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INSTALLATION AND SERVICE MANUAL
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HYDRONIC HEATING BOILERS and DOMESTIC WATER HEATERS 495,000 - 2,065,000 Btu/hr MODELS
Table of Contents
GENERAL PRODUCT INFORMATION
Special Instructions
Unpacking
Codes
Warranty
Page
Page
LOCATING UNIT
Clearances from Combustible Construction
Base for Combustible Floors
FREEZE PROTECTION
Pump Operation
VENTING
General Information
Venting Support
Vertical Vent Termination Clearances and Location
Page
Vent System Options
Barometric Damper Location
TABLE - B Flue Pipe Sizes
TABLEC Minimum Recommended Combustion Air Supply To Boiler Room
1. Conventional Negative Draft Venting
Negative Draft
Flue Outlet Piping
Vertical Vent Termination Clearances and Location
2. Outdoor Installation Venting
TABLE - D Outdoor Vent Kits
CONNECTING TO GAS SUPPLY
Gas Pressure Test
Gas Piping
Connecting Gas Piping to Unit
Gas Train and Controls
Combination Gas Valves
Checking Gas Supply Pressure
Gas Manifold Pressure Adjustment
CONNECTING TO WATER SUPPLY
Inlet and Outlet Connections
TABLE - I NET MANIFOLD PRESSURE Regulator Pressure Less Front Chamber Pressure
Relief Valve
Water Flow Switch
CONNECTING TO ELECTRICAL SUPPLY
External EMS Connection to Terminal Strip for Stage Firing Control of Burners
Terminal Strip Connection Options
TABLE - J Nominal AMP Draw Data
BOILER SYSTEM PIPING
General Plumbing Rules
Water Connections: Heating Boilers Only
Circulator Pump Requirements
Heat Exchanger Pressure Drop Chart
Primary/Secondary Boiler Piping
Low Temperature Return Water Systems
Radiant Floor and Snow Melt Heating Systems
Installation with a Chilled Water System
TABLE - L System Temperature Rise Chart Based on Btu/hr Input
Boiler Flow Rate
Boiler Bypass Requirements
Temperature/Pressure Gauge
FOR YOUR SAFETY READ BEFORE OPERATING
Lighting Instructions
To Turn Off Gas To Appliance
FIG. 32
SETTING TEMPERATURE CONTROL
Locating Temperature Control
Temperature Control Settings
TABLE - M
High-Fire Offset
Outdoor Air Reset Option
Shutdown
Outdoor Air Max (O.A. Max)
Ratio
Temperature Control Sensors
Boiler Application
Water Heater Application
Placement of Sensors
Remote Mounting of Sensor
HOT SURFACE IGNITION SYSTEM Hot Surface Igniter and Ignition Control Module
TABLE - N Remote Wire Connection
Hot Surface Ignition Control Module
Ignition and Control Timings
OPERATION AND DIAGNOSTIC LIGHTS
TABLE - O Status LED Diagnostic Codes
TABLE - P Status LED Diagnostic Codes
DOMESTIC WATER HEATERS
Water Velocity Control
Required Temperature Rise
TABLE - Q Temperature Rise Chart
Water Chemistry
Pipe Size Requirements
Circulating Pump
495,000 - 745,000 985,000 - 2,065,000
TABLE - R Pipe Sizing Chart
DOMESTIC WATER HEATERS
Minimum Pump Performance
Heat Exchanger
Potable Hot Water Temperature Control Settings
Domestic Water Temperatures
MAINTENANCE
Appliance Area
Water Circulating Pump
Burner Flames
Flue Gas Passageways Cleaning Procedures
Heat Exchanger Cleaning
Electrical
Combustion and Ventilation Air
Combustion Air Filter (Models 985,000 - 2,065,000 Btu/hr Only)
Air Flow
MAINTENANCE
Servicing Hot Surface Igniter and Ignition Module
MAINTENANCE
Ignition System Checkout
SEQUENCE OF OPERATION
GLOSSARY
Power Supply
ON/OFF Rocker Switch
Low Voltage Supply Transformer
24VAC Circuit Breaker
Electronic Temperature Controller
Ignition Module
Tw o Speed Blower
Pressur e Switch
Prepur ge
SCHEMATIC DIAGRAM MODELS 495,000 - 745,000 BTU/HR
-
DISCONNECT POWER BEFORE SERVICING THE UNIT
OPTIONAL
OPERATOR
WIRING DIAGRAMS - MAIN UNIT CONNECTIONS MODELS 495,000 - 745,000 BTU/HR
HI-LIMIT
OPTION BOX "C"
P
IGNITION MODULE
WIRING DIAGRAMS - MAIN UNIT CONNECTIONS MODELS 495,000 - 745,000 BTU/HR (CONTINUED)
SPLICE
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OPTIONAL
SCHEMATIC AND WIRING DIAGRAM MODELS 985,000 - 2,065,000 BTU/HR
WIRING DIAGRAM - CONTROL BOX CONNECTIONS MODELS 985,000 - 2,065,000 BTU/HR
CONNECTED UNLESS
5
6
8