1

Installation and service must be performed by a qualified service installer, service agency or the gassupplier.

Factory warranty (shipped with appliance) does notapply to appliances improperly installed or improperlyoperated.

Experience has shown that improper installation orsystem design, rather than faulty equipment, is thecause of most operating problems.

1. Excessive water hardness causing a lime buildup in the copper tube is not the fault of the equipment and is not covered under the manufacturer’s warranty (see Water Treatmentand Water Chemistry).

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).

This manual supplies information for the installation,operation and servicing of the appliance. It is stronglyrecommended that this manual be reviewed completelybefore proceeding with an installation.

Upon receiving equipment, check for signs of shippingdamage. Pay particular attention to parts accompanyingthe appliance which may show signs of being hit orotherwise being mishandled. Verify total number ofpieces shown on packing slip with those actuallyreceived. In case there is damage or a shortage,immediately notify carrier.

Hot Water Heating BoilerWater Heater/Domestic Hot Water Supply Boiler

45,000—500,000 Btu/hr Models

RB/RW-i&s-07

INSTALLATION AND SERVICE MANUAL

WARRANTY

NOTE: Retain this manual for future reference.

SPECIAL INSTRUCTIONS TO OWNER

WARNING:

Improper Installation, Adjustment,Alteration, Service or Maintenancecan cause injury or property damage. Refer to this manual. For assistance or

additional information consult a qualified installer, service agency or the gas supplier.

CHECKING EQUIPMENT

Use this appliance if any part hasbeen under water. The possible damage to aflooded appliance can be extensive and presentnumerous safety hazards. Any appliance that hasbeen under water must be replaced.

DO NOT

If the information in this manual is not followedexactly, a fire or explosion may result causingproperty damage, personal injury or loss of life.

The appliance MUST NOT be installed in anylocation where gasoline or flammable vapors arelikely to be present, unless the installation is such toeliminate the probable ignition of gasoline orflammable vapors.

-• 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

neighbors phone. Follow the gas supplier’sinstructions.

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

Installation and service must be performed by aqualified installer, service agency or the gassupplier.

WARNING:

— WHAT TO DO IF YOU SMELL GAS —

2

The information contained in this manual isintended for use by qualified professional installers,service technicians or gas suppliers. Consult yourlocal expert for proper installation or serviceprocedures.

Your conventionally vented gas appliance must have asupply of fresh air circulating around it during burneroperation for proper gas combustion and proper venting.

1. Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not storematerials against the appliance or the vent-air intakesystem. Use proper care to avoid unnecessary contact (especially children) with the appliance andvent-air intake components.

2. Never cover your appliance, lean anything against it, store trash or debris near it, stand on it or in any way block the flow of fresh air to your appliance.

3. UNDER NO CIRCUMSTANCES must flammablematerials such as gasoline or paint thinner be used or stored in the vicinity of this appliance, vent-air intake system or any location from which fumes could reach the appliance or vent-air intake system.

The equipment shall be installed in accordance withinstallation regulations in force in the local area wherethe installation is to be made. These regulations shall becarefully followed in all cases. Authorities havingjurisdiction shall be consulted before installations aremade. In the absence of such requirements, the installa-tion shall conform to the latest edition of the NationalFuel Gas Code, ANSI Z223.1. Where required by theauthority having jurisdiction, the installation mustconform to American Society of Mechanical Engineers

CONTENTS

WarrantySafety Warnings ......................................................................1Codes ..................................................................................2Location ..................................................................................3Clearances................................................................................4Combustion/Ventilation Air Requirements ............................4Conventional Venting ..............................................................7Masonry Chimney Installations ............................................10Sidewall Venting ....................................................................10Automatic Vent Damper ........................................................11Gas Supply ............................................................................12

Gas Pressures & Piping..........................................12Manifold Pressure Adjustment ..............................15Supply Pressure Measurement ..............................16

Water Connections ................................................................17Relief Valve............................................................................19Flow Switch ..........................................................................19Gas Valve ..............................................................................20Electrical Requirements ........................................................21Temperature Adjustment ......................................................22Temperature Limit Control....................................................22Blocked Vent and Flame Roll-out System............................22Lighting Instructions ............................................................24Ignition & Control Timings ..................................................29Freeze Protection ..................................................................29Maintenance ..........................................................................30

Flame Patterns........................................................30Burner Cleaning ....................................................31Heat Exchanger Inspection ....................................32Lubrication ............................................................32

Gas Train................................................................................33Heating Boiler ......................................................................34

Installation Requirements ......................................34Pump Requirements ..............................................34Pressure Drop Chart ..............................................34Boiler Pump Operation ..........................................34Typical Piping ........................................................35Bypass Requirements ............................................35Low Temperature Systems ....................................36Boiler Flow Rates ..................................................37Temperature Rise Chart ........................................38Placing Boiler in Operation ..................................38Boiler Temperature Control ..................................40

Remote Thermostat Control Connection ............................40Water Heater/Domestic Hot Water Supply Boiler ................40

Water Velocity Control ..........................................41Temperature Rise....................................................41Water Chemistry ....................................................42Piping Requirements ..............................................42Pump Requirements ..............................................43Temperature Adjustment ........................................43Risk of Scald Warnings..........................................44

USER WARNING

IMPORTANT: Consult and follow localBuilding and Fire Regulations and other SafetyCodes that apply to this installation. Consultyour local gas utility company to authorize andinspect all gas and flue connections.

WARNING:Should overheating occur or the gas supply fail toshut off, do not turn off or disconnect the electricalsupply to the pump. Instead, shut off the gassupply at a location external to the appliance.

WARNING: To minimize the possibility of serious personalinjury, fire or damage to your appliance, neverviolate the following safety rules.

CODES

3

1. Locate the appliance so that if water connectionsshould leak, water damage will not occur. Whensuch locations cannot be avoided, it isrecommended that a suitable drain pan, adequatelydrained, be installed under the appliance. The panmust not restrict combustion air flow. Under nocircumstances is the manufacturer to be heldresponsible for water damage in connection withthis appliance, or any of its components.

2. The appliance must be installed indoors where it isprotected from exposure to wind, rain and weather.

3. The appliance must be installed so that the ignitionsystem components are protected from water(dripping, spraying, rain, etc.) during applianceoperation and service (circulator replacement,control replacement, etc.,).

4. Appliances located in a residential garage and inadjacent spaces that open to the garage and are notpart of the living space of a dwelling unit must beinstalled so that all burners and burner ignitiondevices have a minimum clearance of not less than18" (46cm) above the floor. The appliance must belocated or protected so that it is not subject tophysical damage by a moving vehicle.

5. DO NOT install this appliance in any locationwhere gasoline or flammable vapors are likely tobe present.

6. The appliance must be installed on a level,noncombustible floor. A concrete over woodconstruction is not considered a noncombustiblefloor. Maintain required clearances fromcombustible surfaces.

7. The appliance must not be installed on carpet or other combustible material.

8. For installation on a combustible floor only when installed on special base:

Appliances installed over a combustible floor MUSTuse the Special Combustible Floor Base Kit. Theappliance must be centered on the base as shown inFigure 4. The correct part number for the required base kit is noted on the rating plate of eachappliance and listed in Table A.

Safety Code for Controls and Safety Devices for Auto-matically Fired Boilers, ASME CSD-1. All boilersconform to the latest edition of the ASME Boiler andPressure Vessel Code, Section IV. Where required bythe authority having jurisdiction, the installation mustcomply with the Canadian Association Code,CAN/CGA-B149.1 and/or B149.2 and/or local codes.

This appliance meets the safe lighting performancecriteria with the gas manifold and control assemblyprovided as specified in the ANSI standards for gas-fired appliances, ANSI Z21.13.

INSTALLATION PROCEDURE

FIG. 2

Front View399,000—500,000

Btu Models

Front View45,000—360,000

Btu Models

FIG. 3

Rear View45,000—500,000

Btu Models

LOCATION OF UNIT

FIG. 1

4

Clearances from Combustible Construction:

Right Side - 6"Rear - 6"Left Side - 6" (24" suggested for service)Front - (24" suggested for service)

45,000 - 180,000 BTU Models - 6"199,000 - 500,000 BTU Models - ALCOVE*

Top - (measured from draft hood)45,000 - 180,000 BTU Models - 14"199,000 - 500,000 BTU Models - 29"

*An ALCOVE is a closet enclosure without a front door.

Allow sufficient space for servicing pipe connections,pump and other auxiliary equipment, as well as theappliance.

TABLE - ACOMBUSTIBLE FLOOR BASE KITS

Input BTU/hr Kit Number45,000 CFK3045

75,000 CFK3090

90,000 CFK3090

135,000 CFK3135

180,000 CFK3180

199,000 CFK3225

225,000 CFK3225

270,000 CFK3270

315,000 CFK3315

360,000 CFK3360

399,000 CFK3399

500,000 CFK3500

CLEARANCES FROMCOMBUSTIBLE CONSTRUCTION

FIG. 4

FIG. 5A

Provisions for combustion and ventilation air must bein accordance with Section 5.3, Air for Combustion andVentilation, of the latest edition of the National FuelGas Code, ANSI Z223.1, in Canada, the latest editionof CGA Standard B149 Installation Code for GasBurning Appliances and Equipment, or applicableprovisions of the local building codes.

The mechanical room MUST be provided with properlysized openings to assure adequate combustion air andproper ventilation when the appliance is installed withconventional venting.

COMBUSTION AND VENTILATION AIR REQUIREMENTS

FOR CONVENTIONALLYVENTED APPLIANCES

FIG. 5B

ClearancesModels

45,000–180,000

ClearancesModels

199,000–500,000

Combustion Floor Base

29"

6"

6"

6"

14"

5

1. If air is taken directly from outside the building with no duct, provide two permanent openings:

a. Combustion air opening, with a minimum freearea of one square inch per 4000 Btu/hr input (5.5cm2 per kW). This opening must be locatedwithin 12" (30 cm) of the bottom of the enclosure.

b. Ventilation air opening, with a minimum free area of one square inch per 4000 Btu/hr input (5.5cm2 per kW). This opening must be located within 12" (30cm) of the top of the enclosure.

2. If combustion and ventilation air is taken from the outdoors using a duct to deliver the air to the mechanical room, each of the two openings should be sized based on a minimum free area of one square inch per 2000 Btu/hr (11cm2 per kW).

3. If air is taken from another interior space that isadequately ventilated, each of the two openingsspecified above should have a net free area of onesquare inch for each 1000 Btu/hr (22cm2 per kW) ofinput, but not less than 100 square inches(645 cm2).

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 (7cm2 per kW). This opening must be located within 12" (30cm) of the top of the enclosure.

Combustion Air Direct from Outside

FIG. 6

Combustion Air Through Ducts

Combustion Air from Interior Space

Combustion Air from OutsideSingle Opening

FIG. 8

FIG. 7

FIG. 9

6

*Outside air openings shall directly communicate withthe outdoors. When combustion air is drawn from theoutside through a duct, the net free area of each of thetwo openings must have twice (2 times) the free arearequired for Outside Air/2 Openings. The above require-ments are for the appliance only, additional gas firedappliances in the mechanical room will require anincrease in the net free area to supply adequate combus-tion air for all appliances. Combustion air requirementsare based on the latest edition of the National Fuel GasCode, ANSI Z223.1, in Canada refer to NationalStandard CAN B149.1 or B149.2. Check all local coderequirements for combustion air.

All dimensions based on net free area in square inches.Metal louvers or screens reduce the free area of acombustion air opening a minimum of approximately25%. Check with louver manufacturers for exact netfree area of louvers. Where two openings are provided,one must be within 12" (30 cm) of the ceiling and onemust be within 12" (30 cm) of the floor of themechanical room. Each opening must have net free areaas specified in the chart above. Single openings shall belocated within 12" (30 cm) of the ceiling.

The combustion air supply must be completely free ofany flammable vapors that may ignite or chemicalfumes which may be corrosive to the appliance.Common corrosive chemical fumes which must beavoided are fluorocarbons and other halogenatedcompounds, most commonly present as refrigerants orsolvents, such as Freon, trichlorethylene,perchlorethylene, chlorine, etc. These chemicals, whenburned, form acids which quickly attack the heatexchanger finned tubes, headers, flue collectors, and thevent system. The result is improper combustion and anon-warrantable, premature appliance failure.

EXHAUST FANS: Any fan or equipment whichexhausts air from the mechanical room may deplete thecombustion air supply and/or cause a down draft in the venting system, spilling flue products intothe room. Spillage of flue products from the ventingsystem into an occupied living space can cause a veryhazardous condition that must be immediately corrected.If a fan is used to supply combustion air to the

TABLE - BMINIMUM RECOMMENDED COMBUSTION AIR SUPPLY

TO MECHANICAL ROOM

Combustion Air Source Input Outside Air*/2 Outside Air*/1 Inside Air/2Btu/hr Openings Openings Openings

45,000 12 in2 15 in2 100 in2

75,000 19 in2 25 in2 100 in2

90,000 23 in2 30 in2 100 in2

135,000 34 in2 45 in2 135 in2

180,000 45 in2 60 in2 180 in2

199,000 50 in2 67 in2 200 in2

225,000 56 in2 75 in2 225 in2

270,000 68 in2 90 in2 270 in2

315,000 79 in2 105 in2 315 in2

360,000 90 in2 120 in2 360 in2

399,000 100 in2 133 in2 400 in2

500,000 125 in2 167 in2 500 in2

CAUTION: ��Under no circumstances should the mechanicalroom ever be under a negative pressure. Particu-lar care should be taken where exhaust fans, atticfans, clothes dryers, compressors, air handlingunits, etc., may take away air from the unit.

7

mechanical room, the installer must make sure that itdoes not cause drafts which could lead to nuisanceoperational problems with the appliance.

Vent installations for connection to gas vents orchimneys must be in accordance with Part 7, “Ventingof Equipment,” of the latest edition of the National FuelGas Code, ANSI Z223.1, in Canada, the latest edition ofCGA Standard B149 Installation Code for Gas BurningAppliances and Equipment or applicable provisions ofthe local building codes.

Adequate combustion and ventilation air must besupplied to the mechanical room in accordance with thelatest edition of the National Fuel Gas Code, ANSIZ223.1, in Canada, the latest edition of CGA StandardB149 Installation Code for Gas Burning Appliances andEquipment, or applicable provisions of the localbuilding codes.

The distance of the vent terminal from adjacentbuildings, windows that open and building openingsMUST comply with the latest edition of the NationalFuel Gas Code, ANSI Z223.1, in Canada, the latestedition of CGA Standard B149 Installation Code forGas Burning Appliances and Equipment.

Vent connection is made directly to the top of theappliance. This appliance is designed with a built-in draft diverter. No additional draft diverter isrequired. The connection from the appliance vent to thecommon vent or chimney must be made asdirect as possible.

The negative draft in a conventional vent installationmust be within the range of a negative 0.02 to 0.05inches water to insure proper operation. All draftreadings are made while the appliance is in stableoperation (approximately 2 to 5 minutes).

Multiple appliance installations with combined ventingor common venting with other negative draft appliances require that each appliance must havedraft within the proper range. If the draft measuredabove the appliance’s built-in draft hood exceeds thespecified range in a dedicated chimney for a singleappliance installation or in combined venting with othernegative draft appliances, a barometric damper must beinstalled to control draft.

On a conventionally vented, negative draft appliance,the connection from the vent to the chimney or venttermination on the outside of the building MUST bemade with listed Type “B” doublewall (or equivalent)vent connectors and must be direct as possible with noreduction in diameter. Use the National Fuel Gas Codeventing tables for doublewall vent to properly size allvent connectors and stacks. The Type “B” vent andaccessories, such as firestop spacers, thimbles, caps,etc., MUST be installed in accordance with themanufacturer’s listing. The vent connector and firestopmust provide correct spacing to combustible surfacesand seal to the vent connector on the upper and lowersides of each floor or ceiling through which the ventconnector passes.

VENTING

TABLE - CVENT PIPE SIZES

Input BTU/hr Flue Size

45,000 3"

75,000 5"

90,000 5"

135,000 5"

180,000 6"

199,000 6"

225,000 7"

270,000 7"

315,000 8"

360,000 8"

399,000 10"

500,000 10"

Conventional Negative DraftVertical Venting

FIG. 10

A CONVENTIONAL NEGATIVE DRAFTVENTING SYSTEM

8

Any vent materials used must be listed by a nationallyrecognized test agency for use as vent material.

Locate appliance as close as possible to chimney or gasvent.

Avoid long horizontal runs of the vent pipe, 90° elbows,reductions and restrictions. Horizontal portions of theventing system shall be supported to prevent sagging.Horizontal runs must slope upwards not less than 1/4inch per foot (21 mm/m) from the appliance to the ventterminal. Follow manufacturer’s instructions.

Do not use an existing chimney as a raceway for a fluepipe if another appliance or fireplace is vented throughthe chimney.

The weight of the venting system must not rest on theappliance. Adequate support of the venting system mustbe provided in compliance with local codes and otherapplicable codes. All connections should be securedwith rustproof sheet metal screws.

Vent connectors serving appliances vented by naturaldraft shall not be connected to any portion of amechanical draft system operating under positivepressure. Connection to a positive pressure chimneymay cause flue products to be discharged into the livingspace causing serious health injury.

Common venting systems may be too large when anexisting appliance is removed. At the time of removal ofan existing appliance, the following steps shall befollowed with each appliance remaining connected tothe common venting system placed in operation, whileother appliances remaining connected to the commonventing system are not in operation.

(a) Seal any unused opening in the commonventing system.

(b) Visually inspect the venting system for propersize and horizontal pitch and determine there isno blockage or restriction, leakage, corrosionand other deficiencies which could cause anunsafe condition.

(c) Insofar as is practical, close all building doorsand windows and all doors between the space inwhich the appliances remaining connected tothe common venting system are located andother spaces of the building. Turn on clothesdryers and any other appliances not connectedto the common venting system. Turn on any

exhaust fans, such as range hoods and bathroomexhausts, so they will operate at maximumspeed. Do not operate a summer exhaust fan.Close fireplace dampers.

(d) Place in operation, the appliance beinginspected. Follow the lighting instructions.Adjust thermostat so appliance will operatecontinuously.

(e) Test for spillage at the draft hood/relief openingafter five minutes of main burner operation.Use the flame of a match or candle, or smokefrom a cigarette, cigar or pipe.

(f) After it has been determined that eachappliance remaining connected to the commonventing system properly vents when tested asoutlined above, return doors, windows, exhaustfans, fireplace dampers and other gas burningappliances to their previous conditions of use.

(g) Any improper operation of the common ventingsystem should be corrected so that theinstallation conforms to the latest edition of theNational Fuel Gas Code, ANSI Z223.1. InCanada, the latest edition of CGA StandardB149 Installation Code for Gas BurningAppliances and Equipment. When resizing anyportion of the common venting system, thecommon venting system should be resized toapproach the minimum size as determinedusing the appropriate tables in Part 11 in thelatest edition of the National Fuel Gas Code,ANSI Z223.1. In Canada, the latest edition ofCGA Standard B149 Installation Code for GasBurning Appliances and Equipment.

9

The vent terminal should be vertical and exhaust outsidethe building at least 2 feet (0.61m) above the highestpoint of the roof within a 10 foot (3.05m) radius of thetermination. The vertical termination must be aminimum of 3 feet (0.91m) above the point of exit.

A vertical termination less than 10 feet (3.05m) from aparapet wall must be a minimum of 2 feet (0.61m)higher than the parapet wall.

The vent cap should have a minimum clearance of 4 feet(1.22m) horizontally from and in no case above orbelow, unless a 4 foot (1.22m) horizontal distance ismaintained from electric meters, gas meters, regulatorsand relief equipment.

The venting system shall terminate at least 3 feet (0.9m)above any forced air inlet within 10 feet (3.05m).

VENTING TERMINATION

FIG. 11

Vent Termination from Peaked Roof10’ or Less from Ridge

FIG. 12

Vent Termination from Peaked RoofMore Than 10’ from Ridge

RIDGE

MORE THAN 10'

3' MIN

2' MIN

10'

CHIMNEY

FIG. 13

Vent Termination from Flat Roof10’ or Less from Parapet Wall

Vent Termination from Flat RoofMore Than 10’ from Parapet Wall

10’ OR LESS

3’

WALL OR PARAPET

CHIMNEY

NOTE:NO HEIGHT ABOVEPARAPET REQUIREDWHEN DISTANCEFROM WALLS ORPARAPETS IS MORETHAN 10’.

FIG. 14

10

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 anybuilding.

Do not terminate the vent in a window well, stairwell,alcove, courtyard or other recessed area. The vent cannot terminate below grade. The bottom of the ventterminal shall be located at least 12 inches (30cm) abovegrade.

To avoid a blocked vent condition, keep the vent capclear of snow, ice, leaves, debris, etc.

Flue gases will form a white plume in winter. Plumecould obstruct window view.

Flue gas condensate can freeze on exterior surfaces oron the vent cap. Frozen condensate on the vent cap canresult in a blocked vent condition. Flue gas condensatecan cause discoloration of exterior building surfaces.Adjacent brick or masonry surfaces should be protectedwith a rust resistant sheet metal plate.

A masonry chimney must be properly sized for theinstallation of a high efficiency gas fired appliance.Venting of a high efficiency appliance into a cold oroversized masonry chimney can result in operationaland safety problems. Exterior masonry chimneys, withone or more sides exposed to cold outdoor temperatures,are more likely to have venting problems. Thetemperature of the flue gases from a high efficiencyappliance may not be able to sufficiently heat themasonry structure of the chimney to generate properdraft. This will result in condensing of flue gases,damage the masonry flue/tile, insufficient draft andpossible spillage of flue gases into an occupied livingspace. Carefully inspect all chimney systems beforeinstallation. If there is any doubt about the sizing orcondition of a masonry chimney, it must be relined witha properly sized and approved chimney liner system.

Inspection of a Masonry Chimney

A masonry chimney must be carefully inspected todetermine its suitability for the venting of flue gases. Aclay 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 amasonry chimney, it must be relined. An unlinedmasonry chimney must not be used to vent flue gases from this high efficiency appliance. An unlined chimney must be relined with an approvedchimney liner system when a new appliance is beingattached to it. Metallic liner systems (Type “B” doublewall, flexible or rigid metallic liners) arerecommended. Consult with local code officials todetermine code requirements or the advisability of usingor relining a masonry chimney.

This appliance is NOT approved for sidewall ventingwith the negative draft venting system as shipped fromthe factory. An induced draft fan MUST be used if theinstallation requires that the flue gases be vented out asidewall. A properly sized and installed induced draftfan may also be used to vent the flue gases vertically ifrequired by jobsite restrictions. The induced draft fanmust be listed by a nationally recognized test agency, beproperly sized and installed per the recommendations ofthe induced draft fan manufacturer and meet local coderequirements. Use care to ensure that the mechanicallysupplied draft does not exceed the range of a negative

IMPORTANT:

Examine the venting system at least once a year.Check all joints and vent pipe connections fortightness. Also check for corrosion ordeterioration. Immediately correct any problemsobserved in the venting system.

MASONRY CHIMNEYINSTALLATION

SIDEWALL VENTING

Sidewall Venting with anInduced Draft Fan

FIG. 15

11

0.02 to 0.05 inches water to ensure proper operation. Ifdraft exceeds the specified range, the fan must beadjusted or the installation of a barometric damper inthe flue may be required to properly control draft. Aninduced draft fan MUST be interlocked into theappliance’s control circuit to start when the appliancecalls for heat. The induced draft fan MUST also beequipped with a proving switch, properly interlockedinto the appliance’s control circuit to prove fanoperation before the main burners are allowed to fire. Avertical or sidewall vent termination for an induced draftfan MUST be installed per the recommendations of thefan manufacturer and provide proper clearances fromany combustion or ventilation openings, windows,doors or other openings into the building. All induceddraft fan installations must comply with local coderequirements. Consult factory for kits available.

This heating boiler is design certified for use with theautomatic vent damper, part number printed on theboiler’s rating plate. A vent damper must be installed onall residential heating boilers with inputs of less than300,000 Btu/hr to comply with minimum efficiencyrequirements. A vent damper is factory supplied withresidential heating boilers with inputs of 45,000 thru270,000 Btu/hr. A vent damper is optional on heatingboilers with inputs of 315,000 and 360,000 Btu/hr. Avent damper is also available as an option on waterheater models with inputs of 90,000 thru 360,000Btu/hr.

The vent damper is a useful tool for saving energy wheninstalled inside the building envelope where air cancirculate freely around the appliance. The vent damperwill not save as much, if any, energy if it is installed inlocations such as:

- Closet with solid, rather than louvered doors- Outdoors-Unheated garage-Attic-Crawlspace-Mechanical room that is vented outdoors

FOR INSTALLATION AND MAINTENANCE ON THEVENT DAMPER, REFER TO THE INSTRUCTIONSSUPPLIED WITH THE VENT DAMPER.

Residential heating boilers with inputs of less than300,000 Btu/hr must have the vent damper properlyinstalled and the wire harness plugged into the terminalon the side of the control panel to allow the boiler tofunction. Larger input heating boilers and water heaterswill have a plug installed in the damper terminal toallow operation without a damper. Remove damper plugfrom terminal to connect an optional vent damper wireharness. Damper plug MUST be in place if an optionalvent damper is not used on water heaters and largerinput heating boilers.

Install the vent damper to service only the singleappliance for which it is intended. If improperlyinstalled, a hazardous condition such as an explosion orcarbon monoxide poisoning could result.

The damper position indicator must be in a visiblelocation with access for service following installation.The damper must be in open position when appliancemain burners are operating.

THE PART NUMBER FOR THE AUTOMATIC VENTDAMPER REQUIRED ON THIS HEATING BOILERIS PRINTED ON THE RATING PLATE. DAMPERREGULATIONS PER THE LATEST EDITION OFANSI Z21.66.

AUTOMATIC VENT DAMPER

FIG. 16

CAUTION: ��

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

Automatic Vent Damper

12

.

Verify that the appliance is supplied with the type gasspecified on the rating plate. This appliance is orificedfor operation up to 2000 feet altitude. The appliance willbe derated 4% per 1000 feet above 2000 feet elevation.Consult the factory for installations above 2000 feetelevation. Field conversions for operation at highaltitude must be performed by factory authorizedpersonnel only. The appliance will be marked to indicatesuitability for high altitude operation.

INLET PRESSURE: Measured at the inlet pressure taplocated upstream of the combination gas valve(s).

Nat. Gas LPGMax.(Inches-Water Column) 10.5"w.c. 13"w.c.Min. (Inches-Water column) 5"w.c. 11"w.c.

Maximum inlet gas pressure must not exceed the valuespecified. Minimum value listed is for the purposes ofinput adjustment.

MANIFOLD PRESSURE: Measured at the pressuretap on the downstream side of the combination gasvalve(s). The gas regulator on the appliance’scombination gas valve(s) is adjustable to supply propermanifold pressure for normal operation. If adjustment ofregulator pressure is required, see Manifold AdjustmentProcedure. Do not increase regulator pressurebeyond specified pressure setting.

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).

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).

3. The appliance and its gas connection must be leak-tested before placing it in operation.

FIG. 17

CAUTION: ��An appliance which is shut down or will not operatemay experience freezing due to convective air flowdown the flue pipe connected to the unit. Properfreeze protection must be provided, see FreezeProtection Section.

Vent damper must be installed directly on the flueoutlet located on the top of the draft hood (see Figure17). Do not alter the wire harness supplied with thevent damper. Follow the instructions supplied withthe vent damper.

WARNING:

GAS SUPPLY

TABLE - DSUPPLY PRESSURE

GAS PRESSURE TEST

TABLE - EMANIFOLD PRESSURE

BTU/hr Regulator Settings

Input Gas Natural Gas L.P.

45,000 3.5" 10"

75,000 2.3" 6.9"

90,000 - 180,000 3.5" 10"

199,000 2.7" 7.7"

225,000 - 500,000 3.5" 10"

13

1. Safe operation of the appliance requiresproperly sized gas supply piping. See data in Table F.

2. Gas pipe size may be larger than appliance gas connection.

3. Installation of a union is suggested for ease of service.

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.

5. A trap (drip leg) MUST be provided in the inlet of the gas connection to the appliance.

6. The combination gas valve has an integral vent limiting device and does not require venting to atmosphere, outside the building.

7. Optional gas controls may require routing of bleeds and vents to the atmosphere, outside the building when required by local codes.

GAS CONNECTION

TABLE - FSUGGESTED GAS PIPE SIZE

SINGLE APPLIANCE INSTALLATIONSBtu/hr DISTANCE FROM METER

INPUT 0-50' 51'-100' 101'-200' 201'-300' 301'-500'45,000 1/2" 1/2" 3/4" 1" 1 1/4"75,000 1/2" 3/4" 1" 1 1/4" 1 1/4"90,000 1/2" 3/4" 1" 1 1/4" 1 1/4"

135,000 3/4" 1" 1 1/4" 1 1/4" 1 1/2"180,000 1" 1" 1 1/4" 1 1/2" 1 1/2"199,000 1" 1" 1 1/4" 1 1/2" 2"225,000 1" 1 1/4" 1 1/4" 1 1/2" 2"270,000 1" 1 1/4" 1 1/4" 1 1/2" 2"315,000 1 1/4" 1 1/2" 1 1/2" 1 1/2" 2"360,000 1 1/4" 1 1/2" 2" 2" 2 1/2"399,000 1 1/4" 1 1/2" 2" 2" 2 1/2"500,000 1 1/4" 1 1/2" 2" 2" 2 1/2"

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

TABLE - GFITTINGS TO EQUIVALENT

STRAIGHT PIPE

Diameter Pipe (inches) 3/4" 1" 1 1/4" 1 1/2" 2" 3" 4" 5"

Equivalent length of Straight Pipe (feet) 2' 2' 3' 4' 5' 10' 14' 20'

14

All gas connections must be made with pipe jointcompound resistant to the action of liquefied petroleumand natural gas. All piping must comply with localcodes. Tubing installations must comply with approvedstandards and practices.

Install Piping to Control

1. The gas line should be a separate line directfrom the meter unless the existing gas line is ofsufficient capacity. Verify pipe size with your gassupplier.

2. Use new, properly threaded black iron pipe freefrom chips. If tubing is used, make sure the ends are cut squared, deburred and clean. All tubing bends must be smooth and withoutdeformation. 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.

TABLE- HMULTIPLE APPLIANCE INSTALLATIONS

GAS PIPING SIZE CHART

Length of Pipe in Straight Feet

10 20 30 40 50 60 70 80 90 100 125 150 175 200

3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74

1 697 477 384 328 292 267 246 226 210 200 179 164 149 138

1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287

1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441

2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820

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

3 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

4 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

Nominal Iron Pipe Size, Inches

Maximum Capacity of Pipe in Thousands of BTU’s per hour for gas pressures of 14 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, 1025Btu/ft3 @ 0.60 Specific Gravity)

GAS PIPING

FIG. 18

Gas Line Connection

Gas Cock

SedimentTrap

15

4. Install a sediment trap in the supply line to the gasvalve or manifold assembly (see Figure 18).

5. Thread pipe the proper amount for insertion into gasvalve or manifold inlet as shown in Table-I.DO NOT THREAD PIPE TOO FAR. Valvedistortion or malfunction may result if the pipe isinserted too deeply into the gas valve.

TABLE - ILENGTH OF STANDARD

NPT PIPE THREADS (Inches)Pipe Size Effective Length of Thread Overall Length of Thread

1/2" 1/2" 3/4"

3/4" 9/16" 13/16"

1" 9/16" 1"

6. Apply a moderate amount of good quality pipecompound (DO NOT use Teflon tape) to pipeonly, leaving two end threads bare.

7. Remove seal over gas valve or manifold inlet.

8. Connect pipe to gas valve or manifold inlet. Usewrench to square ends of the gas valve.

9. For L.P. gas, consult your L.P. gas supplier forexpert installation.

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

2. Turn gas valve control knob to “PILOT” positionon standing pilot models. Ensure that the standingpilot remains on. If the pilot goes out, follow the“Lighting Instructions” for standing pilot modelsto 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 sideof the gas valve and install a fitting suitable toconnect to a manometer or magnahelic gauge. SeeFigure 20. Minimum range of scale should be upto 5" w.c. for Natural gas models and 10" w.c. forL.P. gas models.

4. The 399,000 and 500,000 Btu/hr models will havetwo gas valves with a pressure regulator on eachvalve. Repeat the following adjustment procedureto set the manifold pressure on each gas valve. Themanifold pressure for each valve should set at 3.5"w.c. for Natural gas and 10" w.c. for L.P. gas.

5. Remove the pressure regulator adjustment capscrew on the gas valve. See Figures 26, 27 and 28for location.

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

IMPORTANT:

Upon completion of any piping connections to the gassystem, leak test all gas connections with a soapsolution while system is under pressure. Immediatelyrepair any leak found in the gas train or relatedcomponents. Do Not operate an appliance with aleak in the gas train, valves or related piping.

GAS MANIFOLD PRESSUREADJUSTMENT PROCEDURE

APPLYWRENCHFROM TOPOR BOTTOMOF CONTROLTO EITHERSHADEDAREA

FIG. 19

Gas Valve

FIG.20

Manifold Pressure Adjustment

16

7. Turn the gas valve control knob to the “ON” posi-tion.

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

9. Observe gas regulator pressure when all burnersare firing. See Table E, Manifold Pressure forproper regulator pressure settings.

10. If adjustment is necessary, turn regulatoradjustment screw clockwise to raise regulator gas pressure, counterclockwise to lower gas pressure toproper setting. Note: Adjustment fitting isplastic and may require slightly greater turningforce than a metal fitting.

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

12. Turn gas valve control knob to “PILOT” positionon standing pilot models. Turn gas valve controlknob to “OFF” position on spark ignition models.

13. Remove fitting from the gas valve and replace the1/8" hex plug that was previously removed andtighten.

14. Repeat the adjustment procedure for the secondgas valve on 399,000 and 500,000 Btu/hr models.

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

16. Turn the power “ON” at the main disconnectswitch. The appliance is now ready to operate.

If manifold pressure cannot be properly adjusted, usethe following procedure to check gas supply pressurewith a manometer connected to the inlet pressure tap onthe gas control.

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

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

3. The 399,000 and 500,000 Btu/hr models will havetwo gas valves. Turn the gas valve control knob oneach valve to the “OFF” position.

4. Shut off the gas supply at the manual valve in thegas piping to the appliance. If fuel supply is L.P.gas, shut off the gas supply at the tank.

5. Remove the 1/8" hex plug, located on the “inlet”side of the gas valve and install a fitting suitable toconnect to a manometer or magnahelic gauge. Ontwo gas valve models, remove the hex plug from thegas valve closest to the gas supply connection.Range of scale should be 14" w.c. or greater tocheck inlet pressure.

5. Turn on the gas supply at the manual valve, turn onL.P. gas at the tank if required.

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

7. Turn the gas valve control knob to the “PILOT”position on the standing pilot models. Follow the“Lighting Instructions” for standing pilot modelsto light the pilot. Turn the gas valve control knob

NOTE: Do not increase regulatorpressure beyond specified pressuresetting.

CHECKING GAS SUPPLY PRESSURE

Gas Valve

Gas Supply Pressure

FIG. 21

17

to the “ON” position when the pilot is established.Turn the gas valve control knob(s) to the “ON”position on spark ignition models. .

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

9. Observe the gas supply pressure with all burnersfiring. Ensure inlet pressure is withinspecified range. Check gas supply pressure with allother gas fired appliances in operation to ensureproper gas volume during periods of peak gasusage. Minimum and Maximum gas supplypressures are:

Natural Gas L.P. GasMax. (Inches-Water 10.5" w.c. 13" w.c.

Column)Min. (Inches-Water 5.0" w.c. 11" w.c.

Column)

10. If gas pressure is out of range, contact gas utility,gas supplier, qualified installer or service agencyto determine necessary steps to provide proper gaspressure to the control.

11. If the gas supply pressure is within the specifiedrange, proceed with the following steps to returnthe appliance to service.

12. Turn the power “OFF” at the main disconnectswitch.

13. Turn the gas valve control knob to the “PILOT” posi-tion on the standing pilot models. Turn the gas valvecontrol knob(s) to the “OFF” position on spark igni-tion models.

14. Shut off the gas supply at the manual valve in thegas piping to the appliance. If fuel supply isL.P. gas, shut off the gas supply at the tank.

15. Remove the manometer and related fittings fromthe “inlet” side of the gas valve, replace 1/8" hexplug in the gas valve.

16. Turn on the gas supply at the manual valve, turn onthe L.P. gas at the tank if required.

17. Turn the power “ON” at the main disconnectswitch.

18. 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 tolight the pilot. Spark ignition models will automat-ically light the pilot on a call for heat.

19. Set the thermostat(s) to call for heat. Theappliance is now ready to operate.

Check burner performance by cycling the system whileyou observe burner response. Burners should ignitepromptly. Flame pattern should be stable, see“Maintenance-Normal Flame Pattern.” Turn system offand allow burners to cool, then cycle burners again toensure proper ignition and flame characteristics.

Inlet and Outlet ConnectionsHeating boilers with inputs from 45,000 to 180,000Btu/hr have 1 1/4" NPT threaded water connections forinlet and outlet. Heating boilers with inputs from225,000 to 500,000 Btu/hr have 1 1/2" NPT threadedflange water connections for inlet and outlet. All waterheaters and hot water supply boilers are supplied with 11/2" NPT threaded flange water connections. For easeof service, install unions on inlet and outlet of theheader. The connection marked “Inlet” on the headershould be used for return from the system. Theconnection marked “Outlet” is to be connected to thesupply side of the system.

WATER CONNECTIONS

FIG. 22

IMPORTANT:

Upon completion of any testing on the gas system,leak test all gas connections with a soap solutionwhile main burners are operating. Immediately repairany leak found in the gas train or related components.

Do Not operate an appliance with a leak in the gastrain, valves or related piping.

InletOutlet

18

REVERSING THE HEAT EXCHANGERWATER CONNECTIONS

a. Turn “OFF” power at the main disconnect switchand disconnect power wire from control panel.

b. Turn “OFF” the external main manual gasshutoff valve.

c. Disconnect water supply and return pipingfrom heat exchanger.

d. Remove temperature sensors and pressuregauge from front header.

e. Remove electrical wiring from combination gasvalve(s) and spark igniter (if equipped). Markwires for proper reassembly.

f. Loosen mounting screws and remove controlpanel.

g. Loosen mounting screws from front jacketpanels and remove.

h. Remove heat exchanger by sliding out towardfront of the appliance. Use caution to preventdamage to burners, refractory, pilot, sparkigniter (if equipped) or wiring.

I. Turn heat exchanger so inlet/outlet header is onthe right and slide back into unit. Ensure that“V” baffles are in place on top of the finnedtubes and heat exchanger is properly positioned.

j. Reinstall front jacket panels and tighten screws.

k. Install water piping to header of reversed heatexchanger. Ensure that the relief valve isinstalled in the outlet from the heat exchanger.Check water piping for leaks.

l. Install control panel and reconnect wiring to gasvalve(s), spark igniter (if equipped) andcontrols.

m. Install temperature sensors and pressure gaugein front header. The operating thermostat(s) isinstalled in the inlet side of the header and thehigh limit is installed in the outlet side of theheader.

n. Reconnect electric supply to control panel.Ensure all wiring is properly reconnected to thecontrols. Turn on power at the main disconnectswitch.

o. Turn “ON” external main manual gas supply.Use a soap solution to test for leaks on any gasline connections that were loosened ordisconnected while reversing the heat exchanger.

p. Cycle the burners on and check for properoperation.

FIG. 23

NOTE:The heat exchanger is reversible from the left toright side. Reversing of the heat exchanger shouldonly be performed by a qualified installer, serviceagency or the gas supplier.

19

A water flow switch is available as a factory suppliedoption on all heating boilers, hot water supply boilersand water heaters. The flow switch should be wired inseries with the 24 VAC power to the gas valve (red wire)on standing pilot models and in series with the 24 VACpower to the ignition module (purple wire to 24Vterminal on module) on intermittent pilot models. Thiswiring connection installs the flow switch in the 24 VACsafety circuit to prove water flow before main burnerignition. A flow switch installed with the factorysupplied minimum adjustment setting requires a specif-ic minimum flow to make the switch and start burneroperation. The minimum flow requirement to actuatethe switch is specified in Table J. The flow rate requiredis a function of the diameter of pipe and tee used forinstallation. Ensure that the pump installed on theboiler or water heater will supply adequate flow to makethe flow switch contacts and operate the boiler. A waterflow switch meets most code requirements for alow-water cut off device on boilers requiring forcedcirculation for operation.

TABLE JMINIMUM FLOW RATE REQUIRED TO

ACTUATE FLOW SWITCH

Pipe Size GPM Flow Rate

1 1/4” 9.8

1 1/2” 12.7

A hot water boiler installed above radiation level must beprovided with a low water cutoff device either as part ofthe unit or installed at the time the boiler is installed. Anelectronic or float type low water cutoff is available as afactory supplied option on all units. Low water cutoffsshould be inspected every six months, including flushingof float types.

This appliance is supplied with a relief valve(s) sized inaccordance with ASME Boiler and Pressure Vessel Code,Section IV (“Heating Boilers”). The relief valve(s) ismounted in the vertical position and installed in a teeimmediately downstream of the heat exchanger hot wateroutlet. No valve is to be placed between the relief valveand the heat exchanger outlet. To prevent water damage,the discharge from the relief valve shall be piped to asuitable floor drain for disposal when relief occurs. Noreducing couplings or other restrictions shall be installedin the discharge line. The discharge line shall allowcomplete drainage of the valve and line. Relief valvesshould be manually operated at least once a year.

RELIEF VALVE

CAUTION: ��Avoid contact with hot discharge water.

FIG.24

WATER FLOW SWITCH (IF EQUIPPED)

FIG.25

LOW WATER CUTOFF (IF EQUIPPED)

ReliefValve

FlowSwitch

20

Each unit has a combination gas valve(s) to control thegas supply to the burners. The 399,000 and 500,000Btu/hr models have two combination gas valves tosupply gas to the burners. Two stage burner operation(M-9) is available as an option on intermittent pilotmodels. A two stage gas valve is used on models withinputs of 90,000 thru 360,000 Btu/hr. The 399,000 and500,000 Btu/hr models achieve two stage burner firingby staging the operation of each combination gas valve.The combination valve consists of a gas regulator andtwo valve seats to meet the requirements for redundantgas valves. The valve has a gas control knob that mustremain in the open position at all times when theappliance is in service. Each gas valve has pressure tapslocated on the inlet and outlet sides. Manifold pressureis adjusted using the regulator located on the valve. Themanifold pressure is preset at the factory andadjustment is not usually required. If the manifoldpressure is to be adjusted, follow the “Gas ManifoldPressure Adjustment Procedure” for proper adjustment.

Venting of Combination Gas ValvesThe combination gas valve regulator used on all modelsis equipped with an integral vent limiting orifice. Thevent limiter ensures that the volume of gas emitted fromthe valve does not exceed the maximum safe leakagerate allowed by agency requirements. Combination gasvalve/regulators equipped with integral vent limiters arenot required to have vent or relief lines piped to theoutdoors. A dust cap is provided at the vent terminationpoint on the valve to prevent blockage of the vent limiterby foreign material. The combination gas valveregulator with an integral vent limiter complies with thesafety code requirements of CSD-1, CF-190(a) asshipped from the manufacturer without the installationof additional vent lines.

OPTIONAL TWO STAGE BURNERCONTROL SYSTEM (M-9)

The 90,000 thru 500,000 Btu/hr models with intermittentpilot may be optionally equipped with a two stage burnercontrol system (M-9). The 90,000 thru 360,000 Btu/hrmodels will be equipped with a two stage gas valve tocontrol high/low burner operation. The 399,000 and500,000 Btu/hr models achieve two stage burner firingby staging the operation of the two combination gasvalves. The optional M-9 control system is equippedwith two operating temperature controls to allow eachburner stage to fire at a different temperature set point.Stage one (Low Fire) must fire before stage two (HighFire) will function. Set the Low Fire operator at thedesired system set point, set the High Fire operator at a

COMBINATION GAS VALVES

FIG.26

FIG. 28

FIG.27

InletPressure

Tap

RedResetButton

GasControlKnob

PilotOutlet

WiringTerminals

Regulator OutletPressure

Tap

F-1 Gas Valve Models 045–135

F-9 Gas Valve Models 045–500

InletPressure

Tap

GasControlKnob

PilotOutlet

WiringTerminalsRegulator Outlet

PressureTap

InletPressure

Tap

GasControlKnob

PilotOutlet

WiringTerminalsRegulator

OutletPressure

Tap

M-9 Gas Valve Models 180–360

21

lower setting, approximately 5-15 degrees lower, forstaged burner operation. Two stage burner controlsystems (M-9) are recommended for application onheating boilers only.

ELECTRICAL CONNECTIONS

This appliance is wired for 120 VAC service. Theappliance, when installed, must be electrically groundedin accordance with the requirements of the authorityhaving jurisdiction or in the absence of suchrequirements, with the latest edition of the NationalElectrical Code ANSI/NFPA No. 70. When the unit isinstalled in Canada, it must conform to the CAE C22.1,Canadian Electrical Code, Part 1 and/or local ElectricalCodes.

1. All wiring between the appliance and fieldinstalled devices shall be made with type T wire [63° F(35° C) rise].

2. Line voltage wire exterior to the appliance must beenclosed in approved conduit or approved metalclad cable.

3. The pump must run continuously when theappliance is being fired.

4. To avoid serious damage, DO NOT energize theappliance until the system is full of water. Seriousdamage may result.

5. Provide the unit with proper overload protection.

6. Install a wall thermostat on the inside wall. DONOT install thermostat in an area affected bydrafts, sunlight, light fixtures, hot or cold waterpipes or near a fireplace. See “Terminal Strip Con-nection of a Room Thermostat” for proper wiringconnection.

TABLE - KAMP DRAW DATA

45,000 thru 500,000 Btu/hr Models

MAXIMUMFIRING TOTAL AMPSCONTROLS @ 120 VAC

F-1 Standing Pilot (Single Stage 45,000-270,000 Btu/hr) 1.20

F-9 Intermittent Pilot (Single Stage 45,000-360,000 Btu/hr) 1.15

F-9 Intermittent Pilot (Single Stage/2 valves 399,000-500,000 Btu/hr) 1.65

M-9 Intermittent Pilot (Two Stage Valve 90,000-360,000 Btu/hr) 1.20

M-9 Intermittent Pilot(Two Stage/2 valves 399,000-500,000 Btu/hr) 1.65

Pump Wiring for a Heating Boiler

The heating boiler circulating pump must be purchasedlocally. The boiler’s internal pump control relay may beused to cycle the pump. The maximum current draw forthe pump switched by this relay must not exceed 12AMPS at 120 VAC, 6 AMPS at 208/240/277 VAC or 3AMPS at 480 VAC. The current draw for a fieldinstalled 120 VAC pump may be added to the boiler’scurrent draw to determine the minimum wire size for120 volt service if a single power supply is provided forthe boiler controls and pump.

STANDING PILOT SYSTEM - F1CONTROL PANEL

HIGH LIMIT

OPERATOR

TERMINALBOARD

FIG. 29

TRANSFORMER

22

OPERATOR

TRANSFORMER

MVMV/PVPVGND

24V24VTH-W

SPARK

1 2 3 4 5 6 7 8 9

HIGH LIMIT

TERMINALBOARD

TEMPERATURE ADJUSTMENT

Operating Temperature ControlAn adjustable immersion operating control is located inthe control panel. F-1 and F-9 control systems use asingle operating control, M-9 control systems use twooperating controls (see Two Stage Burner ControlSystem for operation and setup). The operating controluses a remote sensing bulb mounted in the inlet side ofthe header. Turn the control set point dial to adjust thedesired operating water temperature of the appliance.

High Water Temperature Limit ControlsThe appliance may be supplied with either an adjustableor fixed setting high water temperature limit controlbased on the units application, ignition controls or as aspecified optional control. The sensing bulb for thehigh water temperature limit control is mounted in theoutlet side of the header.

Adjustable High Water Temperature Limit Control The appliance may be supplied with an adjustablesetting, auto-reset high water temperature limitcontrol(s) located in the front control panel, beside thetemperature control. The setting of this control(s) limitsmaximum discharge water temperature. An adjustablehigh water temperature limit control is typically set 40°F(22°C) higher than the set point of the operating temper-ature control or at the limits maximum setting. If watertemperature exceeds the set point, the limit will breakthe control circuit and shut down the appliance. Thelimit control will only be reset after the watertemperature has cooled below the set point of the limit.

The high water temperature limit sensor is mounted inthe outlet side of the front header.

Manual Reset High Water Temperature LimitControl (Optional)The appliance may be supplied with a fixed setting,manual reset high water temperature limit control. Thismanual reset temperature limit control has a fixed limitsetting of 230°F (110°C). If water temperature exceedsthis set point, the limit will break the control circuit andshut down the unit. The limit control can only be resetafter the water temperature has cooled below the setpoint of the limit. Reset of the limit control isaccomplished by pushing the Red Reset Button locatedon the bottom side of the control panel. A label on thecontrol panel indicates the exact location of the resetbutton.

BLOCKED VENT AND FLAME ROLL-OUTSYSTEM (Heating Boilers Only)

NOTE: The limit control will notreset until the water temperature has droppedbelow the set point of the high limit.

FIG. 31

INTERMITTENT PILOT SYSTEM - F9CONTROL PANEL

IGNITIONMODULE

BLOCKED VENT SWITCH 45,000–90,000 BTU MODELS

FIG. 30

Draft Hood

SpillSwitch

23

The 45,000 thru 270,000 Btu/hr Heating Boilers areequipped with a manual reset blocked vent and flameroll-out system. Temperature switches are located onthe front of the burner tray and/or in the relief openingof the boiler’s built-in draft hood. Each switch has a redreset button. In the event the system has actuated toshut off the main burner gas supply, wait for the boilerto cool, then press the red reset to return the boiler tooperation. Operation of a blocked vent and/or flameroll-out switch usually indicates a problem with theventing system, obstruction of the heat exchanger fluegas passageway and/or a combustion air supplyproblem. The cause for operation of the blocked ventand/or flame roll-out switch must be determined andcorrected. If the boiler can not be restored to normaloperation, contact a qualified service installer, serviceagency or the gas supplier.

INITIAL START-UP

Follow instructions on the label applied to the top of theappliance.

A. Pump Operation - MOST IMPORTANT - Thisappliance is designed for continuous pumpoperation when the burners are firing. Aheating boiler may cycle the pump by using thepump control relay located in the control panel(see Circulator Pump Operation-HeatingBoilers). A water heater or hot water supplyboiler cycles the pump by using the pumpdelay. Pump delay controls are standard onwater heaters.

B. Location - The appliance should be locatedwithin a room having a temperature safelyabove freezing [32°F(0°C)].

C. Shutdown and Draining - If, for any reason,the appliance is shut off, the followingprecautionary measures must be taken:

1. Shut off gas supply,2. Shut off water supply.3. Shut off electrical supply.4. Drain the heat exchanger completely. Remove

one 3/8" NPT plug or bulb well from the inletside and one from the outlet side of the frontheader of the heat exchanger. Remove the 3/4"NPT drain plugs located on the rear header.Blow all water out of the heat exchanger.

5. Drain the pump (see Pump Maintenance).

FIG. 32

FIG. 33

FIG. 34

FLAME ROLL-OUT SWITCH 45,000 BTU MODELS

FLAME ROLL-OUT SWITCH 90,000–270,000 BTU MODELS

Burner

BurnerTray

Roll-outSwitch

Burner

BurnersRoll-outSwitch

HEAT EXCHANGER

24

PRE-START CHECKLIST

1. Inspect the burners to be sure they are properlyaligned.

2. Inspect the pilot gas line, thermocouple leads,ignition leads and wire connections to gas valve tobe sure none were damaged during shipment.

3. Check to ensure that gas connections have beenmade properly and the gas line is purged of air.

4. Check to ensure that water connections are tightand the appliance and piping system have beenproperly filled.

5. Ensure that discharge from the relief valve hasbeen piped to a floor drain.

6. Verify that properly sized combustion andventilation air openings are provided and notobstructed in any way.

7. Check carefully for gas leaks.

8. Read the appliance’s safety warnings, lightinginstructions and check out procedure carefully, before firing the system.

LIGHTING INSTRUCTIONS FORSTANDING PILOT MODELS (F-1)

MODELS 45,000 THRU 270,000 Btu/hr INPUTFOR YOUR SAFETY

READ BEFORE OPERATING

A. This appliance has a pilot which must be ignit-ed by hand. When lighting the pilot, follow these instructions exactly.

B. BEFORE OPERATING, smell around theappliance area for gas. Be sure to smell next tothe floor because some gas is heavier than airand 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 anyphone in your building.

Immediately call your gas supplier from aneighbor’s phone. Follow the gas supplier’sinstructions.

If you cannot reach your gas supplier, call thefire department.

C. Use only your hand to push in or turn the gascontrol knob. Never use tools. If the knob willnot turn by hand, don’t try to repair it, call aqualified service technician. Force or attemptedrepair may result in a fire or explosion.

D. Do not use this appliance if any part has beenunder water. Immediately call a qualifiedservice technician to inspect the appliance. Thepossible damage to a flooded appliance can beextensive and present numerous safety hazards.Any appliance that has been under water mustbe replaced.

LIGHTING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat to the lowest setting.

3. Turn off all electrical power to the appliance.

4. Turn the gas control knob on the gas valveclockwise to the “OFF” position.

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

WARNING:

25

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

6. Find the pilot - Follow the metal tube from the gasvalve to the pilot. The pilot is located on the rightside of a burner approximately centered in theburner tray.

7. Turn the control knob on the gas valve counterclockwise to the “PILOT” position.

8. Push down and hold in the red button on the gasvalve. This should start gas flow to the pilot.Immediately light the pilot with a match. Use theloop end of the wire lighting wand, shipped withthe instruction package, to hold the match andreach the pilot. An access slot is provided in thelower front jacket panel, beside the burner, to insertthe lighting wand and match to the pilot. Continueto hold the red button in for about one (1) minuteafter the pilot is lit. Release button and it will popback up. Pilot should remain lit. If it goes out,repeat steps 4 through 8.

If red button does not pop up when released, stopand immediately call your gas supplier.

If the pilot will not stay lit after several tries, turnthe gas control to “OFF” and call yourservice technician or gas supplier.

9. Turn the gas control knob on the gas valvecounterclockwise to the “ON” position.

10. Turn on all electric power to the appliance.

11. Set the thermostat to the desired setting. FIG. 36

FIG. 37FIG. 35

PILOT LOCATION

USING LIGHTING WAND TOLIGHT STANDING PILOT

MAIN BURNER

MAIN BURNER

TOP

SIDE OUTLET

F-1 GAS VALVE - MODELS 045-135ALSO SEE FIG. 26

26

TO TURN OFF GAS TO APPLIANCE

1. Set the thermostat to the lowest setting.

2. Turn off all electric power to the appliance ifservice is to be performed.

3. Turn the gas control knob on the gas valveclockwise to the “OFF” position. Do notforce.

SAFETY SHUTOFF TEST FOR STANDINGPILOT IGNITION SYSTEM

1. With the main burners on and firing, unscrew thethermocouple connection from the gas valve andremove from the fitting. See Figure 29 to locatethermocouple outlet connection on the gas valve.

2. The main gas valve should extinguish the burnersimmediately after removal of the thermocouple.

3. If burners do not extinguish, immediately followsteps in “TO TURN OFF GAS TOAPPLIANCE”.

4. Immediately call a qualified serviceman or install-er to repair an ignition system that fails to operateproperly and shut down the burners.

5. After successful completion of the test, turn thecontrol knob on the gas valve clockwise to the“OFF” position. Do not force.

6. Carefully reconnect the thermocouple to the gasvalve.

7. Follow the Lighting Instructions to relight the pilotand establish normal operation.

LIGHTING INSTRUCTIONS FOR SPARKIGNITION PILOT MODELS (F-9/M-9)

MODELS 45,000 THRU500,000 Btu/hr INPUT

FOR YOUR SAFETY READBEFORE OPERATING

A. This appliance is equipped with an ignitiondevice which automatically lights the pilot. Donot try to light the pilot by hand.

B. BEFORE OPERATING, smell around theappliance area for gas. Be sure to smell next tothe floor because some gas is heavier than airand will settle to the floor.

NOTE: The information package shipped with theappliance contains a wire lighting wand. The loopend of the wand will hold a match. The wand willextend your reach to the pilot and make lighting thepilot easier.

Should overheating occur or the gas fail to shut off,turn off the external manual gas valve to theappliance.

WARNING:

FIG. 38

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

WARNING: PILOT WITH

THERMOCOUPLE

27

WHAT TO DO IF YOU SMELL GAS

Do not try to light any appliance.

Do not touch any electric switch; do not use anyphone in your building.

Immediately call your gas supplier from aneighbor’s phone. Follow the gas supplier’sinstructions.

If you cannot reach your gas supplier, call thefire department.

C. Use only your hand to turn the gas control knob.Never use tools. If the knob will not turn byhand, don’t try to repair it, call a qualifiedservice technician. Force or attempted repairmay result in a fire or explosion.

D. Do not use this appliance if any part has beenunder water. Immediately call a qualifiedservice technician to inspect the appliance. Thepossible damage to a flooded boiler can beextensive and present numerous safety hazards.Any appliance that has been under water mustbe replaced.

OPERATING INSTRUCTIONS

1. STOP! Read the safety information above.

2. Set the thermostat(s) to the lowest setting. M-9(2-stage) models are equipped with twothermostats.

3. Turn off all electrical power to the appliance.

4. This appliance is equipped with an ignition devicewhich automatically lights the pilot. DO NOT tryto light the pilot by hand.

5a. 45,000 - 135,000 and 399,000 - 500,000 Btu/hrmodels, rotate the gas control knob on the gasvalve clockwise to the “OFF” position.

5b. 180,000 - 360,000 Btu/hr models, rotate the gascontrol knob on the gas valve clockwise tothe line on the collar around the knob. Depress theknob and continue rotation to the “OFF” position.

FIG. 39

FIG. 40

TOP

SIDE

OUTLET

F-9 GAS VALVE - MODELS 045-135ALSO SEE FIG. 27

TOP

SIDE OUTLET

F-9 GAS VALVE - MODELS 180-500ALSO SEE FIG. 27

28

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

7a. 45,000 - 135,000 and 399,000 - 500,000 Btu/hrmodels, rotate the gas control knob on the gasvalve counterclockwise to the “ON” position.

7b. 180,000 - 360,000 Btu/hr models, rotate the gascontrol knob on the gas valve counter-clockwise to the line on the collar around theknob. Allow knob to “pop” up, and continuerotation to the “ON” position.

8. Turn on all electric power to the appliance.

9. Set the thermostat(s) to the desired setting. M-9(2-stage) models are equipped with twothermostats.

10. If the appliance will not operate, follow theinstructions “To Turn Off Gas To Appliance” andcall your service technician or gas supplier.

1. Set the thermostat(s) to the lowest setting. M-9(2-stage) models are equipped with twothermostats.

2. Turn off all electric power to the appliance ifservice is to be performed.

3a. 45,000 - 135,000 and 399,000 - 500,000 Btu/hrmodels, rotate the gas control knob on the gasvalve clockwise to the “OFF” position. Donot force.

3b. 180,000 - 360,000 Btu/hr models, rotate the gascontrol knob on the gas valve clockwise to theline on the collar around the knob. Depress theknob and continue rotation to the “OFF” position.Do not force.

SAFETY SHUTOFF TEST FOR SPARKIGNITION PILOT SYSTEM

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

2. Turn thermostat(s) to highest setting.

3. Turn electric power “ON”.

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 90second trial for ignition period on the 45,000 thru399,000 Btu/hr models and after the 15 second trialfor ignition period on the 500,000 Btu/hr model.

7. Immediately call a qualified serviceman orinstaller to repair an ignition system that fails to lock out and properly shut down burner operation.

8. After successful completion of the test, readjustthermostat(s) to normal setting.

9. Turn “ON” gas supply.

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

11. If ignition system fails to operate properly, repairwork must be performed by a qualifiedserviceman or installer.

FIG. 41

Should overheating occur or the gas fail to shut off,turn off the external manual gas valve to theappliance.

WARNING:

TOP

SIDE OUTLET

M-9 GAS VALVEALSO SEE FIG. 28

TO TURN OFF GAS TO APPLIANCE

29

INTERMITTENT PILOT,SPARK IGNITION SYSTEM (F-9/M-9)

The ignition module is not repairable. Anymodification or repairs will invalidate the warranty andmay create hazardous conditions that result in propertydamage, personal injury, fire, explosion and/or toxicgases. A faulty ignition module must be replaced witha new module.

IGNITION and CONTROL TIMINGS

F-1 Standing Pilot Models (thermocouple supervised)

Pilot Flame Failure Response Time - 180 SecondsMaximum

F-9/M-9 Intermittent Spark Ignition Pilot ModelsPilot Trial for Ignition Period - 90 Seconds(45,000 thru 399,000 Btu/hr models)

Pilot Trial for Ignition Period - 15 Seconds(500,000 Btu/hr models)

Pilot Failure Response Time - 0.8 Seconds at less than1.0 µA flame current

Pump Delay Timing - 30 Seconds after burner shutdown

FREEZE PROTECTION

Proper freeze protection must be provided for applianc-es installed in unheated mechanical rooms or wheretemperatures may drop to the freezing point or lower. Iffreeze protection is not provided for the system, a lowambient temperature alarm is recommended for themechanical room. Damage to the heat exchanger byfreezing is non- warrantable.

1. Pump Operation - MOST IMPORTANT - Thisappliance is designed for continuous pumpoperation when the burners are firing. If the systempump does not run continuously an additional pumpmust be installed to provide constant circulationthrough the appliance. This flow of warm water canhelp prevent freezing.

2. Location - Heating boilers, hot water supply boilersand water heaters must be located in a room havinga temperature safely above freezing [32°F(0°C)].

3. Caution - A mechanical room operating under anegative pressure may experience a down draft inthe flue of an appliance which is not firing. Thecold outside air pulled down the flue may freeze aheat exchanger. This condition must be correctedto provide adequate freeze protection.

4. Freeze protection for a heating boiler or hot watersupply boiler using an indirect coil can be providedby using hydronic system antifreeze. Follow themanufacturers instructions. DO NOT useundiluted or automotive type antifreeze.

5. A snow screen should be installed to prevent snowand ice accumulation around the appliance ventingsystem in cold climates.

6. Shut-down and Draining - If for any reason, theappliance is to be shut off, the followingprecautionary measures must be taken:

(a) Shut off gas supply.

(b) Shut off water supply.

(c) Shut off electrical supply.

(d) Drain the unit completely. Remove onethreaded plug or bulb well from the inletside of the front header and one from theoutlet side of the front header on the heatexchanger. Blow all water out of the heatexchanger.

(e) Drain pump and piping.

30

FREEZE PROTECTION FOR A HEATINGBOILER SYSTEM (If Required)

1. Use only properly diluted inhibited glycol anti-freeze designed for hydronic systems. Inhibitedpropylene glycol is recommended for systemswhere incidental contact with drinking water ispossible.

2. A solution of 50% propylene glycol will providemaximum protection of approximately -30°F.

3. Follow the instructions from the glycol antifreezemanufacturer. Quantity of glycol antifreezerequired based on total system volume includingexpansion tank volume.

4. Glycol is more dense than water and changes theviscosity of the system. The addition of glycol willdecrease heat transfer and increase frictional lossin the heating boiler and related piping. A largerpump with more capacity may be required tomaintain desired flow rates in a glycol system.

5. Local codes may require a back flow preventer oractual disconnect from city water supply whenglycol antifreeze is added to the system.

WATER TREATMENT

In hard water areas, water treatment should be used toreduce the introduction of minerals to the system.Minerals in the water can collect in the heat exchangertubes and cause noise on operation. Excessive build upof minerals in the heat exchanger can cause anon-warrantable failure.

MAINTENANCE

The following list contains items that must be checkedto ensure safe reliable operation. Verify proper opera-tion after servicing.

1. Examine the venting system at least once a year.Check more often in the first year to determineinspection interval. Check all joints and pipeconnections for tightness, corrosion ordeterioration. Clean louvers and/or screens in thecombustion air intake system as required. Have theentire system, including the venting system,periodically inspected by a qualified serviceagency.

2. Visually check main burner flames at each start upafter long shutdown periods or at least every sixmonths.

a. Normal Flame: A normal flame is blue, withslight yellow tips, with a well defined innercone and no flame lifting.

b. Yellow Tip: Yellow tip can be caused byblockage or partial obstruction of air flow to theburner(s).

c. Yellow Flames: Yellow flames can be caused byblockage of primary air flow to the burner(s) orexcessive gas input. This condition MUST becorrected immediately.

d. Lifting Flames: Lifting flames can be caused byover firing the burner(s) or excessive primaryair.

If improper flame is observed, examine the ventingsystem, ensure proper gas supply and adequate supplyof combustion and ventilation air.

3. Combustion Air Adjustment: This appliance usesan atmospheric combustion process. Combustion

CAUTION: ��DO NOT used undiluted or automotive type

antifreeze.

CAUTION: ��Label all wires prior to disconnection when servicingcontrols. Wiring errors can cause improper anddangerous operation.

The area around the burners is hot and directcontact could result in burns!

WARNING:

FIG. 42

B

C D

A

31

air is provided to the burners by the gas injectionpressure into the venturi of the burners. Theburners do not have an adjustable air shutter.Adequate combustion air must be supplied to themechanical room to ensure proper burneroperation. Check frequently to be sure the flow ofcombustion and ventilation air to the unit is notobstructed. When the main burners light, observethe burner flame. Flames should be light blue incolor with slight yellow tips; flames should besettled on burner head with no lifting whensupplied with correct volume of combustion air.

4. Flue Gas Passageways Cleaning Procedures: Anysign of soot around the outer jacket, at the burnersor in the areas between the fins on the copper heatexchanger indicates a need for cleaning. Thefollowing cleaning procedure must only beperformed by a qualified serviceman or installer.Proper service is required to maintain safeoperation. Properly installed and adjustedappliances seldom need flue cleaning.

All gaskets on disassembled components must bereplaced with new gaskets on reassembly. Gasket kitsare available from your distributor.

BURNER REMOVAL AND CLEANING

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

b. Turn “OFF” external manual gas shutoff valveto appliance.

c. Disconnect gas supply piping from combination gas valve on 45,000 thru 360,000Btu/hr models. Disconnect the gas supply man-ifold at the unions on the inlet to each of thetwo combination gas valves on the 399,000 thru500,000 Btu/hr models.

d. Remove electrical wiring from combination gasvalve(s) and spark igniter (if equipped). Markwires for proper reassembly.

e. Remove mounting screws from lower frontjacket panel.

f. Remove mounting screws from each side of theburner tray and slide the burner tray assemblyand lower front jacket panel out towards thefront of the unit. Use caution to preventdamage to burners, refractory, pilot or wiring.

Note: The ceramic fiber material used in this appliance isan irritant; when handling or replacing the ceramic

materials it is advisable that the installer follow these safetyguides.

REMOVAL OF COMBUSTION CHAMBER LININGOR BASE PANELS:

• Avoid breathing dust and contact with skin and eyes.• Use NIOSH certified dust respirator (N95)

(http://www.cdc.gov/niosh/hompage.html).• Lightly mist with water (only those areas being handled)

the combustion chamber lining or base insulation to prevent airborne fibers.

• 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.

g. Remove soot from burners with a stiff bristlebrush. Dirt may also be removed from burnerports by rinsing the burner thoroughly withwater. Drain and dry burners beforereinstalling. Damaged burners must bereplaced.

An appliance installed in a dust or dirt contaminatedatmosphere will require cleaning of the burners on a 3to 6 month schedule or more often, based on severity ofcontamination. Contaminants can be drawn in with thecombustion air. Noncombustible particulate mattersuch as dust, dirt, concrete dust or dry wall dust can

� WWAARRNNIINNGG: The combustion chamberlining in this appliance contains ceramic fibermaterials. Ceramic fibers can transform intocristobalite (crystalline silica) when exposed totemperatures above 2192°F (1200°C) dependentupon the length of exposure time.*

The International Agency for Research on Cancer(I.A.R.C.) has concluded, "Crystalline silicainhaled in the form of quartz or cristobalite fromoccupational sources is carcinogenic tohumans."**

Testing has confirmed that the ceramic fibers inthis application do not reach 2192°F (1200°C).

*Reference Dyson, D., Butler, M., Hughes, R.,Fisher, R., and Hicks, G. The Devitrification ofAlumino-silicate Ceramic Fiber Materials - TheKinetics of the Formation of Different CrystallinePhases, Ann. Occup. Hyg. Vol. 41, No. 55, 1997.**Reference I.A.R.C. Monograph 68, June 1997.

32

block burner ports and cause non-warrantable failure.Use extreme care when operating an appliance fortemporary heat during new construction. The burnerswill probably require a thorough cleaning before theappliance is placed in service.

h. Check the heat exchanger surface for sooting.The external surfaces of the copper tubesshould be free of any soot deposits. (A slightblack smudge is normal with some types ofgases.) If abnormal soot deposits are present,the heat exchanger must be cleaned and thecause of the soot problem corrected. Proceed asfollows:

i. Remove gas manifold/burner tray assembly asdescribed in steps a. thru f. in “BurnerRemoval.” Disconnect the gas supply pipingfrom the burner manifold on the 399,000 thru500,000 Btu/hr models.

j. Loosen mounting screws and remove frontcontrol panel.

k. Loosen screws on the upper front jacket paneland remove toward front of the appliance. Usecaution to prevent damage to refractory on thedoors inner surface.

l. Check “V” baffles on top of the heat exchang-er. Remove and clean if necessary.

m. Remove soot from the heat exchanger with a stiffbristle brush. Soot may also be removed from theheat exchanger by washing thoroughly withdetergent and water. Remove the heat exchangerbefore using water for cleaning. Rinse thoroughlyand dry before re-installing. Use a vacuum toremove loose soot from surfaces and innerchamber.

n. The heat exchanger can be removed by slidingtowards the front of the appliance. Once theheat exchanger is removed from the appliance,a garden hose can be used to wash the tubes toensure that all soot is removed from the heatexchanger surfaces.

o. Ensure that all burner ports are cleaned toremove any soot. See Burner CleaningProcedure.

p. Carefully reinstall the heat exchanger, “V”baffles, jacket panels, burner tray assembly andwires.

q. Reassemble all gas and water piping. Test forgas leaks.

r. Cycle the appliance and check for properoperation.

5. Water Circulating Pump: Inspect pump every 6months and oil if required. Use SAE 30non-detergent oil or lubricant specified by pumpmanufacturer.

6. Keep appliance area clear and free fromcombustible materials, gasoline and otherflammable vapors and liquids.

7. Check frequently to be sure the flow of combustionand ventilation air to the boiler is not obstructed.

8. Inspection of Heat Exchanger Waterways:Appliances operated in hard water areas shouldhave periodic inspections of the tubes to be surethat no sediment or scale accumulates on the heattransfer surfaces. Inspection plugs are located atboth ends of the heat exchanger. Inspection plugsshould be removed and tubes inspected at the endof the first 45 days of operation and again at the endof 90 days of operation. If no scale accumulation isobserved, inspections can be made at the end ofeach six months of operation.

9. Pilot Flame Adjustment Procedure - The pilot flameshould envelop 3/8" to 1/2" (10 to 13mm) of the tipof the thermocouple, see Figure 43.

a. Remove pilot adjustment cover screw on gasvalve. See Gas Valve Illustrations in theLighting Instructions section for location ofcover screw.

FIG. 43

PILOT FLAME ON THERMOCOUPLE

HEAT EXCHANGER CLEANING

33

b. Turn inner adjustment screw clockwise todecrease or counterclockwise to increase pilotflame.

c. If difficulty is experienced in adjusting the pilotflame, a tee may be installed in the pilot linefrom the gas valve to the pilot burner.

d. Replace pilot adjustment cover screw on valve.Tighten firmly after adjustment to prevent gasleakage.SYSTE

The drawings in this section show typical heating boilerpiping installations. Before beginning the installation,consult local codes for specific plumbing requirements.The installation should provide unions and valves at theinlet and outlet of the boiler so it can be isolated forservice. The boiler circulating pump, air separator,expansion tank and other components required forproper installation must be purchased locally. An airseparation device must be supplied in the installationpiping to eliminate trapped air in the system. Locate asystem air vent at the highest point in the system. Thesystem must also have a properly sized expansion tankinstalled. Typically, an air charged diaphragm-typeexpansion tank is used. The expansion tank must beinstalled close to the boiler and on the suction side ofthe system pump to ensure proper operation. Caution:This boiler system should not be operated at less than12 PSIG. Hot water piping must be supported bysuitable hangers or floor stands, NOT by the boiler.Copper pipe systems will be subject to considerableexpansion and contraction. Rigid pipe hangers couldallow the pipe to slide in the hanger resulting in noisetransmitted into the system. Padding is recommendedon rigid hangers installed with a copper system. Theboiler pressure relief valve must be piped to a suitablefloor drain. See the Relief Valve Section in this manual.

R CONNECTIONSHEATING BOILERS

IMPORTANT:

Upon completion of any testing on the gas system,leak test all gas connections with a soap solutionwhile main burners are operating. Immediately repairany leaks found in the gas train or relatedcomponents. Do Not operate an appliance with aleak in the gas train, valves or related piping.

FIG. 44

FIG. 45

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.

GAS TRAIN399,000–500,000 Btu/hr MODELS

GAS TRAINS

45,000–180,000 Btu/hr MODELS

199,000–360,000 Btu/hr MODELS

GAS TRAIN AND CONTROLS

PIPING OF THE BOILER SYSTEM

34

ONLYHeating Boilers with inputs of 45,000-180,000 Btu/hrhave 1-1/4" NPT inlet and outlet connections, HeatingBoilers with inputs of 225,000-500,000 Btu/hr have1-1/2" NPT inlet and outlet connections. Caution:Field installed reducing bushings may decrease flow re-sulting in boiler noise or flashing to steam.

This is a low mass, high efficiency hot water boilerwhich must have adequate flow for quiet, efficientoperation. The boiler circulating pump must bepurchased locally. The boiler circulator pump mustoperate continuously while the boiler is firing. Pumpselection is critical to achieve proper operation. A pumpshould be selected to achieve proper system designwater temperature rise. A heat exchanger pressure dropchart (Table L) is provided to assist in proper pumpselection. Also provided is a System Temperature RiseChart (Table N). This table provides GPM and boilerhead-loss at various temperature rises for each boilerbased on Btu/hr input. Temperature rise is thedifference in boiler inlet temperature and boiler outlettemperature while the boiler is firing. Example: Theboiler inlet temperature is 160°F and the boiler outlettemperature is 180°F, this means that there is a 20°Ftemperature rise across the boiler.

1. Maximum operating pressure for the pump mustexceed system operating pressure.

2. Maximum water temperature should not exceednameplate rating.

3. Cast iron circulators may be used for closed loopsystems.

4. A properly sized expansion tank must be installednear the boiler and located on the suction side ofthe pump.

The heating boiler circulating pump must be purchasedlocally. A pump control relay is supplied in the controlpanel of each heating boiler. External wire leads can beinstalled to supply power to the pump, allowing thecontrol relay to cycle the pump on each call for heat (seePump Wiring). Caution: When the power supply forthe pump is wired across switching contacts of thepump control relay, the external power leads to thepump may be “Hot” when the main power switch is“ON” or when the boiler is calling for heat. The fieldinstalled boiler pump using these wire leads must notexceed 12 AMPS at 120 VAC, 6 AMPS at 208/240/277VAC or 3 AMPS at 480 VAC. As shipped from thefactory, this control relay is set to cycle the boiler pumpon each call for heat with an external room thermostatinstalled across terminals R and W on the internalterminal strip. For continuous pump operation, connectthe orange jumper on the terminal board betweenterminals R and A. See wiring diagram shipped withthe unit.

FIG. 46

HEAT EXCHANGER PRESSURE DROP

Pump Relay

WATER CONNECTIONSHEATING BOILERS ONLY

CIRCULATOR PUMP REQUIREMENTS

TABLE - LHEAT EXCHANGER PRESSURE DROP CHART

CIRCULATOR PUMP SPECIFICATIONS

CIRCULATOR PUMP OPERATION(Heating Boilers Only)

35

PUMP INSTALLATION AND MAINTENANCE: Theboiler circulating pump must be purchased locally. Forinstallation and maintenance information on thecirculator pump, refer to pump manufacturersinstruction package included with the pump.

The installer must ensure that the circulating pumpinstalled with the boiler will supply adequate flowwithout excessive temperature rise. It is recommendedthat this boiler be installed with a bypass in the piping,a properly sized circulator and piping system. Thebypass will help to ensure that the boiler can be sup-plied with adequate water flow. A typical bypass with avalve is shown in Figure 47. If the boiler temperaturerise exceeds 40°F, it is an indication that the boiler maynot be receiving adequate flow and adjustment of thebypass is required. If a high temperature rise isexperienced, check the pump for proper operation andcheck the system piping for any obstruction. A largerpump may be necessary. The installation of the recom-mended system bypass as shown in Figure 47 allows anincreased flow through the boiler. If there is any doubtthat the pump may not provide adequate flow, bypasspiping should be provided at the time the boiler isinstalled. The bypass should be fully sized with abalancing valve to allow for proper adjustment. Thebalancing valve allows the flow through the bypass to beadjusted based on the individual system requirements.A bypass is recommended on all multiple zone systems inaddition to a properly sized circulator and system piping.

Heating Boilers with inputs of 225,000 Btu/hr or largerinstalled on multiple zone systems are recommended tobe installed with a primary/secondary piping system asshown in Figure 48. A primary/secondary piping systemmay also be installed on smaller input boilers to ensureproper boiler flow rates. Primary/secondary piping isalso ideal for systems using a mixture of propyleneglycol and water. A primary/secondary piping systemuses 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 systempiping only. The secondary pump, installed in the boilerpiping, ensures a constant water flow rate to the boiler forproper operation. Boiler installation with aprimary/secondary piping system can prevent noiseproblems caused by low system water flows. Aprimary/secondary piping system is recommended onany boiler where low water flow conditions may presentan operational problem.

A primary/secondary piping system is ideal for systemsfilled with a propylene glycol and water mixture. Aglycol and water mixture is more dense than water onlyand may result in a lower boiler flow rate. A lowerboiler flow may cause noise on operation or shortcycling of the burners. A larger secondary pump maybe used on a primary/secondary system to provide anincreased boiler flow rate. A glycol and water systemmay require from 10% to 20% more flow to compensatefor the increased density of the glycol and its effect onthe heat transfer process in the boiler. The exact

FIG. 47

PRIMARY/SECONDARY PIPING OF A SINGLE BOILERMAKE-UP

WATER

PRV

EXPANSION TANK

LWCO(OPTIONAL)

SECONDARYBOILER PUMP12”

FROM SYSTEM

AIRSEPARATOR

SYSTEMPUMP

TOSYSTEM

PRIMARY/SECONDARYBOILER PIPING

FIG. 48

MAKE-UP WATER

HEATING SUPPLY LOOPTO FLOOR

DRAIN

HEATING RETURN LOOP

BYPASS–LOW FLOW SYSTEMS

PRV

EXPANSION TANK

AIRSEPARATOR

SYSTEMPUMP

LWCO(OPTIONAL)

BYPASSBALANCINGVALVE

BOILER BYPASS REQUIREMENTS

36

increase in flow that may be required is based on thetype and percentage of glycol added to the boilersystem. Consult the manufacturer of the glycol foradditional recommendations when using a glycol andwater fill for your boiler system.

The installer must ensure that the boiler has adequateflow without excessive temperature rise. Thetemperature rise on a multiple zone system should bemade when only the zone with the longest length and/orhighest head loss is open. Low system flow can resultin overheating of the boiler water which can cause shortburner on cycles, system noise and in extreme cases, aknocking flash to steam. These conditions indicate theneed to open the bypass adjustment valve, installation ofa larger circulator pump or installation of the boiler witha primary/secondary piping system. System noise mayalso indicate an oversized boiler.

LOW TEMPERATURE BYPASSREQUIREMENTS

A boiler operated with an inlet temperature of less than140°F (60°C) must have a bypass to prevent problemswith condensation. A bypass as shown in Figure 49must be piped into the system at the time of installation.This piping is like a primary/secondary boilerinstallation with a bypass in the secondary boiler piping.Inlet water temperatures below 140°F (60°C) canexcessively cool the products of combustion resulting in

condensation on the heat exchanger and in the flue.Condensation can cause operational problems, badcombustion, sooting, flue gas spillage and reducedservice life of the vent system and related components.The bypass allows part of the boiler discharge water tobe mixed with the cooler boiler return water to increasethe boiler inlet temperature above 140°F (60°C). Thisshould prevent the products of combustion fromcondensing in most installations. The bypass should befully sized with a balancing valve to allow for properadjustment. A valve must also be provided on the boilerdischarge, after the bypass. Closing this discharge valveforces water through the bypass. Start boiler adjustmentwith the bypass valve in the full open position and theboiler discharge valve half open. A small amount of thehigher temperature boiler discharge water is mixed withthe system water to maintain the desired lower systemtemperature. A remote low temperature range operatoris recommended to control the boiler operation based onthe lower system temperature. This remote operatorshould be wired across the R and W terminals (seeRoom Thermostat Connection and Terminal Stripinstructions).

THREE WAY VALVES:

CAUTION: ��At no time should the system pressure be less than

12 PSIG.

BOILER WITH LOW TEMPERATUREBYPASS PIPING

FIG. 49

MAKE-UPWATER

PRV

EXPANSION TANK

LWCO(OPTIONAL)

SECONDARYBOILER PUMP

FROM SYSTEM

AIRSEPARATOR

SYSTEMPUMP

TOSYSTEM

BY PASS12”

BOILER PIPING WITH A 3-WAY VALVE

SYSTEM PUMP

PRV

LWCO(OPTIONAL)

SECONDARYBOILER PUMP

FROMSYSTEM

12”

AIRSEPARATOR

MAKE-UPWATER

TO SYSTEM

EXPANSIONTANK

THREE-WAY VALVESLOWOPENING/SLOWCLOSING

FIG. 50

37

The basic guide for minimum flow in this boiler is basedon a 40°F temperature rise in most installations. Lowerflow and a higher temperature rise is acceptable if theboiler system is specifically designed for thecharacteristics of a higher temperature rise. A systemnot specifically designed for a higher temperature risemay experience overheating of the boiler water. Thiscan cause short burner on cycles, system noise and inextreme cases, a knocking flash to steam. Theseconditions can lead to operational problems andnon-warrantable failures of the boiler. Hightemperature rise systems must be designed by aqualified engineer.

TABLE - MMINIMUM REQUIRED FLOW FOR HEATING

BOILER

Input Btu/hr GPM Flow

45,000 1.9

75,000 3.1

90,000 3.7

135,000 5.6

180,000 7.4

225,000 9.3

270,000 11.1

315,000 13.0

360,000 14.9

399,000 16.5

500,000 20.7

The installation of a three way valve on this boiler is notgenerally recommended because most piping methodsallow the three way valve to vary flow to the boiler. Thisboiler is a low mass, high efficiency unit which requiresa constant water flow rate for proper operation. Lowflow rates can result in overheating of the boiler waterwhich can cause short burner on cycles, system noiseand in extreme cases, a knocking flash to steam. Theseconditions can cause operational problems andnon-warrantable failures of the boiler. If a three wayvalve must be installed, please pipe in aprimary/secondary system as shown in Figure 50.Based on boiler sizing and system flow requirements,this piping may still result in boiler short cycling.

BOILER FLOW RATES

The heat exchanger is generally capable of operatingwithin the flow rates of a residential heating system.Should the flow rate exceed the maximum allowableflow rate through the boiler (30 GPM) an externalbypass must be installed. The bypass should be fullysized with a balancing valve to allow for properadjustment of flow. Flow rate can be determined bymeasuring the temperature rise through the boiler.

CAUTION: ��The maximum flow rate through the boiler with a

copper heat exchanger must not exceed 33 GPM.

NOTE: Minimum flow is based on a 40°F temperature riseacross the boiler. Minimum flow may not prove aflow switch installed in the boiler piping. Use carewhen operating a boiler at or near the minimumrecommended flow because conditions unique tothe installation (system pressure, operation ofmultiple zone valves, glycol, variations in flow,etc.), may result in overheating of the boiler watercausing noise or nuisance operation of safety limit controls. Typical heating boiler applications willoperate with a 20°F to 30°F temperature rise acrossthe boiler.

FIG. 51

MAKE-UPWATER

PRV EXPANSION TANK

LWCO(OPTIONAL)

FROM SYSTEM

AIRSEPARATOR

SYSTEMPUMP

TOSYSTEM

BOILER BYPASS PIPING

BY-PASSVALVE

38

PLACING THE BOILER IN OPERATION

Filling the System: All air must be purged from thesystem for proper operation. An air scoop and air ventmust be located close to the boiler outlet and thereshould be a minimum distance between the cold waterfeed and the system purge valve.

1. Close all drain cocks and air vents.

2. Open the makeup water valve and slowly fill thesystem.

3. If a makeup water pump is employed, adjust thepressure to provide a minimum of 12 psi at thehighest point in the system. If a pressure regulatoris also installed in the line, it should be adjusted tothe same pressure.

4. Close all valves. Purge one circuit at a time asfollows:

A. Open one circuit drain valve and let the waterdrain for at least five minutes. Ensure thatthere are no air bubbles visible in the waterstream before closing the drain valve.

B. Repeat this procedure for each circuit.

5. Open all valves after all circuits have been purged.Make sure there are no system leaks.

TABLE - NSYSTEM TEMPERATURE RISE CHART

Based on Boiler Output in Btu/hr

Btu/hr 10° T 20° T 30° T 40° T 50° TInput Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd

45,000 36,900 7.4 0.6 3.7 0.2 2.5 0.2 1.9 0.2 - -

75,000 61,500 12.3 1.3 6.2 0.4 4.1 0.3 3.1 0.2 - -

90,000 73,800 14.9 1.4 7.4 0.5 5.0 0.3 3.7 0.2 - -

135,000 110,700 22.3 3.2 11.1 1.2 7.4 0.6 5.6 0.3 - -

180,000 147,600 29.7 5.1 14.9 1.6 9.9 0.7 7.4 0.4 - -

225,000 184,500 - - 18.6 1.3 12.4 0.8 9.3 0.4 - -

270,000 221,400 - - 22.3 2.1 14.9 0.9 11.1 0.5 - -

315,000 258,300 - - 26.0 4.1 17.3 2.2 13.0 1.3 - -

360,000 295,200 - - 29.7 5.4 19.8 2.5 14.9 1.5 - -

399,000 327,180 - - 33.0 8.1 22.0 3.6 16.5 2.0 13.2 1.7

500,000 410,000 - - - - 27.6 6.6 20.7 3.5 16.6 2.1

TEMPERATURE/PRESSURE GAUGE

This boiler is equipped with a dial type tempera-ture/pressure gauge. This gauge is factory installed in theoutlet side of the heat exchanger. The gauge has onescale to read system pressure and a separate scale to readwater temperature in °F. The temperature/pressure gaugecan be used to determine temperature rise by firstrecording the temperature of the boiler water with theboiler off. Record the temperature of the boiler water asthe boiler fires and the discharge temperature stabilizes.Subtract the boiler water temperature with the boiler offfrom the stable outlet water temperature with the boilerfiring. This temperature difference is the temperature rise.

TYPICAL HEATING BOILER INSTALLATIONS

General Plumbing Rules

1. Check all local codes.

2. For serviceability of the boiler, always installunions.

3. Always pipe the pressure relief valve to an opendrain.

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

5. Expansion tank must be installed near the boilerand on the suction side of the pump.

6. Support all water piping.

INSTALLATION WITH A CHILLEDWATER SYSTEM

Pipe refrigeration systems in parallel. Install duct coildownstream at cooling coil. Where the hot waterheating boiler is connected to a heating coil located inthe air handling units which may be exposed torefrigeration air circulation, the boiler piping systemmust be equipped with flow control valves or otherautomatic means to prevent gravity circulation of theboiler water during the cooling cycle. The coil must bevented at the high point and hot water from the boilermust enter the coil at this point. Due to the fast heatingcapacity of the boiler, it is not necessary to provide aductstat to delay circulator operation. Also, omitthermostat flow checks as the boiler is cold whenheating thermostat is satisfied. This provides greatereconomy over maintaining standby heat.

39

6. Run the system circulating pump for a minimum of30 minutes with the boiler turned off.

7. Open all strainers in the system and check fordebris.

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

9. Inspect the liquid level in the expansion tank. Thesystem must be full and under normal operatingpressure to ensure proper water level in theexpansion tank. Ensure that diaphragm typeexpansion tanks are properly charged and not waterlogged.

10. Start the boiler according to the “Start-UpInstructions” in this manual. Operate the system,including the pump, boiler and radiation units, forone hour.

11. Recheck the water level in the expansion tank. If itexceeds half the tank volume, open the tank toreduce the water level. Recheck pressure chargeon diaphragm type tanks.

12. Shut down the entire system and vent all radiationunits and high points in the system.

13. Close the water makeup valve and check thestrainer and pressure reducing valve for sedimentor debris. Reopen the water makeup valve.

14. Verify system pressure with the boiler pressuregauge before beginning regular operation.

15. Within three days of start-up, recheck and bleed allair vents and the expansion tank using theseinstructions.

NOTE: Do not use petroleum based stopleak products. All system leaks must be repaired.The constant addition of make-up water can causedamage to the boiler heat exchanger due to scaleaccumulation. Scale reduces flow and heat trans-fer, causing overheating of the heat exchanger.

FIG. 52

40

Remove the jumper between the R and W terminals onthe terminal strip. Refer to the chart in this section todetermine maximum allowable length and wire gaugerecommended to connect the switching contacts of theroom thermostat to the R and W terminals on theterminal strip. Connection to the terminal strip willallow the room thermostat to make and break the 24VAC boiler control circuit turning the boiler on and offbased on the room ambient temperature requirements.Set the boiler operating temperature control asdescribed above.

TABLE - OTERMINAL STRIP WIRING

Wire Gauge Maximum Allowable Length

12 GA 100 ft

14 GA 75 ft

16 GA 50 ft

18 GA 30 ft

DOMESTIC HOT WATERSUPPLY BOILERS

90,000 - 500,000 Btu/hr MODELS WATER HEATERS

90,000 - 360,000 Btu/hr MODELS

This section applies only to those units used to supplydirect fired domestic hot water and installed with astorage tank(s). The use of a properly sized pump andthe control of water velocity, as explained below, areimportant for correct operation of your hot water supplyboiler.

This section contains specific instructions for thoseunits used to supply domestic hot water. All warnings,cautions, notes and instructions in the generalinstallation and service sections apply to theseinstructions. Hot water supply boilers/water heaters aredesigned for installation with a storage tank. The use ofa properly sized pump and the control of water velocity,as explained below, is important for correct operation ofyour water heater/hot water supply boiler.

BOILER OPERATINGTEMPERATURE CONTROL

The operating temperature control is located in thecontrol panel, behind the control panel front access door.The sensing element for the operator is placed in a bulbwell installed in the inlet side of the heat exchanger frontheader. Carefully observe the discharge watertemperature on the initial boiler on cycles. The locationof the temperature sensor will generally require a lowertemperature set point on the operating control to achievethe desired discharge water temperature from the boiler.This sensing element location allows a boiler operatingwith a low to moderate flow rate to sustain longer burneron cycles, preventing short boiler “ON” cycles based onhigh discharge water temperatures. For example, a boileroperating with a 180°F discharge and a 20°F temperaturerise would require approximately a 160°F to 165°F setpoint with the temperature sensor installed on the inletside of the heat exchanger. The exact temperature setpoint is based on your system’s requirements. Turn thecontrol set point dial to the desired operating watertemperature. Observe the boiler discharge temperatureafter each set point adjustment to ensure properoperation.

ROOM THERMOSTAT OR REMOTETHERMOSTAT CONNECTION

TO TERMINAL STRIP

A room thermostat or remote temperature control maybe connected to the boiler. The room thermostat shouldbe installed on an inside wall, away from the influencesof drafts, hot or cold water pipes, lighting fixtures,televisions, sun rays or fireplaces. Follow themanufacturers instructions supplied with the thermostatfor proper installation and adjustment. The boiler isequipped with a terminal strip on the left side of thecontrol panel to allow easy connection.

FIG. 53

TERMINAL STRIP CONNECTIONS

41

WATER VELOCITY CONTROL

IMPORTANT - To ensure proper velocity through theheat exchanger, it is necessary to regulate thetemperature rise across the heat exchanger from inlet tooutlet. This must be done on initial installation andperiodically rechecked. With the correct temperaturerise across the heat exchanger, you may be assured of theproper velocity in the tubes. This will yield long life andeconomical operation from your hot water supply boiler.Excessive lime build-up in the tube is a result of too littlevelocity in the tubes. Excessive pitting or erosion in thetube is caused by too much velocity through the tubes.Care should be taken to measure temperature rise andmaintain a velocity as follows:

1. The pump must run continuously when the burnersare firing.

2. With the pump running and the water heater/hotwater supply boiler off, the inlet and outlet thermometers should read the same temperatures.If they do not, an adjustment must be made to yourfinal calculation.

3. Turn the water heater/hot water supply boiler onand allow time for the temperature to stabilize.Record the difference between the inlet and outlettemperatures. This difference will be the“temperature rise”.

4. Compare the temperature rise on the heater withthe required temperature rise in Table P. Shouldadjustment be needed, proceed as follows:

If the temperature rise is too high, the water velocity istoo low. Check the following:

1. Check for restrictions in the outlet of the waterheater/hot water supply boiler.

2. Be sure all valves are open between the waterheater/hot water supply boiler and the tank.

3. Check the pump to be sure it is running properlyand that the pump motor is running in the properdirection.

4. Be sure the circulation pipes between the waterheater/hot water supply boiler and storage tank arenot less than 1 1/2" diameter for a single unitinstallation.

5. Common manifold piping for multiple unit instal-lations will require larger minimum pipe sizes andtank tappings to ensure proper flow, see Table Q.

6. Multiple unit installations may also require a largercirculating pump to achieve the specified flowagainst the increased head loss of a multiple unitcommon manifold piping.

If the temperature rise is too low, the water velocity istoo high. Adjust as follows:

1. Slowly throttle the valve on the outlet side of thewater heater/hot water supply boiler until thetemperature rise is steady at the required tempera-ture rise as noted in Table P.

2. Sustained high water velocity and low temperaturerise may result in pitting or erosion of thecopper tubes in the heat exchanger. This is anon-warrantable failure. Temperature rise must beproperly adjusted to achieve the specified flowrate.

TABLE - PREQUIRED TEMPERATURE RISE

Based on heating potable water with a hardness of 5 to25 grains per gallon and total dissolved solids notexceeding 350 ppm. See “Water Chemistry.”

Btu/hr

INPUT Temperature Rise oF

90,000 5°

135,000 7°

180,000 10°

199,000 11°

225,000 12°

270,000 15°

315,000 17°

360,000 20°

399,000 22°

500,000 28°

42

WATER CHEMISTRY

The required temperature rise and the standard pumpsizing are based on the heating of potable water with ahardness of 5 to 25 grains per gallon and a totaldissolved solids not exceeding 350 ppm. Consult themanufacturer when heating potable water exceedingthese specifications. Heating of high hardness and/orhigh total dissolved solids water will require a largercirculating pump, an optional cupro-nickel heatexchanger and a revised temperature rise specificationbased on the water chemistry of the water to be heated.Water with a hardness of less than 5 grains per gallonwill usually have a low pH which can be aggressive andcorrosive causing non-warrantable damage to the heater,pump and associated piping. Corrosion due to waterchemistry generally shows up first in the hot watersystem because heated water increases the rate ofcorrosive chemical reactions.

TABLE - QCOMMON WATER MANIFOLD SIZE FORMULTIPLE HOT WATER SUPPLY BOILER

INSTALLATIONS

Pipe sizing chart provides minimum pipe size forcommon manifold piping and tank tappings to ensureadequate flow.

Number of Units Common Manifold Size (Min)

1 1 1/2"

2 2"

3 2 1/2"

4 3"

5 3 1/2"

6 3 1/2"

PUMP OPERATION

1. The water heater/hot water supply boiler must beconnected to a properly sized pump that circulateswater between the heater and storage tank.

2. Pump is sized to heater input and water hardness.Care should be taken to size pumpcorrectly. See “Water Chemistry.”

3. The pump must run continuously when the burnersare firing.

4. Lubricate pump to manufacturers recommendations.Pump damage due to inadequate lubrication is non-warrantable.

5. A standard water heater/hot water supply boiler isfurnished with a 1/6 HP, 120 VAC, 3.6 AMPcirculating pump to be mounted on the units inletwater connection. This pump is sized based oninstallation of a single storage tank and heater inclose proximity. If the number of fittings andstraight pipe exceeds the quantities shown in thissection, a larger pump will be required.

FIG. 54

Typical Water Heater Piping with Storage Tank

COLD WATERSUPPLY

LOCK-TEMPSTORAGETANK

HOTWATERSUPPLY

RELIEFVALVE

DRAIN

RELIEFVALVE

BUILDINGRETURN

CIRCULATINGPUMP

EXPANSION TANK(If Required)

43

The standard pump selection is based on the followingpipe and fittings from the unit to the storage tank:

6 - 90° elbows 2 - ball valves2 - unions 1 - cold water tee

Plus the following length of straight pipe based on theheater size:

90,000 thru 360,000 Btu/hr ModelsNot more than 45 feet of straight pipe

399,000 thru 500,000 Btu/hr ModelsNot more than 25 feet of straight pipe

For every elbow and tee in excess of those shown above,DEDUCT 5 FEET from maximum allowable straightpipe in heater to tank circulating loop.

MINIMUM PUMP PERFORMANCE

Based on heating potable water with a hardness of 5 to25 grains per gallon and total dissolved solids notexceeding 350 ppm. See “Water Chemistry.”

BTU INPUT GPM Ft. Hd.90,000 - 500,000 30 8

HEAT EXCHANGER

This is a highly sophisticated heat exchanger, designedto carry water in such a way that it generates a scouringaction which keeps all interior surfaces free frombuild-up of impurities. The straight-line, two passdesign of the tubes sends water into the headers at aproperly rated velocity. The configuration of theheaders, in turn, creates a high degree of turbulencewhich is sufficient to keep all contaminants insuspension. This “scouring action” provides greatercost savings for owners. Tubes are always able totransfer heat at peak efficiency. Every surface withinthis water containing section is of a nonferrous material,providing clear, clean, rust-free hot water. Straightcopper tubes-finned on the outside for maximum heattransfer-glass lined cast iron one piece cored headersmake up an entirely rustproof unit. On all models,header inspection plugs can be removed for fieldinspection and cleaning of copper tubes. The entire heatexchanger may be easily removed from the unit.

THERMOSTAT SETTINGS

1. The thermostat is adjusted to a low test settingwhen shipped from the factory.

2. Set the thermostat to the lowest settings which willsatisfy hot water demands and prevent risk of scaldinjury.

TEMPERATURE ADJUSTMENT(Domestic Hot Water Use)

This unit has an adjustable thermostat to control watertemperature. See temperature adjustment procedure inthe general section of the manual. The thermostat isfactory preset at approximately 125°F. Households withsmall children or invalids may require 120°F or lowertemperature setting to reduce risk of scald injury. Somestates may require a lower temperature setting. Checkwith your gas supplier for local requirements governingthe temperature setting. Remember, no water heatingsystem will provide exact temperature at all times.Allow a few days of operation at this setting todetermine the correct temperature setting consistentwith your needs.

Incorrect piping of the cold water supply to the systemmay result in excessive low temperature operationcausing condensate formation on the heat exchangerand operational problems. The cold water supply pipingmust be installed in the discharge piping from the heaterto the storage tank. This allows the cold water to betempered in the storage tank before entering the heater.See typical installation drawings provided with the unitfor correct piping. Higher water temperatures reducecondensate formation.

NOTE:

(1) This water heater, when set at the lowertemperature setting, is not capable of producinghot water of sufficient temperature for sanitizingpurposes. (2) Higher stored water temperatureincreases the ability of the water heater to supplydesired quantities of hot water, howeverremember:

CAUTION: ��

Hotter water increases the risk of scald injury.

44

The manufacturer recommends the use of a properlysized thermostatic mixing valve to supply domestic hotwater at temperatures less than 140°F. Storing thewater at a higher temperature and thermostaticallymixing the water will increase the available quantity ofmixed hot water, greatly reduce the possibility ofcondensate formation on the heat exchanger and helpprevent the growth of water born bacteria. Adequatecare MUST be taken to prevent potential scald injurywhen storing water at 140°F and hotter.

HIGH WATER TEMPERATURELIMIT CONTROL

The unit may be equipped with either a fixed setting,manual-reset high water temperature limit control or anadjustable setting, auto-reset high water temperaturelimit. See the “Temperature Adjustment” section of themanual for specific data on the limit provided. A waterheater or hot water supply boiler should have the setpoint of the adjustable temperature limit control set to amaximum of 200°F (93°C). If water temperatureexceeds the set point, the limit will break the controlcircuit and shut down the unit. The limit control willonly be reset after the water temperature has cooledbelow the set point of the limit. The high watertemperature limit control is mounted in the outlet side ofthe front header. A manual reset high watertemperature limit control is available as an optionalcontrol on all units.

AUTOMATIC VENT DAMPERS

Automatic vent dampers are not required or furnishedon potable water heaters. All water heaters will have aplug installed in the damper terminal on the side of thecontrol panel to allow operation without a vent damper.The damper plug MUST be in place if an optional ventdamper is not used on a water heater. Water heaters withinputs of 360,000 Btu/hr and less may be ordered withthe vent damper as an option. Remove damper plugfrom terminal to connect an optional vent damper wireharness. The optional damper must be properlyinstalled and the wire harness plugged into the terminalon the side of the control panel to allow the unit tofunction. See the “Automatic Vent Damper” section inthe basic portion of the manual.

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 normallysupplied with a temperature and pressure relief valve(s)sized in accordance with applicable codes. Units may besupplied with an optional pressure only relief valve(s).When a water heater/hot water supply boiler equippedwith this optional relief valve is piped to a separatestorage vessel, the storage vessel must have a properlyinstalled temperature and pressure relief valve whichcomplies with local codes.

CAUTION: ��Setting the temperature selector to higher settingsprovides hotter water, which increases the risk ofscald injury.

SHOULD OVERHEATING OCCUR OR THEGAS SUPPLY FAIL TO SHUT OFF, DO NOTTURN OFF OR DISCONNECT THEELECTRICAL SUPPLY TO THE PUMP.INSTEAD, SHUT OFF THE GAS SUPPLY AT ALOCATION EXTERNAL TO THEAPPLIANCE.

WARNING:

• 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).

45

THERMAL EXPANSION

A relief valve which discharges periodically may be dueto thermal expansion in a closed system. A hot watersupply boiler installed in a closed system, such as onewith a backflow preventer or check valve installed in thecold water supply, shall be provided with means tocontrol expansion. Contact the water supplier or localplumbing 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 systemthat has not been used for a long period of time(generally two weeks or more). Hydrogen gas isextremely flammable. To prevent the possibility ofinjury under these conditions, we recommend the hotwater faucet be open for several minutes at the kitchensink before you use any electrical appliance which isconnected to the hot water system. If hydrogen ispresent, there will be an unusual sound such as airescaping through the pipe as the hot water begins toflow. There should be no smoking or open flames nearthe faucet at the time it is open.

46

NOTES

47

NOTES

CP-5M-2/04-Printed in U.S.A.