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