495,000 - 2,065,000 Btu/hr MODELS
HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
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Table of Contents
Table of Contents
GENERAL PRODUCT INFORMATION
SAFETY INFORMATION
Warranty
Special Instructions
3.Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-airintake system. Use proper care to avoid unnecessary contact especially children with the appliance and vent-airintake components. Follow all clearances from combustibles contained in this manual
Front View Rear View
PRODUCT IDENTIFICATION
Figure 1 - Front and Rear View
Clearances from Combustible Construction
INSTALLATION
LOCATING UNIT
Base for Combustible Floors
Hydronic System Antifreeze
Outdoor Boiler Installation
FREEZE PROTECTION
Shut-Downand Draining
Combustion Air Filter
Installing Combustion Air Filter
COMBUSTION AND VENTILATION AIR
INSTALLATION
One Opening
Combustion Air Options
2. Outside Combustion Air, Using Ducts
Figure 7 - Outside Combustion Air - Two Openings
Exhaust Fans
INSTALLATION VENTING
General Information
Venting Support
TABLE-A Flue Pipe Sizes
Parapet Wall
TABLE-C
Vent System Options
TABLE - B Flue Pipe Sizes
Barometric Damper Location
Negative Draft
1.Conventional Negative Draft Venting
Flue Outlet Piping
Vertical Vent Termination Clearances and Location
2. Outdoor Installation Venting
INSTALLATION
Inspection of a Masonry Chimney
Outdoor Vent/Air Inlet Location
TABLE - D
Outdoor Vent Kits
The Outdoor Vent Kit
Gas Piping
CONNECTING TO GAS SUPPLY
Gas Pressure Test
TABLE - E Inlet Pressure
TABLE-F
Connecting Gas Piping to Unit
Gas Train and Controls
TABLE-F
TABLE - H
Combination Gas Valves
Checking Gas Supply Pressure
INSTALLATION
Gas Manifold Pressure Adjustment
TABLE - NET MANIFOLD PRESSURE
CONNECTING TO WATER SUPPLY
Inlet and Outlet Connections
Regulator Pressure Less Front Chamber Pressure
Low Water Cutoff
CONNECTING TO ELECTRICAL SUPPLY
Water Flow Switch
Relief Valve
AMP Draw Data
Terminal Strip Connection Options
TABLE - J Nominal AMP Draw Data
INSTALLATION
Water Connections Heating Boilers Only
BOILER SYSTEM PIPING
General Plumbing Rules
Pump Installation and Maintenance
Heat Exchanger Pressure Drop Chart
Circulator Pump Specifications
Primary/Secondary Boiler Piping
Table - K LTV Valve Kits
Low Temperature Return Water Systems
Radiant Floor and Snow Melt Heating Systems
495,000 - 745,000VAL3048
TABLE - L
Installation with a Chilled Water System
System Temperature Risased on Btu/hr Input
INSTALLATION
Boiler Bypass Requirements
Temperature/Pressure Gauge
Boiler Flow Rate
Filling the System
WATER TREATMENT
FOR YOUR SAFETY READ BEFORE OPERATING
OPERATION
Lighting Instructions
Locating Temperature Control
SETTING TEMPERATURE CONTROL
To Turn Off Gas To Appliance
TABLE-L
Temperature Control Settings
TABLE - M
Maximum Set Point Determination Setpoint
Shutdown
Outdoor Air Reset Option
High-FireOffset
Outdoor Air Max O.A. Max
Boiler Application
Temperature Control Sensors
Placement of Sensors
Water Heater Application
Hot Surface Igniter and Ignition Control Module
TABLE - N Remote Wire Connection
HOT SURFACE IGNITION SYSTEM
Remote Mounting of Sensor
Diagnostic Status Indication
Hot Surface Ignition Control Module
Ignition and Control Timings
OPERATION
TABLE - O Status LED Diagnostic Codes
OPERATION AND DIAGNOSTIC LIGHTS
TABLE - P Status LED Diagnostic Codes
DOMESTIC WATER HEATERS
Required Temperature Rise
TABLE - Q Temperature Rise Chart
Water Velocity Control
Water Chemistry
TABLE - R Pipe Sizing Chart
ABLE-P Pipe Sizing Chart
Circulating Pump
DOMESTIC WATER
Potable Hot Water Temperature Control Settings
Domestic Water Temperatures
Minimum Pump Performance
Optional Relief Valve
High Water Temperature Limit Control
Location of Cold Water Supply Piping Connections
Thermal Expansion
Burner Removal and Cleaning
CLEANING AND MAINTENANCE
Flue Gas Passageways Cleaning Procedures
Appliance Area
Combustion Air Fan Adjustment
Heat Exchanger Cleaning
Fan Cleaning
Adjusting Differential Air Pressure
Figure 43 - Air Pressure Switch
CLEANING AND MAINTENANCE CONTINUED
Figure 44 - Adjusting Air Shutter
Servicing Hot Surface Igniter and Ignition Module
Figure 47 - Adjusting Air Shutter
Ignition System Checkout
SEQUENCE OF OPERATION
CLEANING AND MAINTENANCE CONTINUED
Manual Reset High-LimitThermostat
Power Supply
ON/OFF Rocker Switch
Safety Device Terminals
Ignition Module
Electronic Temperature Controller
Heat Transfer Process Gas Valves, Burner
MODELS 495,000 - 745,000
SCHEMATIC DIAGRAM
DISCONNECT POWER BEFORE SERVICING THE UNIT
BTU/HR
HI-LIMITS- PWR SW
OPTIONAL I/O RESET
MAIN UNIT - GAS VALVES - BLOWER PRESSURE SWITCH
OPERATOR
CN7 OPERATOR
MODELS 985,000
WIRING DIAGRAM
SCHEMATIC AND
2,065,000 BTU/HR
CONNECTION DIAGRAM A
CONTROL BOX CONNECTIONS
WIRING DIAGRAM
WIRING BOX
CB-CWE-i&s-06 CP-5M-1/09