Bradford White Brute MagnaTech BMGH1600 Installation And Operation Instructions Manual Download Page 13 | Manualshive

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Table 3.

Allowable Single Wall Stainless Steel Vent Suppliers and Part Numbers

Table 4.

Allowable Polypropylene Vent Manufacturers / Trade Names

Selkirk

DuraVent

NovaFlex

Safe-T Vent EZ Seal

FasNSeal

Z Flex

90° Elbow

9x14

FSELB90xx

2SVEExx90

Pipe

9x07

FSVLxxxx

2SVEPxxxx

Boiler Adapter

5x01BOI

FSAAUx

2SVSAxx (OD)
2SVSTTAxx (ID)

Horizontal Termina

Ɵ

on (bird screen) 9x92

FSBSx

2SVSTPXxx

Ver

Ɵ

cal Termina

Ɵ

on (rain cap)

5X00CI

FSRCx

2SVSRCxx

Inlet Air Termina

Ɵ

on

9xTERM

FSAIHXX*

2SVSTEXxx90

FSA-xxFNSM-xPVCF
Adapter SS to PP

FSAAUx-xPP

2ZDCPVCx**

*4", 6" & 7" only

**up to 6"

Example Components

Trade Name / Model

NOTE:

“x”, “xx”, and “xxxx” refer to varia

Ɵ

ons in nominal size. See manufacturer’s catalog for a par

Ɵ

cular applica

Ɵ

on.

CentroTherm

DuraVent

Selkirk

NovaFlex

InnoFlue

PolyPro

PolyFlue

Z-Dens

Single Wall Pipe

ISVLxxxx

xPPS-x

83x002

ZDPx

Elbow

ISELxxxx

xPPS-E90L

83x08

2ZDEx87

PVC Adapter

ISAMGTxxxx

xPPS-ADL (to 4")

xPPS-xxPVCM-xPPF (>4")

83x040

2ZDCPVCx

Horizontal Termina

Ɵ

on (bird screen)

IASPPxx (2" - 4")

IASSSxx (5" - 12")

xPPS-BG (2" - 6")

83x050

2ZDESx

Ver

Ɵ

cal Termina

Ɵ

on

IASPPxx (2" - 4")

IASSSxx (5" - 12")

xPPS-VKL (<5")

xPPS-VTML (5"-8")

83x050

2ZDESx

Air Inlet

2ZDESx

Trade Name / Model

Example Components

3.1 General

Venting

This product requires a special venting system. Refer
to venting supplier’s instructions for complete parts
list and method of installation. The manufacturers
and product lines listed on the following tables have
been tested and authorized to safely operate with
this equipment. Suppliers of stainless steel and
polypropylene venting that are not listed on these
tables are not permitted for use with
vent category III & IV products.

Manufacturer Model Numbers (abreviated)

Manufacturer Model Numbers (abreviated)

Section 3
VENTING AND COMBUSTION AIR

Do not mix venting suppliers and models in venting
systems. Failure to comply could result in personal
injury, property damage, or death.

Installations must comply with applicable national,
state and local codes.

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11
12
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Summary of Contents for Brute MagnaTech BMGH1600

Page 1: ...U RSHUDWLRQ ZLOO YRLG WKH ZDUUDQW AVERTISSEMENT VVXUH YRXV GH ELHQ VXLYUHV OHV LQVWUXFWLRQV GRQQpHV GDQV FHWWH QRWLFH SRXU UpGXLUH DX PLQLPXP OH ULVTXH G LQFHQGLH RX G H SORVLRQ RX SRXU pYLWHU WRXW GRPPDJH PDWpULHO WRXWH EOHVVXUH RX OD PRUW 1H SDV HQWUHSRVHU QL XWLOLVHU G HVVHQFH RX QL G DXWUHV YDSHXUV RX OLTXLGHV LQÀDPPDEOHV GDQV OH j SUR LPLWp GH FHW DSSDUHLO RX GH WRXW DXWUH DSSDUHLO QUE FAIRE ...

Page 2: ...IPING 4 0 Gas Supply and Piping 18 Section 5 WATER FLOW REQUIREMENTS 5 1 Boiler Flow and Head Requirements 20 5 2 Water Heater Flow and Head Requirements 21 Table of Contents i Section 6 WATER CONNECTIONS BOILER 6 1 Boiler System Piping Hot Supply Connections 22 6 2 Boiler Cold Water Make Up 22 6 3 Boiler Freeze Protection 22 6 4 Condensate Drain Trap 23 6 5 Boiler Suggested Piping Schematics 23 2...

Page 3: ...n Setup Procedure 79 10 3 Shutting Down the Unit 79 10 4 Restarting the Unit 79 Section 11 MAINTENANCE 11 1 System Maintenance 80 11 2 Maintenance Notes 80 11 2 1 Burner 80 11 2 2 Modulating Gas Valve Venturi 80 11 2 3 Controller 81 11 2 4 Spark Ignition Electrodes 81 11 2 5 Flame Sensor 81 11 2 6A Blower Model 1600 81 11 2 6B Blower Model 4000 81 11 2 7 Heat Exchanger Tubes 82 11 2 8 Gas Pressure...

Page 4: ......

Page 5: ...re of 125 F 52 C WARNING Fire or Explosion Hazard Improper configuration can cause fuel buildup and explosion Improper user operation may result in property loss severe physical injury or death Any changes to safety related configuration parameters must only be done by experienced and or licensed burner boiler operators and mechanics If any odor of gas is detected or if the gas burner does not app...

Page 6: ...3 1 NFPA54 In Canada the installation must conform to the latest edition of CSA B149 1 Natural Gas and Propane Gas Installation Code and or local codes Where required by the authority having jurisdiction the installation of MagnaTech boilers must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSI ASME CSD 1 Any modifications to the boiler its gas controls ...

Page 7: ...wiring and to the heat exchanger Touch Screen Heat Exchanger Condensing Unit Air Intake and Filter Water Outlet Water Inlet Vent Power Pack o T T T T T T H C U d d P P P Co C ntrol Pane M M G S G S S G R R M B M M t t t Condensate Trap Gas Supply Main Power Connections er r r s r r r r Field Electrical Connections d d d d d 1 5 Unit Overviews The next 3 pages give a visual reference to the basic c...

Page 8: ... Water Inlet Vent Power Pack Field Electrical Connections d d P s s d d ctr ri ic ica al i i i l t t t r r s Condensate Trap Heat Exchanger Condensing Unit Gas Supply H H H C C C Manual Gas Valve Rating Plate on outside of panel R R Touch Screen T T T T T Spark Generator Control Panel Control ...

Page 9: ...Power Connections Water Outlet Water Inlet Vent Power Pack Field Electrical Connections P ns s d d ctr ri ic ica al i i i l er r r s r r r r r t t t t Condensate Trap Heat Exchanger Condensing Unit Gas Supply H H C C C C C G Rating Plate on outside of panel To T T R R o T T T T T T Spark Generator Control Panel C C C C C C ...

Page 10: ...78 60 8 154 6 4 16 80 8 205 28 8 73 Model 1600 2000 2500 3000 3500 4000 Model 1600 2000 2500 3000 3500 4000 J K L M N P Q R Inches cm 8 4 21 68 4 171 4 10 39 2 100 30 4 77 16 41 23 58 10 2 26 8 4 21 67 4 171 4 10 39 2 100 30 4 77 16 41 23 58 10 2 26 9 8 25 76 4 194 4 3 11 44 4 113 34 5 88 17 7 45 27 2 69 11 8 30 9 8 25 76 8 195 4 3 11 44 4 113 34 5 88 17 7 45 27 2 69 11 8 30 26 5 67 85 6 217 6 5 1...

Page 11: ... box The Installation Kit making sure that all parts are there and not damaged during shipping 1 Gromet Nylon 2 Box containing Outdoor Sensor 3 Box containing System Sensor 4 Tank Sensor 5 Spring Clip used to hold tank sensor in sensor well 1 2 3 4 5 6 7 6 Condensate Trap Assembly some assembly required and document 4312 Condensate Tap Assembly Instructions 7 Installation Instructions for Sensors ...

Page 12: ...erminal terminate through a wall and there is potential for snow accumulation in the local area both terminals should be installed at an appropriate level above grade or the maximum expected snow line The dimensions and requirements that are shown in Table 1 should be met when choosing the locations for the appliance 2 2 Correct Vent Distance from Outside Wall or Roof Termination The forced draft ...

Page 13: ... Adapter ISAMGTxxxx xPPS ADL to 4 xPPS xxPVCM xPPF 4 83x040 2ZDCPVCx Horizontal TerminaƟon bird screen IASPPxx 2 4 IASSSxx 5 12 xPPS BG 2 6 83x050 2ZDESx VerƟcal TerminaƟon IASPPxx 2 4 IASSSxx 5 12 xPPS VKL 5 xPPS VTML 5 8 83x050 2ZDESx Air Inlet 2ZDESx Trade Name Model Example Components 3 1 General Venting This product requires a special venting system Refer to venting supplier s instructions fo...

Page 14: ...ombustion air from the space in which it is installed or the combustion air can be ducted directly to the unit Ventilation air must be provided in either case 3 2 1 Combustion Air From Room In the United States the most common requirements specify that the space shall communicate with the outdoors in accordance with Method 1 or 2 See the following descriptions Where ducts are used they shall be of...

Page 15: ...anel In addition to air needed for combustion air shall also be supplied for ventilation including air required for comfort and proper working conditions for personnel Refer to the applicable codes 3 3 Venting WARNING Selection of improper vent materials for installations that are installed in closets or will be operated in high ambient temperature levels may lead to property damage personal injur...

Page 16: ...s considered to be 5 feet 1 5m Manufacturer offers accessory kits to use with horizontal and vertical exhaust vent systems as shown in Table 8 3 3 1 Common Venting This unit can be common vented however the common venting must be a professionally designed and approved system See Venting Document 1396 pdf available online Catagory II and IV units are never permitted to share a vent with any Catagor...

Page 17: ...RI WKH ÀXH JDV VDPSOLQJ SRUW WR HQVXUH WKDW FRQGHQVDWH LV IUHH WR ÀRZ EDFN LQWR WKH 8QLW DQG not collect anywhere in the vent system including in WKH ÀXH JDV VDPSOLQJ SRUW Exhaust Vent Terminal An exhaust vent terminal must be installed If an exhaust vent terminal is not available with the FHUWL HG YHQW V VWHP 0DQXIDFWXUHU VXJJHVWV WKH XVH RI D FRXSOHU WWLQJ IURP WKH FHUWL HG YHQW system into whic...

Page 18: ...tor vent outlet See note 4 3 feet 91 cm J Clearance to nonmechanical air supply Direct vent only 36 91cm inlet to building or the combustion air inlet Other than Direct vent 4 ft 1 2m below 36 inches 91 cm WR DQ RWKHU DSSOLDQFH RU WR VLGH RI RSHQLQJ IW FP DERYH RSHQLQJ K Clearance to a mechanical air supply inlet 3 feet 91 cm above if within 10 feet 3 m 6 feet 1 83 m horizontally L Clearance above...

Page 19: ...at which it penetrates the roof and high enough above the roof line to prevent blockage from snow When the vent terminates on the roof the combustion air must terminate at least 12 30 cm below the vent terminal 84 213 12 Figure 5 Minimum Venting Distance IMPORTANT All terminals must be placed so that they remain at least 12 above the expected snow line Local codes may have more specific requiremen...

Page 20: ...n of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during said thirty 30 day period a battery operated carbon monoxide detector with an alarm be installed 2 Approved Carbon Monoxide Detectors Each carbon monoxide detector shall comply with NFPA 720 and be ANSI UL 2034 listed and 6 FHUWL HG 3 Signage PHWDO RU SODVWLF LGHQWL ...

Page 21: ...du retrait d une chaudiére existante OHV PHVXUHV VXLYDQWHV GRLYHQW rWUH SULVHV SRXU chaque appareil toujurs raccordé au systéme d évacuation commun et qui fonctionne alors que d autres appareils toujours raccordés au système d évacuation ne fonctionnent pas 1 Sceller toutes les ouvertures non utilisées du système d évacuation 2 Inspecter de facon visuelle le système d évacuation pour déterminer la...

Page 22: ...manual shutoff valves in accordance with state and local requirements 6 A sediment trap must be provided upstream of the gas controls 7 All threaded joints should be coated with piping FRPSRXQG UHVLVWDQW WR DFWLRQ RI OLTXH HG SHWUROHXP JDV 8 The appliance and its individual shutoff valve must be disconnected from the gas supply piping during any pressure testing of that system at test pressures in...

Page 23: ...as Table 13 Pipe Capacity for Propane SCHED 40 METAL PIPE CAPACITY FOR 1 50 SPECIFIC GRAVITY UNDILUTED PROPANE NOMINAL PIPE SIZE 11 W C INLET AND 0 5 W C PRESSURE DROP Nominal 1 2 2 3 4 Actual ID 1 61 2 067 2 469 3 068 4 026 Length ft 10 3 520 6 790 10 800 19 100 39 000 20 2 420 4 660 7 430 13 100 26 800 30 1 940 3 750 5 970 10 600 21 500 40 1 660 3 210 5 110 9 030 18 400 50 1 480 2 840 4 530 8 00...

Page 24: ...utput Max Min 25 F Head loss Feet 30 F Head loss Feet 35 F Head loss Feet 40 F Head loss Feet 1 504 000 122 100 87 76 320 000 26 22 19 16 1 883 000 150 128 109 95 400 000 33 28 24 21 2 374 000 190 158 136 119 499 980 41 34 30 26 2 814 000 226 190 164 142 600 000 49 41 35 31 3 276 000 266 222 190 166 700 000 57 48 41 36 3 724 000 300 255 218 190 800 000 66 55 47 41 19 4 30 34 47 41 48 1600 2000 250...

Page 25: ...2 25 33 0 575 14 10 1 2500 190 25 33 7 719 13 9 10 0 3000 190 30 36 0 719 17 11 0 3500 222 30 30 6 839 17 9 0 4000 224 34 30 0 848 19 9 1 Water Hardness 1 10 grains per gallon Flow Rate Temp Rise Headloss Flow Rate Temp Rise Headloss GPM F Ft LPM C m 177 17 41 0 670 9 4 12 5 177 21 43 9 670 12 13 4 220 21 46 0 833 11 7 14 220 26 46 0 833 14 14 266 25 40 6 1007 14 12 266 29 41 2 1007 16 12 6 Water ...

Page 26: ...ection 6 WATER CONNECTIONS BOILERS 6 1 System Piping Hot Supply Connections Note This appliance must be installed in a closed pressure system with a minimum of 12 psi 82 7 kPa static pressure at the boiler The hot water piping should be supported by VXLWDEOH KDQJHUV RU ÀRRU VWDQGV R QRW VXSSRUW WKH piping with this appliance The hangers used should allow for expansion and contraction of pipe Rigid...

Page 27: ...e vent line This will help prevent excessive condensate from entering the unit at the vent Figure 8 Raised concrete platform Neutralizer kit is not included 6 5 Suggested Piping Schematics Figure 9 on page 24 through Figure 12 on page VKRZ VXJJHVWHG SLSLQJ FRQ JXUDWLRQV IRU boilers These diagrams are only meant as guides All components or piping required by local code must be installed The condens...

Page 28: ...r vent 4 pipe dia max 4 pipe dia max 4 pipe dia max 4 pipe dia max Low temp radiant zone Space heating zone circuits Space heating zone circuit System pump Note This drawing is a schematic representation of a piping style and is not intended to be used as a working installation drawing Local code requirements must be met ...

Page 29: ...iant zone Low temp radiant zone Air vent Water feed controls Expansion tank 4 pipe dia max Indirect DHW tank Anti scald mixing valve Domestic hot water out Cold water Note This drawing is a schematic representation of a piping style and is not intended to be used as a working installation drawing Local code requirements must be met 4 pipe Dia Max ...

Page 30: ...one Space heating zone circuit Air vent Water feed controls Expansion tank Common piping must be sized for the combined water flow of all of the boilers 4 pipe dia max 4 pipe dia max 4 pipe dia max Note This drawing is a schematic representation of a piping style and is not intended to be used as a working installation drawing Local code requirements must be met ...

Page 31: ... water flow of all the boilers High temp space heating zone circuit 4 pipe dia max 4 pipe dia max 4 pipe dia max Indirect DHW tank 4 pipe Dia Max Note Indirect pump must be sized for boiler and indirect Anti scald mixing valve Domestic hot water out Cold water Note This drawing is a schematic representation of a piping style and is not intended to be used as a working installation drawing Local co...

Page 32: ...S 7 1 Water Quality Water heaters must be installed in water conditions of 15 gpg hardness or less with a pH range of 6 5 to 9 5 pH Values outside of this range may reduce the life expectancy of the product Operating the in water with higher hardness levels will cause heat exchanger fouling erosion or corrosion leading to SUHPDWXUH FRPSRQHQW IDLOXUH UHGXFHG HI FLHQF heat exchanger failure or syste...

Page 33: ...mage due to freezing water or condensate is not covered by the warranty If installed indoors and there is an event such as a power outage component failure or other issue when freezing is likely the heater and system must be drained to avoid the risk of damage due to freezing Glycol must not be used in volume water heating applications Cold water supply 2 Expansion tank 1 Pump TPRV 1 Building retu...

Page 34: ...almost always used It is advised that the unit be installed on a raised 4 concrete platform so WKDW WKHUH LV VXI FLHQW HOHYDWLRQ IRU WKH FRQGHQVDWH neutralizer below the included condensate trap See Figure 8 on page 23 Caution Condensate is mildly acidic pH 5 and PD KDUP VRPH ÀRRU GUDLQV DQG RU SLSHV particularly those that are metal Ensure that the drain drainpipe and anything that will come in c...

Page 35: ... been prewired No attempt should be made to connect electrical wires to any other location except the terminal blocks This unit is provided with an electrical junction box in the rear panel for main power connections See Figure 17 All power wires are factory installed between this junction box and the Main High Voltage Box at the front of the unit The unit is available with multiple voltage packag...

Page 36: ...nd DHW pump terminals are found on the Main control board TB1 15A through 20A They are fed 120 Volts internally from the main power feed The current rating of the contacts is 7 4 amps and an appropriately sized contactor PXVW EH VXSSOLHG DQG LQVWDOOHG E D TXDOL HG technician to ensure proper pump operation Once the system has been installed the Pump RQ JXUDWLRQ PHQX ZLOO DOORZ WKH LQVWDOOHU WR adj...

Page 37: ...n any wiring to the right as this will restrict the opening ability of the Control panel WARNING Electrical Shock Hazard Electrical shock can cause severe injury death or property damage Disconnect the power supplybeforebeginninginstallationorchanging thewiringtopreventelectricalshockordamage to the equipment It may be necessary to turn off more than one power supply disconnect All electrical wiri...

Page 38: ...rive 8 6 Field Connections for Lead Lag installations RU HDG DJ LQVWDOODWLRQV WKHUH DUH possible installation scenarios 8 5 Field Connections for Single unit installations Power for Field Connections must be made at Terminal Board 1 at the front of the unit 15 thru 45 of TB1 See Figure 18 and Figure 19 For single unit installations the connections for System Sensor Outdoor Sensor Call for Heat and...

Page 39: ...43 4 20MA 430 10VDC 4 20MA 44 0 10VDC CONN B CONN C 8 7 Control Panel Layout Figure 19 Control Panel Layout VARI PRIME PRINTED CIRCUIT BOARD KIT 9 AUTO RESET HIGH LIMIT CONTROL 8 TOUCH SCREEN ALARM SILENCE SWITCH MANUAL RESET HIGH LIMIT ALARM BELL optional LOW WATER CUT OFF BAS GATEWAY optional 7 6 5 4 Terminal block for field connections 3 2 1 TB1 includes FIELD CONNECTIONS WARNING When servicing...

Page 40: ...s commercial unit can be controlled and monitored with a Gateway BAS using the included Modbus ports Doc 4236 The Gateway Modbus Control H2354400 IRU QHW 06 73 QHW 3 0RGEXV 7 3 3 Metasys N2 and LonWorks Connect the Gateway Control to the COM2 A B and C as shown in Figure 20 6HH SDJH IRU FRQ JXUDWLRQ VHWXS ZLWKLQ WKH touchscreen display Gateway Control H2354400 Doc 4236 ...

Page 41: ...nnected in Lead Lag up to a total of 8 units controllers One as the Lead control and up to 7 more as the Lag controllers For Lead Lag Connections COM2 A B and C must be connected together AND the MB2 A B and C must also be connected together as shown in Figure 20 6HH SDJH IRU FRQ JXUDWLRQ VHWXS ZLWKLQ WKH touchscreen display ...

Page 42: ... 4 DISPLAY 7 DISPLAY 8 LWCO 2 120V N P1 P2 ADDITIONAL HIGH LIMIT BLOCKED FLUE BLOCKED INTAKE THERMAL CUTOUT FLOW SWITCH HIGH GAS MANUAL RESET HIGH LIMIT TO TB1 4C 120V N TO B4 PROBE 2 1 9 2 10 3 11 4 12 5 13 6 14 7 15 PILOT VALVE MAIN VALVE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 7 9 10 LWCO BK G W G W R W W 12 P...

Page 43: ...ROM SHIELDED CABLE BL Y BL V W V OR OR W W BK W V W BK BR Y BR Y G W BK BK BK R BK Y W R W R W R GY BL BR R BR Y GY V GY BK R GY R FLAME ROD BK OR 2 1 3 4 TB1 39C TB1 40C TB1 42C TB1 43C TB1 45C TB1 44C J3 Y W BR BK BR R BK BR G BK O BR V BK V TB1 36C TB1 37C TB1 38C NOTE DASHED LINES DENOTE VARIPRIME PUMP 1 CONTROLS VARIPRIME INSTALLED ON HYDRONIC UNITS ONLY BL BL W W BK BL BL V V R R BL BL Y Y B...

Page 44: ...PARK GENERATOR 15 7 14 6 13 5 12 4 11 3 10 2 9 1 2 TO B4 PROBE TO TB1 4C 120V N MANUAL RESET HIGH LIMIT HIGH GAS FLOW SWITCH THERMAL CUTOUT BLOCKED FLUE BLOCKED INTAKE ADDITIONAL HIGH LIMIT P1 P2 LWCO 2 120V N DISPLAY 8 DISPLAY 7 4 Y W W R W R BL BR W V BK G BK Y W BK BL BR BL W BR Y OR W OR BL Y TO LWCO PROBE AT HX FROM LWCO PROBE TO PROBE 3 8 2 1 TOD G BK W 5 BR R BL Y BR G BR V 6 5 4 2 1 3 120V...

Page 45: ...DASHED LINES DENOTE VARIPRIME PUMP 1 CONTROLS VARIPRIME INSTALLED ON HYDRONIC UNITS ONLY USED ON SIZE 4 0 KBTU ONLY 2 TB1 38C TB1 37C TB1 36C BK V BR V BK O BR G BK BR R BK BR W Y J3 TB1 44C TB1 45C TB1 43C TB1 42C TB1 40C TB1 39C 4 3 1 2 BK OR FLAME ROD GY R R GY BK GY V BR Y BR R GY BL W R W R W R BK Y BK R BK BK W G BR Y BR Y W BK W V W BK OR W OR V V W BL Y BL DRAIN WIRE FROM SHIELDED CABLE IN...

Page 46: ...CTOR L1 L2 BK W W BK W G BR CONVENIENCE RECEPTACLE GFCI 2 AMP N G H 10 AMP 2 AMP PE N L BLOWER TO CONNECTOR E ON DIAGRAM E23512 BR BK R BK BR BK BK 110 VAC NEUTRAL GRND BK W G ND BK WIRE COLOR LEGEND BLACK BK BROWN BR RED R ORANGE O YELLOW Y GREEN G BLUE BL VIOLET V GRAY GY WHITE W 8 11 High Voltage Wiring Diagrams Figure 23 High voltage wiring diagram Model 1600 120V ...

Page 47: ...Page 43 Figure 24 High voltage wiring diagram Model 1600 208V Single Phase ...

Page 48: ...4 SP1000MGMJ R TO CONNECTOR E ON DIAGRAM E23512 L1 L2 G BLOWER L1 BK L2 WIRE COLOR LEGEND BLACK BK BROWN BR RED R ORANGE O YELLOW Y GREEN G BLUE BL VIOLET V GRAY GY WHITE W SCALE NONE INTENDED SIZE SOFTWAR C APPROVALS DRAFT ENGR APPR UNLESS OTHERWISE SPECIFIED DO NOT SCALE DRAWING THIRD ANGLE PROJECTION DIMENSIONS ARE IN INCHES TOLERANCES ARE MATERIAL FINISH NA NA JAT 1 19 15 S AL 1 19 15 DECIMALS...

Page 49: ...3 33 03 03 7 7 217 725 9 9 75 16 250 5 3 33 03 2 5 1 1 03 5 5 1 2 9 5 9 5 219 1 1 5 37 03 1 22 1 1 9 1 87 1 2 5 5 5 5 72 211 725 21 5 0 9 1 7 9 7 8 7 9 3 5 5 127 6 5 5 0 1 2 80 17 Figure 26 High voltage wiring diagram Model 2000 120V ...

Page 50: ... E ON DIAGRAM E23512 XFRMR X4 W X4 X1 L2 L1 G FIELD CONN ECTIONS TB2 5A TB2 5C CONT A2 VFD PE HIGH VOLTAGE 120V G BLOWER L1 L2 L3 BK W 2 5 PE 4 1 0 10V U T1 V T2 W T3 N L1 L2 VFD BL G BK R TB2 7B 0010 SCALE NONE INTENDED SIZE SOFTWARE DWG B VOLTAG DIAGRAM 1 8 TITLE FRACTIONS 1 010 DECIMALS XXX 03 DECIMALS XX 1 GL 1 09 17 S XR 1 09 17 FINISH MATERIAL TOLERANCES ARE DECIMALS X DIMENSIONS ARE IN INCH...

Page 51: ... AMP 5 4 6 1 2 3 G Y BL W BK O BK L3 L2 L1 BLOWER BK R R BK L2 L1 CONTACTOR A2 A1 T2 T1 BK W CONNECT TO MAIN CTRL PANEL H2359100 TB1 45B TB1 44B BK W 5 2 PE 4 1 0 10V U T1 V T2 W T3 N L1 L2 VFD TO CONNECTOR E ON DIAGRAM E23512 BK G SP1000MGMJ H4 H2 H3 H1 X4 X1 X3 X2 HV 220VAC R BL R BK G BK R GND L2 BK W Figure 28 High voltage wiring diagram Model 2000 240V ...

Page 52: ...3 L2 T2 T3 120 VOLT TO CONNECTOR E ON DIAGRAM E23512 SP1000SP H3 H2 TRANSFORMER 208 VOLT H1 H4 X3 X4 X2 X1 R BK W BK SP1000ACP H3 H2 TRANSFORMER 480 VOLT 120 VOLT H1 H4 X3 X4 X2 X1 O BR W BK SP1000ACP H2 TRANSFORMER 600 VOLT 120 VOLT H1 H3 X3 X4 X2 X1 V P W BK XFRMR X1 BK X4 X1 TB1 44B L2 L1 L3 TB1 45B G FIELD CONN ECTIONS TB2 6A TB2 8B TB2 6C CONT A2 VFD PE HIGH VOLTAGE 120V BLOCK FLUE INTAKE SWI...

Page 53: ... PUMP SYSTEM PUMP BOILER PUMP J8 3 TB1 13 J8 6 J8 7 J8 11 J8 12 J4 2 J4 4 TB1 4A TB1 4A J4 6 J4 2 J4 4 J4 6 TB1 4A TB1 4A J6 3 R1 120V 120V 120V 120V 120V 120V FLOW SWITCH TB1 35C TB1 33C OUTLET WATER J8 8 J8 9 J8 4 J8 10 J8 5 3 2 4 1 STACK J9 4 J9 5 J9 6 3 2 4 1 BOILER PUMP SYSTEM PUMP DHW PUMP TB1 4A NOTE WHEN AN OPTIONAL COMPONENT IS NOT PRESENT THE SIGNAL MUST BE JUMPED 1 J10 7 J9 1 J9 2 DISPL...

Page 54: ...Page 50 8 12 Ladder Diagrams continued Figure 31 Model 1600 208V 1 Phase ladder diagram ...

Page 55: ...UMP J8 3 TB1 13 J8 6 J8 7 J8 11 J8 12 J4 2 J4 4 TB1 4A TB1 4A J4 6 J4 2 J4 4 J4 6 TB1 4A TB1 4A J6 3 R1 120V 120V 120V 120V TB1 35C TB1 34C TB1 33C OUTLET WATER INLET WATER J8 8 J8 9 J8 4 J8 10 J8 5 3 2 4 1 STACK J9 4 J9 5 J9 6 3 2 4 1 BOILER PUMP SYSTEM PUMP DHW PUMP TB1 4A NOTE WHEN AN OPTIONAL COMPONENT IS NOT PRESENT 1 THE SIGNAL MUST BE JUMPED J10 7 J9 1 J9 2 DISPLAY 5 J10 4 2 1 L1 L2 L2 L1 B...

Page 56: ...Page 52 8 12 Ladder Diagrams continued Figure 33 Model 2000 208V 1 Phase ladder diagram ...

Page 57: ...24 25 26 28 27 ALARM J6 7 J6 8 J10 2 TOD FEED 41 42 40 39 38 37 36 35 DISPLAY 4 34 33 32 31 29 30 REMOTE RESET MB2 COM 2 DHW SENSOR PUMP 0 10V J10 3 MB2 C MB2 A DISPLAY 6 J10 6 4 20 ma 0 110VDC 43 44 45 0 10VDC J10 5 4 20 ma VARIPRIME ONLY R3 J10 8 J10 1 MB2 B VTB 3 3 VTB 3 4 120 NEUTRAL VARIPRIME ONLY VFD TERM 2 VFD TERM 5 VARIPRIME PUMP CONTROL MOUNTED ON HYDRONIC UNITS ONLY J8 1 J8 3 J8 2 2 P2 ...

Page 58: ...8 17 15 16 FIELD CONNECTIONS TT ANALOG OUTDOOR SYSTEM DHW PUMP SYSTEM PUMP BOILER PUMP J8 3 TB1 13 J8 6 J8 7 J8 11 J8 12 J4 2 J4 4 TB1 4A TB1 4A J4 6 VFD 16 VFD 17 J4 2 J4 4 J4 6 TB1 4A TB1 4A J6 3 R1 120V 120V 120V 120V 120V 120V FLOW SWITCH TB1 35C TB1 34C TB1 33C OUTLET WATER INLET WATER J8 8 J8 9 J8 4 J8 10 J8 5 3 2 4 1 STACK J9 4 J9 5 J9 6 3 2 4 1 BOILER PUMP SYSTEM PUMP DHW PUMP TB1 4A NOTE ...

Page 59: ...0 1 J10 8 R3 VARIPRIME ONLY 4 20 ma J10 5 0 10VDC 45 44 43 4 20 ma 0 110VDC J10 6 DISPLAY 6 MB2 A MB2 C J10 3 PUMP 0 10V DHW SENSOR COM 2 MB2 REMOTE RESET 30 29 31 32 33 34 DISPLAY 4 35 36 37 38 39 40 42 41 TOD FEED J10 2 J6 8 J6 7 ALARM 27 28 26 25 24 23 22 21 TB1 4A 20 19 18 17 15 16 FIELD CONNECTIONS TT ANALOG OUTDOOR SYSTEM DHW PUMP SYSTEM PUMP BOILER PUMP J8 3 TB1 13 J8 6 J8 7 J8 11 J8 12 J4 ...

Page 60: ...uch Screen will automatically present this Home screen See Menu 1 Menu 1 Home Screen T T Figure 37 To access the Touch Screen Figure 39 With Front Doors Open O Color Status Control Icon Blue Normal operation Red Lockout Gray Standby mode Burner switch off Gray and crossed out Communication problem Yellow Hold state This could be Anti short cycle fan speed transitions etc Figure 38 Unit Status Colo...

Page 61: ...p and parameter changes made when the system is installed and some diagnostic and troubleshooting functions The installer level password is lnt lower case LNT User Level no password required Non critical adjustments and functions including adjusting the Central Heat and Domestic Hot Water setpoints monitoring the input and output variables reading parameters from the controller and reading the err...

Page 62: ...s Hazardous burner conditions can happen with improper operations that may result in PROPERTY LOSS PHYSICAL INJURY or DEATH Press OK to continue The system will ask you to login before you make a change For more information on logging in see Section 8 2 2 If you make a change in any group that could affect the safe operation of the unit the control system will ask you to verify the change before i...

Page 63: ...those groups in the same way Do this until the following screen shows Menu 8 Safety Parameter Reset 6 When the process is complete the system will tell you to reset the control system The Reset button is located on the front of the controller You must press the Reset button within 30 VHFRQGV RU WKH YHUL FDWLRQ ZLOO EH FDQFHOOHG A count down timer is shown at the bottom of the screen 9 4 Checking I...

Page 64: ...sed by the system Details Allows you to check the status of all of the setup parameters on the control system RQ JXULQJ 3DUDPHWHUV In this section we will give you a quick explanation of how to change parameters on the controller 1 From the Home Page screen Menu 11 press the icon for the controller Menu 11 Home Page Screen 2 The Status Summary page for that controller will appear See Menu 12 Menu ...

Page 65: ...ill be incorrect The display has a removable battery CR2032 to store time date lockout and alerts in the event of a power failure To set the clock 1 Start at the home screen Menu 14 Home screen 2 Press the Setup button on the lower right corner of the screen The system will present the Setup screen Menu 15 Setup Screen 3 Press the Display Setup button at the bottom of the screen Menu 16 Display Se...

Page 66: ...ay information regarding software date codes model numbers and program name as well as giving the installer access to re name the boiler and to change the modbus addresses for lead lag operation HQWUDO HDW RQ JXUDWLRQ When using the unit for hydronic heating a call for KHDW PXVW EH VXSSOLHG WR WKH 7 7 WHUPLQDOV IRXQG RQ TB1 25A and 26A Once a call for heat is established the control will start the...

Page 67: ...ndirect water heaters that are used with boiler MGH systems 9 7 5 Warm Weather Shutdown RQ JXUDWLRQ Connect the outdoor reset sensor as descibed in Section 8 3 URP WKLV PHQX RX ZLOO EH DEOH WR HQDEOH GLVDEOH WKH Warm Weather Shutdown feature and adjust the set point HPDQG 3ULRULW RQ JXUDWLRQ URP WKH HPDQG 3ULRULW RQ JXUDWLRQ WKH LQVWDOOHU FDQ adjust the priority of the different demand types Centr...

Page 68: ...Time DHW Pump Cycles Boiler Pump Cycles and System Pump Cycles This menu is Read Only 9 7 10 High Limits The outlet High limit can be adjusted using the installer password After a change is made the control will lockout DQG UHTXLUH D 6DIHW 9HUL FDWLRQ VHH 6HFWLRQ IRU PRUH GHWDLOV RQ 6DIHW 9HUL FDWLRQ Installers do not have access to change the Outlet High Limit Response That is only accessible to ...

Page 69: ...LV IHDWXUH 2 7KH QH W WLPH D FDOO IRU KHDW is supplied the unit will light normally 6 VWHP RQ JXUDWLRQ The installer can set the control to display temperature units in F or C can adjust the anti VKRUW F FOH WLPH WKH ORZ UH FXWRII WLPH EXUQHU off inhibit time and can set the time allowed for an alarm to sound before being silenced 6HQVRU RQ JXUDWLRQ The outdoor temperature can be read from the out...

Page 70: ...at as the heating demand increases the Lead Lag system puts more units on line As the heating demand is reduced the Lead Lag system shuts off some of the units The signal from the System sensor is sent to the unit operating as the Lead A Run sequence is initiated when the system temperature falls to the Lead Lag Central Heat setpoint Actually this is the LL CH setpoint less the On Hysteresis value...

Page 71: ... or death When the Run sequence is initiated the unit with the least amount of runtime will UH If the heating demand increases so that WKH ULQJ UDWH RI WKDW UVW XQLW ULVHV WR RXU XQLW FRQ JXUDWLRQV DVH RDG Value see Table 20 the next unit in the VHTXHQFH ZLOO VWDUW XS DQG EHJLQ ULQJ at 20 to 35 fan speed depending on RXU FRQ JXUDWLRQ IWHU WKLV WKH HQWLUH FRQ JXUDWLRQ RI XQLWV ZLOO PRGXODWH XS RU d...

Page 72: ...LQJ RQ 6ODYH QDEOH You will be prompted to sign in This can be done by pressing the LOCK symbol at the top right type in LNT and press OK Then you can select Slave Enable Select Enable Slave for built in Lead Lag Master Then select OK Then select a Modbus address number for that unit Then select OK Repeat on all units keeping them in a sensible sequencial order ...

Page 73: ...eat CH Config Central Heat CH Config Central Heat CH Config Setpoint CH Config Setpoint CH Config Setpoint CH Config Setpoint CH Config Setpoint CH Config Setpoint CH Config Setpoint CH Config Modulation CH Config Modulation CH Config Modulation CH Config Modulation CH Config Modulation Outdoor Reset Config Outdoor Reset Config Outdoor Reset Config Outdoor Reset Config Outdoor Reset Config DHW Con...

Page 74: ...o 22 50 Auto On 100 100 60 100 60 100 CH LL Slave CH DHW LL Slave DHW CH DHW Arrow Points to Loop with Higher Priority Arrow Points to Loop with Higher Priority Shutdown Immediately 95F Shutdown Immediately Disabled 35F 140F 10 0 0 100 0 100 Available settings or Ranges Default DHW Lead Lag 20 DHW Lead Lag Lead Lag DHW 0 100 240 min or 4 Hrs DHW CH 0 min 0 sec 1092 min 0 sec CH DHW DHW CH 10F 5F 2...

Page 75: ... 35F 140F Sequence Order Measured Run Time Shutdown Immediately Shutdown Immediately Disabled 65 0 0 100 DHW CH Enabled CH DHW DHW CH Enable Disable Drop After Priority Time 240 min or 4 Hrs Boost During Priority Time Drop After Priority Time 0 min 0 sec 1092 min 0 sec 120F 100F 40F 195F 40F 195F 140F Disabled 50F 200F STAT Terminal DHW S6 Sensor Shorted Disabled 130F 120F 40F 200F 40F 195F Local ...

Page 76: ... Adv Settings Modulation Lead Lag Master Config Adv Settings Modulation Lead Lag Master Config Adv Settings Modulation Lead Lag Master Config Adv Settings Modulation 10 0 0 100 0 100 5F 20 2F 30F 0 100 210F 10F 50F 210F 0F 30F 0 min 2 sec Disabled 0 min 0 sec 15 min 0 sec All Boilers Off Drop Lead Boiler on Error Threshold 2F 20 0F 50F 0 100 Error Threshold 0 min 2 sec Error Threshold Firing Rate ...

Page 77: ... additional information on purchasing and setting up Modbus and other communication protocols contact your Manufacturer s Representative Starting at the Home Screen tap onto the Display Setup button on the bottom right of the lead units screen RQ JXULQJ IRU WKH DWHZD From the Setup menu tap the Display Setup button Select the COM2 tab and make sure that the COM2 port is enabled Select the Gateway ...

Page 78: ...p output at 100 10 VDC or 20 mA 5 Once the Main Gas valve is energized the PCB will maintain pump output at 100 for 60 seconds to allow the system to stabilize Once the 60 second timer has expired the PCB will then run the pump output speed based on the jumper setpoint KHQ 7 7 LV VDWLV HG WKH 3 ZLOO UXQ SXPS at 100 output for the duration of the pump overrun time MXPSHU RQ WKH 3 WHUPLQDO RQ WKH 9 ...

Page 79: ...KH ORZHU OHIW corner Menu 28 RQ JXUDWLRQ 0HQX URP WKH RQ JXUDWLRQ PHQX VHOHFW WKH OLQH Burner Control Ignition Menu 29 Burner Control Ignition Once there select Pilot Test Hold and turn this feature ON This feature will allow the pilot to stay lit for setup and will NEVER UH WKH PDLQ EXUQHU LYH WKH XQLW D FDOO IRU heat and the boiler will begin its sequence of operation Refer to Section 12 8 for s...

Page 80: ...s only active when the boiler LV LQ 5XQ PRGH 7R VHWXS KLJK UH VHOHFW maximum modulation then Start Test buttons Wait for the boiler to enter run and the fan speed to reach the maximum RPM Using a combustion analyzer dial in the high UH WKURWWOH WR REWDLQ WKH FRUUHFW 2 DQG 2 measurements refer to Table 23 for correct CO2 ranges Menu 32 Modulation Test 2QFH KLJK UH LV VHWXS FRUUHFWO VHOHFW Minimum M...

Page 81: ...U WKDQ KLJK UH 22 0 5 to 1 2 wc Propane 10 0 0 2 ORZHU WKDQ KLJK UH 22 0 5 to 1 2 wc 3 500 Natural 9 0 0 2 ORZHU WKDQ KLJK UH 22 0 5 to 1 2 wc Propane 10 0 0 2 ORZHU WKDQ KLJK UH 22 0 5 to 1 2 wc 4 000 Natural 9 0 0 2 ORZHU WKDQ KLJK UH 22 0 5 to 1 2 wc Propane 10 0 0 2 ORZHU WKDQ KLJK UH 22 0 5 to 1 2 wc Only check the pressures if there are problems getting the CO2 and CO values in range LJK UH ...

Page 82: ... and any gas control that may have been under water Section 10 INITIAL STARTUP INSTRUCTIONS 10 1 Filling the Boiler System 1 Ensure the system is fully connected Close all bleeding devices and open the make up water YDOYH OORZ WKH V VWHP WR OO VORZO 2 If a make up water pump is employed adjust the pressure switch on pumping system to provide a minimum of 12 psi 81 8 kPa at the highest point in the...

Page 83: ...ecked before the unit is put into operation Problems such as failure to start rough ignition strong exhaust odors etc can be due to improper setup Damage to the boiler resulting from improper setup is not covered by the limited warranty 10 2 1 Initial Burner Operation 1 Using this manual make sure the installation is complete and in full compliance with the instructions and all local codes HWHUPLQ...

Page 84: ...ixer assembly to be removed as an assembly to facilitate inspection and cleaning WARNING Disconnect all power to the unit before attempting any service procedures Contact with electricity can result in severe injury or death 11 1 System Maintenance Do the following once a year 1 Lubricate all the pumps in the system per the instructions on the pump 2 Inspect the venting system for obstruction or l...

Page 85: ... be defective install a new spark assembly in the reverse order replacing the gasket if necessary 11 2 5 Flame Sensor 7KH ÀDPH VHQVRU LV D VLQJOH URG V VWHP 7KH PLQLPXP ÀDPH VLJQDO WKDW ZLOO DOORZ WKH XQLW WR UH LV YROWV 7R UHSODFH WKH ÀDPH VHQVRU HOHFWURGH VKXW RII WKH SRZHU supply to the boiler Turn off all manual gas valves connecting the boiler to the main gas supply line Open WKH IURQW GRRUV ...

Page 86: ...t exchanger tubes 7 Once the tubes have been brushed clean rinse the tubes and combustion chamber with a small amount of water to rinse all of the debris RXW RI WKH ERWWRP RI WKH ÀXH FROOHFWRU DQG LQWR the longer condensate trap line which is being diverted into a separate container Note The Warranty does not cover damage caused by lack of required maintenance lack of ZDWHU ÀRZ RU LPSURSHU RSHUDWL...

Page 87: ... the date and time settings The battery is a CR2032 coin type battery and has an expected service life of 6 years If the battery needs to be replaced there is a battery cover on the back of the touchscreen display and it can be easily reached when the panel that the Touchscreen is mounted to is pulled forward ...

Page 88: ...cates that the control system LV ZDLWLQJ IRU D FRQGLWLRQ WR EH VDWLV HG 1R Reset is required to recover from an alert The system maintains a history of the 15 most recent alerts Sometimes it can be helpful to check this list as a troubleshooting aid 12 1 1 Responding to a Lockout Hold or Alert 1 If a problem occurs while the system is starting up the system will declare a Hold A brief explanation ...

Page 89: ...ckout occurances Press Alerts to bring up a list of the last 15 Alerts and Silence Alarm in the event of a lockout condition By silencing the alarm the audible alert has been disabled However the Lockout is still active Reset of the control is needed once the condition has been repaired If you choose ALERTS this menu will appear Menu 36 Alert History If you choose LOCKOUTS this menu will appear Me...

Page 90: ...2 Waiting for safety GDWD YHUL FDWLRQ L HYLFH LQ RQ JXUDWLRQ PRGH DQG VDIHW SDUDPHWHUV QHHG YHUL FDWLRQ DQG D GHYLFH QHHGV UHVHW WR FRPSOHWH YHUL FDWLRQ RQ JXUDWLRQ HQGHG ZLWKRXW YHUL FDWLRQ UH HQWHU FRQ JXUDWLRQ YHULI VDIHW SDUDPHWHUV DQG UHVHW GHYLFH WR FRPSOHWH YHUL FDWLRQ 3 If fault repeats replace module 3 Internal fault Hardware fault H Internal fault 1 Reset module 2 If fault repeats replac...

Page 91: ...cle starts H 24 Internal fault Spark voltage stuck low or high H 25 Internal fault Spark voltage changed too much during ÀDPH VHQVLQJ WLPH H 26 Internal fault 6WDWLF ÀDPH ULSSOH H 27 Internal fault Flame rod shorted to ground detected H 28 Internal fault A D linearity test fails H 29 Internal fault Flame bias cannot be set in range H 30 Internal fault Flame bias shorted to adjacent pin H 31 Intern...

Page 92: ...tch H 1 Reset the low gas pressure valve and the high gas pressure valve 2 Check for power at all Safety Components 3 Check wiring and correct any faults 4 Check all safety interlocks connected to the safety circuit to assure proper function 5 If code persists contact Tech Support 64 PII Pre Ignition Interlock OFF H or L 1 Check wiring and correct any faults 2 Check Preignition Interlock switches ...

Page 93: ...ault persists replace the module 92 Outlet sensor fault H 1 Check wiring and correct any possible errors 2 Replace the Outlet sensor 3 If previous steps are correct and fault persists replace the module 93 DHW Domestic Hot Water sensor fault H 1 Check wiring and correct any possible errors 2 Replace the DHW sensor 3 If previous steps are correct and fault persists replace the module 94 Header sens...

Page 94: ...QVIRUPHU HOHFWURGH ÀDPH GHWHFWRU ÀDPH GHWHFWRU VLWLQJ RU ÀDPH URG position 5 If steps 1 through 4 are correct and the fault persists replace the module 107 Flame lost early in run L 108 Flame lost in run L 1 Check main valve wiring and operation correct any errors 2 Check the fuel supply 3 Check fuel pressure and repeat turndown tests KHFN LJQLWLRQ WUDQVIRUPHU HOHFWURGH ÀDPH GHWHFWRU ÀDPH GHWHFWRU...

Page 95: ...eds 3 Change the VFD 4 If the fault persists replace the module 130 Fan speed failed during ignition H or L 1 Check wiring and correct any potential wiring errors 2 Check the VFDs Variable speed Fan Drive ability to change speeds 3 Change the VFD 4 If the fault persists replace the module 131 Fan movement detected during standby H 1 Check wiring and correct any potential wiring errors 2 Check the ...

Page 96: ...nd sequence the module if code UHDSSHDUV UHSODFH WKH ÀDPH GHWHFWRU 5 Reset and sequence the module if code reappears replace the module 157 RPEXVWLRQ SUHVVXUH DQG ÀDPH 2 L 158 Main valve ON L 1 Check Main Valve terminal wiring and correct any errors 2 Reset and sequence the module If fault persists replace the module 159 Main valve OFF L 160 Ignition ON L 1 Check Ignition terminal wiring and corre...

Page 97: ...put enable setting L 200 Invalid lightoff rate setting L 201 Invalid lightoff rate proving setting L 202 Invalid MFEP Main Flame Establishing Period time setting L 203 Invalid MFEP Main Flame Establishing 3HULRG ÀDPH IDLOXUH UHVSRQVH VHWWLQJ L 204 Invalid NTC sensor type setting L 205 Invalid Outlet high limit response setting L 207 Invalid PII Pre Ignition Interlock enable setting L 210 Invalid P...

Page 98: ...t setpoint setting L 228 Invalid Stack limit setpoint setting L 229 Invalid Modulation output setting L 230 Invalid CH Central Heat demand source setting L 231 Invalid Delta T limit delay setting L 232 Invalid Pressure sensor type setting L 234 Invalid Outlet high limit enable setting L 235 Invalid Outlet connector type setting L 236 Invalid Inlet connector type setting L 237 Invalid DHW Domestic ...

Page 99: ...e Burner Control I O button leads to Menu 40 Menu 40 Burner Control I O Screen A green dot indicates a function that is on 2 Press the Digital I O button to see parameters with the functions that are either on or off See Menu 41 Menu 41 Digital I O Screen 3 The button for Analog I O displays items that change continuously between two limits See Menu 42 Menu 42 Analog I O Screen 4 Press the button ...

Page 100: ... cycles etc Menu 46 6WDWLVWLFV RQ JXUDWLRQ 6FUHHQ 12 6 Analysis The control system includes an Analysis branch that can display the behavior over a period of time for several different parameters fan speed outlet temperature inlet temperature etc Menu 47 Analysis Setup Screen To use this function select the parameter you want to track from the pull down list The system will present a graph that tr...

Page 101: ...VXUH VZLWFKHV 2 DQG High Limit aquastats are completed the unit will start the blower and begin the ignition sequence 7KH XQLW LV HTXLSSHG ZLWK D ORZ DQG KLJK UH DLU pressure switch The unit will pre purge at 65 fan for 30 seconds and prove fan through the blocked intake switch Once fan is proven the blower will proceed to 24 and the 10 second Pre ignition timer will start to allow the spark to be...

Page 102: ...Section 13 REPLACEMENT PARTS Use only genuine Manufacturer replacement parts 13 1 General Information To order or purchase parts for the Manufacturer Unit contact your nearest Manufacturer dealer or distributor If they cannot supply you with what you need contact Customer Service See the back cover for addresses and for telephone and fax numbers Frame and Jacket Assembly ...

Page 103: ...30N3020 30N3020 40N3020 40N3020 13 Panel lower rear 16N3021 20N3021 25N3021 30N3021 40N3021 40N3021 14 Panel right 20N3036 20N3036 30N3036 30N3036 40N3036 40N3036 15 Strut upper panel support 30N3043 30N3043 30N3043 30N3043 30N3043 30N3043 16 Panel top 16N3045 20N3045 30N3045 30N3045 40N3045 40N3045 17 Brace lower left side 20N3047 20N3047 30N3049 30N3049 40N3047 40N3047 18 Hinge mounting bracket ...

Page 104: ...Page 100 1 13 12 4 3 5 13 2 15 DETAIL A 9 10 8 DETAIL Final Assembly ...

Page 105: ...nel drain access 40N3048 40N3048 40N3048 40N3048 40N3048 40N3048 8 Pressure switch E2363100 E2362200 E2362201 E2361900 E2361900 E2361900 9 Pressure switch E2344901 E2362000 E2363400 E2362301 E2362300 E2362300 10 Pressure switch E2362200 N A N A N A E2362302 E2362302 11 Outlet box not shown E2350900 E2350900 E2350900 E2350900 E2350900 E2350900 12 Spacer F2035400 F2035400 F2035400 F2035400 F2035400 ...

Page 106: ...1 2 NPT RE2058300 RE2058300 RE2058300 RE2058300 RE2058300 RE2058300 5 Sensor water temperature duplex RE2319900 RE2319900 RE2319900 RE2319900 RE2319900 RE2319900 6 Coupling flexible victaulic P2086500 P2086500 P2086500 P2086500 P2086600 P2086600 7 Plug MGH N A N A P2088300 P2088300 P2088300 P2088300 MGV N A N A P2080300 P2080300 P2080300 P2080300 8 Grommet rubber S2114000 S2114000 S2114000 S211400...

Page 107: ...Page 103 A 12 10 1 2 2 3 6 16 8 7 11 13 15 14 4 9 5 W2014100 20N3060 17 Spark Generator 17 DETAIL 16N5074 13 2 4 Blower Burner Assembly Part Numbers Model 1600 A2132700 ...

Page 108: ... 10 Blower 11 Ignitor hot surface 12 Pilot tube 13 Compression fitting 14 Gasket filter box flange 15 Pipe flange weldment 16 Pipe flange weldment 17 Gasket venturi gas valve 2000 Part No L2019500 S2125500 20N5037 RF0044800 W2014900 S2125600 A2123300 20N5095 N A A2122100 W2014400 20N5088 P2085000 20N5094 20N5092 20N5090 S2104900 W2014100 20N3060 18 Spark Generator 18 DETAIL See Section 13 2 11 13 ...

Page 109: ... 17 Gasket venturi gas valve 2500 3000 Part No Part No L2020600 L2020600 S2125100 S2125100 30N5037 30N5037 RF0044800 RF0044800 W2014900 W2014900 S2125200 S2125200 30N5092 30N5092 S2125300 S2125300 A2121601 A2121601 A2122100 A2122100 W2014400 W2014400 30N5093 30N5093 P2085000 P2085000 N A N A N A N A N A N A N A N A SEE DETAIL A FOR PILOT TUBE PLACEMENT DETAIL A 8 3 7 9 1 6 12 13 2 11 4 5 10 W20141...

Page 110: ...G 0 0 1 4 2 1 2 S 1 1 E T P A D A 0 0 2 0 9 0 2 P 2 2 R E N R U B 0 0 9 9 1 0 2 L 1 1 W E R C S 7 9 3 0 2 F 8 8 8 3 T U N 0 0 1 3 0 0 0 F 6 1 6 1 16 16 F2037700 WASHE W E R C S 0 0 9 6 0 0 2 F 2 2 R O S N E S 0 0 6 1 2 1 2 A 1 1 M D L E W 0 9 0 5 N 0 4 1 1 E W O L B 7 7 0 5 N 0 4 1 1 A T N I R I A 9 6 0 5 N 0 4 1 1 1 40N6021 GAS TR 3 5 9 6 11 13 12 4 3 7 1 10 11 2 8 14 15 16 17 ...

Page 111: ...ly 40N5069 40N5069 8 Gasket blower intake S2125300 S2125300 9 Blower A2120900 A2120900 10 O Ring S2124800 S2124800 11 Adapter 1 4 tube x 1 8 female P2090200 P2090200 12 Blower tube 40N5077 40N5077 13 Gasket burner S2124600 S2124600 14 Ignitor hot surface W2013900 W2013900 15 Sight glass RF0044800 RF0044800 16 Flame sensor W2014900 W2014900 W2014100 W2014100 40N3060 17 40N3060 Spark Generator See S...

Page 112: ...Page 108 28 26 38 39 26 23 27 16 31 23 20 5 35 11 10 29 7 25 34 37 2 24 9 12 13 14 3 3 4 36 1 17 19 26 39 39 9 6 6 21 17 18 22 30 32 15 8 33 Gas Train Assembly Models 1600 2000 2500 and 3000 ...

Page 113: ...5086 30N6027 30N6027 17 Nipple 1 8 x2 P0011300 P0011300 P0011300 P0011300 18 Elbow 1 8 P2008900 P2008900 P2008900 P2008900 19 Nipple 1 8 P0011100 P0011100 P0011100 P0011100 20 Nipple tee weldment 30N6031 30N6031 30N6031 30N6031 21 Tee 1 8 P0027100 P0027100 P0027100 P0027100 22 Nipple 1 8 x close P0011100 P0011100 P0011100 P0011100 23 Plug 70 236 70 236 70 236 70 236 24 Ball valve V2003300 V2003300...

Page 114: ... Assembly Models 3500 and 4000 1 70 236 1 W200030 2 S2123500 2 P2089600 1 P2089300 1 40N6040 18 23 24 16 22 14 13 12 21 20 1 19 17 14 7 25 26 27 28 29 3 4 5 6 7 8 16 15 2 17 14 14 13 12 9 10 11 32 33 35 36 31 32 34 31 30 ...

Page 115: ...0 15 Tee 1 8 P0027100 P0027100 16 Plug 1 8 70 236 70 236 17 Bushing 1 4 x1 8 P2032400 P2032400 18 Pipe gas inlet 40N6034 40N6034 19 Elbow 90 2 P2091100 P2091100 20 Nipple 2 x2 P0021100 P0021100 21 Flange 2 V2021900 V2021900 22 Elbow 90 1 8 P2008900 P2008900 23 Tee 3 8 P2090600 P2090600 24 Bushing 3 8 x1 8 P2090700 P2090700 25 Nipple 3 8 x2 P2089000 P2089000 26 Ball valve 3 8 V2022200 V2022200 27 P...

Page 116: ...lay touch control E2339800 E2339800 E2339800 E2339800 E2339800 E2339800 6 Bushing 7 8 nylon split S0064900 S0064900 S0064900 S0064900 S0064900 S0064900 7 High limit manual reset E2217800 E2217800 E2217800 E2217800 E2217800 E2217800 8 High limit auto reset E2217700 E2217700 E2217700 E2217700 E2217700 E2217700 9 Plug terminal block E2346300 E2346300 E2346300 E2346300 E2346300 E2346300 10 Vari Prime ...

Page 117: ...Page 113 1 2 3 12 10 7 9 8 14 13 4 5 6 AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS MODEL1600 13 2 11 AC Distribution Box Assemblies and Part Numbers Model 1600 ...

Page 118: ...Page 114 10 16 AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS AND BLOWER MODEL 2000 13 2 12 AC Distribution Box Assembly and Blower Part Numbers Model 2000 ...

Page 119: ...RT NUMBERS AND BLOWERS MODELS 2500 TO 4000 208V 480V 600V 208V 480V 600V 208V 480V 600V 208V 480V 600V 1 VFD With Program XN715008 XN715009 XN715010 XN715005 XN715006 XN715007 XN715011 XN715012 XN715013 XN715005 XN715006 XN715007 2500 3000 3500 4000 13 2 13 AC Distribution Box Assembly and Blower Part Numbers Models 2500 to 4000 ...

Page 120: ...HFL FDWLRQV VXEMHFW WR FKDQJH ZLWKRXW QRWLFH LQ DFFRUGDQFH ZLWK RXU SROLF RI FRQWLQXRXV SURGXFW LPSURYHPHQW Notes H2359201H 200 Lafayette St Middleville MI 49333 Warranty 800 531 2111 ZZZ UDGIRUG KLWH FRP Litho in U S A Bradford White 1710 Document 1293H ...

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