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