Trianco Heatmaker H Series User manual
Heatmaker H, HP and HW
Operating, Installation
& Maintenance Instructions
TRIANCO
HEATMAKER
THIS UNIT MUST BE INSTALLED IN ACCORDANCE WITH STATE AND
LOCAL CODES BY A QUALIFIED INSTALLER.
To the Installer: After installation these instructions must be given to the homeowner or left
on or near the boiler.
To the Homeowner: This booklet contains important information that will help you in
maintaining and operating this boiler. Please retain it for future reference.
HW-M2 Series H-M2 Series HP-M2 Series
HW-M2-130 H-M2-130* HP-M2-130*
HW-M2-100 H-M2-100 HP-M2-100
HW-M2-60 H-M2-60 HP-M2-60
Integrated Hydronic Heating Hydronic Heating Only Hydronic Heating Only
and Domestic Hot Water Appliance For Natural or Propane Gas. For Natural or Propane Gas
For Natural or Propane Gas. (Wall Hung).
*Field conversion only.
Figure 1. HW-M2.
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INSTALLATION
Introduction .......................................................... 2
Schematic Diagram HW - M2 - Series .................. 2
Schematic Diagram H(P) - M2 - Series .................3
Unpacking ............................................................3
Venting Options ................................................... 4
Horizontal / Vertical Venting................................. 6
Direct Venting & Air Source...................................8
Gas & Domestic Water Piping .............................. 9
Hydronic Heat Piping ........................................... 10
Electrical Connections ..........................................13
HP Installation ......................................................14
Modular Home Installation ....................................16
Check, Test & Start Up .........................................17
Maintenance ........................................................ 18
SERVICE
Cleaning Combustion Chamber Coil ................ 19
Boiler Components Descriptions ...................... 19-21
Domestic Water Coil Replacement .................. 21
Tank Replacement .......................................... 21
Delayed Ignition .............................................. 22
Noisy Operation .............................................. 22
High Gas Consumption ................................... 23
Insufficient Hot Water ..................................... 23
Short Cycling ................................................. 23
Cross Contamination ....................................... 24
Lock Outs ...................................................... 24
Sequence of Operation ................................... 25
Trouble Shooting Flow Charts ......................... 26-32
Parts List & Order Information ......................... 33
Electrical Diagrams ......................................... 36-37
HW-SERIES
Model HW(D)-M2-130, HW(D)-M2-100, HW(D)-M2-60
H(P)-SERIES
Model H-M2-130, H-M2-100, H-M2-60.
The HEATMAKER MARK II boiler is a low pressure, hot water
boiler that is available in two (2) design configurations. The
HW series provides domestic hot water as well as hydronic
space heating. It includes an insulated storage tank through
which boiler water is circulated. A heat exchanger within the
tank transfers heat from the boiler to the domestic hot water.
The H and "HP" series boilers are designed to provide hot
water for space heating, and can be plumbed to an indirect
water heater to supply domestic hot water.
By replacing the air and the gas orifices, the basic Heatmaker
boiler has the flexibility to operate on either natural or LP gas
and may be fired at 60,000, 100,000 or 130,000 BTU/HR input.
The Heatmaker can be direct vented by utilizing an optional
concentric vent system that will provide outside air for com-
bustion. H(W)(P)-60,100 & 130 appliances may also be
vented with 3" or 4" diameter stainless steel horizontal /
vertical venting as described on page 6. The maximum length
shall not exceed 50 equivelant feet of 3" diameter or 100
equivelant feet of 4" diameter. H(W)(P)-M2-130 appliances
may also be connected to a lined internal chimney.
The Heatmaker features a forced draft, pre-mixed combus-
tion system. All air for combustion is supplied with the gas to
the burner (flameholder). Both the intake air and the gas are
metered through separate orifices before entering the com-
bustion air blower. The blower forces the air/fuel mixture
through the flameholder and into the combustion chamber.
The mixture is ignited from the hot surface igniter and burns.
Hot gases are forced out between the passes of the heat
exchanger into the flue collector. Flue gases are discharged
into the outside atmosphere through the vent terminal, a
chimney, horizontal or vertical alternate vent.
Model H(W)-M2-60 & H(W)-M2-100 UNITS MUST NOT BE
CHIMNEYCONNECTED.
INSTALLATIONS WITH WATER CONTAINING 10 GRAINS OF
HARDNESS OR HIGHER, MUST BE INSTALLED WITH APPROPRIATE
WATER TREATMENT.
INTRODUCTION
TO THE INSTALLER : BEFORE YOU BEGIN
The Heatmaker is uniquely different from any heating boiler
you have installed in the past. It is important for you to take a
few minutes to review the contents of the Installation and
Operating section of this manual before you begin installa-
tion. This will avoid making mistakes and causing confusion
when installing and operating the unit.
1. Gas Burner*
2. Sealed Combustion* w/ P/N 2400-236 or 2400-238
3. Outside Vent Wall*
4. Outside Air For Combustion*
5. Copper Coil Heat Exchanger*
6. Thermostatic Union (H-M2)
7. Domestic Hot Water Coil (HW(D)-M2)*
8. Heating System Water Outlet
9. Heating System Water Return
10. Gas Supply
*See Figure 1
Figure 2. H-M2.
ï
All vent installations must be made in accordance with:
1). Part 7, Venting of Equipment of the National Fuel Gas
Code, ANSI 223.1- latest edition, or applicable provisions
of the local building codes or
2). CAN/CGA - B149
When required by the jurisdiction authority, the installations
must conform to the American Society of Mechanical Engi-
neers Safety Code for Controls and Safety Devices for
Automatically fired Boilers, No. CSD-l.
UNPACKING THE HEATMAKER
a. Remove all packing and tie down materials.
b. On HW models, remove three (3) shipping bolts from
underside of base.
c. Make immediate claims ( to carrier ) if unit is damaged.
LOCATING THE HEATMAKER
The Heatmaker design is certified by the AGA and CGA for
installation on combustible flooring, in alcoves, basements,
closets, or utility rooms. It must not be installed on carpeting.
IF INSTALLED IN A FINISHED AREA, PROVISION SHOULD
BEMADEFOR DRAINAGEOFANY ACCIDENTALSPILLAGE
ORLEAKAGE.
The location for the unit should be chosen with regard to
venting dimensions, convenient access to piping, ventilation
of operating components and accessibility for service and
cleaning.
The boiler shall be installed so that the gas ignition system
components are protected from water (dripping, spraying,
rain, etc.) during appliance operation or service (circulator
replacement, control replacement, etc.).
CLEARANCES
The following dimensions and criteria should be followed
when choosing the location for the unit:
CODES & STANDARDS
All installations must be made in accordance with:
1). the National Fuel Gas Code, ANSI Z223.1 - latest edition
or
2). CAN/CGA - B149 Installation Codes for Gas Burning
Appliances and Equipment
or with the requirements of the local utility or other authorities
having jurisdiction. Such applicable requirements take pre-
cedence over the general instructions contained herein. All
electrical wiring is to be done in accordance with 1). the
National Electrical Code ANSI/NFPA70-latest edition or 2). the
CSA standard C22.1 Canadian Electrical Code - Part 1 and
local codes.
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A. Minimum clearance from combustible construction to
meet AGA/CGA requirements.
B. Recommended clearance for accessibility and
venting.
A. B.
AGA/
CGA AGA CGA
Left Side 1" 6" 24"
Right Side (controls) 1" 12" 24"
Top 1" 14" 16"
Back 1" 9" 12"
Front 1" 24" 24"
Vent: Direct Vent 0" 0"
Chimney Connect 6" 6"
Alternate 3" 3"
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LOCATING UNIT WITH
RESPECT TO VENTILATION
While the Heatmaker, when direct vented, requires no interior
air for combustion, adequate airflow around the unit and to the
enclosed room must be provided for proper cooling of elec-
trical components.
CHIMNEY VENTING
(USA Only)
Model H(W)-M2-130 is a category l boiler and may be vented
in chimneys subject to the following requirements:
Model H(W)-M2-60 and H(W)-M2-100 MUST NOT BE CHIM-
NEY OR B-VENT CONNECTED.
A. Chimney must be internally lined or B vent type. External
or unlined chimneys may serve as a chase for utilization of
stainless steel alternative venting providing no other equip-
ment is vented into it, or the chimney may have an approved
liner installed into the flue.
B. Two (2) or more vent connectors, from either power or
natural draft units, may enter a common gas vent providing
they conform to the requirements and tables of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54- latest edition, or
applicable provision of the local building code. None may be
connected to equipment with a positive vent pressure.
C. Locate unit as close to chimney as possible for shortest
vent connector.
INSTALLATION
Determine height of chimney or B-Vent and length of lateral
run. Select vent connector diameter from:
1). Table 1 or 2 of the National Fuel Gas Code, ANSI Z223.1
/ NFPA 54- latest edition (see excerpts), or
2). Table G-3 of the Can /CGA - B149 Installation Code.
Install an adaptor at the flue outlet of the unit to step up to the
diameter of the vent connector. Install elbow for vent connec-
tor, if required. This elbow should be full size of the vent
connector. DO NOT install a three (3) inch elbow between the
flue outlet on the unit and the adaptor. DO NOT use plastic vent
pipe in any part of the chimney vent connection.
Install vent connector between elbow, if used, and chimney.
Pitch vent connector up toward chimney ¼" per foot of lateral
run. Secure all joints with sheetmetal screws.
ALTERNATE VENTING METHOD
(Canada Only)
The Heatmaker may be vented vertically up thru a masonary
chimney using a 4" diameter ULC Certification Flexible Stain-
less Steel Vent.
Observe the following requirements:
1). The flexible vent must be run from the boiler up thru the
entire chimney.
2). The chimney must terminate with a suitible vent cap.
3). If chimney is exposed, the vent pipe should be insulated.
4). The vent pipe must be installed with a ¼" per foot upward
slope from the boiler to the chimney.
5). The vent pipe must be supprted every 3' to prevent
sagging.
6). All joints in the vent must be secured with at least two
corrosion resistant screws and sealed with an approved
silicone sealant and checked for gas tightness.
7). The vent system should be checked once a year by a
qualified serviceman.
Note: Boiler may not be vented in common with another gas
appliance or be vented using B-vent.
3.5" deep
Figure 4. H-M2.
SUPPLY
DOMESTIC
RETURN
Figure 3. HW-M2.
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Table 1. Table 2.
Height Lateral
Vent and Connector Diameter (A & D)
4" 5" 6"
Appliance Rating in MBH
H L Fan Assist Fan Assist Fan Assist
(ft) (ft) Min Max Min Max Min Max
6
059 151 85 249 126 373
2 85 156 123 231
4 102 152
6 114 147
8
0 58 164 83 273 123 412
2 59 108 83 176 121 261
5 77 102 107 168
8 122 161
10
0 57 174 82 293 120 444
2 59 117 82 193 119 287
5 76 111 105 185
10 97 100
15
0 56 190 80 325 116 499
2 57 136 80 225 115 337
5 75 128 102 216
10 95 116 128 201
20
0 54 200 78 346 114 537
2 56 148 78 248 113 375
5 73 140 100 239
10 93 129 125 223
30
0 53 211 76 372 110 584
2 55 164 76 281 109 429
5 72 157 98 271
10 91 144 122 255
15 115 131
Capacity of Type B Double-Wall Vents with Single Wall
Metal Connectors Serving a Single Catagory I Appliance.
NOTE: TABLES APPLY TO MODEL H(W)-M2 130
(CATAGORY 1) APPLIANCES ONLY.
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Capacity of Masonary Chimney Flue with Type-B Double
Wall Flue Connector Serving a Single Category Appliance.
Height Lateral
Type B Double Connector Diameter to be used with
chimney areas within the size limits at bottom
7" 8"
Appliance Rating in MBH
H L Fan Assist Fan Assist
(ft) (ft) Min Max Min Max
10 2 68 519
15
2 53 475 64 613
5 99 594
10 126 565
20
2 51 522 61 678
5 80 503 95 658
10 122 627
30
2 47 581 57 762
5 75 561 90 741
10 115 709
50 2 51 840
5 83 819
Minimum Internal
Area of Chimney
Square Inches
50 63
Maximum Internal
Area of Chimney
Square Inches
269 352
Masonry Chimney Serving a
Single Catagory I Appliance.
(See Table 2).
Figure 5. (Tile Lined Chimney).
NOTE: DERATE "FAN MAX" CAPACITY IN TABLE 2 BY 20%
WHEN SIZING FLEXIBLE METAL FLUELINERS.
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INSTALLING STAINLESS STEEL
HORIZONTAL / VERTICAL VENTING
(NON CONCENTRIC)
Stainless Steel Special Gas Vent listed to U.L. Standard 1738
and U.L.C. Standard 636 may be used to vent all Heatmaker
H(W)(P) and DH(P) models. Vent pipe and fittings are
manufactured to these Standards by Heat-Fab, Inc. under
the trade name of Saf-T Vent® and by Z-Flex under the
trade name of Z-Vent. Follow the Special Gas Vent
manufacturers instructions regarding design, location and
assembly of the vent system.
The Heatmaker appliance may be vented with any number of
elbows or fittings provided that the maximum equivalent feet
of venting is not exceeded. 90° elbows in the vent system
shall be considered to be 10 equivalent feet. When vented
with Special Gas Vent, the Heatmaker must not be common
vented with any other appliance.
CONNECTING SPECIAL
GAS VENT TO HEATMAKER
Heatmaker part number 2400-372 (Figure 6) is used to
secure the Special Gas Vent to the flue outlet of the
Heatmaker*. Heat-Fab pipe or fittings (Heatmaker part
numbers 2400-350 or 2400-352) or the male end of Z-Vent
pipe (Z-Vent # 02 SVEPXX030) may be installed over the flue
outlet of the Heatmaker.
*If a duct is used around the Special Gas Vent to bring in
combustion air from another location, the connection of that
duct to the appliance must be secured with sheetmetal
screws.
Each joint between the appliance and the last joint before
the location where the Special Gas vent exits the duct must
also be secured with sheetmetal screws.
In this application, part number 2400-372 is not used at the
boiler flue collar. It is used, and must be used, to secure the
Special Gas Vent at the point where the Special Gas Vent
exits the duct.
The combustion air supply should be protected from debris
entering the duct. This may be done with a Heatmaker Vent
Terminal, part number 2400-277, as shown in Figure 7 or
with a large mesh screen.
Follow the Special Gas Vent manufacturers instructions for
cleaning and sealing all parts before assembling.
APPLIANCE JOINT
PROCEDURE WITH HEATMAKER
PART #2400-350 (SEE FIGURE 8)
Apply 1/4" bead of silicone sealer (GE108 or Novagard 400)
to the 3 inch (3") flue outlet of the Heatmaker approximately
one inch (1") from the end.
Slide flue adapter over the Heatmaker flue outlet (flared up
end) and push down to stop (do not force adapter beyond
stop).
Apply another bead of silicone around this joint and smooth
out.
Apply 1/4" bead of silicone to the straight end of the 2400-
350 pipe approximately 1/4" from the end.
Slide the pipe into the adapter until it bottoms in the adapter.
Apply another bead of silicone around this joint and smooth
out.
APPLIANCE JOINT
PROCEDURE WITH HEATMAKER
PART #2400-352 OR Z-VENT
#02SVEPXX030 (SEE FIGURE 9)
Apply 1/4" bead of Silicone sealer (GE 108 or Novagard 400)
to the 3 inch (3") flue outlet of the Heatmaker approximately
one inch (1") from the end.
Slide pipe over the Heatmaker flue outlet and push down to
stop (do not force pipe beyond stop).
Apply another bead of silicone around this joint and smooth
out.
SECURING SPECIAL GAS VENT
Attach Heatmaker part number 2400-372 to 5" collar on
appliance or end of five inch (5") combustion air duct and
tighten large clamp.
Form tabs on part number 2400-372 onto Special Gas Vent
pipe and secure tabs with the 3" clamp.
After the clamp has been tightened, fold the end of the tabs
down over the clamp.
DO NOT use screws in any portion of the 3"
Special Gas Vent.
For vertical venting see instructions in the Vertical
Vent Kit pertaining to use of raincaps and
condensate drip tee's.
Appliance Design Data (single pipe only)
Minimum clearance from
combustibles (vent) 3"
Max. flue gas temp. 325°F
Max. vent pressure 1.5" W.C.
Max. equiv. ft of venting (any
combination of horiz. or vert.)
50 equiv. ft
3" diameter
Max. equiv. ft of venting (any
combination of horiz. or vert.)
100 equiv. ft
4" diameter
Table 3.
7
Figure 6.
Figure 8 & 9.
Figure 7.
Part # 2400-372
INTAKE AIR
SCREEN
PLUG
5" TEE
3" VENT
4" MIN. DIA
THE DIRECT VENT KITS
(PART NUMBERS 2400-326 or 2400-328)
When using the Direct Vent Kit, the Heatmaker is a sealed
combustion unit. All of its air is drawn in from the outside
through the 5" outer pipe. Flue gases are vented through the
3" vent pipe positioned inside the 5" intake pipe. The hot flue
gases are surrounded by the intake flow of cooler outdoor air.
This vent system may be installed through, and be in contact
with, combustible materials.
INSTALLING DIRECT VENT KITS
The Direct Vent Heatmaker is certified with a maximum of 15
linear feet of vent pipe and one set of elbows. Systems may
be vented with a maximum of three sets of concentric elbows
providing the maximum length is reduced by three linear feet
for each additional elbow set. Provide a minimum of 16" above
the top of the boiler for vent installation and servicing. There
are two vent kits available. Part numbers 2400-326 and 2400-
328 provides all of the required materials. Part number
2400-326 for vent installations which require adjustable height
and horizontal run. This kit will permit vertical and horizontal
lengths of pipe from 2' or 4'. One foot extensions and 2' to 4'
extentions are available to increase vent lengths to the maxi-
mum allowed. Additional sets of elbows are also available.
Part number 2400-328 provides all of the required materials
for vent installations which may have a fixed height of 11
inches and an adjustable horizontal run of 2' - 4'. Accessories
for P/N 2400-326 also fit P/N 2400-328.
LOCATING THE VENT ON AN OUTSIDE
WALL
Exterior vent should terminate 16½" above grade, and at least
13 ½" from any other building opening such as doors, win-
dows, etc. Units terminating below the top of the boiler must
reduce allowable vent length by 1" for every foot of vertical drop
below the top.
Vent opening should be well away from shrubbery or other
obstructions that would prevent free air flow to and from vent
terminal. Do not terminate vent under decks, stairways, or car
ports. When ever possible, locations under windows should
be avoided.
NOTE: Should it be impossible to locate opening center line
16 ½" above grade, use optional Vent Terminal Extension
(Part Number 2400-278). Fig. 4.
Vent terminals must also be at least 3' above any forced air
inlet located within 10', and at least 7' above grade when
located adjacent to a public walkway, and cannot terminate in
a location where condensate or vapor may be a nuisance,
hazard, or could be a detriment to other equipment. Vent
terminals must have a minimum clearance of 4 feet horizon-
tally from, and in no case above or below electrical meters, gas
meters, regulators, and relief equipment unless a 4 foot
horizontal distance is maintained .
Do not locate the vent terminal where blockage by snow is a
possibility, or where flue products could strike against build-
ing materials and cause degradation.
AIR SOURCE FOR COMBUSTION
(WHEN NOT DIRECT VENTED)
When using these venting methods the Heatmaker draws all
combustion air through the top of the unit and from the space
around the boiler. When locating the unit in unconfined spaces
in buildings, infiltration may be adequate to provide air for
combustion and ventilation; however, in buildings of unusu-
ally tight construction, or when locating the unit in a confined
space, additional air should be provided and the following
guidelines must be followed.
1. If the space is in a building of unusually tight construction,
air should be obtained from outdoors, or from spaces which
freely connect with outdoors.
2. For boilers in confined rooms, two permanent openings
shall be provided - one within 12" of the ceiling, and one within
12" of the floor of each room. Each opening shall be at least
one square inch per 1,000 BTU/HR boiler input, but not be less
than 100 square inches. These openings shall freely connect
with areas having adequate infiltration from outside.
3. When all air is provided from outdoors, the confined
space shall be provided with two openings as outlined above.
These openings shall connect directly, or by ducts, with
outdoors or spaces (crawl or attic) that freely connect with the
outdoors, and shall be of the size listed below for that particu-
lar arrangement.
a. One square inch of free area per 4,000 BTU/HR of boiler
input for direct outdoor air supply through an outside wall,
or through vertical ducting directly to outside.
b. One square inch of free area per 2,000 BTU/HR of boiler
input for direct outdoor air through horizontal ducting.
c. All ducting shall be of the same size as the opening to
which it is connected.
H, HP or HW with
Separate Air
Source.
ALTERNATE TO 1. - 3. ABOVE
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Figure 11.
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GAS CONNECTION TO HEATMAKER
A. The Heatmaker requires an inlet gas pressure of at least
4" W.C and no greater than 13" W.C. Check with your local gas
utility or supplier for availability of this pressure range.
B. Referring to Table 4, size supply piping to minimize pres-
sure drop between meter or regulator and unit.
C. Run gas supply line in accordance with all applicable
codes. IF UNIT IS INSTALLED ABOVE GAS SUPPLY, RUN
PIPIING UP TO A POINT ABOVE VENT CENTER LINE AND
BACKDOWNTOUNIT. THIS WILLPREVENTWATERFROM
ENTERINGGASSUPPLYSHOULDALEAKDEVELOP INTHE
BOILER SECTION. (See Figure 12).
D. Locate and install manual shutoff valves in accordance with
state and local requirements.
E. Install drip leg, ground joint union and drip cap to trap
sediment and for test gauge access (Figure 12).
F. Support all piping with proper hangers.
G. All threaded joints should be coated with piping compound
resistant to action of liquified petroleum gas whether LPG is
used or not.
H. The boiler and its individual shutoff valve must be discon-
nected from the gas supply piping system during any pressure
testing of that system at test pressures in excess of 1/2 psig
(3.5kPa).
The boiler must be isolated from the gas supply piping system
by closing its individual 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).
I.The boiler and its gas connection must be leak tested before
placing the boiler in operation.
J. Purge all air from gas lines.
K. Note: Heatmakers are certified for 4" to 13" W.C. We find
on L/P the unit performs better when the low pressure regu-
lator is not set over 9" W.C. Use an appliance regulator
(maxitrol RV48 or equivalent) if more than 3" lock up occurs in
gas supply.
DOMESTIC WATER PIPING (Figure 13.)
1. Connect hot water tempering valve (12) HOT port to hot
water outlet from unit. This valve should be mounted 3" to 6"
below the outlet and set for 120° F mixed delivery temperature
or as local codes dictate. HEATMAKER RECOMMEND ANTI
SCALD VALVE SUCH AS SPARCO OR DANFOSS.
2. Connect gate or shutoff valve (13) to tempering valve (12)
MIX port, and cold water inlet.
3. Install supplied flow restrictor (14) ahead of mix valve tee.
4. Connect pressure relief valve (1) (if required by codes),
maximum 150 PSI as close to the unit as possible. No other
valves or restrictions may be installed between the Heatmaker
and the relief valve.
(DONOTUSEATEMPERATURE/PRESSURERELIEFVALVE
AS THIS IS NOT A STORAGE HOT WATER HEATER).
*Model 60 is not recommended for larger hot water demands.
Warning: Failure to install a hot water tempering valve (12)
creates a scalding hazzard with potential for serious bodily
injury. Some brands of tempering valves are not designed
as anti scold valves.
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1
13
13
14
15
Figure 13. Domestic Water Piping.
CIRCULATOR
OPTIONAL RETURN LINE PIPING
AQUA-
STAT
WATER
SOFTENER
9
SUPPLIED
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6"*
Length
of
Pipe
Capacity of Pipe in MBTU / HR
(.6 Specific Gravity)
½" ¾" 1" 1¼"
10' 132 278 520 1,050
20' 92 190 350 730
30' 73 152 285 590
40' 63 130 245 500
50' 115 215 440
75' 93 175 360
100' 79 150 305
150' 64 120 250
Additional
length to be
added for each
tee or bend
1.3' 1.7' 2.2' 2.7'
Table 4.
Figure 12.
* or per valve manufacturers instructions.
INSTALLATIONS WITH WATER CONTAINING 10 GRAINS OF
HARDNESS OR HIGHER, MUST BE INSTALLED WITH APPROPRIATE
WATER TREATMENT.
desired.
To minimize heat loss from the storage tank (HW) during
standby periods, it is recommended that the piping between
the Heatmaker up to and including the vertical leg be insulated
with ½" - ¾" of insulation.
CAUTION: Unless equipped with optional stainless steel
tank, the HW model must not be direct connected to a heating
system utilizing oxygen permeable tubing, (see warranty).
Provide a water to water heat exchanger between systems to
prevent corrosion of tank or other components.
Nontoxic heating system antifreeze may be added to the
hydronic system provided that the concentration does not
exceed 35% and the antifreeze contains an anti-foamant.
USING IN A COMBINED HOT WATER
HEATING AND CHILLED WATER COOLING
SYSTEM.
When the Heatmaker is used in connection with a refrigera-
tion system, it must be installed so that the chilled medium is
piped in parallel with the boiler with appropriate valves to
prevent the chilled medium from entering it.
The boiler piping system of a Heatmaker boiler connected to
heating coils located in air handling units where they may be
exposed to refrigerated air circulation must be equipped with
flow control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
HYDRONIC HEAT PIPING - H SERIES
Hydronic Connections, Fittings and Accessories. Refer to Fig.
16, page 12.
NOTE:A SEPARATEHEATING CIRCULATORMUST BEPRO-
VIDED IN SYSTEM PIPING, FOR ALL MODELS.
1. Connect system supply to 1" supply connection (A).
1a.Install thermostatic union (supplied) on H, HP boilers.
2. Pipe the discharge of the relief valve, full size, to a drain
or in a manner to prevent injury in the event of pressure
relief.
3. Install an air purger (2) in supply line at or above pipe
height.
4. Install automatic float type air vent (3) on air purger.
5. Connect diaphragm type expansion tank (5) to air
purger.
6. Install a boiler drain valve (8) adjacent to unit in return
line.
7. Connect system return to 1" return connection (B).
8. Install a properly sized circulator (9) with optional
isolation valves (10).
CAUTION: All hot water pipes must be installed with a mini-
mum 1" clearance from combustible materials.
NOTE: H, HP boilers installed in radiant (in floor) systems and
other low mass systems should be provided with a buffer tank
to assure constant supply temperature without excessive
boiler short cycling (Figure 17).
FEEDWATER MAKE-UP
1. Connect boiler feed water supply with shut off valve to inlet
connection of automatic fill valve
(4).
2. If codes require, install suit-
able back-flow preventor (11)
between automatic fill valve and
city main.
3. To ensure sufficient expan-
sion volume of the hydronic
system water due to heat-up and
cool-down during normal opera-
tion, a #30 or larger expansion
tank must be used on all HW
series applications.
HYDRONICPIPING
HW SERIES
HW-M2 boilers are installed in
single and multiple zone sys-
tems ( using either zone valves
or zone circulators) in the same
manner as any other residential
boiler. Systems with zone circu-
lators or single zone systems
require the installation of a hy-
dronic flow check (6) to prevent
gravitycirculationofheatingsup-
ply water when no heat is
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Figure 14. Hydronic Piping (HW).
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Figure 15. Hydronic Piping with Indirect H(P).
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Figure 17. Hydronic Piping H(P) in Radiant in floor or Low Mass Heating Systems
Figure 16. Hydronic Piping H(P) Models.
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ELECTRICAL CONNECTIONS
All electrical wiring must conform to local codes and/or the
1). National Electric Code or
2). Canadian Electrical Code - Part 1.
The unit must be electrically grounded in accordance with the
requirements of the authority having jurisdiction or, in the
absence of such requirement, with the 1). National Electrical
Code. ANSI/NFPA NO.70- latest edition, or the CSA Standard
C22.1 Canadian Electrical Code - Part 1.
Single pole switches, including those of safety controls and
protective devices must not be wired in a grounded line.
All electrical connections are made in the field wiring box
which is located on the right side of the unit.
NOTE: All internal electric components have been pre-wired.
No attempt should be made to connect electric wires to any
other location except the wiring box as described below.
1. Main power
Connect a 15 amp fused 120 volt supply to the main power
switch illustrated (hot leg is connected directly to switch).
Neutral leg to white wire. Ground wire can be connectd to the
grounding screw in the box or on the switch.
2. For single zone installations, connect room thermostat
(T-T) wires to the red and white/red wires. Connect circulator
(120 volt, 5 amps maximum) between the blue wire and the
white wire (neutral) per Fig. 18. Set thermostat anticipator to
0.9 amps.
3. Zone Valves and Thermostats: Fig 19 (Fig 20 for 3 wire
zone valve such as TACO) or DC magnatrol valves.
Install external 24 volt transformer of sufficient V.A. to power
combined load of zone valves. Consult zone valve
manufacturers instructions. Connect circulator (120 volt, 5
amp maximum) between the blue wire and the white wire
(neutral).
4. Multi-Zone/ Multi-Relay-Circulator Installations: Fig. 21
Multiple circulators must not exceed 5 amps when connected
to blue wire. Blue wire must be used on all HW series.
NOTE: On zone valve systems such as Taco, Automag and
others which do not have isolated (dry) contact end switches,
a single pole isolating relay must be utilized. (Fig. 20).
LEGEND
S1 Disconnect Switch
TH1
24-Volt Thermostats.TH2
TH3
C1 Zone Circulators -
Max 5 AMP
120 VAC.
C2
C3
R1 Zone Relays.
Honeywell R845A or
equivelant.
R2
R3
ZV1 Zone Valves.
Honeywell V8043 or
equivelant.
ZV2
ZV3
Figure 21. Zoning with Circulators.
Figure 20. Zoning with 3 wire Zone Valves.
Figure 19. Zoning with Zone Valves.
Set Thermostat Anticipator to 0.9 amp
Figure 18. Single Zone.
R1 R2 R3
Note: Connection of "Blue" wire required on HW only
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The Model HP-M2-Series may be used as either a Paloma
Pak/Hytech boiler replacement or as a new wall-mount instal-
lation. Carefully unpack HP unit. Read all installation
instructions before starting the installation. Remove the Front
removable jacket and find the plumbing accessories pack-
age inside the unit.
WALL MOUNTING INSTRUCTIONS
PALOMA/HYTECH REPLACEMENT
Hang the HP-M2 as assembled from the manufacturer onto
the existing wall bracket. Do not remove the brackets which
are attached to the new unit. If the existing wall bracket does
not align with the slotted mounting holes on the rear of the HP-
M2, removetheoldbracketfrom the wallandfollowinstructions
for new wall mount below.
NEW WALL MOUNT INSTALLATION
Remove the bolts, nuts and washers that secure the two
mounting brackets to the bottom and rear of the HP-M2
cabinet. Remove the U-channel spacer bracket from each
wall bracket and discard. (Spacer brackets are used only with
original bracket in Paloma Pak/Hytech retrofit installations)
Attach the included mounting template to the selected wall
location. Mark and drill holes for appropriate mounting hard-
ware at the template specified locations. Remove template
from the wall and securely affix the two wall brackets to the wall
surface with appropriate mounting hardware (provided by
installer).
Lift the HP-M2 onto the wall brackets and re-assemble the
bolts, nuts and washers to affix the unit onto the wall brackets.
NOTE: DONOTREINSTALLTHEU-CHANNELSPACERBRACK-
ETSWHEN MOUNTINGTHE WALLBRACKETSDIRECTLY TO
A WALL.
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HYDRONIC SYSTEMS CONNECTIONS
The HEATMAKER HP-M2 Series is supplied with the neces-
sary fittings to match the Paloma Pak supply and return piping.
If the original wall bracket is compatible with the slotted
mounting holes on the rear of the HP-M2, the supply and return
pipe unions attach directly to the existing piping. If the
installation is new or if the old bracket is incompatible or
unusable, the return and supply connections will require re-
piping to match the HP-M2 connections.
PLUMBING ACCESSORIES INSTALLATION
1) Attach boiler drain plumbing accessory to the labeled
return on the bottom of the HP-M2.
2) Separate Thermostatic Union Assembly halves and
thread the 1" nipple side to the labeled supply on the
bottom of the HP-M2. Attach the remainder of the union
assembly onto the top half of the union. Be sure to use
appropriate thread sealers to assure leak-tight joints.
3)a. Where the HP-M2 is a direct replacement for a Paloma
Pak/Hytech the installation is completed by connecting
union halves together.
b. If the installation is new, refer to the piping schematics
and instructions on page 10 -12.
GAS SUPPLY CONNECTION
If the installation is a direct retrofit, the gas supply will require
re-piping to connect to the HP-M2 gas inlet. If the gas is
supplied from below the unit, be sure to run supply pipe to a
point higher than the vent center line before connection to the
unit gas valve.
On new installations refer to the gas piping section for gas
pipe sizing and related information.
RED
WHT/RED
BLACK
BLUE
WHITE
HOT 120VAC
INPUT
HP WIRING BOX
PALOMA PAK/HYTECH
TRANSFORMER RELAY
CONTROL PAK
NEUTRAL
SYSTEM
PUMP(S)
VENTING THE HP-M2-SERIES
The HP-M2 may be vented using any of the venting options
available to the H(W)-M2-Series. These options include
Direct Vent, Outside Air vented, Alternate horizontal/vertical
venting (using Special Gas Vent) or internal lined or B Vent
type chimneys.
MODEL HP-M2-60 & HP-M2-100 MUST NOT BE CHIMNEY
CONNECTEDOR BVENT CONNECTED.
AGA
When used as a retrofit boiler vented into a chimney or a B
Vent, be sure to check current vent and vent connector sizing
tables. Only units fired at 130MBTU/hr may be vented with this
option. Under no circumstances shall the HP-M2-60 be
chimney connected or B vented using 3" vent or vent connec-
tors. The unit 3" vent collar must be increased to a size which
will accommodate the chimney system for the appropriate
BTU/hr input of the boiler.
In the event the unit firing rate and masonry chimney param-
eters do not fall within the recommendations in the latest
N.F.G.C.* chimney sizing tables, a flexible chimney liner may
be utilized in the chimney. Sizing capacity for metal chimney
liners may be obtained by 20% de-rating (or 80%) of the fan
max capacity from B vent tables. See page 5 for vent table
excerpts.
*National Fuel Gas Code ANSI Z223.1 / NFPA 54
CGA
Refer to page 4 for Alternate Venting Method.
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ELECTRICAL CONNECTIONS
If the installation is new, wire the unit per the applicable wiring
diagram for line voltage (120VAC) and control (24VAC) wiring
connections.
Do not connect an external voltage source to the HP 24 volt
(T-T) wires. Install an isolation relay if required per diagram
Fig 20.
Where a HP-M2-Series in a Paloma Pak/Hytech retrofit is
connected to a single zone system, the original transformer
relay control-pak should be removed and all field wiring
connected to the unit electrical connection junction box on the
right side of the unit. The 120VAC power input, 120VAC system
circulator output and thermostat should be wired as outlined
in figure 18.
Be sure to set the thermostat heat anticipator to 0.9 amp for
single zone connection.
If a retrofit installation includes multiple zones, any one of the
options provided in this manual may be used, or the existing
transformer relay control-pak may be utilized and re-wired
according to the diagram below. Where two wire or three wire
zone valves are used, this is the preferred wiring method on
retrofits.
MANUFACTURED HOME (MOBILE HOME)
APPLIANCE INSTALLATION INSTRUCTIONS.
These appliances are design certified to conform to the
requirementsofANSZ21.10.3 for installation inmanuafactured
homes (mobile homes) when installed in conformance with
this manual supplement and the manual.
APPLIANCE MOUNTING
Model HP Series appliances are provided with a wall mounting
bracket.
Model H Series appliances are provided with mounting holes
in the base. Either lag bolts or through bolts must be used for
secure attachment of the appliance to the structure.
Model HW Series appliances are attached to the structure by
attaching angle brackets from the structure to the secured
clearance brackets. See Figure 22.
16
Figure 22.
CHECK,TEST & START- UP
FILLINGSYSTEM
1. Open all supply and return valves.
2. Fill heating system to minimum operating pressure -12
psig.
3. Open bleed pet cock and bleed air from boiler coil until a
good stream of water comes out. (H(P)-M2 series), Item 8 on
page 33.
4. Purge all lines by opening vents, or with flushing valves.
5. Close gas valve.
6. Turn on 120 volt power, and listen for unit circulator to start.
Unit will cycle off on lockout.
7. Open all vents again to discharge any additional air and
close off after air is eliminated.
8. System is now ready for operation.
FIRINGBURNER
1. Be sure that system has been filled properly (see above)
and is leak tight.
2. Open gas cock (s). Open manual gas shutoff valve by
turning to on position.
3. Turn on main switch, and set thermostat to call for heat. In
approximately 2 seconds, blower will come on.
NOTE: Burner may not ignite on first attempt because of air in
gas lines. In this case, blower will stop after 5 minutes. Should
this happen, turn off main switch. Wait 5 minutes and turn on
main switch again.
4. If burner fails to ignite after three attempts, refer to Trouble
Shooting Section 2, Service Manual or call service for trouble-
shooting.
CAUTION: SHOULDANYPRONOUNCEDODOROFGASBE
DETECTED, OR IF THE GAS BURNER DOES NOT APPEAR
TOBEFUNCTIONING INANORMAL MANNER,CLOSEMAIN
SHUTOFF VALVE, DO NOT SHUT OFF SWITCH, AND CON-
TACTYOURHEATING CONTRACTOR, GASCOMPANY,OR
FACTORYREPRESENTATIVE.
5. You MUST check flame monitoring control ( ignition system
safety shutoff device).
a. Close gas cock with burner operating.
b. In 3 seconds, FLAME indicator light will go out and blower
will continue to run on post purge cycle. Two additional
attempts to light will follow including pre-purge, igniter on,
valve/flame on and post purge. (Ignition will not occur-gas off).
c. Open gas cock. Switch unit OFF and then ON again.
Burner should start after about 45 seconds. It is recom-
mended that the unit be checked with a standard CO² or O²
tester. Insert tester probe at least 6" into exhaust pipe through
outside vent terminal. Readings should be:
CO2- 8% to 8.5% (nat. gas) 9% to 9.8% (LP gas)
O2 - 7% to 4½%
6. Check Burner Input (other equipment off)
a. Measure the time, in seconds, it takes to use one cubic foot
of gas.
b.Divide the number of seconds into 3,600.
c. Multiply the result by the heating value of the gas to obtain
BTU/HR input.
Example: If it takes 36 seconds to use one cubic foot of gas
and the heating value of the gas is 1,000 BTU/CU FT, (approx.
natural gas value).
INPUT = 3,600/36 x 1,000 = 100,000 BTU/HR
Input Ranges
H(W)-M2-130 - 127,400 TO 132,600 BTU/HR
H(W)-M2-100 - 98,000 TO 102,000 BTU/HR
H(W)-M2-60 - 58,800 TO 61,200 BTU/HR
Because of the altitude and other minor variations, it is
possible the input will not fall within this range and the gas
orifice must be replaced. See chart in an orifice kit.
CHECK LIMIT CONTROL OPERATION
OPERATING AND LOW LIMIT CONTROL HW-M2
a. When water temperature reaches low limit set point (180°F)
with no call for heat, Heatmaker will shut down.
b. Turn up the room thermostat. Boiler pump (inside jacket)
will now run.
c. If water temperature is below operating control cut out
temperature (210°F) burner will fire.
d. When operating control cut-out temperature is reached
(210°F) burner will go off, blower will post purge for 30
seconds and the boiler pump and system circulator will
continue to operate until room thermostat is satisfied.
e. When water temperature drops below low limit cut-in
temperature (150°F) and there is a continued call for heat, the
system circulator will go off. The boiler pump will continue to
operate and the burner will remain on. When low limit cut-out
temperature is reached (180°F) the system circulator will
come on.
OPERATING CONTROL H-M2
a. Burner will run until operating control cut-out temperature
(185°F) is reached.
b. When Operating Control cut-out temperature is reached,
burner will go off and boiler pump will continue to run and
blower will post purge for 30 seconds.
c. When temperature reaches Operating Control cut-in tem-
perature (160°F), burner will start and continue to run until a
call for heat is satisfied or Operating Control cut-out tempera-
ture is reached again.
SAFETY LIMIT OPERATION H(W)-M2
If boiler water temperature exceeds operating control cut-out
temperature for any reason, the safety limit will interrupt power
to the gas valve at approximately 215°F, the blower will post
purge for 30 seconds and the unit will shut down. The safety
limit will reset at 195°F.
Note: temperature of limit operations are all approximate;
allow for gauge and tolerance variations.
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STACK SWITCH OPERATION H(W)-M2
If, for any reason, the combustion air blower fails to provide
adequate air flow, or if the flue is blocked so as to prevent
sufficient air flow for proper combustion, the contacts of the
stack switch will open and the unit will shut down. After 5
minutes, purge light will flash.
Close all covers. Reset room thermostats and place these
instructions in a place convenient to the unit.
Please be sure that the warranty card is mailed to TRIANCO-
HEATMAKER, INC. by either you or the property owner.
COMMON VENT TEST
Required only if Heatmaker is not being chimney connected.
At the time of removal of an existing boiler, the following steps
shall be followed with each appliance remaining connected
to the common venting system placed in operation, while the
other appliances remaining connected to the common vent-
ing 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 restric-
tion, leakage, corrosion and other deficiencies which could
cause an unsafe condition.
c. Insofar as is practical, close all building doors and win-
dows 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 appliance not connected to the common
venting system. Turn on any exhaust fans, such as range
hoods and bathroom exhausts, so they will operate at maxi-
mum 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 the flame of a match
or candle, or smoke from a cigarette, cigar or pipe.
f. After it has been determined that each appliance remain-
ing connected to the common venting system properly vents,
when tested as outlined above, return doors, windows, ex-
haust fans, fireplace dampers and any other gas burning
appliance to their previous conditions of use.
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
1). National Fuel Gas Code, ANSI Z223.1 latest edition.
2). Can / CGA - B149
When re-sizing any portion of the common venting system, the
common venting system should be re-sized to approach the
minimum size as determined using the appropriate tables in
Part 11 in the National Fuel Gas Code, ANSI Z223.1-latest
edition.
LIGHTING AND
SHUTDOWN INSTRUCTIONS
A.LIGHTING
1. Ensure that boiler is filled with water, air is bled from boiler
coil and that boiler water pressure is at a minimum of 12
psi.
2. Open main gas cock.
3. Open gas cock on gas valve.
4. Turn ON disconnect switch (on right side of unit).
5. After 45 seconds, ignition will occur (if there is a call for heat).
B. SHUTDOWN
1. Turn OFF disconnect switch.
2. Close gas cock on gas valve.
3. Close main gas cock.
MAINTENANCE
OWNERCARE ANDMAINTENANCE
1. Inspect venting system - Annually remove screws on vent
terminal and remove terminal. Inspect interior with flashlight.
2. General Housekeeping - Keep boiler area clear and free
from combustible materials, gasoline and other flammable
vapors and liquids.
Keep boiler jacket louvers clear for proper cooling of internal
components.
Do not obstruct boiler room ventilation screens or grills.
SERVICEMAINTENANCE
Cleaning Heat Exchanger to be done by qualified service
person.
1.Turn off electric and gas supplies and remove the jacket.
2.Remove the vent assembly and top cover.
3.Remove the top half of the combustion chamber by remov-
ing the three screws and nuts that clamp the top
half to the bottom half, the clamp on the induction tube and the
1/8" diameter balance lines.
4.Remove the top insulator cap by spreading the retainer.
5.Remove the igniter - to avoid damage during cleaning.
6.Clean the finned tubing with a wire brush and vacuum all
loose material from the combustion chamber. Wipe
flameholder (burner) with a clean dry rag.
7. Replace all parts in the reverse order in which they were
removed.
8. Restart the unit as indicated by the operating instructions
plate.
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ADJUSTING BURNER / INPUT
The HeatMaker burner system is a pre-mixed, forced
combustion system. Outside air is drawn through the air
orifice (located in the air induction system) and mixed with the
gas drawn in downstream of the air orifice. The gas is metered
through an orifice located in the gas orifice union. All the air
required for complete combustion comes into the system in
this manner.
Adjusting the input is limited to changing the gas orifice to
achieve the proper input. The air orifice cannot be altered and
the gas valve pressure setting cannot be changed.
Before changing the gas orifice to correct input, service
representatives should make the following checks:
1. The pressure on the inlet side of the gas valve is
between 4" and 13" water column.
2. The pressure on the outlet side (manifold) of the gas
valve and "T" above air orifice is between negative .05" and
negative .35" water column with the unit operating.
To increase the input, install larger diameter gas orifice. Each
size will change the input approximately 5 C. F. H. Once the
correct input has been achieved, the burner should be checked
with an oxygen (O2) or carbon dioxide (CO2) gas analyzer.
The unit should be in operation 5 minutes before adjusting
input or taking CO2or O2 readings. This time will allow for pre-
heating of the intake air.
Insert the probe of the O2or CO2tester at least 6" into the vent
through the vent terminal. If CO2is being measured, the
readings should be between 8.0 and 8.5 for natural gas and
9.0 and 9.8% for propane. If O2 is being measured, the
readings should be between 7 and 6.
Measuring CO2*
When operating on narural gas, readings below 8.0 generally
indicate a lean mixture (not enough gas). Readings above
9.25 generally indicate a rich mixture (too much gas). Inputs
should be increased or decreased to correct lean or rich
mixtures.
NOTE: If the mixture is very rich (not enough air for complete
combustion), it is possible to get low readings on a CO2
analyzer. This situation does not occur often but it can be
detected if reading continues to go lower as the input is
increased. If this condition is suspected, a CO test should be
taken at the vent outlet. Inputs must be reduced to correct high
CO reading and to bring CO2 readings to proper levels.
* The following numbers apply to natural gas only. The range
of operation for LP is 9.0 to 9.8.
Measuring O2
Readings above 7% indicate a lean mixture (not enough gas).
Readings below 4½% indicate a rich mixture. Input should be
increased or decreased to correct lean or rich mixtures.
CLEANING COMBUSTION CHAMBER COIL
1. Turn off electric and gas supplies and remove the jacket.
2. Remove the vent assembly and top cover.
3. Remove the top half of the combustion chamber by
removing the 3 screws and nuts that clamp the top half to the
bottom half, the clamp on the air orifice hose and the two clear
plastic lines connected to the "T" on the air induction elbow.
4. Remove the top insulator cap by spreading the retainer.
5. Remove the igniter.
6. Clean the finned tubing with a wire brush and vacuum all
loose material from the combustion chamber.
7. Replace all parts in the reverse order in which they were
removed.
8. Restart the unit as indicated by the lighting instruction
label.
UNIT PUMP
The unit pump operates whenever there is a call for heat or hot
water.
It is a wetted-rotor type pump and should always be filled with
water when it is operating so that it will cool properly.
If a pump change is required for any reason, valve off the boiler
and drain approximately 1 or 2 gallons of water from the unit.
Turn off the main disconnect switch and unplug the pump
wires, remove the pump motor. The pump housing need not
be removed. The replacement pump motor should be installed
in the reverse order from which the old pump motor was
removed. After filling the system be sure to bleed the coil.
NOTE: If the pump motor is not defective the pump cartridge
alone may be changed (Taco Pumps Only).
GAS VALVE
The gas valve is a solenoid operated, negative pressure
regulated valve. The outlet pressure is regulated at minus 0.2
inches w.c. It is designed to operate with supply pressures of
4-13 inches w.c. Within that range of supply pressures, the
regulated discharge pressure may vary from minus .05 to
minus .35 inches w.c. The regulator is not adjustable and the
effect of this variation in discharge pressure is not significant.
Because of the fixed regulator setting, gas flow must be
adjusted by changing the gas orifice.
To remove the gas valve, shut off 120 volt power and the
master gas cock in gas line, loosen the nut on the gas orifice
union and remove the orifice union plus piping to the gas valve.
Disconnect the wires from the gas valve. The valve may now
be unscrewed from the inlet piping. It may be necessary to
deflect the inlet piping somewhat in order to clear the boiler
jacket. After the valve has been removed, replace with a new
valve in the reverse order in which the old valve was removed.
Do not over tighten the fittings into the valve body as this may
cause damage to the valve.
NOTE: WhenfueledbyLPgas, HeatMakers performbestwith
9-10 in. W.C. supply pressure. If no other appliances are being
supplied by the LP supply set the low pressure regulator to 9-
10 in. W.C.
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SAFETY LIMIT SWITCH
The Safety Limit Switch has a fixed set point at 215°F. It will
reset automatically.
To replace the switch , shut off the 120 volt power and valve off
the boiler, drain 1 or 2 gallons of water from the boiler and
remove the nut which holds the safety limit bulb in the boiler
discharge fitting. Remove the bulb from the fitting and remove
the 2 screws which hold the switch assembly to the electrical
control box. Disconnect the 2 wires from the quick connects
at switch and remove the safety limit assembly. To replace,
perform the same operations in reverse. Push the sensing
bulb as far into the fitting as possible before tightening sealing
nut. No more than 1/2" of sensing bulb should be visible after
installation. Fill the boiler and be sure to bleed the coil at the
coil bleed petcock. Turn on disconnect switch and check
boiler operation .
OPERATING CONTROL
The Operating Control maintains boiler discharge temperature
between 170-210°F during the space heating cycle. It has a
fixed set point of 210°F (HW-M2 Series only) and a differential
of 40°F, therefore, its contacts open at 210°F and they reclose
at 170°F. If replacement is necessary, shut off the 120 volt
power and disconnect the wires to the sensor. Valve off and
drain 1 or 2 gallons of water from the boiler and remove
sensor. Install new sensor, refill boiler and bleed coil at coil
bleed petcock. Check boiler operation after installation of new
Operating Control. The Operating Control on the H(P)-M2
series has a fixed set point of 185°F. Its contacts open at 185°F
and they reclose at 160°F.
IGNITER
The igniter is a glow bar type silicon carbide unit. It is
energized whenever there is a call for heat and the red
"IGNITER" light on the boiler control is lit. After the igniter is
switchedoffandtheboilercontinues to run, the igniterfunctions
as a flame sensor for the boiler control.
If the ignitor fails and must be replaced, always install a new
igniter gasket with the replacement igniter.
CAUTION: Ignitor gets hot.
PRESSURE DIFFERENTIAL SWITCH
The Pressure Differential Switch is a normally open single
pole switch which is designed to detect pump operation and
water flow. To replace, turn off electrical power & boiler feed
water. Valveoff anddrain1or2 gallons of water fromtheboiler,
unplug wires from the switch and remove switch. Install new
switch in reverse order. Refill boiler and bleed air from the coil
bleed petcock. Turn on electrical power and recycle system.
TRANSFORMER
The control transformer accepts 120 VAC power and provides
40 VA of 24 VAC power for the boiler control only. It is not
capable of supplying control power for external devices such
as zone valves. They must have their own separate power
supply.
LOW LIMIT (HW-M2 Series Only)
The Heatmaker Mark 2 may be equipped with a strap-on Low
Limit. The Low Limit control performs two functions. It controls
the temperature of the water in the transfer tank and it prevents
the house circulator from operating when insufficient tank
water temperature causes the domestic hot water delivery
temperature to drop below 140°F. The Low Limit Control has
a fixed differential of 15°F and is set to turn the burner on at
140°F tank water temperature and to turn it off when the sensor
reaches 155°F. Because of the thermal lag in the sensor, the
tank water temperature will reach about 180°F before the
burner actually is turned off. The boiler temperature may reach
operating temperature due to this thermal lag.
If replacement is necessary, shut off the 120 volt power.
Simply remove and attach wire for wire. Clamp the new Low
Limit to the hot outlet pipe as close to the domestic exchanger
plate as possible and cover area with tank insulation blanket.
Return boiler to service.
BLOWER
The Combustion Air Blower is a high head centrifugal blower.
It is designed to provide about 2" w.c. of suction at 30 CFM. This
performance is necessary to operate the gas valve reliably, to
overcome induction system friction losses and to eliminate
any sensitivity to wind striking the vent terminal. It is powered
by a 120 volt motor which draws about 1.3 amps at rated load.
It is powered by the integrated boiler control whenever there
is a call for heat and 30 seconds thereafter. If a blower change
is required, turn off the 120 volt power and unplug the power
wires from the blower motor. Remove the three nuts from the
blower discharge flange and the four nuts from the blower inlet
flange. The blower may now be deflected enough to permit its
removal. Install the new blower using new gaskets, in the
reverse order from which the old blower was removed. The
four inlet flange nuts, however, should only be finger tight
initially and then tightened with a wrench after all other
operations have been completed. The combustion should be
checked for correct air-fuel ratio whenever the blower is
replaced (see Burner Adjustment).
PRIORITY RELAY - R1
(HW-M2 Series Only)
The Priority Relay is a normally open single pole relay which
accepts a 24 VAC signal from the low limit aquastat and the
T-T wires to provide 120 VAC power to the system circulator
when the tank temperature remains above 150°F.
20
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14
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