Lochinvar 000 - 500 Manual

Installation and service must be performed by a
qualified service installer, service agency or the gas
supplier.
Factory warranty (shipped with appliance) does not
apply to appliances improperly installed or improperly
operated.
Experience has shown that improper installation or
system design, rather than faulty equipment, is the
cause of most operating problems.
1. Excessive water hardness causing a lime
buildup in the copper tube is not the fault of
the equipment and is not covered under the
manufacturer’s warranty (see Water Treatment
and Water Chemistry).
2. Excessive pitting and erosion on the inside of
the copper tube may be caused by too much
water velocity through the tubes and is not
covered by the manufacturer’s warranty (see
Boiler Flow Rates and Temperature Rise for
flow requirements).
This manual supplies information for the installation,
operation and servicing of the appliance. It is strongly
recommended that this manual be reviewed completely
before proceeding with an installation.
Upon receiving equipment, check for signs of shipping
damage. Pay particular attention to parts accompanying
the appliance which may show signs of being hit or
otherwise being mishandled. Verify total number of
pieces shown on packing slip with those actually
received. In case there is damage or a shortage,
immediately notify carrier.
INSTALLATION AND SERVICE MANUAL
HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
45,000 - 500,000 Btu/hr MODELS
RSB-i&s-05
WARRANTY
SPECIAL INSTRUCTIONS TO OWNER
Note: Retain this manual for future reference.
Improper Installation, Adjustment,
Alteration, Service or Maintenance
can cause injury or property damage.
Refer to this manual. For assistance or
additional information consult a qualified
installer, service agency or the gas supplier.
WARNING
CHECKING EQUIPMENT
DO NOT Use this appliance if any part has been
under water. The possible damage to a flooded
appliance can be extensive and present numerous
safety hazards. Any appliance that has been under
water must be replaced.
If the information in this manual is not followed
exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
This appliance MUST NOT be installed in any
location where gasoline or flammable vapors are
likely to be present, unless the installation is such to
eliminate the probable ignition of gasoline or
flammable vapors.
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any
phone in your building.
• Immediately call your gas supplier from a
neighbors phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the
fire department.
• Installation and service MUST BE performed by
a qualified installer, service agency or the gas
supplier.
WARNING
This is a gas appliance and should be installed by a
licensed electrician and/or certified gas supplier.
Service must be performed by a qualified service
installer, service agency or the gas supplier.
IMPORTANT:

Warranty ..................................................................................1
Safety Warnings ......................................................................1
Codes ..................................................................................3
Location ..................................................................................3
Clearances................................................................................4
Combustion/Ventilation Air Requirements ............................4
Conventional Venting ..............................................................7
Masonry Chimney Installations ............................................10
Sidewall Venting....................................................................10
Automatic Vent Damper ........................................................11
Gas Supply ............................................................................12
Gas Pressures & Piping..........................................12
Manifold Pressure Adjustment ..............................15
Supply Pressure Measurement ..............................16
Gas Valves ............................................................................17
Relief Valve ..........................................................................18
Flow Switch ..........................................................................18
Electrical Connections ..........................................................19
Temperature Adjustment ......................................................20
Temperature Limit Control....................................................22
Blocked Vent and Flame Roll-Out System ..........................23
Lighting Instructions ............................................................24
Ignition & Control Timings ..................................................28
Freeze Protection ..................................................................28
Maintenance ..........................................................................29
Flame Patterns........................................................29
Inspection Cleaning Procedure ............................................30
Heat Exchanger/Burner Access ............................30
Inspection and Cleaning ........................................30
Gas Train................................................................................32
Heating Boiler ......................................................................32
Installation Requirements ......................................32
Pump Requirements ..............................................32
Pressure Drop Chart ..............................................33
Boiler Pump Operation ..........................................33
Typical Piping ........................................................33
Bypass Requirements ............................................33
Low Temperature Systems ....................................35
Boiler Flow Rates ..................................................35
Placing Boiler in Operation ..................................36
Temperature Rise Chart ........................................37
Boiler Temperature Control ..................................38
Remote Thermostat Control Connection ............................38
Power Venter Connection......................................................38
Domestic Water Heater..........................................................38
Water Velocity Control ..........................................39
Temperature Rise ..................................................39
Water Chemistry ....................................................40
Pump Operation ....................................................40
Risk of Scald Warnings..........................................42
Troubleshooting ....................................................................44
Wiring Diagrams ..................................................................46
Revision Notes ...................................................... Back Cover
The information contained in this manual is
intended for use by qualified professional installers,
service technicians or gas suppliers. Consult your
local expert for proper installation or service
procedures.
2
CONTENTS USER WARNING
Consult and follow local Building and Fire
Regulations and other Safety Codes that apply to
this installation. Consult your local gas utility
company to authorize and inspect all gas and flue
connections.
Should overheating occur or the gas supply fail to
shut off, do not turn off or disconnect the electrical
supply to the pump. Instead, shut off the gas supply
at a location external to the appliance.
To minimize the possibility of serious personal
injury, fire or damage to your unit, never violate the
following safety rules.
1.Boilers and water heaters are heat producing
appliances. To avoid damage or injury, do not
store materials against the appliance or the vent-
air intake system. Use proper care to avoid
unnecessary contact (especially children) with
the appliance and vent-air intake components.
2.Never cover your appliance, lean anything
against it, store trash or debris near it, stand on it
or in any way block the flow of fresh air to
your appliance.
3.UNDER NO CIRCUMSTANCES must
flammable materials such as gasoline or paint
thinner be used or stored in the vicinity of this
appliance, vent-air intake system or any location
from which fumes could reach the appliance or
vent-air intake system.
WARNING
WARNING
IMPORTANT
Your conventionally vented gas appliance must have
a supply of fresh air circulating around it during
burner operation for proper gas combustion and
proper venting.
IMPORTANT

The equipment shall be installed in accordance with
installation regulations in force in the local area where
the installation is to be made. These regulations shall
be carefully followed in all cases. Authorities having
jurisdiction shall be consulted before installations are
made. In the absence of such requirements, the instal-
lation shall conform to the latest edition of the National
Fuel Gas Code, ANSI Z223.1. Where required by the
authority having jurisdiction, the installation must
conform to American Society of Mechanical Engineers
Safety Code for Controls and Safety Devices for Auto-
matically Fired Boilers, ASME CSD-1. All boilers
conform to the latest edition of the ASME Boiler and
Pressure Vessel Code, Section IV. Where required by
the authority having jurisdiction, the installation must
comply with the Canadian Association Code,
CAN/CGA-B149.1 and/or B149.2 and/or local codes.
This appliance meets the safe lighting performance
criteria with the gas manifold and control assembly
provided as specified in the ANSI standards for
gas-fired appliances, ANSI Z21.13 and ANSI Z21.10.3.
FIG. 1 Typical (Front View) Cabinet Construction
FIG. 2 Typical Boiler (Rear View) Cabinet Construction
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 appliance. The pan
must not restrict combustion air flow. Under no
circumstances is the manufacturer to be held
responsible for water damage in connection with
this appliance, or any of its components.
2. The appliance must be installed indoors where it is
protected from exposure to wind, rain and weather.
3. The appliance must be installed so that the ignition
system components are protected from water
(dripping, spraying, rain, etc.) during appliance
operation and service (circulator replacement,
control replacement, etc.,).
4. Appliances located in a residential garage and in
adjacent spaces that open to the garage and are not
part of the living space of a dwelling unit must be
installed so that all burners and burner ignition
devices have a minimum clearance of not less than
18" (46cm) above the floor. The appliance must be
located or protected so that it is not subject to
physical damage by a moving vehicle.
5. DO NOT install this appliance in any location
where gasoline or flammable vapors are likely to
be present.
3
CODES
INSTALLATION PROCEDURE
LOCATION OF UNIT

Clearances from Combustible Construction:
Right Side - 6"
Rear - 6"
Left Side - 18" (24" suggested for service)
Front - 18" (24" suggested for service)
Top - (measured from the top of the unit)
45,000 - 180,000 Btu/hr Models - 14"
199,999 - 500,000 Btu/hr Models - 29"
All units have been approved for alcove installation (an
ALCOVE is a closet enclosure without a front door).
The boiler must not be installed on carpeting.
All units have been approved for use on combustible
surfaces.
Allow sufficient space for servicing pipe connections,
pump and other auxiliary equipment, as well as the
appliance.
FIG. 3 Clearances Models 45,000 - 180,000 Btu/hr
FIG. 4 Clearances Models 199,999 - 500,000 Btu/hr
Provisions for combustion and ventilation air must be in
accordance with Section 5.3, Air for Combustion and
Ventilation, of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment, or applicable provisions of
the local building codes.
The room where the appliance is installed MUST be
provided with properly sized openings to assure
adequate combustion air and proper ventilation when
the appliance is installed with conventional venting.
4
CLEARANCE FROM
COMBUSTIBLE CONSTRUCTION
29"
6"
18"
6"
18"
COMBUSTION AND VENTILATION AIR
REQUIREMENTS FOR
CONVENTIONALLY VENTED
APPLIANCES
18"
18"
6"
14"
6"

FIG. 5 Combustion Air Direct from Outside
1. If air is taken directly from outside the building
with no duct, provide two permanent openings:
a. Combustion air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5cm2per kW). This opening must be located
within 12" (30cm) of the floor.
b. Ventilation air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5cm2per kW). This opening must be located
within 12" (30cm) of the ceiling.
FIG. 6 Combustion Air Through Ducts
2. If combustion and ventilation air is taken from
the outdoors using a duct to deliver the air
to the room where the appliance is installed, each of
the two openings should be sized based on a
minimum free area of one square inch per
2000 Btu/hr (11cm2per kW).
FIG. 7 Combustion Air from Interior Space
3. If air is taken from another interior space that is
adequately ventilated, each of the two openings
specified above should have a net free area of one
square inch for each 1000 Btu/hr (22cm2per kW)
of input, but not less than 100 square inches
(645cm2).
FIG. 8 Combustion Air from Outside Single Opening
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 Btu/hr
(7cm2per kW). This opening must be located
within 12" (30cm) of the ceiling.
5

6
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. Table A lists the
requirements for the appliance only, additional gas fired
appliances located in the same 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 National Standard CAN B149.1 or B149.2. Check all
local code requirements for combustion air.
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 room
where the appliance is installed. Each opening must
have a net free area as specified in Table A. Single
openings shall be located within 12" (30 cm) of the
ceiling.
The combustion air supply must be completely free of
any flammable vapors that may ignite or chemical
fumes which may be corrosive to the appliance.
Common corrosive chemical fumes which must be
avoided are fluorocarbons and other halogenated
compounds, most commonly present as refrigerants or
solvents, such as freon, tricholorethylene,
perchlorethylene, chlorine, etc. These chemicals, when
burned, form acids which quickly attack the heat
exchanger finned tubes, headers, flue collectors, and the
vent system. The result is improper combustion and a
non-warrantable, premature appliance failure.
45,000 12 in215 in2100 in2
75,000 19 in225 in2100 in2
90,000 23 in230 in2100 in2
135,000 34 in245 in2135 in2
180,000 45 in260 in2180 in2
199,999 50 in267 in2200 in2
215,000 55 in274 in2224 in2
225,000 56 in275 in2225 in2
260,000 67 in289 in2269 in2
270,000 68 in290 in2270 in2
315,000 79 in2105 in2315 in2
360,000 90 in2120 in2360 in2
399,999 100 in2133 in2400 in2
500,000 125 in2167 in2500 in2
TABLE - A
MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY
Combustion Air Source
Input Outside Air/2 Outside Air/1 Inside Air/2
Btu/hr Openings Opening Openings
Under no circumstances should the room where
the appliance is installed ever be under a
negative pressure. Particular care should be
taken where exhaust fans, attic fans, clothes
dryers, compressors, air handling units, etc.,
may take away air from the appliance.
CAUTION

EXHAUST FANS: Any fan or equipment which ex-
hausts air from the room where the appliance is installed
may deplete the combustion air supply and/or cause a
down draft in the venting system, spilling flue products
into the room. Spillage of flue products from the
venting system into an occupied living space can cause
a very hazardous condition that must be corrected im-
mediately. If a fan is used to supply combustion air to
the room where the appliance is installed, the installer
must make sure that it does not cause drafts which could
lead to nuisance operational problems with the
appliance.
Vent installations for connection to gas vents or
chimneys must be in accordance with Part 7, “Venting
of Equipment,” of the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment or applicable provisions of
the local building codes.
Adequate combustion and ventilation air must be
supplied to the room where the appliance is installed in
accordance with the latest edition of the National Fuel
Gas Code, ANSI Z223.1, in Canada, the latest edition of
CGA Standard B149 Installation Code for Gas Burning
Appliances and Equipment, or applicable provisions of
the local building codes.
The distance of the vent terminal from adjacent
buildings, windows that open and building openings
MUST comply with the latest edition of the National
Fuel Gas Code, ANSI Z223.1, in Canada, the latest
edition of CGA Standard B149 Installation Code for
Gas Burning Appliances and Equipment.
Vent connection is made directly to the top of the
appliance. This appliance is designed with a built-in
draft diverter. No additional external draft hood is re-
quired. The connection from the appliance vent to the
common vent or chimney must be made as direct as
possible.
FIG. 9 Conventional Negative Draft Vertical Venting
The negative draft in a conventional vent installation
must be within the range of a negative 0.02 to 0.05
inches water column to ensure proper operation. All
draft readings are made while the appliance is in stable
operation (approximately 2 to 5 minutes).
Multiple appliance installations with combined venting
or common venting with other negative draft applianc-
es require that each appliance must have draft within
the proper range. If the draft measured above the
appliance’s built-in draft diverter exceeds the specified
range in a dedicated chimney for a single appliance
installation or in combined venting with other negative
draft appliances, a barometric damper must be installed
to control draft.
7
VENTING
A CONVENTIONAL NEGATIVE DRAFT
VENTING SYSTEM
Input Btu/hr Flue Size
45,000 4"
75,000 5"
90,000 5"
135,000 6"
180,000 7"
199,999 7"
215,000 7"
260,000 8"
315,000 8"
360,000 9"
399,999 10"
500,000 10"
TABLE - B
VENT PIPE SIZES

On a conventionally vented, negative draft appliance,
the connection from the vent to the chimney or vent
termination on the outside of the building MUST be
made with listed Type “B” double wall (or equivalent)
vent connectors and must be direct as possible with no
reduction in diameter. Use the National Fuel Gas Code
venting tables for double wall vent to properly size all
vent connectors and stacks. The Type “B” vent and
accessories, such as firestop spacers, thimbles, caps,
etc., MUST be installed in accordance with the
manufacturer’s listing. The vent connector and firestop
must provide correct spacing to combustible surfaces
and seal to the vent connector on the upper and lower
sides of each floor or ceiling through which the vent
connector passes.
Any vent materials used must be listed by a nationally
recognized test agency for use as vent material.
Locate appliance as close as possible to a chimney or
gas vent.
Avoid long horizontal runs of the vent pipe, 90° elbows,
reductions and restrictions. Horizontal portions of the
venting system shall be supported to prevent sagging.
Horizontal runs must slope upwards not less than 1/4
inch per foot (21 mm/m) from the appliance to the vent
terminal. Follow manufacturer’s instructions.
Do not use an existing chimney as a raceway for a flue
pipe if another appliance or fireplace is vented through
the chimney.
The weight of the venting system must not rest on the
appliance. Adequate support of the venting system must
be provided in compliance with local codes and other
applicable codes. All connections should be secured
with rustproof sheet metal screws.
Vent connectors serving appliances vented by natural
draft shall not be connected to any portion of a
mechanical draft system operating under positive
pressure. Connection to a positive pressure chimney
may cause flue products to be discharged into the living
space causing serious health injury.
Common venting systems may be too large when an
existing appliance is removed. At the time of removal
of an existing appliance, the following steps shall be
followed with each appliance remaining connected to
the common venting system placed in operation, while
other appliances remaining connected to the common
venting system are not in operation.
(a) Seal any unused opening in the common
venting system.
(b) Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restriction, leakage, corrosion
and other deficiencies which could cause an
unsafe condition.
(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 common venting system are located and
other 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 ex-
haust 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
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
(f) After it has been determined that each
appliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, fireplace dampers and other gas burning
appliances to their previous conditions of use.
(g) Any improper operation of the common
venting system should be corrected so that the
installation conforms to the latest edition of the
National Fuel Gas Code, ANSI Z223.1. In
Canada, the latest edition of CGA Standard
B149 Installation Code for Gas Burning
Appliances and Equipment. When resizing any
portion of the common venting system, the
common venting system should be resized to
approach the minimum size as determined
using the appropriate tables in Part 11 in the
latest edition of the National Fuel Gas Code,
ANSI Z223.1. In Canada, the latest edition of
CGA Standard B149 Installation Code for Gas
Burning Appliances and Equipment.
8

FIG. 10 Vent Termination from Peaked Roof 10’ or Less
from Ridge
FIG. 11 Vent Termination from Peaked Roof More Than 10’
from Ridge
The vent terminal should be vertical and exhaust
outside the building at least 2 feet (0.61m) above the
highest point of the roof within a 10 foot (3.05m) radius
of the termination. The vertical termination must be a
minimum of 3 feet (0.91m) above the point of exit.
A vertical terminal less than 10 feet (3.05m) from a
parapet wall must be a minimum of 2 feet (0.61m)
higher than the parapet wall.
FIG. 12 Vent Termination from Flat Roof 10’ or Less from
Parapet Wall
FIG. 13 Vent Termination from Flat Roof More Than 10’ from
Parapet Wall
The vent cap should have a minimum clearance of 4
feet (1.22m) horizontally from and in no case above or
below, unless a 4 foot (1.22m) horizontal distance is
maintained from electric meters, gas meters, regulators
and relief equipment.
The venting system shall terminate at least 3 feet (0.9m)
above any forced air inlet within 10 feet (3.05m).
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.
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.
9
VENTING TERMINATION
RIDGE
MORE THAN 10'
3' MIN
2' MIN
10'
CHIMNEY
NOTE:
NO HEIGHT ABOVE
PARAPET REQUIRED
WHEN DISTANCE
FROM WALLS OR
PARAPETS IS MORE
THAN 10’.
WALL OR
PARAPET
10’ OR MORE
3’
CHIMNEY

To avoid a blocked vent 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 vent condition. Flue gas condensate
can cause discoloration of exterior building surfaces.
Adjacent brick or masonry surfaces should be protected
with a rust resistant sheet metal plate.
A masonry chimney must be properly sized for the
installation of a gas fired appliance. Venting of an
appliance into a cold or oversized masonry chimney can
result in operational and safety problems. Exterior
masonry chimneys, with one or more sides exposed to
cold outdoor temperatures, are more likely to have
venting problems. The temperature of the flue gases
from an appliance may not be able to sufficiently heat
the masonry structure of the chimney to generate proper
draft. This will result in condensing of flue gases,
damage the masonry flue/tile, insufficient draft and
possible spillage of flue gases 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 gases. A
clay tile lined chimney must be structurally sound,
straight and free of misaligned tile, gaps between
liner sections, missing sections of liner or any signs
of condensate drainage at the breaching or clean
out. If there is any doubt about the condition of a
masonry chimney, it must be relined. An unlined
masonry chimney must not be used to vent flue
gases from this appliance. An unlined chimney must be
relined with an approved chimney liner system when a
new appliance is being attached to it. Metallic liner
systems (Type “B” double wall or flexible or rigid
metallic liners) are recommended. Consult with local
code officials to determine code requirements or the
advisability of using or relining a masonry chimney.
FIG. 14 Sidewall Venting with an Induced Draft Fan
This appliance is NOT approved for sidewall venting
with the negative draft venting system as shipped from
the factory. An induced draft fan MUST be used if the
installation requires that the flue gases be vented out a
sidewall. A properly sized and installed induced draft
fan may also be used to vent the flue gases vertically if
required by jobsite restrictions. The induced draft fan
must be listed by a nationally recognized test agency, be
properly sized and installed per the recommendations of
the induced draft fan manufacturer and meet local code
requirements. Use care to ensure that the mechanical-
ly supplied draft does not exceed the range of a
negative 0.02 to 0.05 inches water column to ensure
proper operation. If draft exceeds the specified range,
the fan must be adjusted or the installation of a baro-
metric damper in the flue may be required to properly
control draft. An induced draft fan MUST be
interlocked into the appliance’s control circuit to start
when the appliance calls for heat. The induced draft fan
MUST also be equipped with a proving switch,
properly interlocked into the appliance’s control circuit
to prove fan operation before the main burners are
allowed to fire. A vertical or sidewall vent termination
for an induced draft fan MUST be installed per the
recommendations of the fan manufacturer and provide
proper clearances from any combustion or ventilation
openings, windows, doors or other openings into the
building. All induced draft fan installations must
comply with local code requirements.
10
SIDEWALL VENTING
Examine the venting system at least once a year.
Check all joints and vent pipe connections for
tightness. Also check for corrosion or
deterioration. Immediately correct any problems
observed in the venting system.
IMPORTANT
MASONRY CHIMNEY
INSTALLATION

This heating boiler is design certified for use with the
automatic vent damper (FIG. 15) part number printed on
the boiler’s rating plate. A vent damper must be
installed on all residential heating boilers with inputs of
less than 300,000 Btu/hr to comply with minimum
efficiency requirements. A vent damper is factory
supplied with residential heating boilers with inputs of
45,000 thru 260,000 Btu/hr. A vent damper is optional
on all heating boilers above 260,000 Btu/hr. A vent
damper is available as an option on all water heaters.
The vent damper is a useful tool for saving energy when
installed inside the living space where air can
circulate freely around the appliance. The vent damper
will not save as much, if any, energy if it is installed in
locations such as:
-Unheated garage
-Attic
-Crawlspace
-Mechanical room that is vented outdoors
For installation and maintenance on the vent damper, refer
to the instructions supplied with the vent damper.
Residential heating boilers with inputs of less than
300,000 Btu/hr must have the vent damper properly
installed and the vent damper wire harness plugged into
the terminal block on the side of the control panel to
allow the boiler to function. Larger input heating
boilers and water heaters will have a jumper plug
installed in the terminal block to allow operation
without a damper. Remove the jumper plug from the
terminal block to connect an optional vent damper wire
harness. The jumper plug MUST be in place if an
optional vent damper is not used on water heaters and
larger input heating boilers.
Install the vent damper to service only the single
appliance for which it is intended. If improperly
installed, a hazardous condition such as an explosion or
carbon monoxide poisoning could result.
The damper position indicator must be in a visible
location with access for service following installation.
The damper must be in an open position when appliance
main burners are operating.
The part number for the automatic vent damper
required on this heating boiler is printed on the rating
plate. Vent damper regulations are design certified per
the latest edition of ANSI Z21.66.
FIG. 15 Vent Damper and Vent Damper Terminal Block
11
AUTOMATIC VENT DAMPER
Do not install the vent damper within 6" (152 mm)
of combustible materials.
CAUTION
The vent damper must be installed directly on the
flue outlet located on the top of the draft hood (see
Figure 15). Do not alter the wire harness supplied
with the vent damper. Follow the instructions
supplied with the vent damper.
WARNING
An appliance which is shut down or will not
operate may experience freezing due to convective
air flow down the flue pipe connected to the unit.
Proper freeze protection must be provided, see
Freeze Protection.
CAUTION

Verify that the appliance is supplied with the type gas
specified on the rating plate. This appliance is orificed
for operation up to 2000 feet altitude. The appliance
will be derated 4% per 1000 feet above 2000 feet eleva-
tion. Consult the factory for installations above 2000
feet elevation. Field conversions for operation at high
altitude must be performed by certified personnel only.
The appliance will be marked to indicate suitability for
high altitude operation.
GAS SUPPLY PRESSURE: Measured at the inlet
pressure tap located upstream of the combination gas
valve(s) see Figures 20 - 22, page 17.
Maximum inlet gas pressure must not exceed the value
specified. Minimum value listed is for the purposes of
input adjustment.
MANIFOLD PRESSURE: Measured at the pressure
tap on the downstream side of the combination gas
valve(s) (see Figures 20 - 22 on page 17). The gas
regulator settings for single stage and two stage
operation are factory set to supply proper manifold
pressure for normal operation. To check manifold
pressure, see Manifold Adjustment Procedure. Do not
increase manifold pressure beyond specified
pressure settings shown below in Table D.
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 PSIG (3.5kPa).
2. The appliance must be isolated from the gas
supply piping system by closing a manual
shutoff valve during any pressure testing
of the gas supply piping system at test
pressures equal to or less than 1/2 PSIG
(3.5kPa).
3. The appliance and its gas connection must
be leak-tested before placing it in operation.
1. Safe operation of the appliance requires
properly sized gas supply piping. See data
in Table E.
2. Gas pipe size may be larger than appliance
gas connection.
3. Installation of a union is suggested for ease
of service, see Figure 16 on page 14.
4. Install a manual main gas shutoff valve,
outside of the appliance gas connection and
before the gas valve or manifold connection,
when local codes require.
5. A trap (drip leg) MUST be provided by the
installer in the inlet of the gas connection to the
appliance, see Figure 16 on page 14.
6. The combination gas valve has an integral
vent limiting device and does not require
venting to atmosphere, outside the building.
12
GAS PRESSURE TEST
GAS CONNECTION
GAS SUPPLY
Nat. Gas LP Gas
Max. (Inches Water Column) 10.5 13
Min. (Inches Water Column) *4.5 11
Min. (Inches Water Column) **5.0 11
*Models 45,000 - 360,000 Btu/hr Only
**Models 399,999 - 500,000 Btu/hr Only
TABLE - C
GAS SUPPLY PRESSURE
Single and Two-Stage Two Stage
Btu/hr Full or High Fire Settings Low Fire Settings
Input Gas Natural Gas L.P. Gas Natural Gas L.P. Gas
45,000 3.5" 10" 0.9" 2.5"
75,000 2.4" 7" 0.9" 2.5"
90,000 - 180,000 3.5" 10" 0.9" 2.5"
199,999 2.9" 7.5" 0.9" 2.5"
215,000 - 399,999 3.5" 10" 0.9" 2.5"
500,000 3.5" 10" (two valves) N/A N/A
TABLE - D
MANIFOLD PRESSURE

7. Optional gas controls may require routing
of bleeds and vents to the atmosphere,
outside the building when required by local
codes.
13
Btu/hr DISTANCE FROM METER (In Feet)
INPUT 0-50 51 - 100 101 - 200 201 - 300 301 - 500
45,000 1/2" 1/2" 3/4" 1" 1 1/4"
75,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
90,000 1/2" 3/4" 1" 1 1/4" 1 1/4"
135,000 3/4" 1" 1 1/4" 1 1/4" 1 1/2"
180,000 1" 1" 1 1/4" 1 1/2" 1 1/2"
199,999 1" 1" 1 1/4" 1 1/2" 2"
215,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
260,000 1" 1 1/4" 1 1/4" 1 1/2" 2"
315,000 1 1/4" 1 1/2" 1 1/2" 1 1/2" 2"
360,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
399,999 1 1/4" 1 1/2" 2" 2" 2 1/2"
500,000 1 1/4" 1 1/2" 2" 2" 2 1/2"
For each elbow or tee, add equivalent straight pipe from Table F to total length .
TABLE - E
SUGGESTED GAS PIPE SIZE
SINGLE APPLIANCE INSTALLATIONS
Diameter Pipe (inches)
3/4 1 1 1/4 1 1/2 2 3 4 5
Equivalent length of Straight Pipe (feet)
2 2 3 4 5 10 14 20
TABLE - F
FITTINGS TO EQUIVALENT
STRAIGHT PIPE
45,000 - 135,000 1/2"
180,000 - 315,000 3/4"
360,000 - 500,000 1"
TABLE G
GAS CONNECTIONS

FIG. 16 Gas Line Connection
All gas connections must be made with pipe joint
compound resistant to the action of liquefied petroleum
and natural gas. All piping must comply with local
codes. Tubing installations must comply with approved
standards and practices. Reference Figure 16 for a
typical installation.
Install Piping to Control
1. The gas line should be a separate line direct
from the meter unless the existing gas line is of
sufficient capacity. Verify pipe size with your gas
supplier.
2. Use new, properly threaded black iron pipe free
from chips. If tubing is used, make sure the ends
are cut squared, deburred and clean. All tubing
bends must be smooth and without deformation.
Avoid flexible gas connections. Internal diameter
of flexible lines may not provide proper volume of
gas.
3. Run pipe or tubing to the gas valve or manifold
inlet. If tubing is used, obtain a tube to pipe
coupling to connect the tubing to the gas valve
or manifold inlet.
4. Thread pipe the proper amount for insertion into gas
valve or manifold inlet as shown in Table H.
DO NOT OVER TIGHTEN. Over tightening may
result in damage to the gas valves. Valve distortion
or malfunction may result if the pipe is inserted too
deeply into the gas valve.
5. Apply a moderate amount of good quality pipe
compound (DO NOT use Teflon tape) to pipe
only, leaving two end threads bare.
6. Remove seal over gas valve or manifold inlet.
7. Connect pipe to gas valve or manifold inlet. Use
wrench to square ends of the gas valve (FIG. 17).
14
Nominal
Iron Pipe Length of Pipe in Straight Feet
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
1 697 477 384 328 292 267 246 226 210 200 179 164 149 138
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 13.5 Inches Water Column
(0.5 PSIG) or less and a pressure drop of 0.5 Inch Water Column (Based on the calorific value of Natural Gas,
1025 Btu/ft3@ 0.60 Specific Gravity)
TABLE - H
MULTIPLE APPLIANCE INSTALLATIONS
GAS PIPING SIZE CHART
GAS PIPING

FIG. 17 Wrench
8. For L.P. gas, consult your L.P. gas supplier for
expert installation.
FIG. 18 Manifold Pressure Adjustment
1. Turn the power “OFF” at the main disconnect
switch.
2. Turn gas valve control knob to “PILOT” position
on standing pilot models. Ensure that the standing
pilot remains on. If the pilot goes out, follow the
“Lighting Instructions” for standing pilot models
to light the pilot. Turn gas valve control knob to
“OFF” position on spark ignition models.
3. Remove the 1/8" hex plug located on the outlet
side of the gas valve and install a fitting suitable to
connect to a manometer or magnahelic gauge. See
Figure 18. Minimum range of scale should be up
to 5" w.c. for Natural gas models and 10" w.c. for
L.P. gas models.
4. The 500,000 Btu/hr model will have two gas
valves with a pressure regulator on each valve.
Repeat the following adjustment procedure to set
the manifold pressure on each gas valve.
5. Remove pressure regulator adjustment cap screw
on the gas valve. See Figure 18 for location.
6. Turn the power “ON” at the main disconnect
switch.
7. Turn gas valve control knob to “ON” position.
8. Set the thermostat(s) to call for heat.
9. Observe gas regulator pressure when all burners
are firing. See Table D, Manifold Pressure for
proper regulator pressure settings.
10. If adjustment is necessary, turn regulator
adjustment screw clockwise to raise regulator gas
pressure, counterclockwise to lower gas pressure,
to proper setting. Note: Adjustment fitting is
plastic and may require slightly greater turning
force than a metal fitting.
11. Turn the power “OFF” at the main disconnect
switch.
12. Turn gas valve control knob to “PILOT” position
on standing pilot models. Turn gas valve control
knob to “OFF” position on spark ignition models.
13. Remove fitting from the gas valve and replace the
1/8" hex plug that was previously removed and
tighten.
15
Upon completion of any piping connections to the
gas system, leak test all gas connections with a soap
solution while system is under pressure.
Immediately repair any leaks found in the gas train
or related components. Do Not operate an
appliance with a leak in the gas train, valves or
related piping.
IMPORTANT
GAS MANIFOLD PRESSURE
ADJUSTMENT PROCEDURE
4
3
2
1
0
1
2
3
4
Manometer
Gas Valve
3.5"
Pressure Regulator Adjustment
(under cap screw)
Do not increase regulator pressure beyond specified
pressure setting.
NOTE:

14. Repeat the adjustment procedure for the second
gas valve on the 500,000 Btu/hr model.
15. Turn the gas valve control knob(s) to “ON”
position.
16. Turn the power “ON” at the main disconnect
switch. The appliance is now ready to operate.
If manifold pressure can not be properly adjusted, use
the following procedure to check gas supply pressure
with a manometer connected to the inlet pressure tap on
the gas control.
FIG. 19 Gas Supply Pressure
1. Turn the power “OFF” at the main disconnect
switch.
2. Turn gas valve control knob(s) to the “OFF”
position.
3. The 500,000 Btu/hr model will have two gas
valves. Turn the gas valve control knob on each
valve to the “OFF” position.
4. Shut off gas supply at the manual valve in the gas
piping to the appliance. If fuel supply is L.P. gas,
shut off gas supply at the tank.
5. Remove the 1/8" hex plug, located on the “inlet”
side of the gas valve and install a fitting suitable to
connect to a manometer or magnahelic gauge. On
two gas valve models, remove the hex plug from
the gas valve closest to the gas supply connection.
Range of scale should be 14" w.c. or greater to
check inlet pressure. See Figures 18 and 19 for
location.
6. Turn on gas supply at the manual valve, turn on
L.P. gas at tank if required.
7. Turn the power “ON” at the main disconnect
switch.
8. Turn gas valve control knob to “PILOT”
position on standing pilot models. Follow the
“Lighting Instructions” for standing pilot models
to light the pilot. Turn gas valve control knob to
the “ON” position when the pilot is established.
Turn gas valve control knob(s) to the “ON”
position on spark ignition models.
9. Set the thermostat(s) to call for heat.
10. Observe the gas supply pressure with all burners
firing. Ensure inlet pressure is within
specified range. Check gas supply pressure with all
other gas fired appliances in operation to ensure
proper gas volume during periods of peak gas
usage.
11. If gas pressure is out of range, contact gas utility,
gas supplier, qualified installer or service agency
to determine necessary steps to provide proper gas
pressure to the control.
12. If the gas supply pressure is within the specified
range, proceed with the following steps to return
the appliance to service.
13. Turn the power “OFF” at the main disconnect
switch.
14. Turn gas valve control knob to “PILOT” position on
standing pilot models. Turn gas valve control
knob(s) to “OFF” position on spark ignition models.
15. Shut off gas supply at the manual valve in the gas
piping to the appliance. If fuel supply is
L.P. Gas, shut off gas supply at the tank.
16. Remove the manometer and related fittings from
the “inlet” side of the gas valve, replace 1/8" hex
plug in gas valve.
17. Turn on gas supply at the manual valve, turn on
L.P. Gas at tank if required.
18. Turn the power “ON” at the main disconnect
switch.
19. Turn the gas valve control knob(s) to the “ON”
position. If the pilot is not burning, follow the
“Lighting Instructions” for standing pilot models to
light the pilot. Spark ignition models will automat-
ically light the pilot on a call for heat.
16
Gas Supply Pressure
Manometer
4
3
2
0
1
2
3
4
1
5
6
7
8
5
6
7
8
Gas Valve
CHECKING GAS SUPPLY PRESSURE

20. Set the thermostat to call for heat. The appliance
is now ready to operate.
Check burner performance by cycling the system while
you observe burner response. Burners should ignite
promptly. Flame pattern should be stable, see
“Maintenance-Normal Flame Pattern.” Turn system
off and allow burners to cool, then cycle burners again
to ensure proper ignition and flame characteristics.
FIG. 20 F1 Gas Valve 90,000 - 270,000 Btu/hr Models
FIG. 21 F9 Gas Valve 90,000 - 500,000 Btu/hr Models
FIG. 22 M9 Gas Valve 45,000 - 399,999 Btu/hr Models
Each unit has a combination gas valve(s) to control the
gas supply to the burners. The 500,000 Btu/hr model
has two combination gas valves to supply gas to the
burners. The combination valve consists of a gas
regulator and two valve seats to meet the requirements
for redundant gas valves. The valve has a gas control
knob that must remain in the open position at all times
when the appliance is in service. Each gas valve has
pressure taps located on the inlet and outlet sides.
Manifold pressure is adjusted using the regulator
located on the valve. The manifold pressure is preset at
the factory and adjustment is not usually required. If
the manifold pressure is to be adjusted, follow the “Gas
Manifold Pressure Adjustment Procedure”, page 15 for
proper adjustment.
Venting of Combination Gas Valves
The combination gas valve regulator used on all models
is equipped with an integral vent limiting orifice. The
vent limiter ensures that the volume of gas emitted from
the valve does not exceed the maximum safe leakage
rate allowed by agency requirements. Combination gas
valve/regulators equipped with integral vent limiters are
not required to have vent or relief lines piped to the
outdoors. A dust cap is provided at the vent termination
point on the valve to prevent blockage of the vent
limiter by foreign material. The combination gas valve
regulator with an integral vent limiter complies with the
safety code requirements of CSD-1, CF-190(a) as
shipped from the manufacturer without the installation
of additional vent lines.
17
Upon completion of any testing on the gas system,
leak test all gas connections with a soap solution
while main burners are operating. Immediately
repair any leak found in the gas train or related
components. Do Not operate an appliance with a
leak in the gas train, valves or related piping.
IMPORTANT
COMBINATION GAS VALVES
Pressure Regulator
Adjustment (under cap screw)
I
nlet
P
ressure
T
ap
Red Reset Button Gas Control
Knob
Pilot Outlet
Outlet Pressure Ta
p

FIG. 23A Relief Valve - Water Heater
FIG. 23B Relief Valve - Boiler
This appliance is supplied with a relief valve(s) sized in
accordance with ASME Boiler and Pressure Vessel
Code, Section IV (“Heating Boilers”). The relief
valve(s) is mounted directly into the heat exchanger
inside the header. To prevent water damage, the dis-
charge from the relief valve shall be piped to a suitable
floor drain for disposal when relief occurs. No reducing
couplings or other restrictions shall be installed in the
discharge line. The discharge line shall allow complete
drainage of the valve and line. Relief valves should be
manually operated at least once a year.
FIG. 24A Water Flow Switch Water Heater - Side Connections
FIG. 24B Water Flow Switch Boiler - Top Connections
A water flow switch is available as a factory supplied
option on all heating boilers and water heaters. The
flow switch should be wired between terminals X and
B. Remove the jumper between the X and B terminals
on the terminal strip. This wiring connection installs
the flow switch in the 24 VAC safety circuit to prove
water flow before main burner ignition. A flow switch
installed with the factory supplied minimum adjustment
setting requires a specific minimum flow to make the
switch and start burner operation. The minimum flow
requirement to actuate the switch is specified in Table I.
The flow rate required is a function of the diameter of
pipe and tee used for installation. Ensure that the pump
installed on the boiler or water heater will supply
adequate flow to make the flow switch contacts and
operate the boiler.
18
RELIEF VALVE
Avoid contact with hot discharge water.
CAUTION
WATER FLOW SWITCH (IF EQUIPPED)
RELIEF
VALVE
FLOW SWITCH
FLOW

A water flow switch meets most code requirements
for a low-water cut off device on boilers requiring
forced circulation for operation.
A hot water boiler installed above radiation level must be
provided with a low water cutoff device either as part of
the unit or installed at the time the boiler is installed. An
electronic low water cutoff is available as a kit on all
units. Low water cutoffs should be inspected every six
months, including flushing of float types.
The 45,000 thru 500,000 Btu/hr boilers (M9) are
equipped with a two stage burner control system. The
45,000 thru 399,999 Btu/hr models will be equipped
with a two stage gas valve to control high/low burner
operation. The 500,000 Btu/hr model achieves two
stage burner firing by staging the operation of the two
combination gas valves.
This appliance is wired for 120 VAC service. The
appliance, when installed, must be electrically
grounded in accordance with the requirements of the
authority having jurisdiction or in the absence of such
requirements, with the latest edition of the National
Electrical Code ANSI/NFPA No. 70. When the unit is
installed in Canada, it must conform to the CSA C22.1,
Canadian Electrical Code, Part 1 and/or local Electrical
Codes.
1. All wiring between the appliance and field
installed devices shall be made with type T wire
[63° F(35° C) rise].
2. Line voltage wire exterior to the appliance must be
enclosed in approved conduit or approved metal
clad cable.
3. The pump must run continuously when the
appliance is being fired.
4. To avoid serious damage, DO NOT energize the
appliance until the system is full of water.
Serious damage may result.
5. Provide the unit with proper overload protection.
6. Install a wall thermostat on the inside wall. DO
NOT install the thermostat in an area affected by
drafts, sunlight, light fixtures, hot or cold water
pipes or near a fireplace. See “Terminal Strip Con-
nection of a Room Thermostat”, page 38 for proper
wiring connection.
Pump Wiring for a Heating Boiler
The heating boiler circulating pump must be purchased
locally. The maximum load for the pump switched by
the internal pump relay must not exceed 1 HP. The
current draw for a field installed 120 VAC pump MUST
be added to the boiler’s current draw to determine the
minimum wire size for 120 volt service.
FIG. 25 Standing Pilot System F1 Control Panel
19
Pipe Size GPM Flow Rate
1 1/2" 13
2" 18
TABLE I
MINIMUM FLOW RATE REQUIRED TO
ACTUATE FLOW SWITCH
LOW WATER CUTOFF (IF EQUIPPED)
TWO STAGE BURNER
CONTROL SYSTEM
ELECTRICAL CONNECTIONS
MAXIMUM
FIRING TOTAL AMPS
CONTROLS @ 120 VAC
F1 Standing Pilot (Single Stage
90,000 - 260,000 Btu/hr) 2.5
F9 Intermittent Pilot (Single Stage
90,000 - 399,999 Btu/hr) 2.5
F9 Intermittent Pilot (Single
Stage/2 valves 500,000 Btu/hr) 2.5
M9 with Internal Pump
(45,000 - 260,000 Btu/hr) 2.0
M9 Intermittent Pilot (Two Stage
Valve 315,000 - 399,999 Btu/hr) 2.0
M9 Intermittent Pilot (Two Stage/2
valves 500,000 Btu/hr) 2.0
TABLE J
AMP DRAW DATA
45,000 thru 500,000 Btu/hr Models

FIG. 26 Intermittent Pilot System F9/M9 Control Panel
FIG. 27 Control Panel Assembly 500,000 Btu/hr
Operating Temperature Control
Locating Temperature Control
Remove the control panel door on the front of the unit in
order to locate and access the temperature control.
Temperature Control Settings
There are three setting knobs on the temperature control
unless your unit is specified as a boiler only with an
outdoor air reset option. If your unit is a boiler only with an
outdoor air reset option, there are additional controls for
this option. They are explained under Outdoor Air Reset
Option, page 22.
The three setting knobs on the temperature control are for
Set point, Differential, and High-Fire Offset (see
Figure 28).
FIG. 28 Temperature Control
Maximum Set Point Determination
The maximum set point for the control is factory set.
Boilers can be set to 240°F max., water heaters are set to
190°F max., and specialty state and local codes to 200°F.
These maximum set points are established by cutting the
OJ1 and OJ2 jumpers located on the right side of the
temperature controller. The maximum set point is
determined as shown below in TABLE-K.
20
TEMPERATURE ADJUSTMENT
The temperature controller is pre-set at the factory with
test settings. You may need to adjust the settings to meet
your specific needs.
Return water temperatures must not be less than
140°F. If lower return water temperatures are
required, follow the instructions for Low
Temperature Bypass Requirements or Three-Way
Valves, see page 35.
WARNING
Max.
OJ1 OJ2 Set Point
Connected Connected 240°F
Cut Connected 190°F
Connected Cut 200°F
Cut Cut 160°F
TABLE K
Maximum Set point Determination
Anytime that OJ1 is the only jumper cut, a new
overlay is required under the Set Point knob on the
temperature controller because the scale has changed
to a maximum of 190°F.
Anytime the OJ2 jumper is cut (with or without OJ1),
a new overlay is required under the Set Point knob on
the temperature controller because the scale has
changed to a maximum of 200°F.
NOTE:
NOTE: