CHF2-i&s-02

INSTALLATION AND SERVICE MANUAL

Hot Water Heating Boilers

Domestic Hot Water Supply Boilers
300,000 and 990,000 — 2,070,000 • BTU Models

Installation and service must be performed by a

CHECKING EQUIPMENT
qualified service installer, service agency or the gas
supplier.
Upon receiving equipment, check for signs of shipping
WARRANTY damage. Pay particular attention to parts accompanying
the boiler which may show signs of being hit or
Factory warranty (shipped with unit) does not apply to otherwise being mishandled. Verify total number of
units improperly installed or improperly operated. pieces shown on packing slip with those actually
received. In case there is damage or a shortage,
Experience has shown that improper installation or immediately notify the carrier.
system design, rather than faulty equipment, is the
cause of most operating problems. DO NOT
Use this appliance if any part has
been under water. The possible damage to a flooded
1. Excessive water hardness causing a lime build up appliance can be extensive and present numerous
in the copper tube is not the fault of the equipment safety hazards. Any appliance that has been under
and is not covered under the manufacturer’s water must be replaced.
war ranty. (See Water Treatment and Water
Chemistry)

2. Excessive pitting and erosion on the inside of the WARNING:

copper tube may be caused by too much water
velocity through the tubes and is not covered by If the information in this manual is not followed
the manufacturer’s warranty (See Boiler Flow exactly, a f ire or explosion may result causing
Rates and Temperature Rise for flow property damage, personal injury or loss of life.
requirements).
Do not store or use gasoline or other flammable
vapors and liquids in the vicinity of this or any other
SPECIAL INSTRUCTIONS TO OWNER
appliance.

NOTE: Retain this manual for future reference. — WHAT TO DO IF YOU SMELL GAS —
-
This manual supplies information for the installation,
operation and servicing of the appliance. It is strongly • Do not try to light any appliance.
recommended that this manual be reviewed completely • Do not touch any electric switch; do not use
before proceeding with an installation. any phone in your building.
• Immediately call your gas supplier from a
WARNING: neighbors phone. Follow the gas supplier’s
Improper instructions.
Installation, Adjustment, • If you cannot reach your gas supplier, call the
Alteration, Service or Maintenance fire department.
can cause injury or property damage.
Refer to this manual. For assistance or Installation and service must be performed by a
additional information consult a qualified qualif ied installer, service agency or the gas
installer, service agency or the gas supplier. supplier.

1
 CONTENTS OWNER WARNING
The information contained in this manual is
Warranty ............................................................................... 1
intended for use by qualified professional installers,
Safety Warnings ................................................................... 1
Codes ............................................................................... 2
service technicians or gas suppliers. Consult your
Location ............................................................................... 3 local expert for proper installation or service
Clearances ............................................................................ 4 procedures.
Combustion/Ventilation Air ................................................. 4
Conventional Venting ........................................................... 6
CAUTION !!
Sidewall Venting ................................................................... 10 Consult and follow local Building and Fire
Vertical DirectAire ............................................................... 12 Regulations and other Safety Codes that apply
Horizontal DirectAire .......................................................... 15 to this installation. Consult local gas utility
Outdoor Installations ............................................................ 17 company to authorize and inspect all gas and flue
Gas Supply ........................................................................... 18 connections.
Gas Pressures & Piping ....................................................... 19
Manifold Pressure Adjustment ............................. 21 Your conventionally vented gas appliance must have a
Supply Pressure Measurement .............................. 22 supply of fresh air circulating around it during burner
Water Connections ............................................................... 23 operation for proper gas combustion and proper
Relief Valve .......................................................................... 23 venting.
Gas Valves ............................................................................ 24
Electrical Requirements ....................................................... 24 WARNING:
Temperature Adjustment (Boiler) ........................................ 25 Should overheating occur or the gas supply fail
Temperature Adjustment (I/O Reset) ................................... 28
to shut off, do not turn off or disconnect the
Temperature Limit Control .................................................. 33
electrical supply to the pump. Instead, shut off
Lighting Instructions ............................................................ 33
the gas supply at a location external to the
Ignition Module ................................................................... 36
appliance.
Operation & Diagnostic Lights ........................................... 37
Ignition & Control Timings ................................................. 39
Freeze Protection .................................................................. 39 WARNING:
Maintenance ......................................................................... 40
To minimize the possibility of serious personal
Flame Patterns ....................................................... 40
injury, fire or damage to your unit, never violate
Burner Cleaning .................................................... 41
Heat Exchanger Inspection ................................... 41
the following safety rules.
Combustion Air Adjustment ................................. 42
Gas Train .............................................................................. 44 1. Always keep the area around your appliance free
Heating Boiler ...................................................................... 44 of combustible materials, gasoline, and other
Pump Requirements ............................................................. 44 flammable liquids and vapors.
Pressure Drop Chart .............................................. 45
Primary/Secondary Piping .................................... 46 2. Never cover your appliance, lean anything against
Low Temperature Systems .................................... 46 it, store trash or debris near it, stand on it or in
Three Way Valves .................................................. 47 any way block the flow of fresh air to your unit.
Temperature Rise Chart ........................................ 47
Boiler Flow Rates .................................................. 48
Bypass Requirements ............................................ 48 CODES
Placing in Operation ............................................. 48
The equipment shall be installed in accordance with
Boiler Temperature Control .................................. 50
Remote Temperature Control Connection (EMS) ............... 50
those installation regulations in force in the local area
Domestic Hot Water Supply Boiler/Water Heater ............... 51 where the installation is to be made. These shall be
Temperature Rise .................................................. 52 carefully followed in all cases. Authorities having
Water Chemistry ................................................... 52 jurisdiction shall be consulted before installations are
Piping Requirements ............................................. 53 made. In the absence of such requirements, the
Pump Operation .................................................... 53 installation shall conform to the latest edition of the
Temperature Adjustment ....................................... 54 National Fuel Gas Code, ANSI Z223.1and/or
Risk of Scald Warnings ......................................... 54 CNA/CGA-B149 Installation Code. Where required by
Temperature Limit Control ................................... 56 the authority having jurisdiction, the installation must
conform to American Society of Mechanical Engineers
2
Safety Code for Controls and Safety Devices for The pan must not restrict combustion air flow.
Automatically Fired Boilers, ASME CSD-1. All boilers Under no circumstances is the manufacturer to be
conform to the latest edition of the ASME Boiler and held responsible for waterdamage in connection
Pressure Vessel Code, Section IV. Where required by with this unit, or any of its components.
the authority having jurisdiction, in Canada, the
installation must comply with the CSA International 2. The indoor units must be installed so that the
CNA/CGA-B149 Installation Code and/or local codes. ignition system components are protected from
water (dripping, spraying, rain, etc.) during
INSTALLATION PROCEDURE appliance operation and service (circulator
replacement, control replacement, etc.)
Front & Rear View 3. Units located in a residential garage shall be
300,000 Btu/hr Models installed so that all burners and burner ignition
devices have a minimum clearance of 18" (46cm)
above the floor. The unit shall be located or
protected so that it is not subject to physical
damage by a moving vehicle.

4. The appliance must be installed on a level,

non-combustible floor. Concrete over wood is
not considered a non-combustible floor. Maintain
required clearances from combustible surfaces.
Front Rear
5. The appliance must not be installed on carpet or
FIG. 1 other combustible material.

This appliance meets the safe lighting performance 6. For installation on a combustible floor only when
criteria with the gas manifold and control assembly installed on the specified special base:
provided, as specif ied in the ANSI standards for
gas-fired units, ANSI Z21.13. 300,000 Btu/hr input units installed over a
combustible floor MUST use the Special Combustible
LOCATION OF UNIT Floor Base. The unit must be centered on the base as
show in FIG. 3. The correct part number for the
required base is noted on the rating plate of each unit
Front & Rear View
and listed below.
990,000 — 2,070,000 Btu/hr
Models
Special Combustible Floor Base
300,000 Btu/hr Model Only

Front

Rear
FIG. 2

1. Locate the appliance so that if water connections

should leak, water damage will not occur. When
such locations cannot be avoided, it is
recommended that a suitable drain pan, adequately
drained, be installed under the unit. FIG. 3

3
 TABLE — A Maintain minimum specified clearances for adequate
operation. Allow sufficient space for servicing pipe
COMBUSTIBLE FLOOR KITS
connections, pump and other auxiliary equipment, as
Input Btu/hr Kit Number well as the appliance. See rating plate for specific
300,000 CFK3300 service clearance requirements.

990,000 through 2,070,000 Btu/hr input units COMBUSTION and VENTILATION

installed over a combustible floor MUST be provided AIR REQUIREMENTS FOR
with a base of hollow clay tile or concrete blocks from
CONVENTIONALLY VENTED
8" to 12" thick and extending 24" beyond the sides.
The blocks must be placed in line so that the holes line APPLIANCES and SIDEWALL
up horizontally to provide a clear passage through the VENTED APPLIANCES
blocks. A 1/2" fire-proof millboard with a 20 gage sheet
metal cover shall be provided over the block base. The Provisions for combustion and ventilation air must be
unit must be countered on the base. This procedure in accordance with section 5.3, Air for Combustion
should also be followed if electrical conduit runs and Ventilation, of the latest edition of the National Fuel
through the floor, and beneath the appliance. A field Gas Code, ANSI Z223.1, in Canada, the latest edition of
installed base must meet all local fire and safety code CAN/CGA-B149 Installation Code for Gas Burning
requirements. Appliances and Equipment, or applicable provisions
of the local building codes.
7. Outdoor models require the installation of an
optional vent cap. Instructions for mounting the
The equipment room MUST be provided with properly
vent cap are included in the venting section.
sized openings to assure adequate combustion air and
Outdoor models must not be installed directly on
proper ventilation when the unit is installed with
the ground. The outdoor unit must be installed on
conventional venting or sidewall venting.
a concrete, brick, block or other non-combustible
pad. Outdoor models have additional special
location and clearance equirements. These are Combustion Air Direct from Outside
specifically addressed in the venting section under
outdoor installation. A windproof cabinet protects
the unit from weather.

Clearances from
Combustible Construction

3” From Top
and Side
Top
Minimum

Right

FIG. 5

Front Left 1. If air is taken directly from outside the building

FIG. 4
with no duct, provide two permanent openings:
Clearances from Combustible Construction:
Right Side - 3" (7.5cm)
a. Combustion air opening, with a minimum free
Rear - 3" (7.5cm) (3" minimum from any surface) area of one square inch per 4000 Btu input
Left Side - 6" (15cm) (24" (0.61m) suggested for service) (5.5cm 2 per kW). This opening must be
Front - ALCOVE* (30" (0.76m) suggested for service) located within 12" (30 cm) of the bottom of
Top - 3" (7.5cm)
Flue - 1" (25.4mm) the enclosure.
Hot Water Pipes - 1" (25.4mm)
*An ALCOVE is a closet without a door.
4
 b. Ventilation air opening, with a minimum free Combustion Air from
area of one square inch per 4000 Btu input Outside Single Opening
(5.5cm 2 per kW). This opening must be
located within 12" (30cm) of the top of the
enclosure.

Combustion Air Through Ducts

FIG. 8

4. If a single combustion air opening is provided to

bring combustion air in directly from the
outdoors, the opening must be sized based on a
minimum free area of one square inch per 3000
FIG. 6 Btu (7cm2 per kW). This opening must be located
within 12" (30cm) of the top of the enclosure.
2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver to the mechanical
room, each of the two openings should be sized CAUTION !!
based on a minimum free area of one square inch Under no circumstances should the equipment
per 2000 Btu (11cm2 per kW). room ever be under a negative pressure.
Particular care should be taken where exhaust
fans, attic fans, clothes dryers, compressors,
Combustion Air from Interior Space air handling units, etc. may rob air from the
unit.

All dimensions are based on net free area in square

inches. Metal louvers or screens reduce the free area
of a combustion air opening a minimum of
approximately 25%. Check with louver manufacturers
for exact net free area of louvers. Where two openings
are provided, one must be within 12" (30 cm) of the
ceiling and one must be within 12" (30 cm) of the floor
of the mechanical room. Each opening must have a
minimum net free area as specified in Table B. Single
openings shall be installed within 12" (30 cm) of the
FIG. 7 ceiling.

3. If air is taken from another interior space, each of The combustion air supply must be completely free of
the two openings specified above should have a any chemical fumes which may be corrosive to the
net free area of one square inch for each 1000 boiler. Common chemical fumes which must be
Btu (22cm2 per kW) of input, but not less than avoided are fluorocarbons and other halogenated
100 square inches (645 cm2 ). compounds, most commonly present as refrigerants or

5
 TABLE — B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO BOILER ROOM
Combustion Air Source
Boiler Input Outside Air*/2 Openings Outside Air*/1 Opening Inside Air/2 Openings
2 2 2 2 2 2
300,000 75 in (484cm ) 100 in (645cm ) 300 in (1936cm )
2 2 2 2 2 2
990,000 248 in (1600cm ) 330 in (2129cm ) 990 in (63886cm )
2 2 2 2 2 2
1,260,000 315 in (2032cm ) 420 in (2710cm ) 1260 in (8130cm )
2 2 2 2 2 2
1,440,000 360 in (2323cm ) 480 in (3097cm ) 1440 in (9291cm )
2 2 2 2 2 2
1,800,000 450 in (2903cm ) 600 in (3871cm ) 1800 in (11,614cm )
2 2 2 2 2 2
2,070,000 518 in (3342cm ) 690 in (4452cm ) 2070 in (13,356cm )
* Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a duct, the
net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings. The above
requirements are for the boiler only, additional gas fired appliances in the boiler room will require an increase in the net free area to supply
adequate combustion air for all appliances. Combustion air requirements are based on the latest edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada refer to CAN/CGA-B149 Installation Code. Check all local code requirements for combustion air.
solvents, such as Freon, trichlorethylene, Appliances and Equipment or applicable provisions of
perchloroethylene, chlorine, etc. These chemicals, the local building codes.
when burned, form acids which quickly attack the
boiler tubes, tube sheets, flue collectors, and the boiler Conventional negative draft venting and sidewall
vent system. The result is improper combustion and a venting applications, where outside air is used, must
non-warrantable, premature boiler failure. have adequate combustion and ventilation air supplied
to the mechanical room in accordance with the latest
EXHAUST FANS: Any fan or equipment which edition of the National Fuel Gas Code, ANSI Z223.1,
exhausts air from the boiler room may deplete the in Canada, the latest edition of CAN/CGA-B149
combustion air supply and/or cause a down draft in Installation Code for Gas Burning Appliances and
the venting system. Spillage of flue products from the Equipment, or applicable provisions of the local
venting system into an occupied living space can cause building codes.
a very hazardous condition that must be immediately
corrected. If a fan is used to supply combustion air to The distance of the vent terminal from adjacent
the boiler room, the installer must make sure that it buildings, windows that open and building openings
does not cause drafts which could lead to nuisance MUST comply with the latest edition of the National
operational problems with the boiler. Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CAN/CGA-B149 Installation Code for Gas
DirectAire Vertical and DirectAire Horizontal Burning Appliances and Equipment.
venting systems have specif ic requirements for
combustion air ducts from the outside which are Vent connection is made directly to the top of the unit.
directly connected to the boiler. See the requirements No additional draft diverter or barometric damper is
for this combustion air duct in the venting section for required on single unit installations when a negative
each specialized vent system. draft is maintained within the specified range. The
connection from the appliance vent to the stack must
VENTING be made as direct as possible.

General IMPORTANT:
Examine the venting

system at least once a year. Check all joints and
Vent installations for connection to gas vents or
vent pipe connections for tightness. Also check
chimneys must be in accordance with Part 7, “Venting
for corrosion or deterioration. Immediately
of Equipment,” of the latest edition of the National Fuel
correct any problems observed in the venting
Gas Code, ANSI Z223.1, in Canada, the latest edition
system.
of CAN/CGA-B149 Installation Code for Gas Burning
6
 Vent connection is made directly to the top of the unit.
VENT SYSTEM OPTIONS No additional draft diverter or barometric damper is
required on single unit installations with a dedicated
This boiler has f ive venting options. They are: stack and a negative draft within the specified range
(1) Conventional Negative Draft Venting with vertical of a negative 0.02 to 0.08 inches water. If the draft in
rooftop flue termination and combustion air supplied a dedicated stack for a single unit installation exceeds
from the mechanical room, (2) Sidewall Venting which the maximum specified draft, a barometric damper
uses a powered vent assembly to exhaust the flue must be installed to control draft. Multiple unit
products out a sidewall vent termination and installations with combined venting or common venting
combustion air supplied from the mechanical room, with other Category I negative draft appliances require
(3) Vertical DirectAire Venting with a vertical that each boiler must have a barometric damper
conventional vent for flue products and a combustion installed to regulate draft within the proper range.
air pipe from either the sidewall or roof top,
(4) Horizontal DirectAire Venting with a powered vent The flue pipe sizes are:
assembly to exhaust the flue products out a sidewall
and a combustion air pipe from the sidewall, TABLE — C
(5) Outdoor Installation with the installation of a
special air inlet/vent cap on top of the unit. All boilers
Input Btu/hr Flue Size
are shipped from the factory equipped for conventional 300,000 5”
negative draft venting. All other optional vent systems
990,000 10”
require the installation of specific vent kits and venting
materials. The following is a detailed explanation of 1,260,000 12”
the installation requirements for each venting system, 1,440,000 12”
components used and part numbers of vent kits for each
model. 1,800,000 14”
2,070,000 14”
Conventional Negative Draft Vertical
Venting with Combustion Air Louvers On a conventionally vented, negative draft unit, the
connection from the vent to the stack or vent
termination outside 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
manufacturers instructions. The vent connector and
firestop must provide correct spacing to combustible
surfaces and seal to the vent connector on the upper
FIG. 9 and lower sides of each floor or ceiling through which
the vent connector passes.

Any vent materials specif ied must be listed by a

A CONVENTIONAL NEGATIVE nationally recognized test agency for use as vent
DRAFT VENTING SYSTEM material.

Conventional Venting Locate units as close as possible to chimney or gas

vent.
The negative draft in a conventional vent installation
must be within the range of a negative 0.02 to 0.08 Avoid long horizontal runs of the vent pipe, 90° elbows,
inches water to insure proper operation. All draft reductions and restrictions. Horizontal portions of the
readings are made while unit is in stable operation venting system shall be supported to prevent sagging.
(approximately 2 to 5 minutes). Horizontal runs must slope upwards not less than 1/4”

7
per foot (21 mm/m) from the appliance to the vent (f) After it has been determined that each appliance
terminal. Follow manufacturers instructions. remaining connected to the common venting
system properly vents when tested as above,
Do not use an existing chimney as a raceway if another return doors, windows, exhaust fans, fireplace
appliance or fireplace is vented thru the chimney. dampers and other gas burning appliances to their
previous conditions of use.
The weight of the venting system must not rest on the
unit. Adequate support of the venting system must be (g) Any improper operation of the common venting
provided in compliance with local codes and other system should be corrected so that the installation
applicable codes. All connections should be secured conforms to the latest edition of the National Fuel
with rustproof sheet metal screws. Gas Code, ANSI Z223.1, in Canada, the latest
edition of CAN/CGA-B149 Installation Code
Vent connectors serving appliances vented by natural for Gas Burning Appliances and Equipment.
draft shall not be connected to any portion of a When resizing any portion of the common venting
mechanical draft system operating under positive system, the common venting system should be
pressure. Connection to a positive pressure stack may resized to approach the minimum size as
cause flue products to be discharged into the living deter mined using the appropriate tables in
space causing serious health injury. Part II of the latest edition of the National
Fuel Gas Code, ANSI Z223.1, in Canada, the latest
Common venting systems may be too large when an edition of CAN/CGA-B149 Installation Code
existing unit is removed. At the time of removal of an for Gas Burning Appliances and Equipment.
existing appliance, the following steps shall be followed
with each appliance remaining connected to the
common venting system placed in operation, while VERTICAL VENTING TERMINATION
other appliances remaining connected to the common
venting system are not in operation. The vent terminal should be vertical and exhaust
outside the building at least 2 feet (0.61m) above the
(a) Seal any unused opening in the common venting highest point of the roof within a 10 foot (3.05m) radius
system. of the termination.

(b) Visually inspect the venting system for proper size The vertical termination must be a minimum of 3 feet
and horizontal pitch and determine there is not (0.91m) above the point of exit.
blockage or restriction, leakage, corrosion and
other unsafe conditions.

(c) Insofar as is practical, close all building doors and

windows and all doors between the space in
which the appliances remaining connected to the Vent Termination from Peaked Roof
common venting system are located and other 10’ or Less from Ridge
spaces of the building. Turn on clothes dryers and
any other appliances not connected to the common
venting system. Turn on any exhaust fans, such as
range hoods and bathroom exhausts, so they will
operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.

(d) Place in operation the appliance being inspected.

Follow the lighting instructions. Adjust thermostat
so appliance will operate continuously.

(e) Test for spillage at the draft hood/relief opening

after 5 minutes of main burner operation. Use FIG. 10
the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.

8
 Vent Termination from Peaked Roof Vent Termination from Flat Roof
More Than 10’ from Ridge More Than 10’ from Parapet Wall

10’ OR LESS

3’

NOTE: NO HEIGHT
ABOVE PARAPET
FIG. 11 REQUIRED WHEN
WALL OR DISTANCE FROM
PARAPET WALLS OR
PARAPETS IS CHIMNEY
A vertical termination less than 10 feet (3.05m) from MORE THAN 10’.
a parapet wall must be a minimum of 2 feet (0.61m) FIG. 13
higher than the parapet wall.

The vent cap should have a minimum clearance of 4

feet (1.22m) horizontally from and in no case above or The venting system shall terminate at least 3 feet (0.9m)
below, unless a 4 foot (1.22m) horizontal distance is above any forced air inlet within 10 feet (3.05m).
maintained from electric meters, gas meters, regulators
and relief equipment. The venting system shall terminate at least 4 feet (1.2m)
below, 4 feet (1.2m) horizontally from, or 1 foot (30cm)
above any door, window or gravity air inlet into any
building.
Vent Termination from Flat Roof
10’ or Less from Parapet Wall Do not terminate the vent in a window well, stairwell,
alcove, courtyard or other recessed area. The vent can
not terminate below grade. The bottom of the vent
terminal shall be located at least 12 inches (30cm)
above grade.

To avoid a blocked flue condition, keep the vent cap

clear of snow, ice, leaves, debris, etc.

Flue gases will form a white plume in winter. Plume

could obstruct window view.

Flue gas condensate can freeze on exterior surfaces or

on the vent cap. Frozen condensate on the vent cap
can result in a blocked flue condition. Flue gas
condensate can cause discoloration of exterior building
surfaces. Adjacent brick or masonry surfaces should
FIG. 12 be protected with a rust resistant sheet metal plate.

9
 MASONRY CHIMNEY SIDEWALL VENTING WITH A
INSTALLATION POWERED VENT CAP
A masonry chimney must be properly sized for the The Sidewall Venting System
installation of a high efficiency gas fired appliance.
Venting of a high efficiency appliance into a cold or This venting system uses a powered vent assembly
oversized masonry chimney can result in operational which pulls the flue products out of the stack. This fan
and safety problems. Exterior masonry chimneys, with generates a negative draft at the unit. Combustion air
one or more sides exposed to cold outdoor is drawn from the mechanical room (see Combustion
temperatures, are more likely to have venting problems. and Ventilation Air Requirements).
The temperature of the flue products from a high
efficiency appliance may not be able to sufficiently Sidewall Venting Installation
heat the masonry structure of the chimney to generate
with Powered Vent Cap
proper draft. This will result in condensing of flue
products, damage the masonry flue/tile, insufficient
draft and possible spillage of flue products into an
occupied living space. Carefully inspect all chimney
systems before installation. If there is any doubt about
the sizing or condition of a masonry chimney, it must
be relined with a properly sized and approved chimney
liner system.

Inspection of a Masonry Chimney

A masonry chimney must be carefully inspected to

determine its suitability for the venting of flue FIG. 14
FIG. 14
products. A clay tile lined chimney must be structurally
sound, straight and free of misaligned tile, gaps 300,000 Btu/hr Models
between liner sections, missing sections of liner or any
signs of condensate drainage at the breeching or clean
The sidewall fan is mounted in a vent cap which is
out. If there is any doubt about the condition of a
installed on an exterior wall. The sidewall fan and
masonry chimney, it must be relined. An unlined
accessories are included in a venting kit which must
masonry chimney must not be used to vent flue
be furnished by the manufacturer in accordance with
products from this high eff iciency appliance. An
CSA International requirements. This venting kit
unlined chimney must be relined with an approved
includes the sidewall fan/cap, proving switch and all
chimney liner system when a new appliance is being
necessary relays to interlock with the heaters control
attached to it. Metallic liner systems (Type “B”
system. The internal damper on the sidewall fan must
double-wall or flexible or rigid metallic liners) are
be adjusted to supply a negative draft within the range
recommended. Consult with local code officials to
of 0.04 to 0.08 inches water negative while unit is
determine code requirements or the advisability of
operating.
using or relining a masonry chimney.
The maximum total equivalent length of the sidewall
vent pipe cannot exceed 50 equivalent feet (15.24m).
Subtract 5 feet (1.52m) for each elbow in the vent. Do
not exceed the limit for total equivalent vent pipe
length.

10
 The sidewall f an/powered vent cap MUST be
Sidewall Venting Installation interlocked with the units control system to start
with and Induced Draft Fan the fan on a call for heat and prove fan operation
and Sidewall Vent before the boiler fires. Plug-in and terminal strip
connections are provided on the unit for easy
connection of the factory supplied vent kit and
control package for the sidewall vent fan. See the
installation instructions provided with the vent kit.

Sidewall Vent Pipe Requirements

The connection from the vent to the powered sidewall

fan/cap MUST be made with listed Type “B” double
wall (or equivalent) vent and accessories. There shall
be no reduction in vent size from the boiler’s flue outlet
FIG. 15 to the inlet of the sidewall vent fan. Vent pipe material
must be supplied by the installer.

990,000 through 2,070,000 Btu/hr Models Follow all requirements in the General Venting and
Sidewall Vent Terminations sections for venting flue
The sidewall fan is mounted on the inside with a products to the outdoors. See the Combustion and
with a sidewall vent hood installed on the exterior Ventilation Air Requirements section to insure that
wall. The sidewall fan and accessories are included adequate combustion and ventilation air is supplied to
in a venting kit which must fur nished by the the mechanical room. All other general installation
manufacturer in accordance with CSA International requirements must be followed.
requirements. The venting kit includes the sidewall
fan, vent hood, tapered vent adaptor, barometric
damper, proving switch and all necessary relays to Sidewall Vent Termination
interlock with the heaters control system. The
tapered vent adaptor reduces the vent size at the inlet The sidewall vent cap shall terminate at least 3 feet
to the fan. There should be no reduction in vent (0.91m) above any forced air inlet within 10 feet
diameter from the unit’s flue outlet to the sidewall (3.05m).
fan. The barometric damper must be installed on the
flue and adjusted to supply a negative draft within The sidewall vent shall terminate at least 4 feet (1.22m)
the range of 0.04 to 0.08 inches water negative while below, 4 feet (1.22m) horizontally from or 1 foot
unit is operating. (0.30m) above any door, window or gravity air inlet to
the building.
The maximum total equivalent length of the sidewall
ve n t p i p e c a n n o t ex c e e d 1 0 0 e q u iva l e n t f e e t Do not terminate the sidewall vent in a window well,
(30.48m). Subtract 5 feet (1.52m) for each elbow stairwell, alcove courtyard or other recessed area, The
in the vent. Do not exceed the limit for total (0.30m) above grade.
equivalent vent pipe length.
The sidewall vent system shall terminate at least 1 foot
Sidewall Vent Cap (0.30m) above normal snow levels and at least 7 feet
(2.13m) above grade when located adjacent to public
The sidewall vent cap must be installed on an walkways. The sidewall vent shall not terminate
exterior sidewall. The sidewall fan/powered sidewall directly above a public walkway.
vent cap and accessories are included in a venting
kit which must be furnished by the manufacturer in The sidewall vent terminal shall not be installed closer
accordance with CSA International requirements. than 3 feet (0.91m) from an inside corner of an
This venting kit includes the powered sidewall fan/ L-shaped structure.
cap, proving switch and all necessary relays to
interlock with the heaters control system.
11
The sidewall vent cap should have a minimum clearance
of 4 feet (1.22m) horizontally from and in no case above A CONVENTIONAL VERTICAL
or below, unless a 4 foot (1.22m) horizontal distance is NEGATIVE DRAFT VENTING SYSTEM
maintained from electric meters, gas meters, regulators WITH A COMBUSTION AIR PIPE
and relief equipment. FROM A SIDEWALL
OR
Flue gas condensate can freeze on exterior walls or on
the vent cap. Frozen condensate on the vent cap can ROOF TOP INLET CAP
result in a blocked flue condition. Some discoloration
™
to exterior building surfaces can be expected. Adjacent The Vertical DirectAire Vent System:
brick or masonry surfaces should be protected with a
rust resistant sheet metal plate. Follow all requirements in the General Venting section
and Conventional Negative Draft Venting for venting
flue products to the outdoors and general installation
Sidewall Vent Kits instructions in the Installation and Service Manual.

The Sidewall Vent Kit MUST be ordered from the boiler The Vertical DirectAire vent system requires the
manufacturer. The part number for each kit is listed by installation of two vent pipes directly to the unit, one
unit size. Each kit includes a powered sidewall fan/ vertical pipe with a roof top termination for the flue
cap assembly, control relay, proving switch and products and one pipe for combustion air. The
instructions for proper installation. combustion air pipe may terminate horizontally with a
sidewall air inlet or vertically with a roof top air inlet.
Vent connection is made directly to the top of the unit.
No additional draft diverter or barometric damper is
TABLE — D required on single unit installations with a dedicated
Input Flue Sidewall stack and a negative draft maintained between 0.02 to
Btu/hr Size Vent Cap Kit 0.08 inches water. The flue may be combined with the
vent from any other negative draft, Category I
300,000 5" SVK3005
appliances. Multiple unit installations common vented
990,000 10" SVK3009 with other negative draft appliances require that each
boiler must have a barometric damper installed to
1,260,000 12" SVK3010 regulate draft within the proper range. The common
1,440,000 12" SVK3010 vent and connectors from multiple boilers must be sized
per the requirements of the venting tables for Type “B”
1,800,000 14” SVK3012 double wall vents in the latest edition of the National
Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149
2,070,000 14” SVK3012
Installation Code.

The sidewall or vertical roof top DirectAire combustion

air supply system has specif ic vent material and
CAUTION !! installation requirements. The air inlet pipe connects
directly to the boiler to supply combustion air. In most
Boilers which are shut down or will not operate
installations, the combustion air inlet pipe will be a
may experience freezing due to convective air
dedicated system with one air inlet pipe per boiler.
flow in flue pipe or from negative pressure in
Multiple air inlets may be combined if the guidelines
the mechanical room. In cold climates,
in “Combined Air Inlet Points” are followed. The air
continuous pump operation is recommended to
inlet pipe will be connected to a combustion air inlet
help prevent freezing of boiler water. Proper
cap as specified in this section.
freeze protection must be provided. See Freeze
Protection.
Combustion air supplied from outdoors must be free
of contaminants ( See Combustion and Ventilation Air
of the Installation and Service Manual).

12
 Vertical DirectAire™ Installation Vertical DirectAire™ Installation
with Sidewall Combustion Air with Roof Top Combustion Air

FIG. 16 FIG. 18

Sidewall Air Inlet Vertical Roof Top Air Inlet

The sidewall air inlet cap is supplied in the Vertical The air inlet cap for the vertical roof top air inlet is
DirectAire Sidewall Air Kit which must be ordered supplied in the Vertical DirectAire Roof Top Air Kit
from the manufacturer. This sidewall cap will supply which must be ordered from the manufacturer. This
combustion air for a single boiler only. roof top cap will supply combustion air for a single
boiler only.
Air Inlet Cap for
Sidewall Termination Air Inlet Cap for
Roof Top Termination

FIG. 17
FIG. 19
Locate boiler as close as possible to sidewall where
the combustion air supply system will be installed. The point of termination for the combustion air inlet
cap MUST be at least 3 feet (0.91m) below the point
To prevent recirculation of flue products from an of flue gas termination (vent cap) if it is located within
adjacent vent cap into the combustion air inlet, follow 10' (3.05m) of the flue outlet.
all applicable clearance requirements in the latest
edition of the National Fuel Gas Code and/or CAN/ The combustion air inlet cap must not be installed
CGA-B149 Installation Code and instructions in this closer than 10 feet (3.05m) from an inside corner of a
manual. L-shaped structure.

The combustion air inlet cap must be installed at least The air inlet point for the combustion air inlet cap must
one foot (0.30m) above ground level and above normal be installed at least one foot (0.30m) above the roof
snow levels. top and above normal snow levels.

13
Incorrect installation and/or location of the air inlet
NOTE:  The use of double wall vent
cap can allow the discharge of flue products to be drawn
into the combustion process on the boiler. This can material for the combustion air inlet pipe is
result in incomplete combustion and potentially recommended in cold climates to prevent the
hazardous levels of carbon monoxide in the flue condensation of airborne moisture in the
products. This will cause operational problems with incoming combustion air.
the boiler and possible spillage of flue products which Length of Air Inlet Pipe
can cause personal injury, death or property damage.
The total equivalent length of the sidewall or vertical
Combined Air Inlet Points roof top DirectAire combustion air inlet pipe must not
exceed a maximum of 50 (15.24m) equivalent feet in
The air inlet pipes from multiple boilers can be length. Subtract 5 feet (1.52m) for each elbow in the
combined to a single common connection if the air intake system. Do not exceed limits for the
common air inlet pipe has a cross sectional area equal combustion air inlet piping length.
to or larger than the total area of all air inlet pipes
connected to the common air inlet pipe. [Example: two Vent Kits
10" air inlet pipes (78.5 in2 area each) have a total
area of 157 in2 and will require a 15"(176.7 in2 area) The Vertical DirectAire Vent Kit for sidewall or roof
common air inlet pipe.] The air inlet point for multiple top air inlet MUST be ordered from the boiler
boiler air inlets must be provided with an exterior manufacturer for single unit installations. The part
opening which has a free area equal to or greater than number for each kit is listed by unit size. Each kit
the total area of all air inlet pipes connected to the includes either a sidewall or roof top combustion air
common air inlet. This exterior opening for combustion inlet cap to supply air to a single boiler and instructions
air must connect directly to the outdoors. The total for proper installation. The flue pipe and roof top vent
length of the combined air inlet pipe must not exceed cap for the flue and air inlet pipe are purchased locally.
a maximum of 50 (15.25m) equivalent feet. Subtract You must specify if the air inlet cap is for a vertical
5 feet (1.52m) for each elbow in the air inlet pipe. You roof top termination or a sidewall termination. The
must deduct the restriction in area provided by any air inlet cap for the combined air supply from multiple
screens, grills or louvers installed in the common air boilers must be purchased locally.
inlet point. These are common on the sidewall air inlet
openings. Screens, grills or louvers installed in the
common air inlet can reduce the free area of the The air inlet cap supplied in the Vertical DirectAire
opening from 25% to 75% based on the materials used. Vent Kit is used to supply combustion air to a single
boiler. The roof top vent cap for flue products should
be a standard commercial cap purchased locally. The
Air Inlet Pipe Materials use of a sidewall or roof top air inlet cap other than the
manufacturers recommended cap for single boiler
The Vertical DirectAire system requires installation of installations or use of a common air inlet cap for
a single wall pipe to supply combustion air from multiple boilers with insuff icient free area and/or
outdoors directly to the unit. protection from wind and weather may result in

TABLE — E
Input Conventional Vent Air Inlet Sidewall Air Rooftop Air
Btu/hr Flue Size Pipe* Inlet Kit Inlet Kit
300,000 5" 5" SVK3005 VDK3005
990,000 10" 10" SVK3013 VDK3009
1,260,000 12" 12" SVK3014 VDK3008
1,440,000 12" 12" SVK3014 VDK3008
1,800,000 14" 12" SVK3014 VDK3012
2,070,000 14" 12" SVK3014 VDK3012
* Minimum diameter, installer may increase diameter one pipe size for ease of installation if needed. A 6" diameter air inlet cap
may be ordered for rooftop air inlet as Rooftop Air Inlet Kit VDK3006.

14
operational problems with the boiler or potentially
hazardous spillage of flue products which can cause HORIZONTAL DIRECTAIRE™
personal injury, death or property damage. WITH A SIDEWALL FLUE AND
SIDEWALL AIR INLET
Venting of Flue Products The Horizontal DirectAire Vent System
Follow all requirements in the General Venting section
For venting flue products vertically to the outdoors,
and Sidewall Venting for venting flue products to the
follow all requirements in the installation instructions
outdoors and general installation instructions.
for conventional venting in the Installation and Service
Manual.
The Horizontal DirectAire vent system requires the
installation of two vent pipes directly to the unit, one
Termination point for the flue products must follow
pipe for flue products and one for combustion air. Both
the clearance requirements in the Vertical Vent
vent pipes are installed horizontally with a sidewall
Termination section of Conventional Venting in the
termination point. Vent connection is made directly to
Installation and Service Manual.
the top of the unit. No additional draft diverter or
barometric damper is required on single unit
A barometric damper is NOT required in the flue on
installations with a dedicated stack and a negative draft
Vertical DirectAire installations if the draft is within
maintained between 0.04 to 0.08 inches water.
the 0.02 to 0.08 inches water negative required for
proper operation. If the draft exceeds this range, a
The Horizontal DirectAire combustion air supply
barometric damper must be installed.
system has specific vent material and installation
requirements. The air inlet pipe connects directly to
the boiler to supply combustion air. The combustion
CAUTION !! air inlet pipe will be a dedicated system with one air
inlet pipe per boiler. The air inlet pipe must be
Boilers which are shut down or will not operate connected to a combustion air inlet cap as specified
may experience freezing due to convective in this section. Combustion air supply pipes for
air flow in the air inlet pipe connected to the unit. multiple boiler installations can NOT be combined
In cold climates, continuous pump operation is into a single pipe and inlet termination point.
recommended to help prevent freezing of boiler
water on DirectAire systems. Combustion air supplied from outdoors must be free
of contaminants (See Combustion and Ventilation Air).
Proper freeze protection must be provided.
See Freeze Protection in the Installation and
Service Manual. Air Inlet Cap for Sidewall Termination

Horizontal DirectAire Installation

FIG. 21

Sidewall Air Inlet

The sidewall air inlet cap is supplied in the Horizontal

DirectAire Vent Kit which must be ordered from the
FIG. 20 manufacturer. This sidewall cap will supply
combustion air for a single unit only.

15
Locate units as close as possible to sidewall where the Length of Air Inlet Pipe
combustion air supply system will be installed.
The total equivalent length of the Horizontal
To prevent recirculation of flue products from an DirectAire combustion air inlet pipe must not exceed
adjacent vent cap into the combustion air inlet, follow a maximum of 50 (15.24m) equivalent feet in length.
all applicable clearance requirements in the latest Subtract 5 feet (1.52m) for each elbow in the air intake
edition of the National Fuel Gas Code and/or system. Do not exceed limits for the combustion air
CAN/CGA-B149 Installation Code and instructions in inlet piping lengths.
this manual.
Vent Kits
The combustion air inlet cap must be installed at least
one foot (0.30m) above ground level and above normal The Horizontal DirectAire Vent Kit for sidewall
snow levels. installation MUST be ordered from the boiler
manufacturer. The part number for each kit is listed
The point of termination for the combustion air inlet by unit size. Each kit includes a sidewall powered
cap MUST be at least 3 feet (0.91m) below the point vent cap, proving switch, controls, combustion air inlet
of flue gas termination (powered vent cap) if it is cap to supply air to a single boiler and instructions for
located within 10' (3.05m) of the flue outlet from the proper installation. The flue pipe and air inlet pipe are
powered vent cap. Use care to insure that the air inlet purchased locally.
cap assembly is properly installed on the air inlet pipe.
TABLE — F
The combustion air inlet cap and the powered vent cap
MUST be installed on the same wall and in the same Input Flue DiectAire Horizontal
pressure zone. Btu/hr Size Inlet Pipe* DirectAire
Kit
The combustion air inlet cap must not be installed 300,000 5" 5" HDK3005
closer than 10 feet (3.05m) from an inside corner of a
L-shaped structure. 990,000 10" 10" HDK3009
1,260,000 12" 12" HDK3010
Incorrect installation and/or location of the air inlet
cap can allow the discharge of flue products to be drawn 1,440,000 12" 12" HDK3010
into the combustion process on the boiler. This can 1,800,000 14” 12” HDK3012
result in incomplete combustion and potentially Outdoor Installation Illustration
2,070,000 14” 12” HDK3012
hazardous levels of carbon monoxide in the flue
products. This will cause operational problems with
*Minimum diameter, installer may increase diameter
the boiler and possible spillage of flue products which
one pipe size for ease of installation if needed.
can cause personal injury, death or property damage.

Air Inlet Pipe Materials The sidewall air inlet cap supplied in the Horizontal
DirectAire Vent Kit is used to supply combustion air
to a single boiler. Combustion air supply pipes from
The Horizontal DirectAire system requires installation
multiple units can NOT be combined into a single air
of a single wall pipe to supply combustion air from
inlet pipe and inlet point. The use of a sidewall air
outdoors directly to the boiler.
inlet cap other than the manufacturers recommended
cap may result in operational problems with the boiler
NOTE:  The use of double wall vent or potentially hazardous spillage of flue products
material for the combustion air inlet pipe is which can cause personal injury, death or property
recommended in cold climates to prevent the
damage.
condensation of airborne mositure in the
incoming combustion air.

16
Venting of Flue Products WARNING: Outdoor models MUST be
installed outdoors and MUST use the vent cap
For venting flue products horizontally to the outdoors, supplied by the manufacturer. Personal injury
follow all requirements in the installation instructions or product damage may result if any other cap is
for sidewall venting. used or if an outdoor model is used indoors. All
covers, doors and jacket panels must be properly
Termination point for the flue products must follow installed to insure proper operation and prevent
the clearance requirements in the Sidewall Vent a hazardous condition.
Termination section of Sidewall Venting.

A barometric damper is NOT required in the flue on CAUTION !!

Horizontal DirectAire installations if the draft is within Boilers which are shut down or will not operate
the 0.02 to 0.08 inches water negative required for may experience freezing due to convective
proper operation. If the draft exceeds this range, a air flow in the outdoor vent cap installed on
barometric damper must be installed. the unit. In cold climates, continuous
pump operation is recommended to help
CAUTION !!
prevent freezing of boiler water on
Boilers which are shut down or will not operate Outdoor systems. Proper freeze protection
may experience freezing due to convective air must be provided. See Freeze Protection.
flow in the air inlet pipe connected to the unit.
In cold climates, continuous pump operation is
recommended to help prevent freezing of boiler Combustion air supply must be free of contaminants
water on Horizontal DirectAire systems. Proper (See Combustion and Ventilation Air). To prevent
freeze protection must be provided. recirculation of the flue products into the combustion
See Freeze Protection. air inlet, follow all instructions in this section.

Outdoor Vent/Air Inlet Location

Outdoor Installation
The venting areas must never be obstructed. Keep area
clean and free of combustible and flammable materials.
Maintain a minimum clearance of 3"(76 mm) to
combustible surfaces and a minimum of 3" (76 mm)
clearance to the air inlet. To avoid a blocked air inlet
or blocked flue condition, keep the outdoor cap air inlet,
flue outlet and drain slot clear of snow, ice, leaves
debris, etc.

A unit should not be located so that high winds can

deflect off of adjacent walls, buildings or shrubbery
causing recirculation. Recirculation of flue products
may cause operational problems, bad combustion or
damage to controls. The unit should be located at least
FIG. 22
3 feet (0.19m) from any wall or vertical surface to
prevent adverse wind conditions from affecting
OUTDOOR INSTALLATION performance.

The Outdoor Vent System Multiple unit outdoor installations require 48" (1.22m)
clearance between each vent cap.
Units are self venting and can be used outdoors when
installed with the optional Outdoor Cap. This cap The outdoor cap must be located 4 feet (1.22m) below
mounts directly to the top of the boiler and covers the and 4 feet (1.22m) horizontally from any window, door,
flue outlet and combustion air inlet openings on the walkway or gravity air intake.
jacket. No additional vent piping is required.

17
The combustion air inlet of the outdoor cap must be The Outdoor Vent Cap Kit
located at least one foot (0.30m) above grade and above
normal snow levels. The required outdoor cap part numbers are listed by
unit size. The venting kit must be furnished by the
The unit must be at least 10 feet (3.05m) away from manufacturer in accordance with CSA International
any forced air inlet. requirements. Each kit includes the flue products
outlet/combustion air inlet assembly and gasket.
The unit must be at least 3 feet (0.91m) outside any
overhang. TABLE — G
Input Outdoor Cap
Clearances around outdoor installations can change
with time. Do not allow the growth of trees, shrubs or Btu/hr Kit Number
other plants to obstruct the proper operation of the 300,000 ODK3003
outdoor vent system.
990,000 ODK3009
Do not install in locations where rain from building 1,260,000 ODK3010
runoff drains will spill onto the boiler. 1,440,000 ODK3010
Flue gas condensate can freeze on exterior walls or on 1,800,000 ODK3011
the vent cap. Frozen condensate on the vent cap can 2,070,000 ODK3011
result in a blocked flue condition. Some discoloration
to exterior building or unit surfaces can be expected.
Adjacent brick or masonry surfaces should be protected CAUTION !!
with a rust resistant sheet metal plate.
Boilers which are shut down or will not operate
may experience freezing due to convective air
Outdoor Vent Cap
flow down the vent cap installed on the unit.
Proper freeze protection must be provided.
See Freeze Protection.

GAS SUPPLY

Verify unit is supplied with type gas specified on rating

plate. This unit is orificed for operation up to 4000
feet altitude. Consult factory for installations above
FIG. 23 4000 feet elevation. The unit will be marked to
indicate suitability for high altitude operation.

Outdoor Vent Cap Installed on Unit INLET PRESSURE: Measured at the inlet pressure
tap located upstream of the combination gas valve.
FLUE OUTLET
OUTDOOR
VENT CAP TABLE — H
SUPPLY PRESSURE
Nat. Gas LPG

Max. (Inches-Water Column) 10.5"w.c. 13"w.c.

Min. (Inches-Water column) 5.0"w.c. 11"w.c.

Maximum inlet gas pressure must not exceed the value

AIR INLET specified. Minimum value listed is for the purposes
FIG. 24 of input adjustment.

18
MANIFOLD PRESSURE: Measured at the pressure 6. The combination gas valve has an integral vent
tap on the downstream side of the combination gas limiting device and does not require venting to
valve. The gas regulator on the boiler’s combination atmosphere, outside the building. The unit will
gas valve is adjustable to supply proper manifold not operate properly if the reference hose is
pressure for normal operation. If adjustment of removed or a vent to atmosphere is installed.
regulator pressure is required, see Manifold Adjustment
Procedure. Do not increase regulator pressure 7. Optional gas controls may require routing of
beyond specified pressure setting. bleeds and vents to the atmosphere, outside the
building when required by local codes.
TABLE — I
Btu/hr Regulator Settings
Input Natural Gas [Link]
300,000 4.0” 10”
990,000 - 2,070,000 3.5” 10”

GAS PRESSURE TEST

SINGLE UNIT INSTALLATIONS
1. The appliance must be disconnected from the gas
supply piping system during any pressure testing
of that system at a test pressure in excess of 1/2 TABLE — J
PSIG (3.5kPa). SUGGESTED GAS PIPE SIZE
SINGLE UNIT INSTALLATIONS
2. The appliance must be isolated from the gas
supply piping system by closing a manual shutoff BTU DISTANCE FROM METER
valve during any pressure testing of the gas supply INPUT 0-50’ 51’-100’ 101’-200’ 201’-300’ 301’-500’
piping system at test pressures equal to or less
than 1/2 PSIG (3.5kPa). 300,000 1 1/4” 1 1/4” 1 1/2” 1 1/2” 2”

990,000 2” 2” 2 1/2” 2 1/2” 3”

3. The boiler and its gas connection must be
leak-tested before placing it in operation. 1,260,000 2” 2 1/2” 2 1/2” 3” 3”

1,440,000 2” 2 1/2” 3” 3” 3 1/2”

GAS CONNECTION 1,800,000 2 1/2” 2 1/2” 3” 3 1/2” 4”

2,070,000 2 1/2” 3” 3” 3” 3 1/2”

1. Safe operation of unit requires properly sized gas
supply piping. See data below. For each elbow or tee, add equivalent straight pipe to
total length from table below.
2. Gas pipe size may be larger than heater
connection.
TABLE — K
3. Installation of a union is suggested for ease of
FITTINGS TO
service.
EQUIVALENT STRAIGHT PIPE
4. Install a manual main gas shutoff valve, outside
of the appliance gas connection and before the gas Diameter Pipe (inches)
valve, when local codes require. 3/4” 1” 1 1/4” 1 1/2” 2” 3” 4” 5”

5. A trap (drip leg) MUST be provided in the inlet Equivalent length of Straight Pipe (feet)
of the gas connection to the unit. 2' 2' 3' 4' 5' 10' 14' 20'

19
 TABLE — L
MULTIPLE UNIT INSTALLATIONS GAS PIPING SIZE CHART

Nominal Length of Pipe in Straight Feet

Iron Pipe Size,
Inches
10 20 30 40 50 60 70 80 90 100 125 150 175 200

3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74
1 697 477 384 328 292 267 246 256 210 200 179 164 149 138
1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287
1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441
2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820
2 1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300
3 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340
4 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720
Maximum Capacity of Pipe in Thousands of BTU's per hour for gas pressures of 14 Inches Water Column (0.05 PSIG) or less and a
pressure drop of 0.05 Inch Water Column (Based on NAT GAS, 1025•BTU's per Cubic Foot of Gas and 0.60 Specific Gravity).

GAS PIPING Install Piping to Control

1. The gas line should be a separate line direct from

the meter unless the existing gas line is of
Gas Line Connection
sufficient capacity. Verify pipe size with your gas
USE supplier.
WRENCH
TO HOLD
PIPING
2. Use new, properly threaded black iron pipe free
from chips. If tubing is used, make sure the ends
are square, deburred and clean. All tubing bends
GROUND
JOINT must be smooth and without deformation. Avoid
UNION
MANUAL flexible gas connections. Internal diameter of
MAIN
SHUT-OFF
flexible lines may not provide unit with proper
VALVE volume of gas.
NIPPLE

3. Install a manual main gas shutoff valve at the

CAP
boiler gas inlet, outside of the boiler and before
the gas valve.

4. Run pipe or tubing to the boiler’s gas inlet. If

FIG. 25 tubing is used, obtain a tube to pipe coupling to
connect the tubing to the boiler’s gas inlet.
All gas connections must be made with pipe joint
compound resistant to the action of liquefied petroleum 5. Install a sediment trap in the supply line to the
and natural gasses. All piping must comply with local boiler’s gas inlet. (See Figure 25)
codes and ordinances. Tubing installations must
comply with approved standards and practices.

20
6. Apply a moderate amount of good quality pipe
compound (DO NOT use Teflon tape) to pipe Manifold Gas Pressure Measurement
only, leaving two end threads bare. 990,000 — 2,070,000 Btu/hr Models

7. Remove seal over gas inlet to boiler.

8. Connect gas pipe to inlet of unit. Use wrench to

support gas manifold on the unit.
MANOMETER
9. For L.P. gas, consult your L.P. gas supplier for
INLET
expert installation.
PRESSURE
10. Insure that all air is properly bled from the gas MANIFOLD PRESSURE REGULATOR
ADJUSTMENT
line before starting the ignition sequence. Startup (UNDER CAP
SCREW)
without properly bleeding air from the gas line may
require multiple reset functions of the ignition GAS
control module to achieve proper ignition. CONTROL
KNOB MANIFOLD
PRESSURE
GAS MANIFOLD PRESSURE OUTLET
TAP
FIG. 27
ADJUSTMENT PROCEDURE
4. Remove the “hex plug, located on manifold piping
IMPORTANT:
The combination gas to burners (300,000 Btu/hr models) or on the
valve has an adjustable gas regulator to control “outlet” side of the gas valve (990,000-2,070,000
manifold pressure. A manometer or magnahelic Btu/hr models) and install a fitting suitable to
gauge legible in 0.1” increments up to 10” water connect to a manometer or magnahelic gauge. See
column is required to check and adjust the Figure 26 and 27. Minimum range of scale should
manifold pressure. The regulator cover screw on be up to 5A” w.c. for natural gas and 10” w.c. for
the gas valve must be in place and tight for the propane gas.
appliance to operate properly.
5. Remove pressure regulator adjustment cap screw.
1. Turn the power switch to the “OFF” position. See Figure 35 and 36 for location.

2. Remove the top front jacket panels. 6. Turn the power switch to “ON” position.

3. Turn gas valve knob(s) and manual gas cock to 7. Turn gas valve knob(s) and manual gas cock to
“OFF” position. “ON” position.

Manifold Gas Pressure Measurement 8. Set the thermostat(s) or electronic temperature

300,000 Btu/hr Model control to call for heat.

9. Observe gas regulator pressure when burners are

firing at full rate input. Models with inputs of
990,000 through 2,070,000 Btu/hr will have multiple
gas valves and regulators. Each regulator must be
MANOMETER GAS
INLET adjusted when the individual stage is firing. See
CONTROL
KNOB
Manifold Pressure for proper setting. Do not
increase regulator pressure beyond specified
PRESSURE
pressure setting.
MANIFOLD PRESSURE
REGULATOR
ADJUSTMENT
(UNDER CAP 10. If adjustment is necessar y, tur n regulator
SCREW)
adjustment screw clockwise to raise regulator gas
MANIFOLD
OUTLET PRESSURE
pressure, counter clockwise to lower gas pressure,
FIG. 26
TAP to proper setting.

21
 NOTE:  Adjustment fitting is plastic
4. Remove the 1/8" hex plug, located on “inlet” side
of the gas valve. An inlet pressure tapping is
and may require slightly greater turning force
located on the top side of the valve body, beside
than a metal fitting.
the gas control knob on the redundant seated
combination valves. A tapping on the f ield
11. Turn the power switch to “OFF” position. installed main manual gas cock may also be used.
Install a f itting in the inlet pressure tapping
12. Turn gas valve knob(s) and manual gas cock to suitable to connect to a manometer or magnahelic
“OFF” position. gauge. Range of scale should be 14" w.c. or greater
to check inlet pressure.
13. Remove fitting from the gas valve and replace with
1/8" hex plug (that was previously removed) and 5. Turn on gas supply at the manual gas cock, turn
tighten. on L.P. gas at tank if required.

14. Turn the gas valve knob(s) and manual gas cock 6. Turn the power switch to the “ON” position.
to “ON” position.
7. Turn the gas valve knobs to the “ON” position.
15. Turn the power switch to “NO” position. The Set the electronic temperature control or
appliance is now ready to operate. thermostat to call for heat.

If manifold pressure can not be properly adjusted, use 8. Observe the gas supply pressure as all burners are
the following procedure to check gas supply pressure f iring. Insure that inlet pressure is within the
with a manometer connected to the inlet pressure tap specif ied range. Minimum and Maximum Gas
on the gas control. Supply Pressures are specif ied in Gas Supply
CHECKING GAS Section.
SUPPLY PRESSURE
9. If gas supply pressure is out of range, contact gas
1. Turn the main power switch to the “OFF” position. utility, gas supplier, qualified installer, or service
agency to determine necessary steps to provide
2. Turn gas valve knobs to the “OFF” position. proper gas pressure to the control.

3. Shut off gas supply at the field installed manual 10. If gas supply pressure is within normal range,
gas cock in the gas piping to the appliance. If proceed to remove gas manometer and replace
fuel supply is L.P. gas, shut off gas supply at the pressure tap fittings in the gas control.
tank.
11. Turn the power switch to the “OFF” position.
Gas Supply Pressure Measurement
at Combination Gas Valve 12. Turn gas valve knob to the “OFF” position.

13. Shut off gas supply at the manual gas cock in the
gas piping to the appliance. If fuel supply is L.P.
gas, shut off gas supply at the tank.

MANOMETER
INLET
14. Remove the manometer and related fittings from
“inlet” side of the gas valve, replace 1/8" hex plug
SUPPLY
INLET in gas valve and tighten.
PRESSURE
TAP
15. Turn on gas supply at the manual valve, turn on
L.P. gas at tank if required.
GAS
CONTROL
KNOB
16. Turn the power switch to the “ON” position.

OUTLET
FIG. 28

22
17. Turn the gas valve knob to the “ON” position. Inlet and Outlet Connections

18. Set the electronic temperature control or For ease of service, install unions on inlet and outlet
thermostat to call for heat. If proper ignition and of the unit. The connection to the unit marked “Inlet”
burner operation is not achieved after checking gas on the header should be used for return from the
supply pressure and setting the correct net system. The connection on the header marked “Outlet”
manifold pressure, see the Maintenance section is to be connected to the supply side of the system.
for Combustion Air Adjustment. Follow the
procedure to adjust the combustion air fan.
RELIEF VALVE
If proper ignition and burner operation is not achieved
after checking gas supply pressure and setting the This unit is supplied with a relief valve(s) sized in
correct net manifold pressure, see the Maintenance accordance with ASME Boiler and Pressure Vessel
section for Combustion Air Adjustment. Follow the Code, Section IV (“Heating Boilers”). The relief
procedure to adjust the combustion air fan. valve(s) is installed in the vertical position and mounted
in the hot water outlet. No valve is to be placed between
IMPORTANT:
Upon completion of any
the relief valve, and the unit. To prevent water damage,
the discharge from the relief valve shall be piped to a
testing on the gas system, leak test all gas
suitable floor drain for disposal when relief occurs. No
connections with a soap solution while main
reducing couplings or other restrictions shall be
burners are operating. Immediately repair any leak
installed in the discharge line. The discharge line shall
found in the gas train or related components. Do
allow complete drainage of the valve and line. Relief
Not operate an appliance with a leak in the gas
valves should be manually operated at least once a year.
train, valves or related piping.

Check burner performance by cycling the system while CAUTION !!

you observe burner response. Burners should ignite
promptly. Flame patter n should be stable, see Avoid contact with hot discharge water.
“Maintenance-Normal Flame Pattern.” Turn system
off and allow burners to cool, then cycle burners again A boiler installed above radiation level must be
to insure proper ignition and flame characteristics. provided with a low water cutoff device either as part
of the unit or at the time of installation.
WATER CONNECTIONS
WATER FLOW SWITCH
(IF EQUIPPED)
A water flow switch is factory installed on the 300,000
Btu/hr and 990,000 through 2,070,000 Btu/hr heating
boilers and hot water supply boiler. The flow switch is
wired in series with the 24 VAC safety control circuit at
the boiler’s terminal strip. This wiring connection installs
the flow switch in the 24 VAC safety circuit to prove water
flow before main burner ignition. The factory supplied
GAS
INLET
flow switch is installed in the outlet side of the front
ELECTRICAL
header. The 300,000 Btu/hr model requires a minimum
JUNCTION flow of 19 GPM to make the switch and start burner
BOX
operation and the 990,000 through 2,070,000 Btu/hr
models require a minimum flow of 26 GPM to make the
flow switch and start burner operation. Insure that the
WATER
OUTLET
pump installed on the boiler will supply adequate flow to
INSPECTION
make the flow switch contacts and operate the boiler. A
PLUGS WATER
INLET
water flow switch meets most code requirements for a
FIG. 29 low-water cut off device on boilers requiring forced
circulation for operation.
23
 LOW WATER CUTOFF Venting of Combination Gas Valves
(IF EQUIPPED)
The combination gas valve/regulator used on all models
If this boiler is installed above radiation level, a low is equipped with an integral vent limiting orifice per
water cut-off device must be installed at the time of ANSI Z21.78. This vent limiter insures that the volume
boiler installation. Electronic or float type low water of gas emitted from the valve does not exceed the
cut-offs are available as a factory supplied option on maximum safe leakage rate allowed by agency
all units. Low water cut-offs should be inspected every requirements. Combination gas valve/regulators
six months, including flushing of float types. equipped with integral vent limiters are not required
to have vent or relief lines piped to the outdoors. The
termination of the vent limited opening on the
combination gas valve/regulator complies with the
COMBINATION GAS VALVES safety code requirements of CSD-1, CF-190 (a) as
shipped from the manufacturer without the installation
of additional vent lines.
300,000 Btu/hr Input:

This unit has a single combination gas valve to cycle ELECTRICAL CONNECTIONS
the gas supply on and off and regulate gas to the
burners. The combination valve consists of a gas
regulator and two valve seats to meet the requirements This appliance is wired for 120 VAC service. The unit,
for redundant gas valves. The valve has a gas control when installed, must be electrically grounded in
knob that must remain in the open position at all times accordance with the requirements of the authority
when the unit is in service. The gas control valve has having jurisdiction or in the absence of such
pressure taps located on the inlet and discharge sides requirements, with the latest edition of the National
of the valve. Manifold pressure is adjusted using the Electrical Code ANSI/NFPA No. 70. When the unit is
regulator located on the valve. installed in Canada, it must conform to the CAE C22.1,
Canadian Electrical Code, Part 1 and/or local Electrical
Codes.
990,000 through 2,070,000 Btu/hr Input:
1. All wiring between the unit and field installed
These models fire in multiple stages of burner input. devices shall be made with type T wire [63 o F
Each stage of burner operation has a single combination (35o C) rise].
gas valve(s) to cycle the gas supply on and off and
regulate gas to the burners. Each combination valve 2. Line voltage wire exterior to the appliance must
consists of a gas regulator and two valve seats to meet be enclosed in approved conduit or approved
the requirements for redundant gas valves. The valve metal clad cable.
has a gas control knob that must remain in the open
position at all times when the unit is in service. The 3. The pump must run continuously when unit is
gas control valve has pressure taps located on the inlet being fired (hot water heating boilers or hot water
and discharge sides of the valve. Manifold pressure is supply boilers must use the optional pump delay
adjusted using the regulator located on the valve. A or intermittent pump controller if the pump is to
manifold gas pressure tap for each burner stage is be cycled. See Freeze Protection when cycling
located on the discharge side of the valve. the pump).

The manifold pressure is preset at the factory and 4. To avoid serious damage, DO NOT energize the
adjustment is not usually required. If the manifold boiler until the system is full of water. Serious
pressure is to be adjusted, follow the “Gas Manifold damage may result.
Pressure Adjustment Procedure” for proper adjustment.
5. Provide the boiler with proper overload protection.

24
 TABLE — M manual reset function is available. A small red reset
button, located beside the knob, must be pushed
AMP DRAW DATA
whenever water temperature has exceeded the set point
300,000 through 2,070,000
of the manual reset limit.
Btu/hr Models
Btu/hr Fan Controls Approximate
Input Total AMPS
@ 120 VAC
300,000 3.6 2.6 6.2 NOTE:  The control will not reset until
990,000 7.2 7.2 14.4 the water temperature has dropped below the
1,260,000 7.2 7.2 14.4 set point of the high limit.
1,440,000 7.2 7.2 14.4
1,800,000 10.8 7.2 18.0
2,070,000 10.8 7.2 18.0

Component Location Drawing of Control Panel

300,000 Btu/hr Model
IGNITION
MODULE HIGH LIMIT

TRANSFORMER TERMINAL
BOARD OPERATOR FIG. 30

TEMPERATURE ADJUSTMENT ELECTRONIC OPERATING

TEMPERATURE CONTROL
300,000 Btu/hr Models: 990,000 through 2,070,000 Btu/hr Models

Operating Temperature Control These units use an adjustable electronic temperature

control to provide staged ON/OFF control. Operation
An adjustable immersion operating control is located is based on temperature input from two immersion
beneath top jacket panel on the control panel. The sensors. Each sensor is a positive coefficient platinum
control uses a remote sensing bulb mounted in the inlet thermistor. Sensor A is placed in the inlet side of the
side of the front header. Turn the control setpoint dial front header and sensor B is placed in the outlet side
to adjust the desired operating water temperature of of the front header. A liquid crystal display is provided
the unit. to indicate sensed temperature and operating
parameters. The temperature control for the 990,000
Btu/hr units operates with three (3) stages of control,
High Water Temperature Limit Control 1,260,000 through 2,070,000 Btu/hr units operate with
four (4) stages of control. Heating boilers may be
An adjustable high limit control(s) is located beneath supplied with an optional electronic control with an
the top jacket panel, on control panel beside the outdoor reset function which will operate the boiler in
temperature control. The setting of this control(s) limits two (2) stages, see Electronic Operating Control with
maximum discharge water temperature. An optional Outdoor Reset Function.
25
 Component Location Drawing of Control Panel
990,000 - 2,070,000 Btu/hr Models

FIG. 31

Select Key - Sequentially prompts the user as to what

Electronic Temperature Control, LCD
parameter is being displayed: set point, differential,
Display and Programming Keys T775 stage energized, operation mode (heat), indication of
assigned stage (1,2,3). Once the last parameter value
has been viewed, pressing the Select key will display
the control values again from the beginning of the
display loop.

Up and Down Arrow Keys - Allow the displayed

parameter to be increased or decreased. After pressing
the Select key, a control value can be changed by using
the Arrow keys. Control values will be increased or
decreased by 1° F for each time the Arrow keys are
depressed.

Enter Key - Places the new value into the memory of

the microprocessor.
FIG. 32
IMPORTANT:

A control value or operation will not be entered
SPECIFICATIONS in the memory of the microprocessor until the
Enter key is pressed.

Set Point Adjustment Range: Max setting 220° F. Control values and operation selection will remain in
Temperature Accuracy: +/- 1° F. the device memory even after power is removed.
Display Resolution: 1° F via Liquid Crystal Display
Sensor: Thermistor 4.8 ohms/° F. Select and Enter Keys simultaneously pressed -
Operating Humidity: 5 - 95% RH Noncondensing. changes operation mode of the control from heat to
Operating Ambient Temperature: -30° to 125° F. cool mode. DO NOT CHANGE THIS SETTING.
This control must always be in the “heat” position for
Access to the control is achieved by removing the jacket proper operation of the boiler.
panel covering the diagnostic control lights. Four
programming keys are provided to program set point When all stages have been programmed the display will
and differential values for each stage and to control revert back to sensed temperature and load energized
the display. The four keys are Select, Up arrow, Down status.
arrow and Enter.

26
 DISPLAY SETUP OF THE
TEMPERATURE CONTROLLER

Once power is applied to the temperature controller,

the display will count down from 210 until the display Each stage on the controller has its own independent
reads zero. All outputs are de-energized at this time. set point and differential which are determined by
This countdown process will repeat each time main the programming keys. Each stage of heating is
power is interrupted. To avoid viewing this entire de-energized as the sensed temperature reaches the
countdown, press the Select key. The display will now programmed set point. Each available stage of heating
show normal readings: load (sensed) temperature, is energized as the sensed temperature reaches the set
stages energized, and which sensor is being read point minus the differential.
(Sensor A or Sensor B). At any time during the
programming procedure, the display will revert back EXAMPLE:
to showing the sensed temperature and stage status
Using stage one of the control as an example, the
indication 60 seconds after the last programming key
corresponding load would be energized and
is pushed.
de-energized at the following temperatures based
on the programmed settings.
The display can be configured with three options to
Settings
Set point: 160 ° F
show sensed temperature. The display can lock on
Sensor A temperature, lock on Sensor B temperature,
Differential: 8° F
or be configured to alternatively indicate “Sensor A”
Output Energized
and “Sensor B” sensed temperature at a 5 second rate.
Stage One: Energized at 152° F
This allows comparison of temperatures to determine
Output De-energized
Stage One: De-energized at 160° F
temperature rise.

This selection is accomplished by stopping at “Sensor

A” or “Sensor B” sensed temperature points in the
Select key scrolling loop. To lock on to either sensor, Each available stage of operation must be programmed
the user must scroll the Select key through the loop to with a set point and a differential. If two stages are
the sensed temperature prompt of interest. The display programmed with the same set point and differential
will stick to that parameter until the Select key is the control will sequence both stages on and off with
activated to advance the loop. When the loop is stopped only a slight delay between switching of the stages.
at any other prompt, the display will alternatively The control is normally programmed with a few
indicate “Sensor A” and “Sensor B” sensed temperature degrees difference between the set point of each stage
after 60 seconds from the last key closure or to sequence individual stages on as required by
immediately after the Select key has been pressed at demand. This will allow input to be balanced to system
the end of the programming sequence. demand. The exact settings will be determined by your
system heat requirements. The set point minus
differential should not be lower than 140° F to prevent
SELECTION OF sweat and condensate formation on the heat exchanger.
OPERATING SENSOR See Low Water Temperature Systems section for
applications at lower temperatures.

The control, as shipped from the factory, is preset to Based on your system requirements, determine the set
use Sensor A to operate a heating boiler or a hot water point and switching differential for each stage of
supply boiler. Sensor B to provides a discharge operation and enter into the worksheet below.
thermometer function. Adjustment of these internal
settings on the temperature controller should not be These values will be programmed into the temperature
made without consulting the factory. Improper controller.
adjustment can allow over temperature operation which
may cause personal injury or property damage.

27
 4. Press Select to display the current stage set point.
PROGRAMMING WORKSHEET
Stage 1: 5. Press Up Arrow key to increase or Down Arrow
Set Point 1 ___________ Off at __________ key to decrease to the desired set point.
Differential 1 ________ On at __________
Stage 2: 6. Press Enter to enter the displayed value into
Set Point 2 ___________ Off at __________ memory.
Differential 2 ________ On at __________
Stage 3: 7. Press Select to display the current stage switching
Set Point 3 ___________ Off at __________ differential.
Differential 3 ________ On at _________
Stage 4: 8. Press Up Arrow key to increase or Down Arrow
Set Point 4 ___________ Off at __________ key to decrease to the desired switching
Differential 4 ________ On at _________ differential.

9. Press Enter to enter the displayed value into

PROGRAMMING memory.

10. Repeat steps 4 thru 9 to program each additional

NOTE:  When power is initially applied stage.
to a new boiler the control points will be
pre-programmed. The factory final quality test 11. Press Select Select Select Select (4 times) to return
sets the unit for test firing. to stage 1 parameters. Scroll through the
programming loop a second time to confirm that
The preset values are as follows: the appropriate values have been entered into
memory by pressing Select.
Stage Set Point Differential
1 125° F 2° F 12. Press Select after viewing the switching
123° F 2° F
differential for the final stage to display Sensor A
2
temperature only (inlet water temperature).
3 121° F 2° F
4 120° F 2° F 13. Press Select again to display Sensor B
temperature only (outlet water temperature).
Re-program the set points and differentials to meet your
system requirements. 14. Press Select again to alternate the display between
Sensor A temperature and Sensor B temperature
The operating control uses an Liquid Crystal Display at approximately 5 second intervals (to determine
for interactive prompting during programming and temperature rise).
display of sensed and assigned set point and differential
values. Programming is accomplished through the use NOTE:  The control values programmed
of the four programming keys.
into memory will not be lost because of a power
1. Verify that the boiler is properly applied as either failure.
a heating boiler or hot water supply boiler, and
ELECTRONIC OPERATING
the model number on the rating plate correctly
identifies the boiler. CONTROL WITH
OUTDOOR RESET FUNCTION
2. Turn the power switch to the ON position. The (Optional on Heating Boilers)
control will begin counting down from 210. This
countdown sequence will last for approximately The temperature control is now ready for operation.
3-1/2 minutes.
This boiler is available with an optional adjustable
3. To override this time delay, press Select. electronic temperature control to provide staged
ON/OFF control and an adjustable reset function based

28
on outdoor temperature. Operation as a reset controller Up and Down Arrow Keys - Allow the displayed
is based on temperature input from two sensors, one parameter to be increased or decreased. After pressing
immersion sensor for boiler water and one for outdoor the Select key, a control value can be changed by using
air reset. Each sensor is a positive coefficient platinum the Arrow keys. Control values will be increased or
thermistor. Sensor A is the boiler water temperature decreased by 1° F for each time the Arrow keys are
sensor and sensor B is outdoor air temperature sensor. depressed.
A liquid crystal display is provided to indicate sensed
temperature and operating parameters. The temperature Enter Key - Places the new value into the memory of
control with the outdoor reset function operates with the microprocessor.
two (2) stages of control.
IMPORTANT:

Outdoor Reset Electronic
Temperature Control Display A control value or operation will not be entered in
the memory of the microprocessor until the Enter
And Programming Keys
key is pressed.

Control values and operation selection will remain in

the device memory even after power is removed.

Select and Enter Keys simultaneously pressed -

Changes operation mode of the control from heat to
cool mode. DO NOT CHANGE THIS SETTING.
This control must always be in the “heat” position for
proper operation of the boiler.

When all stages have been programmed the display will

revert back to sensed temperature and load energized
FIG. 33 status.

DISPLAY
SPECIFICATIONS
Once power is applied to the temperature controller
Set Point Adjustment Range: Max setting 220° F. the display will countdown from 210 until the display
Temperature Accuracy: +/- 1° F. reads zero. All outputs are de-energized at this time.
Display Resolution: 1o F via Liquid Crystal Display This countdown process will repeat each time main
Sensor: Thermistor 4.8 ohms/° F. power is interrupted. To avoid viewing this entire
Operating Humidity: 5 - 95% RH Noncondensing. countdown, press the Select key. The display will now
Operating Ambient Temperature: -30° to 140° F. show normal readings: load (sensed) temperature,
stages energized, and which sensor is being read
Access to the control is achieved by removing the jacket (Sensor A or Sensor B). At any time during the
panel covering the diagnostic control lights. Four programming procedure, the display will revert back
programming keys are provided to program set point to showing the sensed temperature and stage status
and differential values for each stage and to control indication 60 seconds after the last programming key
the display. The four keys are Select, Up arrow, Down is pushed.
arrow and Enter.
The display can be configured with three options to
Select Key - Sequentially prompts the user as to what show sensed temperature. The display can lock on
parameter is being displayed: set point, differential, Sensor A temperature, lock on Sensor B temperature,
stage energized, operation mode (heat), indication of or be configured to alternatively indicate “Sensor A”
assigned stage (1,2). Once the last parameter value has and “Sensor B” sensed temperature at a 5 second rate.
been viewed, pressing the Select key will display the This allows comparison of boiler water temperature
control values again from the beginning of the display and outdoor temperature to check reset operation.
loop.

29
This selection is accomplished by stopping at “Sensor degrees difference between the set point of each stage
A” or “Sensor B” sensed temperature points in the to sequence individual stages on as required by
Select key scrolling loop. To lock on to either sensor, demand. This will allow input to be balanced to system
the user must scroll the Select key through the loop to demand. The exact settings will be determined by your
the sensed temperature prompt of interest. The display system heat requirements. The set point minus
will stick to that parameter until the Select key is differential should not be lower than 140° F (60° C) to
activated to advance the loop. When the loop is stopped prevent sweat and condensate formation on the heat
at any other prompt, the display will alternatively exchanger. See Low Water Temperature Systems
indicate “Sensor A” and “Sensor B” sensed temperature section for applications at lower temperatures.
after 60 seconds from the last key closure or
immediately after the Select key has been pressed at Based on your system requirements, determine the set
the end of the programming sequence. point and switching differential for each of the two
stages of operation and enter them into the worksheet
below.
OPERATING SENSORS
PROGRAMMING WORKSHEET
The control is configured to use Sensor A as the heating
boiler water temperature sensor and Sensor B as
outdoor air temperature sensor for the controls reset
function. Stage 1:
Set Point 1 ___________ Off at ___________
Differential 1 ________ On at __________
SETUP OF THE
TEMPERATURE CONTROLLER Stage 2:
Set Point 2 ___________ Off at ___________
Each stage on the controller has its own independent Differential 2 ________ On at __________
set point and differential which are determined by
the programming keys. Each stage of heating is
de-energized as the sensed temperature reaches the
programmed set point. Each available stage of heating
is energized as the sensed temperature reaches the set RESET CONTROL ALGORITHM
point minus the differential.
The reset control is capable of providing two stages of
EXAMPLE: burner input based on programmed setpoints and the
reset configuration. The reset ratio expresses the
Using stage one of the control as an example, the amount of change in the heating control point caused
corresponding load would be energized and by a change in the outdoor temperature. The reset ratio
de-energized at the following temperatures based is preset to function in an inverse ratio (as the outdoor
on the programmed settings. temperature goes down, the control temperature goes
up).
Settings
Set point: 160° F Determining the Reset Ratio
Differential: 8° F
Output Energized Change in Outside Temperature = B
Stage One: Energized at 152° F Change in Control Temperature A
Output De-energized
Stage One: De-energized at 160° F Example of how the Reset Ratio is calculated:

Each available stage of operation must be programmed When the outdoor temperature is 70° F (21° C) the
with a setpoint and a differential. If two stages are desired boiler water temperature is 140° F (60° C), when
programmed with the same setpoint and differential the outdoor temperature drops to -10° F (-23° C) the
the control will sequence both stages on and off with boiler water temperature needs to be 200° F (93° C).
only a slight delay between switching of the stages.
The control is normally programmed with a few

30
 5. Press Up Arrow key to increase or Down Arrow
70° - (-10 °) = 80° = 8° key to decrease to the desired set point.
200° - 140° 60° 6°
6. Press Enter to enter the displayed value into
Therefore, the reset ratio is 8:6. The values for the reset memory.
ratio must be whole numbers from 1 to 30 to achieve
proper operation. 7. Press Select to display the current stage switching
differential.
CAUTION !!
8. Press Up Arrow key to increase or Down Arrow
A reset ratio lower than one can result in unstable
key to decrease to the desired switching
control. Widening the differential will minimize differential.
this effect.
9. Press Enter to enter the displayed value into
These values will be programmed into the temperature memory.
controller.
10. Repeat steps 4 through 9 to program the second stage
of burner operation.
PROGRAMMING
11. Press Select to display the cur rent reset
NOTE:  When power is initially compensation setpoint for the outdoor sensor
applied to a new heating boiler the control points .
will be pre-programmed. The factory final 12. Press Up Arrow key to increase or Down Arrow
quality test sets the unit for test firing. The preset key to decrease to the Reset Compensation
values are as follows: Setpoint for the Outdoor Sensor (Sensor B) -
Remember this value is the outdoor temperature
Stage Set Point Differential at which the boiler control setpoint will begin to
1 150°F 2°F be increased as the outdoor temperature falls.

2 145°F 2°F 13. Press Enter to enter the desired value into
memory.
Re-program the set points and differentials to meet your
system requirements. 14. Press Select to display the Reset Ratio B value.

The operating control uses a Liquid Crystal Display 15. Press Up Arrow key to increase or Down Arrow
for interactive prompting during programming and key to decrease to the numerical value for the Reset
display of sensed and assigned set point and differential Ratio B. Remember this value is the Change in
values. Programming is accomplished through the use Outside Temperature ( for the example enter 8).
of the four programming keys.
16. Press Select to display the Reset Ratio A value.
1. Verify that the boiler is properly applied as either
a heating boiler and the model number on the 17. Press Up Arrow key to increase or Down Arrow
rating plate correctly identifies the boiler. key to decrease to the numerical value for the Reset
Ratio A. Remember this value is the Change in
2. Turn the power switch to the ON position. The Control Temperature ( for the example enter 6).
control will begin counting down from 10. This
count down sequence will last for approximately 18. Press Select Select Select Select (4 times) to
3-1/2 minutes. return to stage 1 parameters. Scroll through the
programming loop a second time to confirm that
3. To override this time delay, press Select. the appropriate values have been entered into
memory by pressing Select.
4. Press Select to display the current stage set point.

31
The electronic temperature control has three options 4. Do not locate temperature sensor wiring near
for displaying the sensed temperatures. welding equipment.

1. Sensor A only. 5. Make sure good mechanical connections are made

2. Sensor B only to both the sensor, any interconnecting wiring and
3. Alternating between Sensor A and Sensor B. the controller.

19. Press Select after viewing the switching 6. Do not mount sensor with leadwire end pointing
differential for the final stage to display Sensor A up in an area where condensation can occur.
temperature only (boiler water temperature).
7. Use shielded wiring to connect the sensor to the
20. Press Select again to display Sensor B temperature control when the possibility of an electrically noisy
only (Reset Compensation Setpoint). environment exists. Shielded cable is
recommended on all cable runs of more than 25
21. Press Select again to alternate the display between feet in length.
Sensor A temperature and Sensor B temperature
at approximately 5 second intervals.
NOTE: 
The temperature control is now ready for operation. Ground the cable shield at the connection to the
boiler/electronic temperature control only.
DO NOT ground the shielded cable at the sensor
NOTE: 
end.
The control values programmed into memory
will not be lost because of a power failure.
To maintain temperature accuracy, sensor wires should
be 18 AWG two conductor (18/2). Use shielded wire
if required. If the length of the sensor wire to a remote
mounted sensor exceeds 400 feet, recalibration may
REMOTE MOUNTING
be necessary to maintain accuracy. Sensor wire lengths
OF THE SENSORS of 400 to 599 feet will require a 1°F calibration offset,
FOR THE BOILER’S ELECTRONIC 600 to 799 feet will require a 2°F calibration offset
TEMPERATURE CONTROL and 800 to 1000 feet will require a 3°F calibration
offset. This temperature offset should be added to the
The operating sensor (Sensor A) may need to be desired temperature setpoint for these applications.
installed in the system piping on low temperature
application, outdoor reset controls or other specialized ERROR MESSAGES DISPLAYED
applications. Use care when remote mounting the
BY THE ELECTRONIC
operating temperature sensor or outdoor reset sensor
from the boiler’s electronic temperature control. The TEMPERATURE CONTROL
outdoor temperature sensor (Sensor B) on an electronic
temperature control with the optional outdoor reset There are seven error messages that can be displayed
function must be installed outside the building. Erratic in response to software or hardware problems with the
temperature readings can be caused by poor wiring boiler’s internal electronic temperature control. The
practices that must be avoided to assure proper error codes that may be seen flashing on the display
operation. are:

1. Do not route temperature sensor wiring with SF - Sensor Failure

building power wiring. The display flashing SF indicates an out-of-range
or defective sensor. Make sure sensors are
2. Do not locate temperature sensor wiring next to properly installed, wired and connected to the
control contactors. control. Correct sensor installation or replace
sensor.
3. Do not locate temperature sensor wiring near
electric motors.

32
EF- EEPROM Failure High Water Temperature Limit Control
The values read form the EEPROM are not the
same as the values written into the EEPROM. This 990,000 through 2,070,000 Btu/hr models
error cannot be field repaired. Replace the boiler’s
electronic temperature control. An adjustable high limit control is located behind the
front control panel, beside the temperature control and
CF - Calibration Failure indicating lights. The setting of this control limits
The calibration resistor reading was not within maximum discharge water temperature. An optional
the range of the Analog to Digital converter. This manual reset function is available. A small red reset
error cannot be field repaired. Replace the boiler’s button, located beside the knob, must be pushed
electronic temperature control. whenever water temperature has exceeded the set point
of manual reset limit.
OF - Stray Interrupt Failure
An unused interrupt occurred. This error cannot
be field repaired. Replace the boiler’s electronic NOTE: 
temperature control. The limit control will not reset until the water
temperature has dropped below the set point of
CE - Configuration Error the high limit.
The device hardware was conf igured to an
nonexistent device. This error cannot be field
repaired. Replace the boiler’s electronic LIGHTING INSTRUCTIONS
temperature control.
FOR YOUR SAFETY READ
OE - ROM Error
BEFORE OPERATING
The internal ROM of the microprocessor in the
boiler’s electronic temperature control is
defective. This error cannot be field repaired. WARNING:
Replace the boiler’s electronic temperature
control. If you do not follow these instructions exactly, a
fire or explosion may result causing property
AE - RAM Error damage, personal injury or loss of life.
The internal RAM of the microprocessor in the
boiler’s electronic temperature control is A. This appliance does not have a pilot. It is equipped
defective. This error can not be field repaired. with an ignition device which automatically lights
Replace the boiler’s electronic temperature the burner. DO NOT try to light the burner by
control. hand.
HIGH WATER TEMPERATURE
LIMIT CONTROL B. BEFORE OPERATING, smell around the
appliance area for gas. Be sure to smell next to
the floor because some gas is heavier than air and
willsettle to the floor.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.
MANUAL
RESET
• Do not touch any electric switch; do not use
BUTTON any phone in your building.
• Immediately call your gas supplier from
a neighbor’s phone.
• Follow the gas supplier’s instructions.
C. Use only your hand to turn the gas control knob.
• If you cannot reach your gas supplier, call
HIGH LIMIT CONTROL FIG. 34 the fire department.

33
 Never use tools. If the knob will not turn by 7. Wait f ive (5) minutes to clear out any gas. If
hand, don’t try to repair it, call a qualified service you smell gas, STOP! Follow “B” in the safety
technician. Force or attempted repair may information. If you don’t smell gas go on to
result in a fire or explosion. the next step.

D. Do not use this boiler if any part has been under 8. Turn the gas control knob counterclockwise
water. Immediately call a qualif ied ser vice to the “ON” position.
technician to inspect the boiler. The possible
damage to a flooded boiler can be extensive and 9. Set the ther mostat to the desired setting.
present numerous safety hazards. Any appliance
that has been under water must be replaced. 10. Replace control access panel.

11. Turn on all electric power to the appliance and

press the ignition reset button.
LIGHTING INSTRUCTIONS
12. If the appliance will not operate, follow the
300,000 Btu/hr MODELS instructions “To Turn Off Gas To Appliance”
and call your service technician or gas supplier.
1. STOP! Read the safety information.

2. Turn Off all electrical power to the appliance. TO TURN OFF GAS TO APPLIANCE

3. Open the left top jacket panel to access the 1. Turn off all electric power to the appliance if
controls. service is to be performed.

4. Set the thermostat to the lowest setting. 2. O p e n t h e t o p l e f t j a c ke t p a n e l t o a c c e s s

controls.
5. This appliance is equipped with an ignition
device which automatically lights the burners. 3. Push in the gas control knob slightly and turn
DO NOT try to light the burners by hand. clockwise to the “OFF” position. Do not
force.
6. Push in the gas control knob slightly and turn
clockwise to the “OFF” position. 4. Replace control access panel.

LIGHTING INSTRUCTIONS

990,000 through 2,070,000 Btu/hr Models

1. STOP! Read the safety information.

2. O p e n t h e f r o n t a c c e s s p a n e l t o p r og r a m
temperature control.

GAS VALVE 300,000 3. Set each stage of control to the lowest setting
FIG. 35 Btu/hr MODELS (See Temperature Adjustment).

4. Turn Off all electrical power to the appliance.

NOTE:  On the 39C valve, knob
5. This appliance is equipped with an ignition
cannot be turned to “OFF” unless knob is
device which automatically lights the burners.
pushed in slightly. Do Not Force.
DO NOT try to light the burners by hand.

34
 Combination Gas Valve for WARNING:
990,000 — 2,070,000 Btu/hr Models Should overheating occur or the gas fail to
INLET
shut off, turn off the manual gas control
INLET
PRESSURE
TAP
PRESSURE
REGULATOR
valve to the appliance.
ADJUSTMENT
(UNDER CAP SCREW)

IGNITION SYSTEM CHECKOUT

300,000 Btu/hr Models
REFERENCE
HOSE 1. Turn off gas supply to unit.
CONNECTION

2. Tur n ther mostat and high limit controls to

highest setting.
GAS
VALVE
CONTROL
KNOB
3. Turn electric power on.

4. The ignition module will lock out.

WIRING
OUTLET TERMINALS
PRESSURE
TAP
5. Readjust thermostat and high limit to normal
OUTLET
FIG. 36 setting.

6. Turn the manual gas cock clockwise to 6. Turn on gas supply.

the “OFF” position.
7. Turn power off then press the ignition reset button
7. Wait f ive (5) minutes to clear out any gas. If to reset module.
you smell gas, STOP! Follow “B” in the
safety information. If you don’t smell gas go 8. If ignition system fails to operate properly,
on to the next step. repair work must be performed by a qualif ied
serviceman or installer.
8. Turn the manual gas cock counterclockwise
to the “ON” position.
990,000 through 2,070,000 Btu/hr Models
9. Turn on all electric power to the appliance and
press the ignition reset button. 1. Turn off gas supply to unit.

10. P r og r a m t h e t e m p e r a t u r e c o n t r o l t o t h e 2. Turn electric power on.

desired settings.
3. Program each stage of the temperature control
11. Close the control access panel. to settings above water temperature or to
highest safe setting.
1 2 . If the appliance will not operate, follow the
instructions “To Turn Off Gas To Appliance” 4. Each ignitor will cycle on trial(s) for ignition.
and call your service technician or gas supplier.
5. Each ignition module will lock out and turn on
the flame failure lights.
TO TURN OFF GAS TO APPLIANCE
6. Program each stage of temperature control to
desired temperature set points.
1. Turn off all electric power to the appliance if
service is to be performed. 7. Turn on gas supply.

2. Tu r n t h e m a n u a l g a s c o c k c l o c k w i s e 8. Tu r n p owe r o ff t h e n o n t o r e s e t i g n i t i o n
to the “OFF” position. modules.
35
9. If ignition system fails to operate properly,
repair work must be performed by a qualif ied
HOT SURFACE IGNITION CONTROL MODULE
serviceman or installer. Ignition Module Lockout Functions

HOT SURFACE IGNITION SYSTEM The ignition module(s) may lockout in either a hard
lockout condition requiring pushing of the reset button to
recycle the control or a soft lockout condition which may
Hot Surface Ignition
recycle in a fixed time period to check for correction of
Control Module
the fault condition. A typical hard lockout fault is a flame
failure condition. An ignition module that is in a hard
lockout condition may only be reset by pushing the reset
300,000 Btu/hr models & button for the ignition control. The reset button is located
990,000-2,070,000 inside front control panel on the side of the ignition
models reset module. The reset button is active after the post purge
cycle when there is hard lockout condition as indicated
by the Status LED. Turning main power “OFF” and then
“ON” or cycling the thermostat will not reset a hard
lockout condition. Wait five seconds after turning on main
power before pushing the reset button when the ignition
module is in a hard lockout. The ignition module will go
into a soft lockout in conditions of low air, low voltage or
low hot surface igniter current. A soft lockout condition
will operate the combustion air fan for the post purge cycle
and then the ignition module will pause for a fixed time
period. The timed length of the pause is based on the type
FIG. 37 of fault sensed by the control module. At the end of this
timed pause, the ignition module will attempt a new trial
Service Parts for ignition sequence. If the soft lockout fault condition
This unit uses a proven pilot electronic hot surface ignition has subsided or has been corrected at the end of the timed
control module and a hot surface igniter. The hot surface pause, main burner ignition should be achieved with the
ignition module is not repairable. Any modification or resumption of the normal trial for ignition sequence. If
repairs will invalidate the warranty and may create the control sensed fault is not corrected, the ignition
hazardous conditions that result in property damage, module will continue in the soft lockout condition. If the
personal injury, fire, explosion and/or toxic gases. A faulty electronic thermostat opens during the soft lockout period,
hot surface igniter or ignition module MUST be replaced the ignition module will exit soft lockout and wait for a
with a new OEM unit only. An OEM specification igniter new call for heat from the thermostat. A soft lockout
and ignition control module for this specific unit is condition may also be reset by manually cycling the
available from your local distributor. DO NOT use electronic thermostat or turning the main power switch
general purpose field replacement ignition modules or “OFF” and then “ON” after the control sensed fault has
igniters. been corrected.

Hot Surface Igniter Diagnostic Status Indication

The ignition module has an LED which indicates the status

of the safety circuits. A remote Ignition Module Status
indicating light(s) is wired from the ignition module Status
LED and mounted on the front control panel (990,000
FIG. 38 through 2,070,000 Btu/hr models). The flashing operation
of this light/LED indicates the diagnostic status of the
Hot Surface Igniter and Ignition Module ignition control module. The status LED, mounted on the
ignition module, flashes a code sequence from the Ignition
The 300,000 Btu/hr models have one ignition module and one Module to indicate the status of the ignition process. The
hot surface igniter. The 990,000 through 2,070,000 Btu/hr following listing gives the flashing diagnostic status codes
models have two ignition modules and two hot surface igniters. as signaled by the ignition module.

36
 Status LED Diagnostic Codes out. The control panel contains the ignition module, transformer
Code Sequence Condition for the 24 VAC control circuit, circuit breaker for the control
Constant ON - System OK, no faults present. circuit (990,000 through 2,070,000 Btu/hr models only),
Constant OFF - Possible control fault, check power; LED switching relays for component operation and wiring harness
may be defective, do not replace connections to the boiler’s components. The control panels for
control if all operational sequences the 990,000 through 2,070,000 Btu/hr models are common and
function properly - see Trouble may be switched between these boilers for trouble shooting.
Shooting Guide. The control panels for the 300,000 Btu/hr model is unique to
One Flash - Low Air, check air pressure switch and this model and may only be switched between 300,000 Btu/hr
hoses to pressure sensing points, fan, models for trouble shooting.
venting and sealing of pressurized IGNITION AND CONTROL TIMINGS
chamber. Note: Brief flashing normal
on fan start-up/proving. Proven Pilot Hot Surface Ignition System
Two Flashes - Flame without call for heat, check for a
gas valve stuck in the open position, air, F-9 on 300,000 Btu/hr Models with a Single Hot
venting, burners and the combustion Surface Ignition Module
process. Fan will remain on.
Three Flashes - Lockout due to flame failure, push reset M-9 on 990,000 through 2,070,000 Btu/hr Models with
button on inner control panel after Two Hot Surface Ignition Modules
correcting ignition problem. Initial
heater start up without properly Hot Surface Ignition Module Timings
bleeding air the gas line may require Prepurge : 15 Seconds
multiple reset functions to achieve Hot Surface Ignitor Heat-up Time : 25- 35 seconds
proper ignition. Main Burner Flame Establishing Period : 4 Seconds
Four Flashes - Igniter failure, igniter will not maintain Failure Response Time : 0.8 Seconds at less than 0.5 µA
minimum 3.1 amp current draw , caused flame current
by, low voltage, bad wiring/continuity, Flame Current : 5 - 15 µA
high resistance or igniter failure Time Delay Between Stages 1&2 and 3&4 - 15 Seconds
Five Flashes - Power supply problem, check for low (990,000 through 2,070,000 Btu/hr Models only)
supply voltage or transformer output Post-purge : 30 seconds
less than 18VAC.
Six Flashes - Replace ignition module, internal fault. Pump Delay Timing : 30 Seconds after burner shutdown
(on boilers equipped with an optional, factory supplied
Access to Internal Control Panel pump delay or intermittent pump control system only).
The interior control panel is accessed by turning the mounting OPERATION AND DIAGNOSTIC
screw located at the bottom center of the exterior control panel. LIGHTS
Pull the panel out at the bottom and slide down to remove. The
300,000 BTU/HR MODELS
outer control panel has a Mylar label attached to the exterior surface
which indicates the function of each of the boiler’s indicating lights
OPERATIONAL/DIAGNOSTIC LIGHTS
and a clear window to view the digital temperature display from
the electronic temperature control. A typical wiring diagram is
attached to the inside surface of the exterior control panel. Removal
of the exterior panel reveals the interior control panel. The interior
control panel allows access to the individual indicating lights for
each stage of operation; the Status LED for control sensed
malfunctions from the ignition module (See Operation and
Diagnostic Lights); the manual ON/OFF power switch; the reset
button for a hard lockout condition from the ignition module (See
Ignition Module Lockout Functions); and the LCD display and 300,000 BTU Model
programming buttons for the electronic temperature control (See FIG. 39
Electronic Operating Temperature Control). The control panel
The control panel has an ON/OFF power switch and
assembly is mounted on a slide out chassis to allow easy access to
4 indicating lights to show operation and control
the components on the panel. Remove shipping bracket to slide
sensed malfunctions.

37
 TABLE — O TABLE — P
OPERATION and DIAGNOSTIC LIGHTS
Status LED Diagnostic Codes
Indicating Function
Light Code
Power On - Power switch in on position Sequence Condition
Flame Failure - Ignition module unable to
properly prove ignition
Indicating Light Function
Burner On - Burners operating
Trial for Ignition - Hot surface ignitor Power On -Power switch in on position
prepared to light burners. Prepurge -Operation of combustion
Low Air - Improper level of air fan before ignition
combustion air provided or Trial for Ignition 1 -Hot surface ignitor 1
a blockage in the flue. prepared to light burners.
990,000 through 2,070,000 Btu/hr Models Trial for Ignition 2 -Hot surface ignitor 2
prepared to light
990,000 - 2,070,000 burners.
BTU Models
Stage 1 On -Burners for stage 1
operating.
Stage 2 On -Burners for stage 2
operating.
Stage 3 On -Burners for stage 3
operating.
Stage 4 On -Burners for stage 4
FIG. 40 operating (if equipped).
Flame Failure 1 -Ignition module 1 unable
The control panel has an ON/OFF power switch and to properly prove
15 indicating and diagnostic lights to show all major ignition.
steps of operation and control sensed malfunctions. Flame Failure 2 -Ignition module 2 unable
to properly prove
NOTE:  It is normal for the Low Air ignition.
2 light to be illuminated when only Stage 1 is Low Air 1 -Improper level of
firing. The Low Air 2 light will turn off when combustion air provided
Stage 2 calls for heat, the second combustion by fan 1.
air fan turns on and the low air switch proves
Low Air 2 -Improper level of
proper operation.
combustion air provided
Interior Control Panel with Operation/ by fan 2.(See Note)
Diagnostic Lights, LCD Display and Reset Low Air 3 -Improper level of
combustion air provided
by fan 3 (if equipped).
STATUS STATUS
1 2

Blocked Flue -Improper operation of

flue (blockage).
Service -Improper operation of
optional device
(if equipped).
Status 1 - Remote status light for
ignition module #1
Status 2 - Remote status light for
FIG. 41 ignition module #2
38
 2. Location - Indoor boilers and hot water supply
IGNITION and CONTROL TIMINGS boilers must be located in a room having a
F-9 Proven Pilot Hot Surface Ignition Models - temperature safely above freezing [32° F(0° C)].
300,000 Btu/hr
Single Hot Surface Ignition Module 3. Caution - A mechanical room operating under a
Prepurge - 15 Seconds negative pressure may experience a down draft in
Hot Surface Ignitor Heat-up Time - 20- 45 the flue of a boiler which is not firing. The cold
seconds outside air pulled down the flue may freeze a heat
Main Burner Flame Establishing Period - 4 exchanger. This condition must be corrected to
Seconds provide adequate freeze protection.
Failure Response Time - 0.8 Seconds at 0.5 µA
flame current 4. Freeze protection for a heating boiler or hot water
Post-purge - 30 seconds supply boiler using an indirect coil can be provided
by using hydronic system antifreeze. Follow the
M-9 Proven Pilot Hot Surface Ignition Models manufacturers instr uctions. DO NOT use
990,000 through 2,070,000 Btu/hr undiluted or automotive type antifreeze.
Two Hot Surface Ignition Modules
Prepurge - 15 Seconds 5. Outdoor Boiler Installation - Adequate hydronic
Hot Surface Ignitor Heat-up Time - 20- 45 system antifreeze must be used. A snow screen
seconds should be installed to prevent snow and ice
Main Burner Flame Establishing Period - 4 accumulation around the boiler or its venting
Seconds system.
Failure Response Time - 0.8 Seconds at 0.5 µA
flame current 6. Shut-down and Draining - If for any reason, the
Time Delay Between Stages 1&2 and 3&4 - 15 boiler is to be shut off, the following precautionary
Seconds measures must be taken:
Post-purge - 30 Seconds (a) Shut off gas supply.
(b) Shut off water supply.
Pump Delay Timing - 30 Seconds after bur ner (c) Shut off electrical supply.
shutdown (on units equipped with an optional, (d) Drain the boiler completely. Remove one
factory supplied pump delay or intermittent pump threaded plug or bulb well from the inlet side
of the front header and one from the outlet side
control system only).
of the front header on the heat exchanger.
Blow all water out of the heater exchanger.
FREEZE PROTECTION (See Figure 29).
(e) Drain pump and piping.
Although these units are CSA International design
certified for outdoor installations - such installations
are not recommended in areas where the danger of
FREEZE PROTECTION FOR A
freezing exists. Proper freeze protection must be HEATING BOILER SYSTEM
provided for outdoor installations, units installed in (If Required)
unheated mechanical rooms or where temperatures may
1. Use only properly diluted inhibited glycol
drop to the freezing point or lower. If freeze protection
antifreeze designed for hydronic systems.
is not provided for the system, a low ambient
Inhibited propylene glycol is recommended for
temperature alarm is recommended for the mechanical
systems where incidental contact with drinking
room. Damage to the unit by freezing is non-
water is possible.
warrantable.
CAUTION !!
1. Pump Operation - MOST IMPORTANT - This
boiler is designed for continuous pump operation DO NOT use undiluted or automotive type
when the burners are firing. If the system pump attifreeze.
does not run continuously an additional pump must
2. A solution of 50% antifreeze will provide
be installed to provide constant circulation through
maximum protection of approximately -30° F.
the unit. This flow of warm boiler water can
help prevent freezing.
39
3. Follow the instructions from the antifreeze
WARNING:
manufacturer. Quantity of antifreeze required is
based on total system volume including The area around the burner viewport is hot and
expansion tank volume. direct contact could result in burns.

4. Glycol is denser than water and changes the Flame Pattern Illustration
viscosity of the system. The addition of glycol will
decrease heat transfer and increase frictional loss
in the boiler and related piping. A larger pump
with more capacity (15% to 25% more) may be
a. CORRECT FLAME b. YELLOW TIPS
required to maintain desired flow rates and prevent
a noise problem in a glycol system.

5. Local codes may require a back flow preventer

or actual disconnect from city water supply when
antifreeze is added to the system. c. YELLOW FLAME d. FLAME LIFT OFF

WATER TREATMENT FIG. 42

In hard water areas, water treatment should be used to

a. Normal Flame: A normal flame is blue, with
reduce the introduction of minerals to the system.
slight yellow tips, with a well defined inner
Minerals in the water can collect in the heat exchanger
cone and no flame lifting.
tubes and cause noise on operation. Excessive
build-up of minerals in the heat exchanger can cause a
b. Yellow Tip: Yellow tip can be caused by
non-warrantable failure.
blockage or partial obstruction of air flow to
the burner(s).
MAINTENANCE
c. Yellow Flames: Yellow flames can be caused
by blockage of primar y air flow to the
Listed below are items that must be checked to insure
burner(s) or excessive gas input. This condition
safe reliable operations. Verify proper operation after
MUST be corrected immediately.
servicing.
CAUTION !! d. Lifting Flames: Lifting flames can be caused
Label all wires prior to disconnection when by over firing the burner(s), excessive primary
servicing controls. Wiring errors can cause air or high draft.
improper and dangerous operation.
If improper flame is observed, examine the venting
system, insure proper gas supply and adequate supply
of combustion and ventilation air.
1. Examine the venting system at least once a year.
Check more often in f irst year to determine
3. Flue Gas Passageways Cleaning Procedures: Any
inspection interval. Check all joints and pipe
sign of soot around the outer jacket, at the burners
connections for tightness, cor rosion or
or in the areas between the fins on the copper
deterioration. Clean screens in the venting air
heat exchanger indicates a need for cleaning. The
intake system as required. Have the entire system,
following cleaning procedure must only be
including the venting system, periodically
performed by a qualified serviceman or installer.
inspected by a qualified service agency.
Proper service is required to maintain safe
operation. Properly installed and adjusted units
2. Visually check main burner flames at each startup
seldom need flue cleaning.
after long shutdown periods or at least every
six months. A burner viewport is located on the
All gaskets on disassembled components must be
left side of the boiler, below the water connections
replaced with new gaskets on reassembly. Gasket kits
on the front header.
are available from your distributor.

40
 k. Remove inner jacket panel mounting screws
BURNER REMOVAL and CLEANING
and slide burner/door assembly out toward front
a. Turn off main power to boiler. of the boiler. Use caution to prevent damage to
the refractory and hot surface ignitor.
b. Turn off main manual gas shutoff to boiler.
l. Check “V” baffles on top of heat exchanger.
c. Remove the front outer jacket panels. Remove and clean if necessary.

d. Disconnect manifold from gas train using m. Remove soot from heat exchanger with a stiff
union(s) just below each gas valve(s). bristle brush. Use a vacuum to remove loose
soot from surfaces and inner chamber.
e. Remove mounting screws from manifold
mounting brackets. Pull the manifold/orifice n. The heat exchanger can be removed by
assembly away from burners. Repeat for each disconnecting all water piping and sliding
manifold assembly on 990,000 Btu/hr and towards the front of the boiler. Once the heat
larger units. exchanger is removed from the boiler, a garden
hose can be used to wash the tubes to insure
f. Remove two mounting screws from burner that all soot is removed from the heat exchanger
and slide burner out toward front of boiler. Use surfaces. NOTE: Do not wet the boiler’s
caution to prevent damage to bur ners, refractory.
refractory, hot surface ignitor or wiring.
o. Insure that all burner ports are cleaned to
g. Remove soot from burners with a stiff bristle remove any soot. See Bur ner Cleaning
brush. Dirt may be removed from burner ports Procedure.
by rinsing the burner thoroughly with water.
Drain and dry burners before re-installing. p. Carefully reinstall the heat exchanger and “V”
Damaged burners must be replaced. baffles if removed from the boiler.

A unit installed in a dust or dirt contaminated q. Carefully reinstall inner jacket panels, burners,
atmosphere will require cleaning of the burners on a 3 manifolds, wires and hoses. Use new gasket
to 6 month schedule or more often, based on severity material to insure a proper air seal.
of contamination. Contaminants can be drawn in with
the combustion air. Non-combustible particulate matter r. Reassemble all gas and water piping. Test for
such as dust, dirt, concrete dust or dry wall dust can gas leaks.
block burner ports and cause non-warrantable failure.
Use extreme care when operating a boiler for temporary s. Reassemble outer jacket panels.
heat during new construction. The burners will
probably require a thorough cleaning before the boiler t. Cycle unit and check for proper operation.
is placed in service.
4. Combustion Air Fan: The combustion air fan
HEAT EXCHANGER CLEANING should be checked every 6 months. Clean fan as
required when installed in a dust or dir t
h. While burners are removed, check the heat contaminated location.
exchanger surface for sooting. If soot is
present, heat exchanger must be cleaned and 5. Water Circulating Pump: Inspect pump every 6
problem corrected. Proceed as follows. months and oil as necessar y. Use SAE 30
non-detergent oil or lubricant specified by pump
i. Remove gas manifold(s)/orifice assemblies as manufacturer.
described in steps a. through e. in “Burner
Removal.” 6. Keep boiler area clear and free from
combustible materials, gasoline and other
j. Disconnect wiring from hot surface ignitor(s) flammable vapors and liquids.
and hoses from burner pressure tap.

41
7. Check frequently to be sure the flow of combustion
COMBUSTION AIR ADJUSTMENT
and ventilation air to the boiler is not obstructed.
300,000 Btu/hr Model
8. This boiler uses a transformer to supply a low ADJUSTING SCREW
voltage control circuit. The voltage on the
secondary side should be 24 to 28 VAC when
measured with a volt meter. The 990,000 through
2,070,000 Btu/hr models have a 7 AMP circuit
breaker provided on the secondary side of the
transformer. A tripped circuit breaker indicates a
shor t in the 24VAC controls that must be
corrected.

9. Combustion Air Adjustment: This unit uses a

fan assisted combustion process. The 300,000 Btu/ FIG. 43
hr model has one combustion air fan, 990,000 through
2.070,000 Btu/hr models have multiple fans to 300,000 Btu/hr Models - Loosen the four (4) screws
supply combustion air to the burners. They are holding the air shutter in place. With the fan run-
factory pre-set and should not need adjustment in ning, slowly close the air shutter until the low air
most cases. The 300,000 Btu/hr model has a fan light comes on. Slowly open the air shutter until
located in the right side of the top chamber, the low air light goes off, plus an extra 1/8". Re-
990,000 thru 2,070,000 Btu/hr models have fans tighten the four (4) holding screws.
located left, center and right (if equipped) in the
top chamber. Units with three fans will not have a
low air light on the “right” fan until the low air
condition on the left and center fans have been Combustion Air Adjustment
corrected. It is normal for the Low Air 2 light to 990,000 - 2,070,000 Btu/hr Models
be illuminated when only Stage 1 is firing. Follow
the steps below to adjust fan if a continuous Low “A”
Air Light condition is observed:

a. Check for proper installation and draft in

venting system. Correct as required.

b. Single fan units hae one low air light. On

units with multiple fans, determine
which fan is to be adjusted by observing
ADJUSTING
the low air lights. On two fan units, Low SCREW

Air 1 indicates left fan and Low Air 2

indicates right fan. On three fan units,
Low air 2 indicates center fan and Low
FIG. 44
Air 3 indicates right fan.
990,000 through 2,070,000 Btu/hr Models -
c. Open the right top jacket panel to access The following is a recommended method for setting
the fan on single fan units. Remove the the differential air pressure (∆P) for each fan on
top front jacket panel (s) to access the models with multiple fans.
combustion air fans on units with multiple
fans. Beside each fan is a low air pressure switch with a
large and small tube delivering pressure from points
d. Fan air shutter adjustment: inside the unit. The positive pressure in the large
tube and the negative pressure in the small tube act
t og e t h e r t o m a k e t h e p r e s s u r e sw i t c h . B y
d i s c o n n e c t i n g t h e t u b e s f r o m t h e sw i t c h a n d

42
connecting them to either side of a manometer, you 2. Adjust the air shutter on the left fan until
can read the differential pressure to the switch. This the differential pressure is 1.35 inches water
procedure and the noted pressure requirements are column. (See Figure 44 for air shutter
for 990,000 through 2,070,000 Btu/hr models with adjustment procedure)
a serial number beginning at F001353.
3. Reconnect the wires to the fan on the right.
SETUP PROCEDURE: Connect the tubing from the matching low
air switch to either side of your manometer.
Remove the upper front jacket from the unit to
access the fan(s). Remove the electrical access door 4. Adjust the air shutter on the right fan until
under the gas train entrance to the jacket and locate the differential pressure is 1.35" w.c. Note:
the terminal strip below the gas train. Disconnect the left fan must be running as you set the
the wires or remove the jumper across terminals X right fan. Also, the DP of the left fan will
and B. This will interrupt the f iring process and increase above 1.35" w.c. with the right fan
allow the fans to run continuously without firing on. This is normal.
the main burner. Note: if the appliance has been
f iring recently, allow the appliance to cool for f ive 5. Once the adjustment procedure is complete,
minutes with the fans running before beginning the reconnect the tubing to the pressure
adjustment procedure. switches and check all tubing and wire
connections for snug f it. Reconnect wire
ADJUSTMENT PROCEDURE or jumper to the X and B terminals on the
terminal [Link] f ire the unit. Install
990,000 through 1,440,000 Btu/hr Models upper panel and access door.

Combustion Air Adjustment

ADJUSTMENT PROCEDURE
with a Manometer to set
Differential Pressure
1,800,000 and 2,070,000 Btu/hr Models
TEE

1. Remove the large and small black tubing

MANOMETER
from each pressure switch beside each fan.
Beginning with the fan on the far left,
connect these tubes to either side of your
manometer. Disable the fan on the right
PRESSURE
side by disconnecting the fan’s 2-pin molex
SWITCH plug (black & white wires).

2. Adjust the air shutter on the left fan until

TEE the differential pressure is 1.35 inches water
column. Then move the manometer to the
FIG. 45 tubing for the center fan; adjust the air
shutter o n t h e c e n t e r f a n u n t i l t h e
The connection on the manometer connects to differential pressure is 1.35" w.c. Go back
the tubing from the units front chamber and the to the left fan, check the pressure and, if
connection on the manometer connects to necessary, readjust the pressure to 1.35" w.c.
the tubing from the burner venturi. Note: you may need to sw i t c h b a c k a n d
forth between the left and center fan to f ine
1. Remove the large and small black tubing tune both to 1.35" w.c. (See Figure 44 for
from the pressure switch beside each fan. air shutter adjustment procedure)
Beginning with the f an on the far left,
connect these tubes to either side of your 3. Reconnect the wires to the fan on the right.
manometer. Disable the fan on the right side Connect the tubing from the matching low
by disconnecting the fan’s 2-pin molex air switch and connect to either side of your
plug (black & white wires). manometer.

43
 4. Adjust the air shutter on the right fan until
PIPING OF THE BOILER SYSTEM
the differential pressure is 1.35" w.c. Note:
the left and center fans must be running The drawings in this section show typical boiler
as you set the right fan. Also, the ∆P of p i p i n g i n s t a l l a t i o n s . B e f o r e b eg i n n i n g t h e
the left and center fans will increase installation, consult local codes for specif ic
above 1.35" w.c. with the right fan on. This plumbing requirements. The installation should
is normal. provide unions and valves at the inlet and outlet of
the boiler so it can be isolated for service. An air
5. Once the adjustment procedure is complete, s e p a r a t i o n d ev i c e m u s t b e s u p p l i e d i n t h e
reconnect the tubing to the pressure installation piping to eliminate trapped air in the
switches and check all tubing and wire system. Locate a system air vent at the highest point
connections for snug f it. Reconnect wire in the system. The system must also have a properly
or jumper to the X and B terminals on the sized expansion tank installed. Typically, an air
terminal strip. Test f ire the unit. Install charged diaphragm-type compression tank is used.
upper panel and access door. The expansion tank must be installed close to the
boiler and on the suction side of the system pump
GAS TRAIN AND CONTROLS to insure proper operation. Caution: this boiler
system should not be operated at less than 12
PSIG. Hot water piping must be supported by
Gas Train Drawing suitable hangers or floor stands, NOT by the boiler.
300,000 Btu Model Copper pipe systems will be subject to considerable
expansion and contraction. Rigid pipe hangers could
allow the pipe to slide in the hanger resulting in
noise transmitted into the system. Padding is
recommended on rigid hangers installed with a
copper system. The boiler pressure relief valve must
be piped to suitable floor drain. See the relief valve
section in the Installation and Service Manual.

CAUTION !!
FIG. 46 A leak in boiler “system” will cause the “system”
to intake fresh water constantly, which will cause
the tubes to accumulate a lime/scale build up.
Gas Train Drawing
This will cause a NON-WARRANTABLE
990,000 - 2,070,000 Btu Models
FAILURE.

WATER CONNECTIONS
HEATING BOILERS ONLY

The 300,000 Btu/hr boiler has 2" NPT inlet and

outlet connections. The 990,000-2,070,000 Btu/hr
input boilers have 2 1/2 " NPT inlet and outlet
FIG. 47 connections. Caution: f ield installed reducing
bushings may decrease flow resulting in boiler noise
or flashing to steam.
NOTE:  The gas train and controls CIRCULATOR PUMP
assembly provided on this unit have been tested
REQUIRMENTS
under the applicable American National
Standard to meet minimum safety and This is a low mass, high eff iciency hot water boiler
performance criteria such as safe lighting, which must have adequate flow for quiet, eff icient
combustion and safety shutdown operation. operation. Pump selection is critical to achieve
44
proper operation. A pump should be selected to
CIRCULATOR PUMP
achieve proper system design water temperature
rise. A heat exchanger head-loss chart (FIG. 48 &
SPECIFICATIONS
49) is provided to assist in proper pump selection.
Also provided is a System Temperature Rise Chart
(Table S). This table provides GPM and boiler 1. M a x i m u m o p e r a t i n g p r e s s u r e f o r p u m p
head-loss at various temperature rises for each must exceed system operating pressure.
boiler based on Btu/hr input. Temperature rise is
the difference in boiler inlet temperature and boiler 2. M a x i m u m wa t e r t e m p e r a t u r e s h o u l d n o t
outlet temperature while the boiler is f iring. exceed nameplate rating.
Example: The boiler inlet temperature is 160°F
(71°C) and the boiler outlet temperature is 180°F, 3. C a s t i r o n c i r c u l a t o r s m ay b e u s e d f o r
(82°C) this means that there is a 20°F (11°C) closed loop systems.
temperature rise across the boiler.
4. A p r o p e r ly s i z e d ex p a n s i o n t a n k m u s t b e
HEAT EXCHANGER PRESSURE installed near the boiler and on the
DROP CHART suction side of the pump.

Pressure Drop Chart CIRCULATOR PUMP OPERATION

300,000 Btu/hr Model (Heating Boilers Only)

The boiler pump should run continuously unless the

boiler is provided with the optional intermittent
pump or pump delay control system. These optional
pump control systems are available as factor y
installed options. These pump control systems
consist of a relay and a time delay wired into the
control circuit of each heating boiler. External wire
leads are furnished with this option to allow the
power supply for the pump to be switched across
the normally open contacts of the relay, allowing the
control relay to cycle the pump on each call for heat.
FIG. 48 The f ield installed boiler pump using the optional
factory supplied pump control system must not
exceed 10 AMPS at 120VAC. As shipped from the
factory, the optional control systems are is set to
Pressure Drop Chart
cycle the boiler pump on at each call for heat before
990,00 — 2,070,000 Btu/hr Models the burners f ire and run the pump for a 30
second period after the thermostat is satisf ied. This
will remove any residual heat from the combustion
chamber before turning the pump off. See wiring
diagram shipped with the unit.

PUMP INSTALLATION AND MAINTENANCE:

For installation and maintenance information on the
circulator pump, refer to pump manufacturers
instructions included in the instruction package.

FIG. 49

45
 PRIMARY/SECONDARY Primary/Secondary Piping
BOILER PIPING of Multiple Boilers
EXPANSION TANK
Primary/Secondary Piping MAKE-UP
WATER PRV
MAKE-UP of a Single Boiler LWCO
TO
WATER SYSTEM
(OPTIONAL)

SYSTEM
PUMP
PRV
AIR
12” SEPARATOR
EXPANSION TANK

TO
SYSTEM

LWCO FROM
(OPTIONAL) SYSTEM

SYSTEM SECONDARY
PUMP 12” SECONDARY BOILER PUMP FIG. 51
BOILER PUMP

AIR FROM FIG. 52 must be piped into the system at the time
SEPARATOR SYSTEM
FIG. 50
of installation. this piping is like a primar y/
Boiler installations with a primary/secondary piping secondary boiler installation with a bypass in the
system as shown in FIG. 50 are recommended. This secondary boiler pieping. Inlet water temperatures
type of system uses a dedicated pump to supply flow below 140°F (60°C) can excessively cool the heat
to the boiler only. This secondary pump is sized exchanger and in the flue. Condensation can cause
based on desired boiler flow rate, boiler head loss operational problems, bad combustion, sooting, flue
and head loss in the secondary system piping only. gas spillage and reduced service life of the vent
A properly sized system pump provides adequate system and related components. The bypass allows
flow to carry the heated boiler water to radiation, part of the boiler discharge water to be mixed with
air over coils, etc. The points of connection to the
CAUTION !!
primary system should be a maximum of 12" (or 4
pipe diameters) apart to insure connection at a point At no time should the system pressure be
of zero pressure drop in the primar y system. less than 12 PSIG.
Multiple boilers may also be installed with a
primary /secondary manifold system as shown in LOW TEMPERATURE
FIG. 51. The multiple boilers are connected to the BYPASS REQUIREMENTS
manifold in reverse return to assist in balancing flow
to multiple boilers. Boiler with Low Temperature
MAKE-UP
WATER Bypass Piping
The installer must insure that the boiler has adequate
flow without excessive temperature rise. Low
system flow can result in overheating of the boiler PRV
water which can cause short burner on cycles, EXPANSION TANK

system noise and in extreme cases, a knocking flash TO

SYSTEM
to steam. These conditions indicate the need to
increase boiler flow by installation of a larger
LWCO
circulator pump or the installation of a system (OPTIONAL)

bypass. System noise may also indicate an oversized

boiler.
SYSTEM
PUMP
12”
A boiler operated with an inlet temperature of less BY PASS SECONDARY
AIR BOILER PUMP
than 140°F (60°C) must have a bypass to prevent SEPARATOR
FROM
problems with condensation. A bypass as shown in SYSTEM
FIG. 52

46
the cooler boiler return water to increase the boiler
inlet temperature above 140°F (60°C). This should THREE WAY VALVES
p r eve n t t h e p r o d u c t s o f c o m b u s t i o n f r o m
condensing in most installations. The bypass should Boiler Piping with a 3-Way Valve
be fully sized with a balancing valve to allow for
SECONDARY
proper adjustment. A valve must also be provided BOILER PUMP
on the boiler discharge, after the bypass. Closing
this discharge valve forces water through the FROM
SYSTEM
EXPANSION PRV
bypass. Start boiler adjustment with the bypass TANK
valve in the full open position and the boiler
MAKE-UP
discharge valve half open. A small amount of the WATER
higher temperature boiler discharge water is mixed 12”

with the system water to maintain the desired lower

system temperature. A remote low temperature
range operator is recommended to control the boiler LWCO THREE-WAY
operation based on the lower system temperature. TO SYSTEM
(OPTIONAL) VLAVE
SLOW OPENING/
This remote operator should be wired across the R SLOW CLOSING
and W terminals (See Thermostat Connection and AIR
SEPARATOR
Terminal Strip instructions). SYSTEM PUMP FIG. 53
RADIANT FLOOR AND SNOW MELT
HEATING SYSTEMS
The installation of a three way valve on this boiler
This type of heating boiler application operates in is not generally recommended because most piping
a low temperature range which requires a boiler methods allow the three way valve to vary flow to
bypass as described under Low Temperature Bypass the boiler. This boiler is a low mass, high efficiency
requirements. A non-mettallic rubber or plastic unit which requires a constant water flow rate for
tubing installed in a radiant (in floor) system must proper operation. Low flow rates can result in
have an oxygen barrier to prevent oxygen from overheating of the boiler water which can cause
entering the system through the walls of the short burner on cycles, system noise and in extreme
installed tubing. Excessive oxygen absorption into cases, a knocking flash to steam. These conditions
the system will result in an accelerated rate of can cause operational problems and non-warrantable
corrosion causing a sludge buildup. This excessive failures of the boiler. If a three way valve must be
oxygen in the system can restrict water flow installed, please pipe in a primary/secondary system
resulting in a premature boiler failure. Any boiler as shown in FIG. 53. Based on boiler sizing and
damage due to excessive oxygenation is non- system flow requirements, this piping may still
warrantable. result in boiler short cycling.

TABLE — S
SYSTEM TEMPERATURE RISE CHART
Based on Btu Input
∆Τ ∆Τ ∆Τ ∆Τ ∆Τ ∆Τ
10º 20º 30º 40º 50º 60º
Input Output GPM [Link] GPM [Link] GPM [Link] GPM [Link] GPM [Link] GPM [Link]
300,000 252,000 51 5.2 26 1.3 17 0.6 13 0.6 10 0.6 9 0.5
990,000 831,600 166+ * 83 5.4 55 2.6 42 1.5 33 1.0 28 0.9
1,260,000 1,058,400 212+ * 106 * 71 4.4 53 2.7 42 1.7 35 1.2
1,440,000 1,209,000 242+ * 121+ * 81 6.3 61 3.8 48 2.3 40 1.8
1,800,000 1,512,000 303+ * 151+ * 101+ * 76 6.6 61 4.4 50 3.0
2,070,000 1,738,800 348+ * 174+ * 116+ * 87 9.0 70 6.2 58 4.6
+These flow rates exceed recommended flow rates of boiler. If these system temperature rises are used, an external piping
by-pass must be installed.
*These foot head calculations exceed the maximum allowable flow rate of the boiler.

47
 The installer must insure that the boiler is supplied
MAXIMUM REQUIRED FLOW
with adequate flow without excessive temperature
FOR HEATING BOILER rise. It is recommended that this boiler be installed
w i t h a by p a s s i n t h e p i p i n g i f t h e m a x i m u m
recommended flow rate is exceeded. The bypass
CAUTION !! will help to insure that the boiler can be supplied
The maximum flow rate through the boiler with adequate water flow. Flow rates exceeding the
with a copper heat exchanger must not exceed maximum recommended flow will result in erosion
the following: of the boiler tubes. A typical bypass with a valve
is shown in FIG. 54 will allow control of boiler flow.

Input-Btu/hr Maximum Flow TEMPERATURE/PRESSURE

300,000 60 GPM GAUGE
990,000 - 2,070,000 90 GPM This boiler is equipped with a dial type temperature/
pressure gauge. This gauge is factory installed in
the outlet side of the heat exchanger. The gauge
If higher flow rates are required through the boiler,
has one scale to read system pressure and a separate
a n o p t i o n a l C u p r o - N i c ke l h e a t ex c h a n g e r i s
s c a l e t o r e a d wa t e r t e m p e r a t u r e i n ° F. T h e
ava i l a bl e . C o n s u l t t h e f a c t o r y f o r s p e c i f i c
temperature/pressure gauge can be used to
application requirements.
determine temperature rise by f irst recording the
temperature of the boiler water with the boiler off.
The heat exchanger is generally capable of operating
Record the temperature of the boiler water as the
within the design flow rates of the building heating
boiler fires and the discharge temperature stabilizes.
system. Should the flow rate exceed the maximum
Subtract the boiler water temperature with the boiler
allowable flow rate through the boiler an external
off from the stable outlet water temperature with
bypass must be installed. The bypass should be fully
the boiler f iring. This temperature difference is the
sized with a balancing valve to allow for proper
temperature rise.
adjustment of flow. Flow rate can be determined
by measuring the temperature rise through the TYPICAL HEATING
boiler.
BOILER INSTALLATIONS

General Plumbing Rules

BOILER BYPASS REQUIREMENTS
1. Check all local codes.
2. For ser viceability of boiler, always install
Boiler Bypass Piping unions.
MAKE-UP
WATER
3. Always pipe pressure relief valve to an open
drain.
4. Locate system air vents at highest point of
system.
PRV EXPANSION TANK 5. Expansion tank must be installed near the
boiler and on the suction side of the pump.
TO
SYSTEM
6. Support all water piping.

LWCO PLACING THE BOILER

(OPTIONAL)
IN OPERATION
Filling the System: All air must be purged from the
SYSTEM
system for proper operation. An air scoop and air
PUMP vent must be located close to the boiler outlet and
AIR
there should be a minimum distance between the
SEPARATOR BY-PASS FROM cold water feed and the system purge valve.
VALVE SYSTEM FIG. 54

48
1. Close all drain cocks and air vents. 11. Recheck the water level in the expansion tank.
If it exceeds half the tank volume, open the tank
2. Open the makeup water valve and slowly f ill to reduce the water level. Recheck pressure
the system. charge on diaphragm type tanks.

3. If a makeup water pump is employed, adjust 12. Shut down the entire system and vent all
the pressure to provide a minimum of 12 psi radiation units and high points in the system.
at the highest point in the system. If a pressure
regulator is also installed in the line, it should 13. Close the water makeup valve and check the
be adjusted to the same pressure. s t r a i n e r a n d p r e s s u r e r e d u c i n g va l ve f o r
sediment or debris. Reopen the water makeup
4. Close all valves. Purge one circuit at a time valve.
as follows:
14. Verify system pressure with the boiler pressure
A. Open one circuit drain valve and let the gauge before beginning regular operation.
water drain for at least five minutes. Ensure
that there are no air bubbles visible in the 15. Within three days of startup, recheck and bleed
water stream before closing the drain valve. all air vents and the expansion tank using
these instructions.
B. Repeat this procedure for each circuit.
INSTALLATION WITH A
5. Open all valves after all circuits have been CHILLED WATER SYSTEM
purged. Make sure there are no system leaks.
FIG. 55
NOT[Link]  Do not use petroleum based
stop leak products. All system leaks must be
repaired. The constant addition of make-up
water can cause damage to the boiler heat
exchanger due to scale accumulation. Scale
reduces flow and heat transfer, causing
overheating of the heat exchanger.

6. Run the system circulating pump for a minimum

of 30 minutes with the boiler turned off.

7. Open all strainers in the system and check for Pipe refrigeration systems in parallel. Install duct
debris. coil downstream at cooling coil. Where the hot water
heating boiler is connected to a heating coil located
8. Recheck all air vents as described in step 4 in the air handling units which may be exposed to
above. refrigeration air circulation, the boiler piping system
must be equipped with flow control valves or other
9. Inspect the liquid level in the expansion tank. automatic means to prevent gravity circulation of
The system must be full and under normal the boiler water during the cooling cycle. The coil
operating pressure to insure proper water level must be vented at the high point and hot water from
in the expansion tank. Ensure that diaphragm the boiler must enter the coil at this point. Due to
type expansion tanks are properly charged and the fast heating capacity of the boiler, it is not
not water logged. necessary to provide a ductstat to delay circulator
operation. Also, omit thermostat flow checks as the
10. Start the boiler according to the “Start-Up boiler is cold when heating thermostat is satisf ied.
Instructions” in the Installation and Service This provides greater economy over maintaining
Manual. Operate the system, including the standby heat. (See FIG. 55)
pump, boiler and radiation units, for one hour.

49
 BOILER OPERATING Remove the jumper between the R and W terminals
on the terminal strip. Refer to the chart in this
TEMPERATURE CONTROL
section to determine maximum allowable length and
The operating temperature control for the 300,000 wire gauge recommended to connect the switching
Btu/hr model is located on the control panel, inside contacts of the remote thermostat to the R and W
of the top of the unit. The digital electronic terminals on the terminal strip. Connection to the
operating temperature control for the 990,000 thru terminal strip will allow the remote thermostat to
2,070,000 Btu/hr models is located in the front make and break the 24 VAC boiler control circuit
control panel, behind the front access door. The turning the boiler on and off based on the remotely
sensing element for the unit’s operator is placed in sensed temperature requirements. Set the boiler
a bulb well installed in the inlet side of the heat operating temperature control as a high limit when
exchanger front header. The operating sensor for the a remote thermostat or EMS is used as the operating
digital electronic temperature control may be remote control.
mounted in the system piping if required. See
“Remote Mounting of Sensor” instructions in this
manual. Carefully obser ve the discharge water
temperature on the initial boiler on cycles. The
location of the temperature sensor will generally
r e q u i r e a l owe r t e m p e r a t u r e s e t p o i n t o n t h e
operating control to achieve the desired discharge Terminal Strip
water temperature from the boiler. This sensing 300,000 Btu Models
element location allows a boiler operating with a
low to moderate flow rate to sustain longer burner
on cycles, preventing short boiler “ON” cycles
based on high discharge water temperatures. For
example, a boiler operating with a 180°F (82° C)
discharge and a 20°F (11° C) temperature rise would
require approximately a 160°F (71° C) to 165°F
(74° C) set point with the temperature sensor
installed on the inlet side of the heat exchanger. The
exact temperature set point is based on your system’s
requirements. Set the control set point(s) to the
desired operating water temperature. Observe the FIG. 56
boiler discharge temperature after each set point
adjustment to insure proper operation.

EMS or REMOTE
THERMOSTAT CONNECTION EMS Terminal Strip
TO TERMINAL STRIP 990,000 — 2.070,000 Btu Models

An EMS, remote thermostat or other remote

temperature control may be connected to the boiler.
Follow the manufacturers instructions supplied with
the remote thermostat for proper installation and
adjustment. The boiler is equipped with a terminal
strip to allow easy connection of a remote device.
The terminal strip on a 300,000 Btu/hr unit is
located on the control panel. The terminal strip on
a 990,000 thru 2,070,00 Btu/hr unit is located in
the electrical junction box, below the main gas
connection. Connection of a set of dry switching FIG. 57
contacts or a remote thermostat to the R and W
terminals will allow the unit to be switched on and
off by making and breaking the 24 VAC control
circuit.
50
 EXTERNAL ENERGY MANAGEMENT DOMESTIC HOT WATER
SYSTEM CONNECTION TO TERMINAL SUPPLY BOILERS
STRIP FOR CONTROL OF STAGE 300,000 and 990,000 - 2,070,000
Btu/hr Models
FIRING OF BURNERS ON 990,000 This section applies only to those units used to supply
THRU 2,070,000 BTU/HR MODELS potable hot water for domestic use. The hot water supply
boiler must be installed with a storage tank.
The 990,000 thru 2,070,000 Btu/hr models are
equipped with a factory installed terminal strip for
connection of a energy management system (EMS) This section contains specif ic instructions for those
to the burner stages. The EMS terminal strip is units used to supply domestic hot water. All
located in the unit’s junction box. The terminal strip warnings, cautions, notes and instructions in the
has up to three pairs of terminal connections for general installation and service sections apply to
operation of the 990,000 Btu/hr model and four pairs these instructions. Hot water supply boilers are
of terminal connections for operation of the designed for installation with a properly sized storage
1,260,000 thru 2,070,000 Btu/hr models. There is tank. The use of a properly sized pump and the
one pair of terminal connections for each stage of control of water velocity, as explained below, are
burner operation. Connection to these terminals important for correct operation of your water heater
requires a set of dry switching contacts to be used or hot water supply boiler.
for each stage of burner operation. The jumper
installed between the C and NO terminals of each
stage MUST be removed when making connection
to the EMS dry switching contacts for each stage.
The connection to the stages on the terminal strip WATER VELOCITY CONTROL
must always sequence on the stages in increasing
order (1,2,3,4) and sequence off in reverse order IMPORTANT:
To insure proper velocity
(4,3,2,1). Insure that all wiring used for connection through the heat exchanger, it is necessary to regulate
to this ter minal strip is properly sized per the the temperature rise across the heat exchanger from
recommendations in Table T. When connecting an inlet to outlet. This must be done on initial installation
EMS to this terminal strip to sequence on each stage and periodically rechecked. With the correct
of burner operation, the unit’s internal thermostat temperature rise across the heat exchanger, you may
or electronic sequencer should be set as an be assured of the proper velocity in the tubes. This
additional high limit control. This will prevent will yield long life and economical operation from
problems between the set points of the EMS and the your hot water supply [Link] lime build-up
in the tube is a result of too little velocity in the tubes.
boiler’s internal controller.
Excessive pitting or erosion in the tube is caused by
too much velocity through the tubes. Care should be
TABLE — T taken to measure temperature rise and maintain a
velocity as follows:
REMOTE WIRE CONNECTION
Wire Gauge Maximum Allowable 1. T h e p u m p m u s t r u n c o n t i n u o u s ly u n l e s s
Length equipped with a factor y supplied optional
i n t e r m i t t e n t p u m p c o n t r o l o r p u m p d e l ay
12 GA 100 ft
system.
14 GA 75 ft
16 GA 50 ft 2. With the pump running and the water heater or
18 GA 30 ft hot water supply boiler off, the inlet and outlet
thermometers should read the same
temperatures. If they do not, an adjustment
must be made to your f inal calculation.

51
3. Turn the water heater or hot water supply boiler
on and allow time for the temperature to
REQUIRED TEMPERATURE RISE
stabilize. Record the difference between the
inlet and outlet temperatures. This difference Based on heating potable water with a hardness of
will be the “temperature rise.” 5 to 25 grains per gallon and/or total dissolved
s o l i d s n o t ex c e e d i n g 3 5 0 p p m . S e e “ Wa t e r
4. Compare the temperature rise on the heater with Chemistry.”
t h e r e q u i r e d t e m p e r a t u r e r i s e i n Ta bl e U.
Should adjustment be needed, proceed as TABLE — U
follows: Btu/hr Temperature
Input Rise °F
If the temperature rise is too high, the water
velocity is too low. Check the following: 300,000 9°
990,000 19°
1. Check for restrictions in the outlet of the
water heater or hot water supply boiler. 1,260,000 24°
1,440,000 27°
2. Be sure all valves are open between the water 1,800,000 34°
heater or hot water supply boiler and the tank.
2,070,000 39°
3. C h e c k t h e p u m p t o b e s u r e i t i s r u n n i n g
properly and that the pump motor is running WATER CHEMISTRY
in the proper direction.

4. B e s u r e t h e i n s t a l l e d c i r c u l a t i o n p i p e s
between the water heater or hot water supply The required temperature rise and the standard pump
boiler and storage tank are not less than: 2" sizing are based on the heating of potable water with
diameter - for a single 300,000 Btu/hr unit; a hardness of 5 to 25 grains per gallon and a total
2 1/2 " Diameter - for a single 990,000 through dissolved solids not exceeding 350 ppm. Consult
2,070,000 Btu/hr unit the manuf acturer when heating potable water
exceeding these specif ications. Heating of high
5. Common manifold piping for multiple unit hardness and/or high total dissolved solids water
installations will require larger minimum pipe will require a larger circulating pump, an optional
sizes and tank circulating tappings to insure c u p r o - n i c k e l h e a t ex c h a n g e r a n d a r ev i s e d
proper flow. See Table V. temperature rise specif ication based on the water
chemistry of the water to be heated. Water with a
If the temperature rise is too low, the water hardness of less than 5 grains per gallon will usually
velocity is too high. Adjust as follows: have a low pH which can be aggressive and corrosive
causing non-warrantable damage to the heater, pump
1. Slowly throttle the valve on the outlet side of and associated piping. Corrosion due to water
the water heater or hot water supply boiler chemistry generally shows up first in the hot water
until the temperature rise is steady at the system because heated water increases the rate of
required temperature rise as noted in Table U. corrosive chemical reactions.

2. S u s t a i n e d h i g h wa t e r v e l o c i t y a n d l ow
temperature rise may result in pitting or erosion
of the copper tubes in the heat exchanger. This
is a non-warrantable failure. Temperature rise
m u s t b e p r o p e r ly a d j u s t e d t o a c h i eve t h e
specif ied flow rate.

52
 Typical Water Heater Piping PUMP OPERATION
with Storage Tank
COLD WATER 1. The water heater or hot water supply boiler must
HOT SUPPLY
WATER be connected to a properly sized pump that
SUPPLY EXPANSION TANK
(If Required) circulates water between the heater and storage
tank.
CIRCULATING
PUMP
RELIEF
VALVE
2. P u m p i s s i z e d t o h e a t e r i n p u t a n d wa t e r
hardness. Care should be taken to size pump
correctly. See “Water Chemistry.”
LOCK-TEMP
RELIEF
STORAGE
TANK VALVE
3. The pump must run continuously unless the
water heater or hot water supply boiler is
equipped with a factor y supplied optional
i n t e r m i t t e n t p u m p c o n t r o l o r p u m p d e l ay
system.

DRAIN BUILDING 4. L u b r i c a t e pump to manufacturers

RETURN
FIG. 58 recommendations. Pump damage due to
inadequate lubrication is non-warrantable.

COMMON WATER MANIFOLD 5. Standard water heaters or hot water supply

SIZE FOR MULTIPLE b o i l e r s a r e f u r n i s h e d w i t h t h e f o l l ow i n g
HOT WATER SUPPLY circulating pump to be mounted on the units
inlet water connection.
BOILLER INSTALLATIONS
300,000 Btu/hr Models
1/4 HP, 120 VAC, 5.8 Amp
Pipe sizing chart provides minimum pipe size for
common manifold piping to insure adequate flow 990,000 -2,070,000 Btu/hr Models
1/2 HP, 120 VAC, 7.4 Amp

TABLE — V This pump is sized based on installation of a

Number of Units Common Manifold single storage tank and heater in close proximity.
300,000 Size (Min) If the number of f ittings and straight pipe exceeds
Btu/hr the quantities shown in this section, a larger pump
will be required.
1 2"
2 3" The standard pump selection is based on the
3 3 1/2” following pipe and f ittings from the unit to the
4 4" storage tank:
5 5"
6 - 90 ° elbows 2 - ball valves
6 5" 2 - unions 1 - cold water tee
Number of Units Common Manifold Not more than 45 feet of straight pipe.
990,000 - 2,070,000 Size (Min)
Btu/hr For every elbow and tee in excess of those shown
above, DEDUCT 5 FEET from maximum allowable
1 2 1/2" straight pipe in heater to tank circulating loop.
2 4"
3 4"
4 5"
5 6"
6 6"
53
 FIG. 59 Water temperature over 125ºF can cause severe burns
instantly or death from scalds.

Children, disabled and elderly are at highest risk of

being scalded.

See instruction manual before setting temperature at

heating appliance.

Feel water before bathing or showering.

If this appliance is used to produce water that could

scald if too hot, such as domestic hot water use, adjust
the outlet control (limit) or use temperature limiting
valves to obtain a maximum water temperature of 125ºF.
See manual.

MINIMUM PUMP PERFORMANCE TEMPERATURE CONTROL

SETTINGS FOR
Based on heating potable water with a hardness of POTABLE HOT WATER
5 to 25 grains per gallon and/or total dissolved solids
not exceeding 350 ppm. See “Water Chemistry.”
Domestic Water Temperatures:
BTU/HR INPUT GPM Ft. Hd.
This high eff iciency hot water supply boiler should
300,000 55 10
be operated at a temperature setting high enough to
990,000 - 2,070,000 90 15 prevent condensing of the products of combustion
on the unit’s heat exchanger or in the attached
venting system. A minimum water temperature setting
HEAT EXCHANGER of 140° F (60°C) is recommended to keep flue products
from cooling to their dew point and condensing. Use
extreme caution when storing water at elevated
This is a highly sophisticated heat exchanger,
t e m p e r a t u r e s . A wa t e r t e m p e r a t u r e s e t t i n g
designed to car r y water in such a way that it
maintained above the dew point of the products of
generates a scouring action which keeps all interior
g a s c o m b u s t i o n s h o u l d p r eve n t c o n d e n s a t e
surfaces free from build-up of impurities. The
formation and insure proper performance of the
straight-line, two pass design of the tubes sends
venting system. A properly sized thermostatic mixing
water into the headers at a properly rated velocity.
valve MUST be used to supply domestic hot water at
The conf iguration of the headers, in turn, creates a
temperatures less than 140° F to prevent a risk of scald
high degree of turbulence which is suff icient to keep
injury. Storing the water at a higher temperature
all contaminants in suspension. This “scouring
and thermostatically mixing the water will increase
action” provides greater cost savings for owners.
the available quantity of mixed hot water, greatly
Tubes are always able to transfer heat at peak
reduce the possibility of condensate formation on
e ff i c i e n cy. E ve r y s u r f a c e w i t h i n t h i s wa t e r
the heat exchanger or in the venting system and help
containing section is of a non-ferrous material,
prevent the growth of water born bacteria.
providing clear, clean, rust-free hot water. Straight
copper tubes-f inned on the outside for maximum
heat transfer-coated cast iron one piece cored CAUTION!!
headers make up an entirely rust-proof unit. On all
Adequate care MUST be taken to prevent a
models, header inspection plugs can be removed for
potential scald injury when storing water at
f ield inspection and cleaning of copper tubes. The
elevated temperatures for domestic use.
entire heat exchanger may be easily removed from
the unit.
54
300,000 Btu/hr Models:
This unit is equipped with an adjustable immersion
DOMESTIC HOT WATER
thermostat to control potable water temperatures. TEMPERATUARES
The thermostat is adjusted to a low test setting when
shipped from the factory. Turn the temperature This unit has an adjustable temperature control to
adjustment knob to the desired setting that will maintain the desired water temperature set point.
supply hot water suitable for your application. See temperature adjustment procedure in the
When water is stored at temperatures above 130°F, general section of the manual for instructions to
(54°C) a ther mostatic mixing valve MUST be program the digital temperature control on 990,000
installed on the hot water outlet from the tank to through 2,070,000 Btu/hr models. The immersion
supply lower temperature water and prevent the risk thermostat or electronic control is factory pre-set
of a scald injury when supplying hot water for at approximately 125 o F (52°C) or less. Households
domestic use. with small children or invalids may require 120 o F
(40°C) or lower temperature hot water to reduce risk
990,000 through 2,070,000 Btu/hr Models: of scald injury. A thermostatic mixing valve MUST be
1. These units are equipped with an electronic used to provide domestic hot water at temperatures lower
operating temperature control. than 140° F (60°C). Some states may require a lower
water temperature setting for specif ic applications.
2. T h e e l e c t r o n i c c o n t r o l s e t p o i n t s a r e Check with local codes or your gas supplier for local
pre-programmed to a low test setting when s p e c i f i c a t i o n s g ove r n i n g t h e t e m p e r a t u r e
shipped from the factory. requirements for domestic hot water. Remember,
n o wa t e r h e a t i n g s y s t e m w i l l p r ov i d e ex a c t
3. Reprogram the temperature set points to the temperature at all times. Allow a few days of
lowest settings which will satisfy hot water operation at the settings you have programmed into
demands, eliminate a possible condensate the control to determine the correct temperature
problem and prevent a risk of scald injury. setting consistent with your needs.

4. The temperature set points for all stages should

NOTE:  (1) This water heater, when set
be set at the same temperature when supplying at a lower temperature setting, is not capable of
potable hot water for domestic use. producing hot water of sufficient temperature for
sanitizing purposes.
5. S t a g e f i r i n g i s a c h i eve d by s e t t i n g t h e (2) Higher stored water temperature increases the
differentials at approximately 3°F, 5°F, 7°F and ability of the water heater to supply desired
9°F for stages 1, 2, 3, and 4. Stage f iring of a quantities of hot water, however remember—
potable water heater should only be used to
replace system standby heat loss.
CAUTION !!
6. All stages of burner operation should fire when Hotter water increases the risk of scald injury.
there is a major draw from the potable hot water
s t o r a g e s y s t e m . T h i s p r eve n t s p o s s i bl e
c o n d e n s a t e p r o bl e m s a n d i n s u r e s a r a p i d Location of Cold Water Supply
recovery of the hot water used. Piping Connections

When water is stored at temperatures above 130°F, Incorrect piping of the cold water supply to the
(54°C) a ther mostatic mixing valve MUST be system may result in excessive low temperature
installed on the hot water outlet from the storage operation causing condensate formation on the heat
tank to supply lower temperature water and prevent the exchanger and operational problems. The cold water
risk of a scald injury when supplying hot water for supply piping must be installed in the discharge
domestic use. piping from the heater to the storage tank. This
allows the cold water to be tempered in the storage
CAUTION!!
tank before entering the heater. See FIG. 58 and
Setting the temperature selector to higher typical installation drawings provided with the unit
settings provides hotter water, which for correct piping. Higher water temperatures
increases the risk of scald injury. reduce condensate formation.

55
 WARNING: CATHODIC PROTECTION
Should overheating occur or the gas fail to shut Hydrogen gas can be produced in a hot water system
off, turn off or disconnect the electrical supply that has not been used for a long period of time
to the pump. Instead, shut off the gas supply (generally two weeks or more). Hydrogen gas is
at a location external to the appliance. extremely flammable. To prevent the possibility
of injury under these conditions, we recommend the
hot water faucet be open for several minutes at the
HIGH WATER TEMPERATURE
kitchen sink before you use any electrical appliance
LIMIT CONTROL which is connected to the hot water system. If
hydrogen is present, there will be an unusual sound
The unit is equipped with an adjustable setting, such as air escaping through the pipe as the hot
auto-reset high water temperature limit control. This water begins to flow. There should be no smoking
water heater or hot water supply boiler temperature or open flames near the faucet at the time it is open.
and limit control has a maximum limit setting 200°F
(93°). If water temperature exceeds the set point,
the limit will break the control circuit and shut down
the unit. The limit control will only be reset after
the water temperature has cooled below the set point
of the limit. The high water temperature limit
control is mounted in the outlet side fo the front
header. A manual reset high water temperature limit
control is available as an optional control.

OPTIONAL RELIEF VALVE

This water heater or hot water supply boiler is

normally supplied with a temperature and pressure
relief valve(s) sized in accordance with applicable
codes. Units may be supplied with an optional
pressure only relief valve(s). When a water heater
or hot water supply boiler equipped with this
optional relief valve is piped to a separate storage
vessel, the storage vessel must have a properly
installed temperature and pressure relief valve
which complies with local codes.

THERMAL EXPANSION

A relief valve which discharges periodically may

be due to thermal expansion in a closed system. A
hot water supply boiler installed in a closed system,
such as one with a backflow preventer or check valve
installed in the cold water supply, shall be provided
with means to control expansion. Contact the water
supplier or local plumbing inspector on how to
correct this situation. Do not plug or cap the relief
valve discharge!

56
 Component Location Drawing
300,000 Btu/hr Models

FIG. 61

Component Location Drawing

990,000 through 2,070,000 Btu/hr Models

FIG. 62

57
NOTES

58
NOTES

59
 CP—5M—5/01—Printed in U.S.A.
60