HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
495,000 - 2,065,000 Btu/hr MODELS
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Table of Contents
Table of Contents
SAFETY INFORMATION
Warranty
GENERAL PRODUCT INFORMATION
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
PRODUCT IDENTIFICATION
Front View Rear View
Figure 1 - Front and Rear View
INSTALLATION
LOCATING UNIT
Clearances from Combustible Construction
Base for Combustible Floors
Outdoor Boiler Installation
FREEZE PROTECTION
Hydronic System Antifreeze
Shut-Downand Draining
Installing Combustion Air Filter
COMBUSTION AND VENTILATION AIR
Combustion Air Filter
INSTALLATION
Combustion Air Options
2. Outside Combustion Air, Using Ducts
One Opening
Figure 7 - Outside Combustion Air - Two Openings
INSTALLATION VENTING
General Information
Exhaust Fans
Venting Support
TABLE-A Flue Pipe Sizes
Parapet Wall
Vent System Options
TABLE - B Flue Pipe Sizes
TABLE-C
Barometric Damper Location
1.Conventional Negative Draft Venting
Negative Draft
Flue Outlet Piping
2. Outdoor Installation Venting
INSTALLATION
Vertical Vent Termination Clearances and Location
Inspection of a Masonry Chimney
TABLE - D
Outdoor Vent Kits
Outdoor Vent/Air Inlet Location
The Outdoor Vent Kit
CONNECTING TO GAS SUPPLY
Gas Pressure Test
Gas Piping
TABLE - E Inlet Pressure
Connecting Gas Piping to Unit
Gas Train and Controls
TABLE-F
TABLE-F
Combination Gas Valves
Checking Gas Supply Pressure
TABLE - H
INSTALLATION
Gas Manifold Pressure Adjustment
CONNECTING TO WATER SUPPLY
Inlet and Outlet Connections
TABLE - NET MANIFOLD PRESSURE
Regulator Pressure Less Front Chamber Pressure
CONNECTING TO ELECTRICAL SUPPLY
Water Flow Switch
Low Water Cutoff
Relief Valve
Terminal Strip Connection Options
TABLE - J Nominal AMP Draw Data
AMP Draw Data
INSTALLATION
BOILER SYSTEM PIPING
Water Connections Heating Boilers Only
General Plumbing Rules
Heat Exchanger Pressure Drop Chart
Circulator Pump Specifications
Pump Installation and Maintenance
Primary/Secondary Boiler Piping
Low Temperature Return Water Systems
Radiant Floor and Snow Melt Heating Systems
Table - K LTV Valve Kits
495,000 - 745,000VAL3048
Installation with a Chilled Water System
System Temperature Risased on Btu/hr Input
TABLE - L
INSTALLATION
Temperature/Pressure Gauge
Boiler Flow Rate
Boiler Bypass Requirements
Filling the System
FOR YOUR SAFETY READ BEFORE OPERATING
OPERATION
WATER TREATMENT
Lighting Instructions
SETTING TEMPERATURE CONTROL
Locating Temperature Control
To Turn Off Gas To Appliance
Temperature Control Settings
TABLE - M
TABLE-L
Maximum Set Point Determination Setpoint
Outdoor Air Reset Option
High-FireOffset
Shutdown
Outdoor Air Max O.A. Max
Temperature Control Sensors
Placement of Sensors
Boiler Application
Water Heater Application
TABLE - N Remote Wire Connection
HOT SURFACE IGNITION SYSTEM
Hot Surface Igniter and Ignition Control Module
Remote Mounting of Sensor
Hot Surface Ignition Control Module
Ignition and Control Timings
Diagnostic Status Indication
OPERATION
OPERATION AND DIAGNOSTIC LIGHTS
TABLE - O Status LED Diagnostic Codes
TABLE - P Status LED Diagnostic Codes
Required Temperature Rise
TABLE - Q Temperature Rise Chart
DOMESTIC WATER HEATERS
Water Velocity Control
TABLE - R Pipe Sizing Chart
ABLE-P Pipe Sizing Chart
Water Chemistry
Circulating Pump
Potable Hot Water Temperature Control Settings
Domestic Water Temperatures
DOMESTIC WATER
Minimum Pump Performance
High Water Temperature Limit Control
Location of Cold Water Supply Piping Connections
Optional Relief Valve
Thermal Expansion
CLEANING AND MAINTENANCE
Flue Gas Passageways Cleaning Procedures
Burner Removal and Cleaning
Appliance Area
Heat Exchanger Cleaning
Fan Cleaning
Combustion Air Fan Adjustment
Adjusting Differential Air Pressure
CLEANING AND MAINTENANCE CONTINUED
Figure 43 - Air Pressure Switch
Figure 44 - Adjusting Air Shutter
Servicing Hot Surface Igniter and Ignition Module
Figure 47 - Adjusting Air Shutter
SEQUENCE OF OPERATION
Ignition System Checkout
CLEANING AND MAINTENANCE CONTINUED
Power Supply
ON/OFF Rocker Switch
Manual Reset High-LimitThermostat
Safety Device Terminals
Electronic Temperature Controller
Ignition Module
Heat Transfer Process Gas Valves, Burner
SCHEMATIC DIAGRAM
DISCONNECT POWER BEFORE SERVICING THE UNIT
MODELS 495,000 - 745,000
BTU/HR
HI-LIMITS- PWR SW
MAIN UNIT - GAS VALVES - BLOWER PRESSURE SWITCH
OPERATOR
OPTIONAL I/O RESET
CN7 OPERATOR
WIRING DIAGRAM
SCHEMATIC AND
MODELS 985,000
2,065,000 BTU/HR
CONTROL BOX CONNECTIONS
WIRING DIAGRAM
CONNECTION DIAGRAM A
WIRING BOX
CB-CWE-i&s-06 CP-5M-1/09