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Gasmaster R Series Installation Manual Download Page 74

 

CH Supply

 

CH supply sensor

 

201-0196

 

106-0435

 

16

 

CH Supply

 

Magnetite Filter C/H100 C/H140

 

202-1023

 

106-1278

 

16

 

CH Supply

 

Magnetite Filter C/H200

 

202-1179

 

106-1279

 

18

 

Hydroblock

 

IWC Hydroblock C/H100 C/H140

 

202-1235

 

106-1272

 

18

 

Hydroblock

 

IWC Hydroblock C/H200

 

202-1236

 

106-1273

 

18

 

Hydroblock

 

SPARE PUMP HEAD

 

206-0463

 

106-1259

 

 

 

C/H100 & C/H140

 

 

 

18

 

Hydroblock

 

SPARE PUMP HEAD C/H200

 

206-0464

 

106-1260

 

18

 

Hydroblock

 

O-Ring Hydroblock D18 (o-ring

 

202-0130

 

106-1099

 

 

 

CH connections hydroblock)

 

 

 

18

 

Hydroblock

 

O-ring Hydroblock D10

 

202-1080

 

106-1092(10pcs)

 

 

 

(expansion vessel pipe

 

 

 

 

 

connection)

 

 

 

18

 

Hydroblock

 

O-ring Hydrocoupling (connection

 

202-1081

 

106-1093(10pcs)

 

 

 

pipe hydroblock left/right)

 

 

 

 

 

 

 

 

18

 

Hydroblock

 

Plug D10 (expansion vessel

 

202-1124

 

106-1094(5pcs)

 

 

 

connection closing plug)

 

 

 

18

 

Hydroblock

 

O-ring Hydroblock D12 (o-ring

 

202-1129

 

106-1096(10pcs)

 

 

 

DHW connections hydroblock)

 

 

 

18

 

Hydroblock

 

Metal clip D10 (mouting clip for

 

202-1136

 

106-1097(5pcs)

 

 

 

expansion vessel connection)

 

 

 

18

 

Hydroblock

 

Plastic quick connect clips for

 

202-1139

 

106-1098

 

 

 

Hydroblock connections, D18

 

 

 

 

 

(Quick connection clips for pipes

 

 

 

 

 

to PHE)

 

 

 

19

 

Flow Sensor

 

Flow Sensor

 

206-0432

 

109-1062

 

 

 

3-WAY VALVE MOTOR

 

206-0431

 

109-1059

 

20

 

Pressure sensor

 

Pressure sensor

 

202-1135

 

106-1061

 

21

 

Burner control

 

HAG-C04-IT02 Canada

 

202-1233

 

106-1243

 

 

 

SERIGRAFIA

 

 

 

21

 

Burner control

 

CABLE FOR HAGC04 TO

 

202-1044

 

106-1048

 

 

 

DISPLAY

 

 

 

21

 

Burner control

 

DISPLAY

202-1045

 

 

22

 

Exterior Housing

 

Front Housing

 

 

 

23

 

Cable tree

 

Cable tree 1 sensor & stepper

 

 

 

 

 

Motor

 

 

 

23

 

Cable tree

 

Cable tree 2 Gas Valve

 

 

 

23

 

Cable tree

 

Cable tree 4 Sensor Flue Temp

 

 

 

23

 

Cable tree

 

Cable tree 6 Spark plug

 

202-1216

 

106-1244

 

23

 

Cable tree

 

Cable tree 8 Ignition ground Cable

 

 

 

23

 

Cable tree

 

Cable tree 5 Fan & Pump

 

 

 

23

 

Cable tree

 

Cable tree 9 Ground Plumbing

 

 

 

23

 

Cable tree

 

POWER Cable

 

 

 

24

 

Expansion tank

 

Internal expansion tank

 

202-1012

 

106-1069

 

25

 

Automatic air vent

 

AUTOMATIC AIR VENT

 

206-0434

 

106-1065

 

 

Pressure relief valve

 

Pressure relief valve (Watts type

 

202-1246

 

106-1240

 

 

 

374A

)

 

 

 

 

Seal gasvalve connections

 

O RING 3/4" UNITEC 300

 

202-0135

 

106-1101

 

 

Seal expansion vessel

 

O RING 1/2" UNITEC300

 

202-0136

 

106-1102

 

 

connection

 

 

 

 

 

Seal hydro connection

 

O RING 3/4" NBR

 

202-0137

 

106-1103

 

 

adapters

 

 

 

 

Table 13.1. Parts list 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 
 
 
72 

Summary of Contents for R Series

Page 1: ...the windows Do not try to light any appliance Do not touch any electric switch Do not use any phone in your building Leave the house Immediately call your gas supplier from a neighbour s phone Follow...

Page 2: ...f a vent system configuration with roof terminal 25 Additional instructions for termination through a roof with a roof terminal 26 Mounting instructions for roof terminal Installation 26 Mandatory Pre...

Page 3: ...Part 11 Installation check list 66 Installation 66 Start up 66 Operational Checklist 66 Before Leaving 66 Instructions to Installing Contractor 66 Part 12 Annual maintenance and inspection 67 Annual...

Page 4: ...ant but not related to personal injury or property damage Throughout this manual units of measure are often expressed in both imperial and metric units of measure Note that for absolute temperature in...

Page 5: ...stem and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above very carefully 2 Turn off all electric power to the appliance 3 Set the thermostat t...

Page 6: ...A B51 has not been verified due to an exemption provided in a provincial pressure vessel code The installation of the gas appliance must conform to the requirements of this manual your local authority...

Page 7: ...erious injury or death This manual contains information of the boiler before installing Perform steps in the order given Store the manual in the transparent envelope adjacent to the boiler The install...

Page 8: ...r located in the back of the boiler makes sure that the heat that becomes available during the gas burning process is transferred to the DHW circuit Fan The air necessary for gas burning is propelled...

Page 9: ...Part 1 Introduction Boiler dimensions All dimensions mentioned in the figures below are in inches 9...

Page 10: ...smooth water flows F Burner and heat exchanger G Pump vent H CH Supply sensor I Magnetite filter B J Hydroblock K Connections L Internal expansion tank A L Figure 1 2 Hydroblock B C B 3 way valve C He...

Page 11: ...stems as described in this manual The boiler does not have certification for other flue gas systems CH and DHW circuit Warning If no diffusion tight plastic pipes for supply and return are applied for...

Page 12: ...syst 80mm 3 need adapter if using C PVC General Metric Eco King C140 H140 Eco King C200 H200 Imperial Dimensions h x mm inch 695x480x410 695x480x410 695x480x410 w x d 27 4x18 9x16 1 27 4x18 9x16 1 27...

Page 13: ...ble 1 1 Technical specifications continued 13 Other technical data Allowed Pa Psi 200 0 029 200 0 029 200 0 029 resistance of flue gas system PH value of the 4 5 5 4 5 5 4 5 5 condensed water Availabl...

Page 14: ...ondensate trap A wall able to carry the appliance s weight Remove any combustible materials gasoline and other flammable liquids from the installation area If the boiler is to replace an existing boil...

Page 15: ...ended clearances Residential Garage Installations When installed in a residential garage mount the appliance a minimum of 457 mm 18 above the floor Locate or protect the appliance so it cannot be dama...

Page 16: ...oom temperature Wall mounting Determine and mark the location for the CH supply and discharge pipes Secure the wall mounting bracket to a solid wall using field supplied lag screws anchors when mounti...

Page 17: ...00 50000 40000 30000 20000 10000 Power 0 1 0 015 0 0302 0 0453 0 058 4 0 073 5 Figure 4 1 Pressure resistance vs power Pressure Have horizontal runs sloping backwards to the boiler not less than 5 cm...

Page 18: ...pand and contract under normal operation This venting system must be supported in accordance with these instructions Assure unrestricted vent movement where required through walls ceilings and roof pe...

Page 19: ...e precautions with horizontal installation the slope must be at least 5 cm mtr 0 60 inch feet towards the boiler 4 Shortening this type of concentric is not allowed use when necessary a telescopic or...

Page 20: ...lete vent system This product is a cut able concentric vent air section that must be installed as part of the concentric vent and air system It s not allowed to build a complete system with cut able s...

Page 21: ...maximum distance of 15 cm 6 inch from the female end see figure 4 5 dimension A Figure 4 5 Bracket fixing 7 Mount the vent section in the system and fix the brackets if necessary 8 It is recommended t...

Page 22: ...shall not pass through rated fire separations The distance between the point of termination of system shall be 1 8 m 6 feet or more from combustion air inlet of any appliance More than 0 91m 3 feet fr...

Page 23: ...ever the venting system penetrates a floor or ceiling and is not running in a fire rated shaft a fire stop is required Nail the fire stop to the structure and pass the venting sections through the hol...

Page 24: ...4 11 Correct position wall seal 5 To prevent rainwater from collecting in the inlet air system Ensure that the flue terminal is not installed upside down See figure 4 12 Insert the flue terminal into...

Page 25: ...is found at joints the A venting system must not be routed into thru or within any other vent such as an existing masonry or factory built chimney flue Plastic venting systems shall not pass through r...

Page 26: ...rainwater to escape from the venting system The drain must include a trap to prevent combustion gases from entering the living space Fire stops Whenever the venting system penetrates a floor or ceili...

Page 27: ...imilar device See figure 4 19 8 Fix the wall clamp supplied around the flue terminal Do not tighten the clamp See figure 4 19 Figure 4 19 Positioning of roof terminal 9 Connect the flue terminal to th...

Page 28: ...ce gas supply shut off valve in the off position 3 Disconnect electrical leads Ensure the cables are placed in a fashion where they will not arc to ground or other conductor Vent Air Intake Pipe Lengt...

Page 29: ...te location 5 Flue Gas Hazard Position the vent termination where vapors cannot make accidental contact with people and pets or damage nearby shrubs and plants 6 Elbow Extensions Elbows on outside of...

Page 30: ...er line above or below meters regulators and relief 915 mm 36 devices6 Above a paved sidewalk driveway or parking lot on public property if 2 13 m 7 ft adjacent 7 Above a sidewalk driveway or parking...

Page 31: ...llowing 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 venting system are...

Page 32: ...on in United States Canada Sheet Metal Approved but no applicable standard exists Approved but no applicable standard exists ABS UL Listed Approved but no applicable standard exists PVC Cellular Foam...

Page 33: ...parts in order to maintain a safe approved system Do not mix parts or try to match with other products or use improvised solutions Do not use any solvents or adhesives with single wall PP pipe other...

Page 34: ...nd shipped ideally for use with 80mm 125mm concentric pipe in pipe venting connection at the top of the boiler In cases where twin pipe systems are used a black O ring seal on the concentric air intak...

Page 35: ...ollows The exhaust pipe can terminate in an open vertical orientation without concern about rain infiltration because this will drain away through a properly configured condensate trap If used in a ve...

Page 36: ...Figure 5 58 2 Adhere to normal clearance restrictions as seen in Table 5 1 on page 30 Straight pipe exhaust termination is permitted when intake pipe is minimum 24 away from exhaust pipe to avoid re c...

Page 37: ...any other reason the combustion chamber door must be removed and the inside of the appliance must be inspected for component damage by a certified technician e g the internal insulation at the front a...

Page 38: ...37...

Page 39: ...iler by a turning movement to the left 4 Clean the drain by rinsing washing it with tap water 5 Refill the drain water lock with clean tap water 6 Reinstall the drain by turning the drain into the boi...

Page 40: ...H system before putting it into operation Any synthetic pipes used must be oxygen diffusion tight If not place a partition e g a heat exchanger between the boiler circuit and the circuit with the plas...

Page 41: ...utoff protection Especially when the boiler is installed above radiation level Follow low water cutoff manufacturer s instructions Backflow preventer Use a backflow preventer This valve should be inst...

Page 42: ...figure above D Connect the other end of the T piece to the return connection of the boiler Electric Disconnect the power to the appliance Connect the 10k Ohm NTC sensor in the tank to the tank connect...

Page 43: ...e installation is maximized to 30 Gallon 115 liters If the installation operates at 176 140 F 80 60 C and 22 PSI 1 5 Bar installation pressure the volume of the installation is maximized to 40 Gallon...

Page 44: ...ting Only appliance IET Internal Expansion Tank OEET Optional External Expansion Tank AV Air Vent Automatic FL Filling Loop PRV Pressure Relief Valve A CH supply B Not used capped B Mains w ater sup p...

Page 45: ...central heating and optional connection with an indirect tank for DHW Only use this option if heat system heat loss is less then 50 000 BTU and consists of one zone of heating If not please use syste...

Page 46: ...H Model System layout 2 H model boiler using Primary Secondary piping via closely spaced T s or a Low Loss Header LLH Can also be connected to an indirect tank for DHW Recommended piping schematic 45...

Page 47: ...one high temp heating and one low temp heating zone Also can be used with an indirect tank for DHW H Model System layout 3 H Model boiler with two temperature zones for heating one high temp heating a...

Page 48: ...pump for central heating and on demand DHW Only use this option if heat system heat loss is less then 50 000 BTU and consists of one zone of heating If not please use system layout 2 External expansi...

Page 49: ...C Model System layout 5 Combi model boiler using Primary Secondary piping via closely spaced T s or a Low Loss Header LLH On Demand DHW Recommended piping schematic 48...

Page 50: ...hot water WITH storage tank for DHW C Model System layout 7 Combi model boiler using direct supply piping via for heating and on demand hot water WITH re circulation pump for DHW 49 Use al temp senso...

Page 51: ...rnal control ie Tekmar 261 required to cascade boilers Legend For boiler details refer to layout no 1 and 2 LLH Low Loss Header EC External control cascade control RT Room Thermostat 11 System layout...

Page 52: ...enough for all the appliances in the home No appreciable drop in line pressure should occur when any unit or combination of units lights or runs Use common gas line sizing practices Make sure the gas...

Page 53: ...line cord gets damaged it must be fully replaced with an official line cord See section 13 for part numbers The line cord and wall socket must be at any time reachable with regard to service purposes...

Page 54: ...stat on of or Open Therm Outside sensor Tank Flue gas 3 w ay valve CH supply sens Flow DHW Temp DHW Pressure CH return Treturn CH Figure 9 3 Print circuit board main connections To Pump Ground CONNECT...

Page 55: ...ce ensure all aspects of the installation are complete and in conformance with the instructions provided in this manual including the Vent Air Intake sections and the manuals delivered with the vent s...

Page 56: ...he control system and any gas control which has been under water OPERATING INSTRUCTIONS 1 STOP Read the safety information above very carefully 2 Turn off all electric power to the appliance 3 Set the...

Page 57: ...the front side of the boiler lights up in orange The display shows the system pressure The boiler is provided with a special filling system By opening the filling valve the CH system will be filled Re...

Page 58: ...vent cycle can be activated by unplugging wait 30 seconds and plugging back in the supply cable After approximately 5 minutes the air vent cycle is finished Disconnect your tube and close the manual a...

Page 59: ...nection point is closed after performance of the calibration procedure Failure to do so may result in serious injury or death Important NOTE Before starting calibration make sure the boiler can transp...

Page 60: ...INIMUM 8L flow on the screen of the boiler before starting calibration 1 Simultaneously press P1 and P3 for 5 seconds until the text test appears in the display The ladder symbol flashes in the displa...

Page 61: ...r 5 seconds b Put the number on the left side of the display to 08 with P3 or P4 c Press P2 to confirm You have accessed the installer level 2 Press P3 or P4 to select the required parameter index num...

Page 62: ...i 2 Hxx storage tank operation 12 Required tap water C F 61 142 40 101 70 158 temperature 14 Flue gas sensor 2 0 2 0 High limit switch type 1 NTC 2 High limit switch and NTC 15 Gas type 1 1 2 1 Natura...

Page 63: ...ect the RT and the HRU contact on the burner control PCB for weather dependent control in night mode The lower the outside temperature the higher the CH temperature must be When it becomes warmer outs...

Page 64: ...e hot water comfort The hot water can be set to three comfort types Eco The hot water is only heated when there is a hot water demand The temperature of the DHW heat exchanger is not maintained This s...

Page 65: ...done via the table on page 61 Read out measured values 1 Simultaneously press P3 and P4 for 5 seconds The first value is displayed 2 Scroll with P3 and P4 through the values left on the display The v...

Page 66: ...P 10 Flue gas temperature C F t4 11 Outside temperature C F t5 12 Temperature Tank C F t6 21 Room temperature of C F rt OpenTherm thermostat 22 Setpoint room temperature C F rt SP of OpenTherm thermos...

Page 67: ......

Page 68: ...nit must not kettle bang hiss Ensure gas line pressure is in accordance with section 8 System is free of combustion leaks Unit must operate smoothly Ensure the flue gas combustion readings are within...

Page 69: ...e cause when water is leaking from the air supply pipe This may be found in the roof surface Open the condensate trap and remove any dirt present Flush if the condensed water coming from the condensat...

Page 70: ...chamber is clean If necessary use some plastic to protect electrical components from being damaged by liquid dripping Inspect the insulation disc located at the back side of the combustion chamber Re...

Page 71: ...ne Silica Certain components confined in the combustion chamber may contain this potential carcinogen Improper installation adjustment alteration service or maintenance can cause property damage serio...

Page 72: ...ers the risks recommended handling procedures and acceptable disposal practices contact the organization below Canada CCOHS Telephone directory listing under Government Blue Pages Canada Health and Sa...

Page 73: ...H140 106 1163 3 Burner Burner C H200 106 1036 4 Burner Gasket Burner 106 1091 5 Burner Inlet Pipe 106 1002 6 Backplate Backplate Uni 106 1010 8 Exhaust Pipe Exhaust Pipe 106 1011 9 Condensate hose Con...

Page 74: ...ps for 202 1139 106 1098 Hydroblock connections D18 Quick connection clips for pipes to PHE 19 Flow Sensor Flow Sensor 206 0432 109 1062 3 WAY VALVE MOTOR 206 0431 109 1059 20 Pressure sensor Pressure...

Page 75: ...e appliance operation appears to be incorrect or it is not responding at all to a demand for heat the following is suggested to determine and correct the problem Displaying faults LED indicators show...

Page 76: ...e led SERVICE lights up To erase Reset fault In a number of occasions in which a fault has occurred the user can reset the fault and restart the system In those cases the text reset is shown in the di...

Page 77: ...rature too high during DHW operation 5 8 16 17 18 19 34 35 39 41 42 43 37 Supply voltage too low 55 56 40 Fan feedback signal fault 41 57 58 59 60 77 41 CH pressure sensor deactivated 75 42 CH pressur...

Page 78: ...es for damage and friction free routing 42 Sensors switched Check sensor positions and connections 43 Supple sensor broken Check sensor in diagnose menu 4 and replace when required 44 Siphon cluttered...

Page 79: ...e it is inserted fully and twisted to secure fully completed 5 Propane if using See page 53 and 54 to change boiler setting from NG to LP If using H200 or C200 must change gas pipe on these models ONL...

Page 80: ...t for leaks and signs of aging Confirm gas pressure and note pressure drop upon start up Confirm CO2 at high and low fire ideal 9 Visual and Temperature Do visual inspection of all system components a...

Page 81: ...202 1262 5 ID 2021...

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