Improper Installation, Adjustment
WARRANTY
SPECIAL INSTRUCTIONS TO OWNER
CHECKING EQUIPMENT
USER WARNING
CONTENTS
FIG. 1 Typical Front View Cabinet Construction
INSTALLATION PROCEDURE
CODES
LOCATION OF UNIT
Clearances from Combustible Construction
CLEARANCE FROM COMBUSTIBLE CONSTRUCTION
COMBUSTION AND VENTILATION AIR REQUIREMENTS FOR
CONVENTIONALLY VENTED APPLIANCES
with no duct, provide two permanent openings
Input
TABLE - A
MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY
Combustion Air Source
Input Btu/hr
VENTING
A CONVENTIONAL NEGATIVE DRAFT VENTING SYSTEM
TABLE - B VENT PIPE SIZES
On a conventionally vented, negative draft appliance, the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type “B” double wall or equivalent vent connectors and must be direct as possible with no reduction in diameter. Use the National Fuel Gas Code venting tables for double wall vent to properly size all vent connectors and stacks. The Type “B” vent and accessories, such as firestop spacers, thimbles, caps, etc., MUST be installed in accordance with the manufacturer’s listing. The vent connector and firestop must provide correct spacing to combustible surfaces and seal to the vent connector on the upper and lower sides of each floor or ceiling through which the vent connector passes
VENTING TERMINATION
Inspection of a Masonry Chimney
MASONRY CHIMNEY INSTALLATION
SIDEWALL VENTING
AUTOMATIC VENT DAMPER
GAS CONNECTION
GAS SUPPLY
GAS PRESSURE TEST
TABLE - C
TABLE G GAS CONNECTIONS
SINGLE APPLIANCE INSTALLATIONS
TABLE - E SUGGESTED GAS PIPE SIZE
TABLE - F FITTINGS TO EQUIVALENT STRAIGHT PIPE
Install Piping to Control
TABLE - H MULTIPLE APPLIANCE INSTALLATIONS
GAS PIPING SIZE CHART
GAS PIPING
GAS MANIFOLD PRESSURE ADJUSTMENT PROCEDURE
CHECKING GAS SUPPLY PRESSURE
Venting of Combination Gas Valves
COMBINATION GAS VALVES
RELIEF VALVE
WATER FLOW SWITCH IF EQUIPPED
TWO STAGE BURNER CONTROL SYSTEM
ACTUATE FLOW SWITCH
TABLE MINIMUM FLOW RATE REQUIRED TO
LOW WATER CUTOFF IF EQUIPPED
Locating Temperature Control
TEMPERATURE ADJUSTMENT
Temperature Control Settings
Operating Temperature Control
1.Inlet Water Temperature Sensor
Temperature Control Sensors
Installation of Remote Sensors
Wiring of Remote Sensors
Outdoor Air Shutdown Enable/Disable Switch
OUTDOOR AIR RESET OPTION
ADDITIONAL TEMPERATURE CONTROLS
Outdoor Air Reset Option
Manual Reset High Water Temperature Limit
ROLL-OUT/FLAMEINTERLOCK SWITCH
BLOCKED VENT AND FLAME
INITIAL START-UP
WHAT TO DO IF YOU SMELL GAS
PRE-STARTCHECKLIST
INPUT FOR YOUR SAFETY READ BEFORE OPERATING
MODELS 90,000 THRU 270,000 Btu/hr
3.Set the thermostat to the lowest setting OFF
LIGHTING INSTRUCTIONS FOR SPARK
SAFETY SHUTOFF TEST FOR
TO TURN OFF GAS TO APPLIANCE
STANDING PILOT IGNITION SYSTEM
TO TURN OFF GAS TO APPLIANCE
SAFETY SHUTOFF TEST FOR SPARK
OPERATING INSTRUCTIONS
IGNITION PILOT SYSTEM
FREEZE PROTECTION FOR A HEATING
INTERMITTENT PILOT SPARK IGNITION SYSTEM F9/M9
IGNITION and CONTROL TIMINGS
FREEZE PROTECTION
FIG. 37 Burner Flames
MAINTENANCE
WATER TREATMENT
INSPECTION AND CLEANING
INSPECTION CLEANING PROCEDURE
HEAT EXCHANGER/BURNER ACCESS
OUTER AIR
FIG. 38B Pilot Flame on Thermocouple
UPPER FRONT
JACKET PANEL
CIRCULATOR PUMP REQUIREMENTS
GAS TRAIN AND CONTROLS
WATER CONNECTIONS HEATING BOILERS ONLY
PIPING OF THE BOILER SYSTEM
BYPASS PUMP 45,000 - 260,000 Btu/hr
CIRCULATOR PUMP SPECIFICATIONS
TABLE - L
CIRCULATOR PUMP OPERATION Heating Boilers Only
PRIMARY/SECONDARY BOILER PIPING
FIG. 45 Boiler Piping with a 3-WayValve
LOW TEMPERATURE BYPASS REQUIREMENTS
THREE WAY VALVES
BOILER FLOW RATES
PLACING THE BOILER IN OPERATION
TYPICAL HEATING BOILER INSTALLATIONS
TABLE - M MINIMUM REQUIRED FLOW FOR
HEATING BOILER
Based on Boiler Output in Btu/hr
INSTALLATION WITH A CHILLED WATER SYSTEM
TABLE - N
ROOM THERMOSTAT OR REMOTE THERMOSTAT CONNECTION
BOILER OPERATING TEMPERATURE CONTROL
POWER VENTER CONNECTION TO TERMINAL STRIP
TABLE - O TERMINAL STRIP WIRING
Btu/hr
REQUIRED TEMPERATURE RISE
TABLE - P REQUIRED TEMPERATURE RISE
WATER VELOCITY CONTROL
PUMP OPERATION
WATER CHEMISTRY
SOFTENED WATER SYSTEMS
TABLE - Q
HEAT EXCHANGER
REMOTE SENSOR INSTALLATION INSTRUCTIONS
THERMOSTAT SETTINGS
MINIMUM PUMP PERFORMANCE
Hotter water increases the risk of scald injury
AUTOMATIC VENT DAMPERS
OPTIONAL RELIEF VALVE
Do not plug or cap the relief valve discharge
THERMAL EXPANSION
CATHODIC PROTECTION
STEP
TROUBLESHOOTING GUIDE
STEP
STEP
90,000 - 270,000 Btu/hr Models - Water Heaters F1
STEP STEP
TROUBLESHOOTING GUIDE
90,000 - 270,000 Btu/hr Models
Schematic Diagram - F1 Unit
Wiring Diagram - F1 Unit
90,000 - 270,000 Btu/hr Models
90,000 - 399,999 Btu/hr Models
Schematic Diagram - F9 Unit
Wiring Diagram - F9 Unit
90,000 - 399,999 Btu/hr Models
45,000 - 399,999 Btu/hr Models
Schematic Diagram - M9 Unit
Wiring Diagram - M9 Unit
45,000 - 399,999 Btu/hr Models
500,000 Btu/hr Models
Schematic Diagram - F9/M9 Unit
500,000 Btu/hr Models
Wiring Diagram - F9/M9 Unit
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CP-5M-4/08
RSB-i&s-05