WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance
INSTALLATION AND SERVICE MANUAL
Save this manual for future reference
Immediately call your gas supplier from a
Table of Contents
Table of Contents
Hydronic Heating Boilers and Domestic Water Heaters
Programming Temperature Control Quick Programming Overview
Special Instructions
Warranty
GENERAL PRODUCT INFORMATION
Codes
DANGER Carbon Monoxide poisoning may lead to death
SAFETY INFORMATION
Hydronic Heating Boilers and Domestic Water Heaters
Front View Rear View FIG. 1 Front and Rear View
PRODUCT IDENTIFICATION
Installation and Service Manual
Clearances from Combustible Construction
INSTALLATION
LOCATING UNIT
Right Side
FREEZE PROTECTION
Outdoor Boiler Installation
Location
Pump Operation
Freeze Protection for a Heating Boiler System if required
INSTALLATION Continued
Shut-Down and Draining
COMBUSTION AND VENTILATION AIR
1. Outside Combustion Air, No Ducts
FIG. 5 Moving Air Filter/Bracket Assembly from Rear of Unit to Side
Combustion Air Options
FIG. 4 Metal Panel Covering Side Combustion Air Inlet
FIG. 7 Outside Combustion Air - Two Openings
2. Outside Combustion Air, Using Ducts
3. Outside Combustion Air - Using Direct Venting
4. Combustion Air from Interior Space
General Information
VENTING
Exhaust Fans
Vertical Vent Termination Clearances and Location
FIG. 12 Vent Termination from Flat Roof 10’ or Less from Parapet Wall
Sidewall Vent Termination Clearances and Location
FIG. 11 Vent Termination from Peaked Roof More Than 10’ From Ridge
INSTALLATION Continued
Sidewall Air Inlet
Combustion Air Inlet Piping
Length of Air Inlet Pipe
FIG. 14 Sidewall Combustion Air Inlet
FIG. 15 Air Inlet Cap for Sidewall Termination
Continued
Vertical Rooftop Air Inlet
FIG. 16 Roof Top Combustion Air Inlet
Combined Air Inlet Points
Vent System Options
Barometric Damper Location
Flue Outlet Piping
1. Conventional Negative Draft Venting
Negative Draft
INSTALLATION Continued
Vertical Vent Termination Clearances and Location
2. Vertical DirectAire Venting
Installation and Service Manual
FIG. 19 Air Inlet Cap for Sidewall Termination
INSTALLATION Continued Vent Kits
Venting of Flue Products
Hydronic Heating Boilers and Domestic Water Heaters
Sidewall Venting Termination
3. Sidewall Venting
Sidewall Fan
Sidewall Venting Without Fan
FIG. 22 Sidewall Vent
Drain Tee Installation
Venting Guidelines
INSTALLATION Continued
Installation and Service Manual
Masonry Chimney Installation
4. Horizontal DirectAire Venting
Sidewall Vent Termination Clearances and Location
INSTALLATION Continued
Vent Kits
5. Direct Venting
Hydronic Heating Boilers and Domestic Water Heaters
Drain Tee Installation
Vertical DV Venting Termination
Installation and Service Manual
Masonry Chimney Installation
Horizontal Vent Termination Clearances and Location
Connecting the Air Inlet Pipe to the Unit
Horizontal DV Venting Termination
Flue Pipe Materials
Sealing Type-B Double-Wall Vent Pipe or Galvanized Vent Pipe
FIG. 25 Moving Air Filter Assembly and DV Box Adapter
Air Inlet Piping Materials
Sealing PVC, CPVC, ABS, Dryer Vent, and Flex Duct Vent Pipe
6 MAXIMUM
6. Outdoor Installation Venting
Multiple Sidewall Direct Vent Installations
Vertical Combustion Air Inlet Clearances
The Outdoor Vent Cap Kit
FIG. 27 Outdoor Vent Cap Installed on Rear of Unit
Outdoor Vent/Air Inlet Location
Installation and Service Manual
Gas Piping
CONNECTING TO GAS SUPPLY
Connecting Gas Piping to Unit
Gas Pressure Test
FIG. 29 Typical Boiler Gas Train Drawing
Gas Train and Controls
FIG. 28 Gas Line Connection
TABLE-J
Venting of Combination Gas Valves
Combination Gas Valves
Checking Gas Supply Pressure
INSTALLATION Continued
FIG. 30 Measuring Gas Supply Pressure at Combination Gas Valve
Gas Manifold Pressure Adjustment
TABLE - L Multiple Unit Installations Gas Supply Pipe Sizing
Installation and Service Manual
Retain this cap for future use
CONNECTING TO WATER SUPPLY
Inlet and Outlet Connections
FIG. 31 Measuring Manifold Gas Pressure
Relief Valve
CONNECTING TO ELECTRICAL SUPPLY
Water Flow Switch
Low Water Cutoff
General Plumbing Rules
BOILER SYSTEM PIPING
TABLE-N AMP Draw Data
Water Connections Heating Boilers Only
Pump Installation and Maintenance
Heat Exchanger Pressure Drop Chart
Circulator Pump Specifications
FIG. 34 Pressure Drop Chart 399,999 - 750,000
Input LTV Valve Kit Btu/hr
Low Temperature Return Water Systems
Table - O LTV Valve Kits
399,999 - 750,000VAL3048 990,000 - 2,070,000 VAL3047
10ºF
TABLE-P System Temperature Rise Chart Based on Btu/hr Input
Radiant Floor and Snow Melt Heating Systems
20ºF
Placing the Boiler in Operation
Temperature/Pressure Gauge
Boiler Flow Rate
Boiler Bypass Requirements
FIG. 41 Installation with a Chilled Water System
Installation with a Chilled Water System
Boiler Operating Temperature Control
Installation and Service Manual
INSTALLATION Continued
WATER TREATMENT
Terminal Strip Connection Options
Hydronic Heating Boilers and Domestic Water Heaters
Figure 42C
FOR YOUR SAFETY READ BEFORE OPERATING
OPERATION
Figure 42B
LIGHTING INSTRUCTIONS
FIG. 43 Control Panel Cover FIG. 44 ON/OFF Switch
OPERATION Continued
WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance
Quick Programming Overview
Power Up
PROGRAMMING TEMPERATURE CONTROL
To Turn Off Gas To Appliance
TABLE-R View Menu Information
Adjust Menu Setting Descriptions
TABLE-Q Adjust Menu Settings for Operating Modes
Menu Description
Ignition Systems and Stages
Adjust Menu
FIG. 48 Adjust Menu
Operating Modes
Placement of Sensors
Access Levels
Temperature Control
FIG. 49 User Access Level Dip Switch Location
FIG. 50 Graphic Symbols
Graphic Symbols
Settings
Staging Logic
Remote Mounting of Sensors
Programming For Mode 2, Water Heating Operation
Programming For Mode 3, Sequenced Operation
TABLE-S Programming Worksheet
HOT SURFACE IGNITION SYSTEM
Error and Warning Messages
TABLE-T Remote Wire Connection
Hot Surface Igniter and Ignition Control Module
Ignition Control Diagnostic Codes
Diagnostic Status Indication
Access to Internal Control Panel
Removing the Control Panel
Pump Delay Timing
OPERATION AND DIAGNOSTIC LIGHTS
Time Delay Between Stages 1&2 and 3&4
Status LED Diagnostic Codes
DOMESTIC WATER HEATERS
Required Temperature Rise
Temperature Rise Chart
Water Velocity Control
TABLE-X
Pipe Size Requirements
Circulating Pump
FIG. 54 Typical Water Heater Piping with Storage Tank
DOMESTIC WATER
Potable Hot Water Temperature Control Settings
Domestic Water Temperatures
HEATERS Continued
Thermal Expansion
High Water Temperature Limit Control
Optional Relief Valve
Location of Cold Water Supply Piping Connections
Burner Removal and Cleaning
CLEANING AND MAINTENANCE
Flue Gas Passageways Cleaning Procedures
Appliance Area
Combustion Air Fan Adjustment
Heat Exchanger Cleaning
Fan Cleaning
Electrical
FIG. 56 Adjusting Air Shutter 399,999 - 750,000 Btu/hr Models
CLEANING AND MAINTENANCE Continued
Adjusting Differential Air Pressure
FIG. 58 Adjusting Air Shutter 990,000 - 2,070,000 Btu/hr Models
SEQUENCE OF OPERATION
POWER SUPPLY
ON/OFF ROCKER SWITCH
Servicing Hot Surface Igniter and Ignition Module
ELECTRONIC TEMPERATURE CONTROLLER
MANUAL RESET HIGH-LIMIT THERMOSTAT
SAFETY DEVICE TERMINALS
PRESSURE SWITCH
POST-PURGE
IGNITION
HEAT TRANSFER PROCESS
IDLE
Step
TROUBLESHOOTING GUIDE 399,999 - 750,000 Btu/hr Models
Hydronic Heating Boilers and Domestic Water Heaters
Step
Step
TROUBLESHOOTING GUIDE 990,000 - 2,070,000 Btu/hr Models
Installation and Service Manual
Step
Domestic Water Heaters
WIRING BOX CONNECTIONS - WIRING
DIAGRAM A
Hydronic Heating Boilers
Installation and Service Manual
LADDER DIAGRAM 399,999 - 750,000 BTU/HR MODELS
LBL20008 REV A
SCHEMATIC DIAGRAM
Hydronic Heating Boilers and Domestic Water Heaters
Installation and Service Manual
Hydronic Heating Boilers and Domestic Water Heaters
LADDER DIAGRAM 990,000 - 2,070,000 BTU/HR MODELS
LBL20012 REV A
120 VAC 15AMPS
CONNECTOR
WIRING DIAGRAM
MODELS
CONNECTION DIAGRAM A
Hydronic Heating Boilers and Domestic Water Heaters
DIAGRAM B CONNECTIONS 990,000 - 2,070,000
BTU/HR MODELS CONTINUED
CF-CHE-i&s-08 1/09