water boiler

which must have adequate flow for quiet, efficient

operation. The boiler circulating pump must be

purchased locally. The boiler circulator pump must

operate continuously while the boiler is firing. Pump

FIG. 40 Gas Train 500,000 Btu/hr Model

selection is critical to achieve proper operation.

PIPING OF THE BOILER SYSTEM

pump should be selected to achieve proper system

design water temperature rise. A heat exchanger

pressure drop chart (Table L) is provided to assist in

proper pump selection. Also provided is a System

Temperature Rise Chart (Table N). This table provides

GPM and boiler head-loss at various temperature rises

for each boiler based on Btu/hr input. Temperature rise

is the difference in boiler inlet temperature and boiler

outlet temperature while the boiler is firing. Example:

The boiler inlet temperature is 160°F and the boiler

outlet temperature is 180°F, this means that there is a

20°F temperature rise across the boiler.

The drawings in this section show typical heating

boiler piping installations. Before beginning the instal-

lation, consult local codes for specific plumbing

requirements. The installation should provide unions

and valves at the inlet and outlet of the boiler so it can

be isolated for service. The boiler circulating pump, air

separator, expansion tank and other components

required for proper installation must be purchased

locally. An air separation device must be supplied in

the installation piping to eliminate trapped air in the

system. Locate a system air vent at the highest point in

the system. The system must also have a properly sized

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TABLE - L

HEAT EXCHANGER PRESSURE DROP CHART

FOOT HEAD LOSS

FIG. 41 Boiler Wiring - Circulation Pump to Junction Box

CIRCULATOR PUMP SPECIFICATIONS

PUMP INSTALLATION AND MAINTENANCE: The

boiler circulating pump must be purchased locally. For

installation and maintenance information on the

circulator pump, refer to the pump manufacturers

instruction package included with the pump.

1. Maximum operating pressure for the pump must

exceed system operating pressure.

2. Maximum water temperature should not exceed

nameplate rating.

BYPASS PUMP 45,000 - 260,000 Btu/hr

(Heating Boilers Only)

3. Cast iron circulators may be used for closed loop

systems.

These units are equipped with an integral bypass pump,

which is designed to provide efficiency optimization by

maintaining a constant flow through the unit’s heat

exchanger loop when building system flow is reduced.

The bypass pump assembly is standard equipment and is

NOT to be used as a system pump.

4. A properly sized expansion tank must be installed

near the boiler and located on the suction side of

the pump.

CIRCULATOR PUMP OPERATION

(Heating Boilers Only)

NOTE:

The bypass pump is dedicated to the unit and does not

affect the building’s system or primary/secondary

flow characteristics and will not circulate the

building.

Boilers are equipped with a relay for controlling the

circulation pump for the hot water loop. The relay turns

ON and OFF in response to the “W” input from the wall

thermostat or zone control.

EXPANSION TANK

The field installed boiler pump MUST NOT exceed

1 h.p. For continuous pump operation, wire the system

pump to the 120V supply. The pump should be

connected at the junction box as shown in Figure 41.

MAKE-UP WATER

AIR SEPARATOR

HEATING RETURN

LOOP

HEATING SUPPLY LOOP

FIG. 42 - Single Boiler Full System Flow

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The installer must ensure that the boiler has adequate

flow without excessive temperature rise. The

PRIMARY/SECONDARY

BOILER PIPING

temperature rise on a multiple zone system should be

made when only the zone with the longest length and/or

highest head loss is open. Low system flow can result

in overheating of the boiler water which can cause short

burner on cycles, system noise and in extreme cases, a

knocking flash to steam. These conditions indicate the

need to open the bypass adjustment valve, installation

of a larger circulator pump or installation of the boiler

with a primary/secondary piping system. System noise

may also indicate an oversized boiler.

ƽ CAUTION

At no time should the system pressure be less than

12 PSIG.

MAKE-UP

WATER

FIG. 43 Primary/Secondary Piping of a Single Boiler

Heating boilers with inputs of 315,000 - 500,000 Btu/hr

or larger installed on multiple zone systems are recom-

mended to be installed with a primary/secondary piping

system as shown in Figure 43. A primary/secondary

piping system may also be installed on smaller input

boilers to ensure proper boiler flow rates. Primary/sec-

ondary piping is also ideal for systems using a mixture of

propylene glycol and water. A primary/secondary piping

system uses a dedicated pump to supply flow to the

boiler only. This pump is sized based on desired boiler

flow rate, boiler head loss and head loss in the secondary

system piping only. The secondary pump, installed in

the boiler piping, ensures a constant water flow rate to

the boiler for proper operation. Boiler installation with a

primary/secondary piping system can prevent noise

PRV

EXPANSION TANK

TO SYSTEM

LWCO

(OPTIONAL)

SYSTEM

PUMP

SECONDARY

BYPASS

12"

BOILER PUMP

AIR SEPARATOR

FROM

SYSTEM

FIG. 44 Boiler with Low Temperature Bypass Piping - Models

315,000 - 500,000 Btu/hr

problems caused by low system water flows.

A boiler operated with an inlet temperature of less than

140°F (60°C) must have a bypass to prevent problems

with condensation. A bypass as shown in Figure 44

must be piped into the system at the time of installation.

primary/secondary piping system is recommended on

any boiler where low water flow conditions may present

an operational problem.

A primary/secondary piping system is ideal for systems

filled with a propylene glycol and water mixture. A

glycol and water mixture is more dense than water only

and may result in a lower boiler flow rate. A lower

boiler flow may cause noise on operation or short

cycling of the burners. A larger secondary pump may

be used on a primary/secondary system to provide an

increased boiler flow rate. A glycol and water system

may require from 10 to 20% more flow to compensate

for the increased density of the glycol and its effect on

the heat transfer process in the boiler. The exact

increase in flow that may be required is based on the

type and percentage of glycol added to the boiler

system. Consult the manufacturer of the glycol for

additional recommendations when using a glycol and

water fill for your boiler system.

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Low flow rates can result in overheating of the boiler

water which can cause short burner on cycles, system

noise and in extreme cases, a knocking flash to steam.

These conditions can cause operational problems and

non-warrantable failures of the boiler. If a three way

LOW TEMPERATURE BYPASS

REQUIREMENTS

This piping is like a primary/secondary boiler

installation with a bypass in the secondary boiler

piping. Inlet water temperatures below 140°F (60°C)

can excessively cool the products of combustion

resulting in condensation on the heat exchanger and in

the flue. Condensation can cause operational problems,

bad combustion, sooting, flue gas spillage and reduced

service life of the vent system and related components.

The bypass allows part of the boiler discharge water to

be mixed with the cooler boiler return water to increase

the boiler inlet temperature above 140°F (60°C). This

should prevent the products of combustion from

condensing in most installations. The bypass should be

fully sized with a balancing valve to allow for proper

adjustment. A valve must also be provided on the boiler

discharge, after the bypass. Closing this discharge

valve forces water through the bypass. Start boiler

adjustment with the bypass valve in the full open

position and the boiler discharge valve half open. A

small amount of the higher temperature boiler discharge

water is mixed with the system water to maintain the

desired lower system temperature. A remote low tem-

perature range operator is recommended to control the

boiler operation based on the lower system temperature.

This remote operator should be wired across the R and

W terminals (see Room Thermostat Connection and

Terminal Strip Instructions).

valve must be installed, please pipe in

primary/secondary system as shown in Figure 45.

Based on boiler sizing and system flow requirements,

this piping may still result in boiler short cycling.

BOILER FLOW RATES

ƽ CAUTION

The maximum flow rate through the boiler with a

copper heat exchanger must not exceed 30 GPM.

MAKE-UP WATER

PRV

EXPANSION TANK

TO SYSTEM

LWCO

(OPTIONAL)

SYSTEM PUMP

AIR SEPARATOR

BYPASS VALVE

FROM SYSTEM

THREE WAY VALVES:

FIG. 46 Boiler Bypass Piping

SECONDARY

BOILER PUMP

The heat exchanger is generally capable of operating

within the flow rates of a residential heating system.

Should the flow rate exceed the maximum allowable

flow rate through the boiler (30 GPM) an external

bypass must be installed. The bypass should be fully

sized with a balancing valve to allow for proper

adjustment of flow. Flow rate can be determined by

measuring the temperature rise through the boiler.

FROM

EXPANSION

TANK

SYSTEM

PRV

MAKE-UP

WATER

LWCO

(OPTIONAL)

THREE-WAY VALVE

SLOW

The basic guide for minimum flow in this boiler is

based on a 40°F temperature rise in most installations.

Lower flow and a higher temperature rise is acceptable

if the boiler system is specifically designed for the

characteristics of a higher temperature rise. A system

not specifically designed for a higher temperature rise

may experience overheating of the boiler water. This

can cause short burner on cycles, system noise and in

extreme cases, a knocking flash to steam. These

conditions can lead to operational problems and

OPENING/SLOW

CLOSING

TO SYSTEM

AIR SEPARATOR

SYSTEM PUMP

FIG. 45 Boiler Piping with a 3-Way Valve

The installation of a three way valve on this boiler is not

generally recommended because most piping methods

allow the three way valve to vary flow to the boiler.

This boiler is a low mass, high efficiency unit which

requires a constant water flow rate for proper operation.

non-warrantable failures of the boiler.

High

temperature rise systems must be designed by a

qualified engineer.

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PLACING THE BOILER IN OPERATION

TABLE - M

MINIMUM REQUIRED FLOW FOR

HEATING BOILER

Filling the System: All air must be purged from the

system for proper operation. An air scoop and air vent

must be located close to the boiler outlet and there

should be a minimum distance between the cold water

feed and the system purge valve.

Input Btu/hr

GPM Flow

45,000

75,000

1.9

3.1

1. Close all drain cocks and air vents.

90,000

3.7

2. Open the makeup water valve and slowly fill the

system.

135,000

180,000

215,000

260,000

315,000

360,000

399,999

500,000

5.6

7.4

3. If a makeup water pump is employed, adjust the

pressure to provide a minimum of 12 psi at the

highest point in the system. If a pressure regulator

is also installed in the line, it should be adjusted to

the same pressure.

8.9

10.7

13.0

14.9

16.5

20.7

4. Close all valves. Purge one circuit at a time as

follows:

A. Open one circuit drain valve and let the water

drain for at least five minutes. Ensure that

there are no air bubbles visible in the water

stream before closing the drain valve.

NOTE:

Minimum flow is based on a 40°F temperature rise

across the boiler. Minimum flow may not prove a

flow switch installed in the boiler piping. Use care

when operating a boiler at or near the minimum

recommended flow because conditions unique to the

installation (system pressure, operation of multiple

zone valves, glycol, variations in flow, etc.,) may

result in overheating of the boiler water causing

noise or nuisance operation of safety limit

controls. Typical heating boiler applications will

operate with a 20°F to 30°F temperature rise across

the boiler.

B. Repeat this procedure for each circuit.

5. Open all valves after all circuits have been purged.

Make sure there are no system leaks.

NOTE:

Do not use petroleum based stop leak products. All

system leaks must be repaired. The constant

addition of make-up water can cause damage to the

boiler heat exchanger due to scale accumulation.

Scale reduces flow and heat transfer, causing

overheating of the heat exchanger.

TYPICAL HEATING BOILER

INSTALLATIONS

6. Run the system circulating pump for a minimum of

30 minutes with the boiler turned off.

General Plumbing Rules

1. Check all local codes.

7. Open all strainers in the system and check for

debris.

2. For serviceability of the boiler, always install

unions.

8. Recheck all air vents as described in step 4,

3. Always pipe pressure relief valves to an open

drain.

General Plumbing Rules.

9. Inspect the liquid level in the expansion tank. The

system must be full and under normal operating

pressure to ensure proper water level in the

expansion tank. Ensure that diaphragm type

expansion tanks are properly charged and not

water logged.

4. Locate system air vents at the highest point of the

system.

5. Expansion tank must be installed near the boiler

and on the suction side of the pump.

6. Support all water piping.

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10. Start the boiler according to the “Start-Up

Instructions” in this manual. Operate the system,

including the pump, boiler and radiation units, for

one hour.

INSTALLATION WITH A CHILLED

WATER SYSTEM

EXPANSION

11. Recheck the water level in the expansion tank. If

it exceeds half the tank volume, open the tank to

reduce the water level. Recheck pressure charge

on diaphragm type tanks.

TANK

HEATING AND

COOLING COIL

LOW WATER

FLOW SWITCH

PUMP

12. Shut down the entire system and vent all radiation

units and high points in the system.

OUT

GAS

13. Close the water makeup valve and check the

strainer and pressure reducing valve for sediment

or debris. Reopen the water makeup valve.

CHILLER

SUPPLY

WATER

SUPPLY

BOILER

FIG. 47 Installation with a Chilled Water System

14. Verify system pressure with the boiler pressure

gauge before beginning regular operation.

Pipe refrigeration systems in parallel. Install duct coil

downstream at the cooling coil. Where the hot water

heating boiler is connected to a heating coil located in

the air handling units which may be exposed to

refrigeration air circulation, the boiler piping system

must be equipped with flow control valves or other

automatic means to prevent gravity circulation of the

boiler water during the cooling cycle. The coil must be

vented at the high point and hot water from the boiler

must enter the coil at this point. Due to the fast heating

capacity of the boiler, it is not necessary to provide a

ductstat to delay circulator operation. Also, omit

thermostat flow checks as the boiler is cold when

heating thermostat is satisfied. This provides greater

economy over maintaining standby heat.

15. Within three days of start-up, recheck and bleed all

air vents and the expansion tank using these

instructions.

TABLE - N

SYSTEM TEMPERATURE RISE CHART

Based on Boiler Output in Btu/hr

Btu/hr

10°F ꢀT

20°F ꢀT

30°F ꢀT

40°F ꢀT

50°F ꢀT

Input

Output

36,900

GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd

45,000

75,000

7.4

12.3

14.9

22.3

29.7

0.6

1.3

1.4

3.2

5.1

3.7

6.2

0.2

0.4

0.5

1.2

1.6

1.3

2.1

4.1

5.4

8.1

2.5

4.1

0.2

0.3

0.6

0.7

0.8

0.9

2.2

2.5

3.6

6.6

1.9

3.1

0.2

0.3

0.4

0.5

1.3

1.5

2.0

3.5

61,500

90,000

73,800

7.4

5.0

3.7

135,000

180,000

215,000

260,000

315,000

360,000

399,999

500,000

110,700

147,600

176,300

213,200

258,300

295,200

327,180

410,000

11.1

14.9

17.0

21.5

26.0

29.7

33.0

7.4

5.6

9.9

7.4

11.8

14.3

17.3

19.8

22.0

27.6

8.9

10.7

13.0

14.9

16.5

20.7

13.2

16.6

1.7

2.1

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BOILER OPERATING

TEMPERATURE CONTROL

The operating temperature control is located in the

control panel, behind the control panel front access door.

The sensing element for the operator is placed in a bulb

well installed in the heat exchanger. Carefully observe

the discharge water temperature on the initial boiler on

cycles. The exact temperature set point is based on your

system’s requirements. Turn the control set point dial to

the desired operating water temperature. Observe the

boiler discharge temperature after each set point

adjustment to ensure proper operation.

ROOM THERMOSTAT OR REMOTE

THERMOSTAT CONNECTION

TO TERMINAL STRIP

FIG. 48 Terminal Strip Connections

A room thermostat or remote temperature control may

be connected to the boiler. The room thermostat should

be installed on an inside wall, away from the influences

of drafts, hot or cold water pipes, lighting fixtures,

televisions, sun rays or fireplaces. Follow the

manufacturers instructions supplied with the thermostat

for proper installation and adjustment. The boiler is

equipped with a terminal strip on the left side of the

control panel to allow easy connection (Figure 48).

POWER VENTER CONNECTION

TO TERMINAL STRIP

A terminal connection strip is provided for ease of

connection for Power Venting Systems, see Figure 48,

inset A.

TABLE - O

TERMINAL STRIP WIRING

Remove the jumper between the R and W terminals on

the terminal strip. Refer to the chart in this section to

determine maximum allowable length and wire gauge

recommended to connect the switching contacts of the

room thermostat to the R and W terminals on the

terminal strip. Connection to the terminal strip will

allow the room thermostat to make and break the

24VAC boiler control circuit turning the boiler on and

off based on the room ambient temperature

requirements. Set the boiler operating temperature

control as described in this section

Wire Gauge

Allowable Length

Maximum

12 GA

14 GA

16 GA

18 GA

100 ft

75 ft

50 ft

30 ft

DOMESTIC WATER HEATERS

90,000 - 500,000 Btu/hr MODELS

This section applies only to those units used to supply

direct fired domestic hot water and installed with a

storage tank(s). The use of a properly sized pump and

the control of water velocity, as explained in the Water

Velocity Control section, are important for correct

operation of your hot water heater.

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This section contains specific instructions for those

units used to supply domestic hot water. All warnings,

cautions, notes and instructions in the general

installation and service sections apply to these

instructions. Water heaters are designed for installation

with a storage tank. The use of a properly sized pump

and the control of water velocity, as explained below, is

important for correct operation of your water heater.

tank tappings to ensure proper flow. See Table Q

on page 40.

6. Multiple unit installations may also require a larger

circulating pump to achieve the specified flow

against the increased head loss of a multiple unit

common manifold piping.

If the temperature rise is too low, the water velocity is

too high. Adjust as follows:

WATER VELOCITY CONTROL

1. Slowly throttle the valve on the outlet side of the

water heater until the temperature rise is steady at

the required temperature rise as noted in Table P.

IMPORTANT - To ensure proper velocity through the

heat exchanger, it is necessary to regulate the

temperature rise across the heat exchanger from inlet to

outlet. This must be done on initial installation and

periodically rechecked. With the correct temperature

rise across the heat exchanger, you may be assured of

the proper velocity in the tubes. This will yield long life

and economical operation from your water heater.

Excessive lime build-up in the tube is a result of too

little velocity in the tubes. Excessive pitting or erosion

in the tube is caused by too much velocity through the

tubes. Care should be taken to measure temperature rise

and maintain a velocity as follows:

2. Sustained high water velocity and low temperature

rise may result in pitting or erosion of the

copper tubes in the heat exchanger. This is a

non-warrantable failure. Temperature rise must be

properly adjusted to achieve the specified flow

rate.

REQUIRED TEMPERATURE RISE

Temperature rise is based on the hardness of the potable

water to be heated. A different temperature rise is

specified for soft water with a hardness of 0 to 7 grains

per gallon or for unsoftened water with a hardness of 8

to 25 grains per gallon. The total dissolved solids shall

not exceed 350 ppm. If there is any doubt about the

hardness or total dissolved solids content of the

water to be heated, follow the temperature

guidelines for water with 8 to 25 grains of hardness

in Table P below. The majority of all potable water

supplies will fall within the range of 8 to 25 grains of

hardness. See Water Chemistry, page 40.

1. The pump must run continuously when the burners

are firing.

2. With the pump running and the water heater off,

the inlet and outlet thermometers should read the

same temperatures. If they do not, an adjustment

must be made to your final calculation.

3. Turn the water heater on and allow time for the

temperature to stabilize. Record the difference

between the inlet and outlet temperatures. This

difference will be the “temperature rise.”

TABLE - P

REQUIRED TEMPERATURE RISE

4. Compare the temperature rise on the heater with

the required temperature rise in Table P. Should

adjustment be needed, proceed as follows:

If the temperature rise is too high, the water velocity is

too low. Check the following:

Btu/hr

INPUT

0 to 7 Grains

Hardness

Temp. Rise F

8 to 25 Grains

Hardness

Temp. Rise °F

1. Check for restrictions in the outlet of the water

heater.

90,000

135,000

180,000

199,999

225,000

270,000

315,000

360,000

399,999

500,000

2. Be sure all valves are open between the water

heater and the tank.

3. Check the pump to be sure it is running properly

and that the pump motor is running in the proper

direction.

4. Be sure the circulation pipes between the water

heater and storage tank are not less than 1 1/2"

diameter for a single unit installation.

5. Common manifold piping for multiple unit instal-

lations will require larger minimum pipe sizes to

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need to be increased. The tubes should not have a

bright shiny copper look. This would indicate that the

erosion process has begun and the flow rate will need to

be decreased. Once the proper flow rates have been

established the inspection intervals can be increased to

every 30 days, once a quarter, or to a bi-annual

inspection. This procedure should ensure proper

operation of the unit as long as the water quality stays

consistent.

NOTE:

Lower flows with soft water mean a higher

temperature rise. A higher temperature rise may

cause nuisance tripping of a high limit or opening

of a relief valve when providing very hot water. If

this presents a problem, increase the flow to the

temperature rise specified for 8 to 25 grains

hardness water.

COLD WATER SUPPLY

WATER CHEMISTRY

HOT WATER SUPPLY

EXPANSION TANK (IF REQUIRED)

The required temperature rise and the standard pump

sizing are based on the heating of potable water with

chemistry within the specified limits. Caution should

be used when heating water softened to less than 5

grains per gallon. Many commercial water softeners

reduce hardness to 0 grains which may result in long

term problems in the system. Softened water will

usually have a lower pH which can be aggressive and

corrosive causing non-warrantable damage to the

heater, pump, and associated piping.

RELIEF

VALVE

CIRCULATING PUMP

RELIEF

VALVE

LOCK-TEMP

STORAGE

TANK

DRAIN

BUILDING

RETURN

Corrosion due to water chemistry generally shows up

first in the hot water system because heated water

increases the rate of corrosive chemical reactions.

Follow the temperature rise recommendations when

heating soft water. Unsoftened water with a hardness of

8 to 25 grains per gallon and/or total dissolved solids

not exceeding 350 ppm requires a higher velocity and

lower temperature rise. As water is heated it becomes

less soluble. The dissolved minerals and solids will

precipitate and collect as scale if water velocity is not

properly controlled. Follow the temperature rise

requirements for unsoftened water. Consult the

manufacturer when heating potable water with hardness

or total dissolved solids exceeding these specifications.

Heating of high hardness and/or high total dissolved

solids water may require a larger circulating pump, an

optional cupro-nickel heat exchanger and a revised

temperature rise specification based on the water

chemistry of the water to be heated.

FIG. 49 Typical Water Heater Piping with Storage Tank

TABLE - Q

COMMON WATER MANIFOLD SIZE FOR

MULTIPLE HOT WATER SUPPLY BOILER

INSTALLATIONS

Pipe sizing chart provides minimum pipe size for

common manifold piping and tank tappings to in-

sure adequate flow.

Number of Units Common Manifold Size (Min)

2 1/2"

3 1/2"

SOFTENED WATER SYSTEMS

Decreasing the flow rate will reduce the erosion

process, however the heat exchanger should be

monitored to ensure the scale/liming process is not

made worse. The unit should be placed on a

comprehensive inspection schedule until optimum flow

rates can be established. Problematic water areas may

require heat exchanger inspection every two weeks.

The total scale accumulation should never exceed the

PUMP OPERATION

1. The water heater/hot water supply boiler must be

connected to a properly sized pump that circulates

water between the heater and storage tank.

2. Pump is sized to heater input and water hardness.

Care should be taken to size the pump

correctly. See “Water Chemistry”, this page.

thickness of a piece of paper.

Should scale

accumulation exceed this thickness the flow rate will

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3. The pump must run continuously when the burners The sensor must also be connected to two blue wires

are firing.

provided in the upper left-hand corner of the control

panel. It will be necessary to add additional wire to

reach from the appliance to the remote water source.

Use twisted pair wire, minimum 18 gauge or larger. See

Table O, page 38 regarding distance versus wire gauge.

4. Lubricate the pump to the manufacturers recommen-

dations. Pump damage due to inadequate lubrica-

tion is non-warrantable.

5. A standard water heater/hot water supply boiler is

furnished with a 1/6 HP, 120 VAC, 3.6 AMP

circulating pump to be mounted on the units inlet

water connection. This pump is sized based on

installation of a single storage tank and heater in

close proximity. If the number of fittings and

straight pipe exceeds the quantities shown in this

section, a larger pump will be required.

EXTERNAL SENSOR FOR TANK, SYSTEM OR PUMP DELAY

NOTE: COLOR OF WIRES AND

REMOTE SENSOR CONNECTOR IS

LOCATED ON SIDE OF UNIT.

LEAD STYLES MAY VARY

WITH SENSOR PROVIDED.

CONNECTIONS ARE POLARITY

INSENSITIVE.

SIDE PANEL

The standard pump selection is based on the following

pipe and fittings from the unit to the storage tank:

6 - 90° elbows

2 - unions

2 - ball valves

1 - cold water tee

FIG. 50 External Sensor for Tank, System, or Pump Delay

HEAT EXCHANGER

Plus the following length of straight pipe based on the

heater size:

This is a highly sophisticated heat exchanger, designed

to carry water in such a way that it generates a scouring

action which keeps all interior surfaces free from

build-up of impurities. The straight-line, two pass

design of the tubes sends water into the headers at a

properly rated velocity. The configuration of the

headers, in turn, creates a high degree of turbulence

which is sufficient to keep all contaminants in

suspension. This “scouring action” provides greater

cost savings for owners. Tubes are always able to

transfer heat at peak efficiency. Every surface within

this water containing section is of a nonferrous material,

providing clear, clean, rust-free hot water. Straight

copper tubes-finned on the outside for maximum heat

transfer-glass lined cast iron one piece cored headers

make up an entirely rustproof unit. On all models,

header inspection plugs can be removed for field

inspection and cleaning of copper tubes. The entire

heat exchanger may be easily removed from the unit.

90,000 thru 360,000 Btu/hr Models

Not more than 45 feet of straight pipe

399,999 thru 500,000 Btu/hr Models

Not more than 25 feet of straight pipe

For every elbow and tee in excess of those shown

above, DEDUCT 5 FEET from maximum allowable

straight pipe in heater to tank circulating loop.

MINIMUM PUMP PERFORMANCE

Based on heating potable water with a hardness of 8 to

25 grains per gallon and total dissolved solids not

exceeding 350 ppm. See “Water Chemistry”, page 40.

BTU/hr INPUT

90,000 - 500,000

GPM

Ft. Hd.

THERMOSTAT SETTINGS

REMOTE SENSOR

INSTALLATION INSTRUCTIONS

1. The thermostat is adjusted to a low test setting

when shipped from the factory.

Water heaters are provided with an extra temperature

sensor that MUST BE field installed. The sensor is

shipped loose in the I & O packet. This remote

mounted sensor will be the primary temperature sensor

which will inform the appliance’s built-in thermostat

control. For domestic water heating, the sensor MUST

BE installed into a bulbwell on the storage tank. This

is required to maintain the desired temperature in the

tank and reduce cycling of the heater.

2. Set the thermostat to

maximum water

temperature of 125°F which will satisfy hot water

demands and prevent risk of scald injury.

Households with small children or invalids may

require 120°F or lower temperature setting to

reduce risk of scald injury. Some states may

require a lower temperature setting. Check with

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your gas supplier for local requirements governing

the temperature setting. Remember, no water

heating system will provide exact temperature at

all times. Allow a few days of operation at this

setting to determine the correct temperature setting

consistent with your needs.

• Water temperature over 125°F (52°C)

can cause severe burns instantly or

death from scalds.

• Children, disabled and elderly are

at highest risk of being scalded.

• See instruction manual before

setting temperature at heating

appliance.

• Feel water before bathing or showering.

• If this appliance is used to produce

water that could scald if too hot,

such as domestic hot water use,

adjust the outlet control (limit) or use

temperature limiting valves to obtain

a maximum water temperature of

125°F (52°C).

NOTE:

(1) This water heater, when set at the lower

temperature setting, is not capable of producing

hot water of sufficient temperature for sanitizing

purposes. (2) Higher stored water temperature

increases the ability of the water heater to supply

desired quantities of hot water, however

remember:

ƽ WARNING

SHOULD OVERHEATING OCCUR OR THE

GAS SUPPLY FAIL TO SHUT OFF, DO NOT

TURN OFF OR DISCONNECT THE

ELECTRICAL SUPPLY TO THE PUMP.

INSTEAD, SHUT OFF THE GAS SUPPLY AT

ƽ CAUTION

Hotter water increases the risk of scald

injury.

LOCATION EXTERNAL TO

THE

APPLIANCE.

Incorrect piping of the cold water supply to the system

may result in excessive low temperature operation

causing condensate formation on the heat exchanger

and operational problems. The cold water supply

piping must be installed in the discharge piping from

the heater to the storage tank. This allows the cold water

to be tempered in the storage tank before entering the

heater. See typical installation drawings provided with

the unit for correct piping. Higher water temperatures

reduce condensate formation.

AUTOMATIC VENT DAMPERS

Automatic vent dampers are not required or furnished

on potable water heaters. All water heaters will have a

plug installed in the damper terminal on the side of the

control panel to allow operation without a vent damper.

The damper plug MUST be in place if an optional vent

damper is not used on a water heater. Water heaters with

inputs of 360,000 Btu/hr and less may be ordered with

the vent damper as an option. Remove the damper plug

from the terminal to connect an optional vent damper

wire harness. The optional damper must be properly

installed and the wire harness plugged into the terminal

on the side of the control panel to allow the unit to

function. See the “Automatic Vent Damper” section in

the basic portion of the manual.

ƽ CAUTION

Setting the temperature selector to higher settings

provides hotter water, which increases the risk of

scald injury.

The manufacturer recommends the use of a properly

sized thermostatic mixing valve to supply domestic hot

water at temperatures less than 140°F. Storing the

water at a higher temperature and thermostatically

mixing the water will increase the available quantity of

mixed hot water, greatly reduce the possibility of

condensate formation on the heat exchanger and help

prevent the growth of water born bacteria. Adequate

care MUST be taken to prevent potential scald injury

when storing water at 140°F and hotter.

ƽ CAUTION

Do not install an optional vent damper within 6"

(152mm) of combustible materials.

OPTIONAL RELIEF VALVE

This water heater/hot water supply boiler is normally

supplied with a temperature and pressure relief valve(s)

sized in accordance with applicable codes. Units may

be supplied with an optional pressure only relief

valve(s). When a water heater/hot water supply boiler

equipped with this optional relief valve is piped to a

separate storage vessel, the storage vessel must have a

properly installed temperature and pressure relief valve

which complies with local codes.

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THERMAL EXPANSION

A relief valve which discharges periodically may be due

to thermal expansion in a closed system. A hot water

supply boiler installed in a closed system, such as one

with a backflow preventer or check valve installed in

the cold water supply, shall be provided with means to

control expansion. Contact the water supplier or local

plumbing inspector on how to correct this situation.

Do not plug or cap the relief valve discharge!

CATHODIC PROTECTION

Hydrogen gas can be produced in a hot water system

that has not been used for a long period of time

(generally two weeks or more). Hydrogen gas is

extremely flammable. To prevent the possibility of

injury under these conditions, we recommend the hot

water faucet be open for several minutes at the kitchen

sink before you use any electrical appliance which is

connected to the hot water system. If hydrogen is

present, there will be an unusual sound such as air

escaping through the pipe as the hot water begins to

flow. There should be no smoking or open flames near

the faucet at the time it is open.

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TROUBLESHOOTING GUIDE

45,000 - 500,000 Btu/hr Models - Boilers & Water Heaters F9/M9

Check for an open

Check continuity of the spark

cable. Check for 24VAC on

the TH terminal (gray wire) on

the ignition module.

Is the spark

sensor. If not open,

replace temperature

controller.

STEP 1:

STEP 2:

igniter sparking?

YES

Check the pilot

Is the pilot

staying ON?

tube for gas.

YES

Check for draft.

Replace ignition

module.

YES

Is there 24VAC

(tan wire) on the

4-pin connector

plug on the

Is there 24 VAC (purple

wire) on the 4-pin

connector plug on the

temperature controller?

YES

temperature

controller?

Replace ignition

module.

STEP 3:

Is the gas valve

getting 24VAC?

YES

Check X and B on the

terminal strip if the flow

switch is installed. Check

for an open auto reset high

limit.

Check vent damper, 3-pin

louver relay connectors, and

venter proving.

Check the vent damper or

the vent damper plug and

the voltage to and from the

transformer.

Check 24VAC at R and W on

the (EMS) terminal strip.

YES

Check all safety limit devices.

Check 4-pin low water cutoff

connector.

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TROUBLESHOOTING GUIDE

90,000 - 270,000 Btu/hr Models - Water Heaters F1

Check for an open

sensor. If not open,

replace temperature

controller.

Check for gas. Check the pilot

STEP 1:

STEP 2:

assembly and thermocouple.

Check the gas valve for proper

operation. Clean and replace.

Is the pilot lit?

YES

Is there 24 VAC

Is there 24VAC

(tan wire) on the

4-pin connector

plug on the

temperature

controller?

Is the gas valve

getting 24VAC?

(purple wire) on the 4-

pin connector plug on

the temperature

controller?

YES

STEP 3:

Unit is running.

Check X and B on the

terminal strip if the flow

switch is installed. Check for

an open auto reset high limit.

Check vent damper 3-pin,

louver relay connectors, and

venter proving.

Check the vent damper or

the vent damper plug and

the voltage to and from the

transformer.

Check 24VAC at R and W on

the (EMS) terminal strip.

YES

Check all safety limit devices.

Check 4-pin low water cutoff

connector.

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Schematic Diagram - F1 Unit

90,000 - 270,000 Btu/hr Models

Wiring Diagram - F1 Unit

90,000 - 270,000 Btu/hr Models

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Schematic Diagram - F9 Unit

90,000 - 399,999 Btu/hr Models

Wiring Diagram - F9 Unit

90,000 - 399,999 Btu/hr Models

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Schematic Diagram - M9 Unit

45,000 - 399,999 Btu/hr Models

Wiring Diagram - M9 Unit

45,000 - 399,999 Btu/hr Models

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Wiring Diagram - F9/M9 Unit

500,000 Btu/hr Models

Schematic Diagram - F9/M9 Unit

500,000 Btu/hr Models

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NOTES

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NOTES

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Revision 4 (RSB-i&s-04) reflects the removal of the inlet

pipe and installing the inlet sensor inside the header.

Revision 5 (RSB-i&s-05) reflects changes made to the

O.A. section.

RSB-i&s-05

CP-5M-4/08

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