Laars NEOTHERM NTH Installation And Operation Instructions Manual Download

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Page 45

SECTION 7
INSTALLATION AND WIRING

7.A Installation Warnings

WARNING

The appliance must be electrically grounded in

accordance with the requirements of the authority

having jurisdiction or, in the absence of such

requirements, with the latest edition of the National

Electrical Code, ANSI/NFPA 70, in the U.S. and with

the latest edition of CSA C22.1 Canadian Electrical

Code, Part 1, in Canada. Do not rely on the gas or

water piping to ground the metal parts of the boiler.

Plastic pipe or dielectric unions may isolate the boiler

electrically. Service and maintenance personnel, who

work on or around the boiler, may be standing on wet

floors and could be electrocuted by an ungrounded

boiler. Electrocution can result in severe injury or

death.

Single pole switches, including those of safety

controls and protective devices, must not be wired in

a grounded line.

All electrical connections are made on the terminal

blocks that are located inside the control panel.

Wiring connections are shown in Figure 34.

All internal electrical components have been

prewired. No attempt should be made to connect

electrical wires to any other location except the

terminal blocks.

Caution

The supply voltage to the unit must not be
disconnected, except for service or isolation, or

unless otherwise instructed by procedures outlined

in this manual. To signal a call for heat, use the 24V

field interlock, as shown in the wiring diagram.

DO NOT MAKE AND BREAK THE LINE VOLTAGE

TO THE UNIT TO SIGNAL A CALL FOR HEAT.

A call for heat/ end call for heat MUST be connected

to the field interlock terminals. Some components

are designed to have constant voltage during normal

operation. If the units’s supply voltage is toggled

as a call for heat signal, premature failure of these

components may result.

The unit does not recognize 4mA as a call for heat.

If the call for heat is not connected between the

field interlock terminals, the unit will remain in low

fire when it sees 4mA as a modulating signal. See

Section 7.4 for more details.

7.B Main Power Connections

The size of the main power supply should be

determined by Table 16 and Table 17 on page 47
These tables indicate the unit’s maximum overcurrent

protection (MOP) and Minimum Circuit Ampacity (MCA).

An overcurrent protection value should be selected

based on these numbers.
Please note that all units with Laars supplied pumps

399 and greater, it is necessary to use two circuits.

One circuit is to feed the boiler/water heater while

the other is for the pump. Again, MCA and MOP are

provided for both the unit and Laars provided pump.

7.B.1

Pump Connections and Operation

The unit energizes the boiler pump contacts (dry) when

it receives a call for heat. Once the call for heat is

satisfied, the pump will remain on for the defined pump

overrun time.

The contacts for the system and DHW pump are dry

contacts. Appropriate voltage must be supplied to the

system and DHW pumps or relay controlling the pumps

for proper operation.
All pump connections are located on terminal block

5 (TB5) in the control panel (See Figure 33 on page

46).

Any pump using the unit’s control relay may not

exceed 7.4 amps as governed by the integrated control

board. If more current is required, and additional pump

contactor must be installed.
Pump contactors are not included, unless the unit was

ordered with a pump, and its FLA exceeds 7.4 amps.

Included pump contactors are rated for 3hP. Power for

the coil may be supplied by TB5. TB5 is a dry contact,

and will accomodate low voltage, as well as 120V.
When units are purchased with a pump, the unit and

the pump may be powered with a single circuit. See

Table 16 and Table 17 on page 47

for electrical data.

When using one circuit, review the available MCA

and MOP. If the appropriate over-current protection

exceeds 18 amps, the circuits should be separated. In

this case, additional 120VAC circuits will be required

for the pump(s) and potentially for a separate pump

contactor.

HERM

Commercial Boilers and Water Heaters

Summary of Contents for NEOTHERM NTH

Page 1: ...f you cannot reach your gas supplier call the fire department Installation and service must be performed by a qualified installer service agency or gas supplier AVERTISSEMENT Assurez vous de bien suivres les instructions données dans cette notice pour réduire au minimum le risque d incendie ou d explosion ou pour éviter tout dommage matériel toute blessure ou la mort Ne pas entreposer ni utiliser ...

Page 2: ...r 32 5 B Water Heater Flow and Head Requirements Heater 32 SECTION 6 WATER CONNECTIONS 6 A Boiler 34 6 A 1 Boiler Water Piping 34 6 A 2 Boiler Cold Water Make Up 34 6 A 3 Condensate Drain 35 6 A 4 Freeze Protection 35 6 A 5 Boiler Suggested Piping Schematics 35 6 A 6 Recognized Chemicals 36 6 B Water Heater 42 6 B 1 Heater Water Quality 42 6 B 2 Piping Requirements 42 6 B 3 Cold Water Make Up 42 6...

Page 3: ...nfiguration 59 8 G 2 a CH Central Heat Configuration 59 8 G 2 b Setting Up 4 20 mA Setpoint 59 8 G 3 Outdoor Reset Configuration 60 8 G 4 DHW Domestic Hot Water Config 60 8 G 5 Warm Weather Shutdown Config 60 8 G 6 Demand Priority Configuration 61 8 G 7 Modulation Configuration 61 8 G 8 Pump Connections 61 8 G 9 Statistics Configuration 62 8 G 10 High Limits 62 8 G 11 Stack Limits 62 8 G 12 Anti C...

Page 4: ...LAARS Heating Systems ...

Page 5: ...rm Some NeoTherms may require that the PRV be installed prior to filling the system Refer to Figures 2 9 for PRV locations Consult the Rating Plate on the side of the unit The following information describes the Model Identification Model Nomenclature 1 2 Model Series Designation N T NeoTherm 3 Usage H Hydronic V Volume Water 4 6 Size 1 5 0 150 000 BTU hr input NTV only 1 9 9 199 000 BTU hr input ...

Page 6: ...uld scald if too hot such as domestic hot water use adjust the outlet control limit or use temperature limiting valves to obtain a maximum water temperature of 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 paramete...

Page 7: ...pair these substances become airborne and if inhaled may be hazardous to your health Do not remove or replace RCF parts or attempt any service or repair work involving RCF without wearing the following protective gear 1 A National Institute for Occupational Safety and Health NIOSH approved respirator 2 Long sleeved loose fitting clothing 3 Gloves 4 Eye Protection NOTE All installations must be mad...

Page 8: ...thertight enclosure that hides the touchscreen Whereas the indoor model is not fully weathertight and the touchscreen can be accessed without having to open the unit See Figure 1 through Figure 9 Both the indoor and the outdoor models have the On Off switch on the outside of the unit Both also have the Rating Plate on the outside panel to the right See Figure 8 on page 12 The only component interi...

Page 9: ...E AIR PRESSURE SWITCH DRAIN VALVE CONDENSATE TRAP AIR TRANSITION ON OFF SWITCH Figure 2 Location of Components Sizes 150 199 EXHAUST VENT CONNECTION GAS CONNECTION AIR PRESSURE SWITCH TOUCHSCREEN HEAT EXCHANGER GAS VALVE VENTURI AIR GAS BLOWER PRESSURE RELIEF VALVE WATER INLET WATER OUTLET AIR INLET CONNECTION DRAIN VALVE CONDENSATE TRAP AIR TRANSITION ON OFF SWITCH NEOTHERM Commercial Boilers and...

Page 10: ...P GAS VALVE ON OFF SWITCH Figure 4 Location of Components Indoor Size 399 Figure 5 Location of Components Indoor Size 500 EXHAUST VENT CONNECTION PRESSURE RELIEF VALVE TOUCHSCREEN HEAT EXCHANGER MANUAL SHUTOFF GAS VALVE VENTURI GAS VALVE WATER INLET WATER OUTLET AIR INLET CONNECTION DRAIN VALVE CONDENSATE TRAP GAS CONNECTION AIR GAS BLOWER GAS PRESSURE SWITCH AIR PRESSURE SWITCH ON OFF SWITCH LAAR...

Page 11: ... OUTLET AIR INLET CONNECTION DRAIN VALVE CONDENSATE TRAP GAS VALVE MANUAL SHUTOFF GAS VALVE ON OFF SWITCH Figure 7 Location of Components Sizes 750 and 850 WATER INLET WATER OUTLET AIR INLET DRAIN VALVE CONDENSATE TRAP AIR GAS BLOWER PRESSURE RELIEF VALVE TOUCHSCREEN HEAT EXCHANGER EXHAUST VENT CONNECTION VENTURI GAS VALVE GAS CONNECTION MANUAL SHUTOFF GAS VALVE ON OFF SWITCH NEOTHERM Commercial B...

Page 12: ...Table 1 on page 14 GAS CONNECTION CONDENSATE TRAP OUTLET Trap is built in RATING PLATE Figure 8 Connection piping is on the BACK for ALL Outdoor Sizes GAS CONNECTION EXHAUST VENT WATER INLET WATER OUTLET AIR INLET CONDENSATE TRAP OUTLET Trap is built in Indoor 150 MBH For piping dimensions locations for all Indoor units See Table 1 on page 14 LAARS Heating Systems ...

Page 13: ...lation RATING PLATE For piping dimensions locations for all Outdoor units See Table 2 on page 16 CONDENSATE TRAP OUTLET Trap is built in RATING PLATE WATER INLET WATER OUTLET AIR INLET FILTER BOX GAS CONNECTION PRV must be added to this pipe during installation EXHAUST VENT CONDENSATE TRAP OUTLET Trap is built in Outdoor 150 MBH For piping dimensions locations for all outdoor units See Table 2 on ...

Page 14: ...50 4 11 15 38 20 51 20 52 19 48 26 66 18 48 13 33 600 29 76 5 13 19 50 4 11 15 38 20 51 3 8 19 48 26 66 18 48 8 21 750 35 90 6 15 19 50 5 13 19 48 40 103 3 8 19 48 30 78 18 48 8 21 850 39 101 6 15 19 50 5 13 19 48 44 114 3 9 19 48 35 89 18 48 8 21 L AIR INLET VENT SIZE in cm in cm in cm 150 19 49 3 7 6 3 7 6 199 26 68 3 7 6 3 7 6 285 26 68 4 11 4 11 399 31 80 4 11 4 11 500 37 96 4 11 4 11 600 37 9...

Page 15: ...ry similiar component design with piping dimensions locations that increase as the unit size increases Water and gas piping is always on the left side of the unit Table 1 gives the exact dimensions for all of the different model sizes ALL Models See Table 3 Suggested Service Clearances on page 20 NEOTHERM Commercial Boilers and Water Heaters ...

Page 16: ...cm in cm in cm in cm in cm in cm in cm in cm 150 6 1 4 16 11 28 13 33 17 1 4 43 8 23 1 2 60 18 45 7 27 69 23 1 2 60 5 1 4 13 199 6 1 4 16 11 28 13 33 17 1 4 43 8 23 1 2 60 18 45 7 27 69 24 1 2 60 5 1 4 13 285 6 15 5 11 28 5 13 17 1 4 43 8 24 61 19 48 28 1 4 72 12 30 5 7 1 4 18 4 399 8 15 5 19 1 2 50 7 3 4 20 17 1 4 43 8 24 61 19 48 28 1 4 72 12 30 5 6 15 2 31 500 5 13 17 3 4 45 5 13 8 1 4 21 24 61...

Page 17: ... 8 1 4 21 24 61 19 48 29 1 4 74 12 30 5 5 5 14 600 33 1 2 85 3 0 8 5 13 8 1 4 21 24 61 19 48 29 1 4 74 12 30 5 5 3 4 14 6 750 32 3 4 83 2 3 0 8 5 1 4 13 4 17 1 4 43 8 24 61 19 48 29 1 4 74 12 30 5 5 3 4 14 6 850 32 3 4 83 2 3 0 8 5 1 4 13 4 17 1 4 43 8 24 61 19 48 29 1 4 74 12 30 5 5 3 4 14 6 E F A B C D G J K n cm in cm in cm in cm in cm in cm 7 69 23 1 2 60 5 1 4 13 20 60 25 1 2 65 3 7 6 7 69 24...

Page 18: ...Indoor Pump Kit 1 H The Installation Kit installation parts box The Indoor models are shipped in a single crate with the Installation Kit cardboard box Check the contents of the Installation Kit with the items listed in Figure 10 and Figure 11 Additional parts may be packed inside the unit Figure 10 Standard Installation Components Figure 11 Additional Components depending on model size and config...

Page 19: ...ANEL PUMP COVER NTOD 4 1 1 1 50D7605 HARNESS PUMP NTOD 150 500 3 D C B 2 DWG NO 50D4140 SH 1 REV A CJ 5 17 16 REVISIONS REV CHANGE APPR ENGR APPR ECN DRAFT CHECK REMOVED ITEM 2 A2116100 FROM 50D4140 A 15 127N 05 XR 5 17 16 HARNESS AIR FILTER OUTLET WATER WATER INLET BOX GAS INLET CONDENSATE TRAP OUTLET D B J A C G E F VENT K 8 21 13 33 9 23 38 1 2 98 VIEW RIGHT SIDE VIEW BACK VIEW TOP VIEW L 5 1 2...

Page 20: ...ition system components are protected from water dripping spraying rain etc during operation and service circulator replacement control replacement etc When vented vertically the unit must be located as close as practical to the vertical section of the vent If the vent terminal and or combustion air terminal terminate through a wall and there is potential for snow accumulation in the local area bo...

Page 21: ...oid debris pick up falling into the appliance is required For any combination of vent and intake lengths up to 40 equivalent feet any even or uneven combination of length is allowed For overall lengths greater than 40 equivalent feet the exhaust may be up to 20 feet greater than the intake length Combustion Intake and Vent must be the same size Minimum Combustion Air Intake Pipe Length 0 0M Minimu...

Page 22: ... xPPF 4 83x040 2ZDCPVCx Horizontal Termination bird screen IASPPxx 2 4 IASSSxx 5 12 xPPS BG 2 6 83x050 2ZDESx Vertical Termination IASPPxx 2 4 IASSSxx 5 12 xPPS VKL 5 xPPS VTML 5 8 83x050 2ZDESx Air Inlet 2ZDESx Manufacturer Approved Hanger Straps Distance between Hanger Straps H Ho or ri iz zo on nt ta al l R Ru un n 3 3 M MA AX X Distance between Hanger Straps V Ve er rt ti ic ca al l R Ru un n ...

Page 23: ...rd Flush Mount CA010102 Standard 80 incl opt opt opt opt opt 105 incl opt opt opt opt opt 150 incl opt opt 199 210 incl opt opt 285 opt opt opt incl opt n a 399 n a n a n a incl opt n a 500 n a n a n a incl opt n a 600 n a n a n a incl opt opt 750 n a n a n a incl n a opt 850 n a n a n a incl n a opt Concentric vent terminal 10 ft pipe length incl incl opt opt opt opt Table 7 PVC Vent Terminal Kit...

Page 24: ...opylene that complies with ULC S636 Class IIb or a stainless steel venting system that complies with UL 1738 Standard See Table 6 The unit s vent can terminate through the roof or through an outside wall When using PVC CPVC for vent material venting must be connected to the CPVC section included with sizes 80 850 The CPVC vent section included with the unit may be broken by CPVC fittings if necess...

Page 25: ... more than 245 C Class II venting systems are suitable for gas fired appliances producing flue gas temperatures of 135 C or less Class II venting systems are further classified into four temperature ratings as follows A Up to and including 65 C B Up to and including 90 C C Up to and including 110 C and D Up to and including 135 C IMPORTANT It is also the responsibility of the installer to ensure t...

Page 26: ... walkway or over an area where condensate or vapor could create a nuisance or hazard 3 Locate the vent terminal so that vent gases cannot be drawn into air conditioning system inlets 4 Locate the vent terminal so that vent gases cannot enter the building through doors windows gravity inlets or other openings Whenever possible avoid locations under windows or near doors 5 Locate the vent terminal s...

Page 27: ...must terminate at least 12 30cm below the vent terminal Installations in the Commonwealth of Massachusetts In Massachusetts the following items are required if the side wall exhaust vent termination is less than seven 7 feet above finished grade in the area of the venting including but not limited to decks and porches From Massachusetts Rules and regulations 248 CMR 5 08 begininning on 2nd page fo...

Page 28: ...ote 5 See Note 5 r e n r o c e d i s n i o t e c n a r a e l C G H Clearance to each side of centerline extended above meter regulator assy 3 ft 91 cm within a height of 15 ft 4 6 m m c 1 9 t f 3 t e l t u o t n e v r o t a l u g e r e c i v r e s o t e c n a r a e l C I J Clearance to nonmechanical air supply inlet to building or the combustion air inlet to any other appliance 6 in 15 cm for appl...

Page 29: ...m height of eight 8 feet above grade directly in line with the exhaust vent terminal for horizontally vented gas fueled heating appliance or equipment The sign shall read in Figure 21 Multiple Side Wall Terminals IMPORTANT Terminals must be place such that they remain a minimum of 12 above the expected snow line Local codes may have more specific requirements and must be consulted Refer to the NFP...

Page 30: ...reste connecté à la système de ventilation commun mis en opération alors que les autres appareils connectés restants à la politique commune de système d aération ne sont pas en opération 1 Joint les ouvertures inutilisées dans le système de ventilation commun 2 Inspecter visuellement le système de ventilation à la taille correcte et espacement horizontal et déterminer il n y a pas de blocage ou de...

Page 31: ...ak tested before placing it in operation 11 Purge all air from gas lines Notes Consult and confirm with Applicable Fuel Gas Code before beginning work Verify gas inlet pressure is correct using Table 8 before starting boiler NOTE This appliance and all other gas appliances sharing the gas supply line must be firing at maximum capacity to properly measure the inlet supply pressure The pressure can ...

Page 32: ...174 1 4 1 155 2 40 15 20 25 30 35 8 11 14 17 19 22 Commercial table 12 Flow and Head Requirements Flow H L Flow H L Flow H L Flow H L Flow H L Flow gpm feet gpm feet gpm feet gpm feet gpm feet gpm 150 19 0 39 4 14 3 24 1 11 4 16 3 9 5 11 9 8 1 9 0 7 1 210 26 7 28 1 20 0 15 6 16 0 9 9 13 4 6 9 11 3 4 9 9 9 285 36 0 29 6 27 0 19 1 22 0 13 9 18 0 10 2 15 0 7 7 13 0 399 50 5 33 8 39 0 22 8 31 0 16 0 2...

Page 33: ... 35 9 8 7 32 3 7 3 29 4 6 2 26 9 5 3 ow H L Flow H L Flow H L Flow H L Flow H L Flow H L pm m lpm m lpm m lpm m lpm m lpm m 0 7 2 8 26 9 2 2 23 8 1 8 21 6 1 5 19 7 1 3 18 2 1 1 2 8 1 5 37 5 1 1 33 7 0 9 30 3 0 7 27 6 0 6 25 4 0 5 6 8 2 3 49 2 1 9 45 4 1 6 40 9 1 4 37 1 1 2 34 1 1 1 3 3 2 9 71 9 2 3 63 6 1 9 57 5 1 6 52 2 1 4 47 7 1 2 2 2 2 5 90 8 2 1 79 9 1 7 71 9 1 4 65 5 1 2 59 8 1 0 4 9 3 6 109...

Page 34: ... jurisdiction must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation 6 A 3 Condensate Drain A condensate drain trap is built into the unit No additional or secondary trap is required BOILER PIPE SIZE HEATER PIPE SIZE SIZE INCHES SIZE INCHES 150 1 199 1 285 2 399 1 399 2 500 1 500 2 600 1 600 2 750 2 750 2 850 2 850 2 Table 15 Water Conn...

Page 35: ...o fire and or the water is not able to circulate there is a risk of freezing in the boiler or in the pipes in the system When water freezes it expands which may result in bursting of pipes or damage to the boiler which could result in leaking or flooding conditions Do not use automotive antifreeze To help prevent freezing the use of inhibited glycol concentrations between 20 and 35 glycol Typicall...

Page 36: ...Page 36 Figure 22 Hydronic Piping Single Boiler Zoning with Circulators LAARS Heating Systems ...

Page 37: ...Page 37 Figure 23 Hydronic Piping Single Boiler Low Temp Radiant Space Heating Using Low Loss Header and Zone Valves NEOTHERM Commercial Boilers and Water Heaters ...

Page 38: ...Page 38 Figure 24 Hydronic Piping Multiple Boilers Zoning with Circulators Figure 25 Hydronic Piping Multiple Boilers with Indirect DHW Tank Piped from System Loop LAARS Heating Systems ...

Page 39: ...Page 39 Figure 26 Hydronic Piping Multiple Boilers Reverse Return Multi Temp Zones Zoning with Circulators NEOTHERM Commercial Boilers and Water Heaters ...

Page 40: ...ure 27 Hydronic Piping Heating Zones with Indirect DHW Tank Piped with Zone Pumps The indirect DHW tank is piped directly off of the boiler The boiler pump must shut down during DHW operation LAARS Heating Systems ...

Page 41: ...Page 41 Figure 28 Hydronic Piping Multiple Boilers with Indirect DHW Off of One Boiler The boiler pump must shut down during DHW operation NEOTHERM Commercial Boilers and Water Heaters ...

Page 42: ...ch are designed exclusively for volume water domestic hot water applications Refer to the proper section for instructions on installing and piping your product Refer to Table 15 on page 34 for the connection pipe sizes required 6 B Water Heater 6 B 1 Water Quality Water heaters must be installed in water conditions of 10gpg hardness or less with a pH range of 8 2 to 9 5 Operating the Heater in wat...

Page 43: ...tion and valving Check with local codes and ordinances for additional requirements Figure 29 DHW Piping One Heater One Vertical Tank NOTES 1 Optional CWMU Recirc line location 2 Locate Heater DHW sensor or remote aquastat well in lower 1 3 of tank 3 Back flow preventer may be required check local codes 4 Thermal expansion tank may be required check local codes 5 Factory supplied pumps are sized fo...

Page 44: ... job site WARNING This drawing shows suggested piping configuration and valving Check with local codes and ordinances for additional requirements NOTES 1 Optional CWMU Recirc line location 2 Locate Heater DHW sensor or remote aquastat well in lower 1 3 of tank 3 Back flow preventer may be required check local codes 4 Thermal expansion tank may be required check local codes 5 Factory supplied pumps...

Page 45: ... interlock terminals the unit will remain in low fire when it sees 4mA as a modulating signal See Section 7 4 for more details 7 B Main Power Connections The size of the main power supply should be determined by Table 16 and Table 17 on page 47 These tables indicate the unit s maximum overcurrent protection MOP and Minimum Circuit Ampacity MCA An overcurrent protection value should be selected bas...

Page 46: ...d pump controller that is optional equipment for all commercial NeoTherm boilers Pump speed is controlled to maintain a user chosen temperature rise between the inlet and outlet of the unit VARI PRIME will operate the boiler pump at maximum flow during boiler startup to ensure stable operation is reached before introducing variable water flow This key feature keeps the boiler s combustion and vari...

Page 47: ...Cycle feature to prevent hunting and possible premature component failure Table 16 Boiler and Pump Electrical Data Table 17 Water Heater and Pump Electrical Data If amp draw exceeds 7 4A max an external pump contactor will be required All Boiler Water Heater and Pump Circuits are 120V MMERCIAL NEOTHERM MANUAL H2374 Boiler Size MBH 399 500 600 850 150 399 500 600 850 FLA 4 amp 5 amp 4 amp 6 amp 12 ...

Page 48: ...nnections These units can be connected in a Lead Lag series up to a total of 8 controllers One as the Lead control and 7 more as the following controllers See Figure 34 For general info and menu set up for Lead Lag using your Touchscreen See Section 8 page 69 About Lead Lag Gateway Control H2354400 Doc 4236 LAARS Heating Systems ...

Page 49: ...tem to terminal block 7 TB7 in the control panel See Figure 33 The connections are labeled Remote Analog Input When making the connections follow the polarity designations shown on the label Signals from a Building Automation System can be connected to the MB2 Modbus connections on the controller See Figure 34 For additional information on setting up Modbus and other communication protocols contac...

Page 50: ...TIONS SAFETY CHAIN TB4 24V COMMON TB3 24V HOT Y R TN TN Y BR BR WH R Y R GY R Y DKB Y BLK WH R Y GY BL Y GY R LOW WATER CUTOFF FIELD INSTALLED OPTIONS WH GY GR VT GR BL Y BL ADD L HIGH LIMIT R FLOW SWITCH TO TB1 PIN2 TO TB2 PIN2 WH GY BL GR BL R GR VT GY R WH R GN TO J6 2 Y TO J4 10 OUTDOOR TEMP SENSOR TO GAS VALVE P1 1 2 2 1 6 1 6 1 6 1 Y WH GR TB6 FIELD CONNECTIONS ALARM TO J6 7 TO J6 8 BL BL Y ...

Page 51: ...BL DKB DKB Y DKB FS 2 DKB DKB WH BL WH BL WH R WH R FS 1 DKB Y PK R BLK WH GN GR R WH CL CL CL CL CL WH R GN TN BRN OR TN BL TN R Y VT WH WH BLK BLK BLK TO XFORMER WH TO XFORMER WH R BRN WH BRN R Y PUR PUR BLK TN Y TN WH TN BLK WH OR WH GY TO TB6 P2 TO TB6 P1 TO TB4 P1 GY DKB GY BLK TO TB8 P1 BLK WH GR CRIMP NUT GY NEUTRAL L PUMP NEUTRAL L FIELD OPTIONS DRY CONTACTS ONLY SEE I O MANUAL SECT 5 3 WH...

Page 52: ...Page 52 Figure 36 Ladder Diagram 7 H Ladder Diagram LAARS Heating Systems ...

Page 53: ...operation the Touch Screen will automatically present this Home Screen See Menu 1 Menu 1 Home Screen Menu 2 Status Summary The home screen shows a picture of the unit s controller The color of the controller depends on the status as shown below Color Status Control Icon Blue Normal operation Red Lockout Gray Standby mode Burner switch off Gray and crossed out Communication problem Yellow Hold stat...

Page 54: ...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 error log For some special safety related functions besides entering the correct password the system will ask you to go through an additional verification process For more information see the section on Conf...

Page 55: ... group that could affect the safe operation of the unit the control system will ask you to verify the change before it is accepted 3 Once all parameters have been changed return to the configure menu In the lower right hand corner of the screen you will see VERIFY Press VERIFY then press BEGIN to start verification Notes Once you change one of these safety related parameters you must finish the ve...

Page 56: ...econds or the verification will be cancelled A count down timer is shown at the bottom of the screen 8 E Checking Individual Parameters 1 From the Home screen Menu 9 press the icon for the controller Menu 9 Home screen 2 The Status Summary page for the controller will appear This shows the current operating condition of the controller and also shows some of the configuration settings See Menu 10 M...

Page 57: ... Setup button on the lower right corner of the screen The system will present the Setup screen Menu 12 Setup Screen 3 Press the Display Setup button at the bottom of the screen Menu 13 Display Setup Screen 4 Press Set Date Time button Menu 14 Date and Time 5 Use the arrows to change the date and time and then press the OK button Battery The display has a removable battery CR2032 to store time date...

Page 58: ...m the Configuration Menu there are 18 Configuration Sub Menus Use the scroll tab on the right to view them all The next section of this manual will show the installer these sub menus and the basics on how to setup adjust these configurations 8 G The Configuration Menu is the gateway to the parameters that the factory the installer or the end user will need in order to setup service maintain or adj...

Page 59: ...supplied to the T T terminals found on TB7 labeled T T or Interlock Once a call for heat is established the control will start the appropriate selected pumps and begin the ignition process 8 G 1 System Identification Access This sub menu will display 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 t...

Page 60: ...t to each and adjusting their setpoints in those sub menus 8 G 4 DHW Domestic Hot Water Config DHW Domestic Hot Water is used to configure the DHW temperature parameters for water heaters Heater and for indirect water heaters that are used with boiler Boiler systems Press on the Setpoint box to get to the adjustment sub menu Then adjust it up or down to your desired DHW setpoint 8 G 5 Warm Weather...

Page 61: ... Demand Priority Configuration From the Demand Priority Configuration the installer can adjust the priority of the different demand types Central Heat Lead Lag Domestic Hot Water The control uses arrows as indicators to point to the loop with higher priority 8 G 7 Modulation Configuration From this sub menu the installer has the ability to adjust the range of modulation for the CH and DHW demands ...

Page 62: ... Verification 8 G 11 Stack Limits 8 G 12 Anti Condensation Configuration Anti condensation frost protection is enabled disabled on this screen 8 G 13 Frost Protection Frost protection will assist in keeping the unit from freezing when the unit is not able to fire but is still able to run the pumps The frost overrun time can be changed on this screen 8 G 14 System Configuration The installer can se...

Page 63: ...he fan control loop reacts to an increase in fan speed adjust the Fan gain up parameter The minimum duty cycle is a view only parameter To set a fixed RPM at which the fan should ramp up or down adjust the Speed up ramp or Speed down ramp respectively 8 G 16 Sensor Configuration The outdoor temperature can be read from the outdoor sensor that is shipped with the unit NEOTHERM Commercial Boilers an...

Page 64: ...ler is operating as part of a Lead Lag system it does not use the normal CH set point it uses the Lead Lag CH set point on the Master control It is STRONGLY recommended to start each boiler to complete combustion set up and perform all safety checks before setting up Lead Lag cascade See Combustion Setup in this manual Before tapping on Lead Lag Follower Configuration in the Configuration Menu you...

Page 65: ...nfiguration menu by pressing the Back arrow Next you will need to confirm that the master configuration is Disabled Then you will need to confirm that the Follower configuration is Enabled Repeat these steps on all follower units Press Disabled In the configuration menu scroll down to the bottom and press onto Lead Lag Master Configuration 8 G 17 Lead Lag Follower Config continued NEOTHERM Commerc...

Page 66: ... labeled MB1 and MB2 MB1 has the wiring connections to the User Interface display on each unit and MB2 is used to communicate with the other boilers in the Lead Lag system For wiring connections to Lead Lag see Figure 34 on page 48 To reach the controller open the cabinet of the unit The front panels on the indoor model pop off when pulled forward The outdoor model has two latches that must be rel...

Page 67: ...reen Adjust the Base Load Common value to the number of boilers in the cascade system See chart for values Chart for base values From this screen use the Left or Right arrows to scroll to other screens Make adjustments if needed If you are using Outdoor Reset for Lead Lag adjust the Maximum Outdoor Temp Minimum Outdoor Temp and Low Water Temp by touching each set point line The set point screen wi...

Page 68: ... on Follower Enable From the Status Summary Screen press the Config ure button Scroll down and press Lead Lag Follower Configura tion Press Disabled Choose Enable Follower for built in Lead Lag Master Then press OK The lead boiler Master control is now configured 8 G 18 Lead Lag Leader Config continued LAARS Heating Systems ...

Page 69: ...s 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 The default setting for On Hysteresis is 5 F but this is adjustable Notice that when a boiler is operating as part of a Lead Lag system it does not use the normal CH setpoint it uses the special LL CH setpoint on the Lead Lag Leader The unit acting as...

Page 70: ...tion in a System with Eight Boilers Note The Displays on Boilers 2 through 8 will display information pertaining only to that specific boiler Touch Screen Lead Lag Master Addr 1 Addr 2 Addr 3 Boiler 4 Addr 4 Boiler 5 Addr 5 Boiler 6 Addr 6 Boiler 7 Addr 7 Boiler 8 Addr 8 Boiler 3 Boiler 2 Boiler 1 Control Settings for Lead Lag Sys tem Part 1 1 Power up all of the boilers in the system 2 In an inst...

Page 71: ...t and Modulation as shown on Menu 18 on page 59 For additional information on setting up Modbus and other communication protocols contact the factory Starting at the Home Screen tap onto the Display Setup button on the bottom right of the lead boilers screen 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 tab and m...

Page 72: ... injury or death 1 On the Gas Valve locate the adjustments for High Fire and Low Fire See Figure 45 on page 74 thru Figure 47 on page 76 Refer to Table 18 on page 74 and Table 19 on page 75 for appropriate CO2 ranges 2 Press the Control Icon at the center of the Home Screen Menu 23 Home screen 3 The system will present the Status Summary screen Menu 24 Status Summary Screen 4 Press the Diagnostics...

Page 73: ...yzer time to get a stable reading after making the Hi Fire adjustment at the gas valve 9 Once Hi Fire CO2 is within an acceptable range press Stop Test 12 Repeat steps 6 through 11 a few times to confirm that both Hi Fire and Low Fire are within the acceptable levels for your unit See Figure 45 thru Figure 47 10 Press Minimum Modulation 11 Press Start Test You will have 5 minutes to adjust Low Fir...

Page 74: ...s pulled forward and then off Always be patient with your combustion analyzer when making adjustments to the valve at both Hi Fire and Low Fire Be sure to put the cap back onto the valve when you are done making your adjustments at the gas valve under cap Figure 45 Gas Valve 80 285 Mbtu GAS TYPE HIGH FIRE CO2 LOW FIRE CO2 DIFFRNTL PRESSURE inches wc Natural 8 8 to 9 8 0 5 lower than 3 6 to 3 9 Pro...

Page 75: ...15 wc Table 19 Commercial sizes 399 850 Mbtu CO2 Range and Manifold Pressure 399 500 The Gas Valve in the 399 and 500 is at the front of the unit and can be reached after the front panel is pulled forward and then off Always be patient with your combustion analyzer when making adjustments to the valve at both Hi Fire and Low Fire NEOTHERM Commercial Boilers and Water Heaters ...

Page 76: ...e unit and can be reached after the front panel is pulled forward and then off The Gas Valve in the 750 and 850 models can only be reached by removing the top panel of the unit It cannot be accessed from the front like the smaller units Always be patient with your combustion analyzer when making adjustments to the valve at both Hi Fire and Low Fire Be sure to put the cap back onto the valve when y...

Page 77: ...gency shutoff devices WARNING Do not use this appliance if any part has been under water Manufacturer requires boilers and water heaters to be replaced not repaired if they have been partially or completely submerged SECTION 9 FIRST START UP AND ADJUSTMENT 9 A Filling the Boiler System 1 Ensure the system is fully connected Close all bleeding devices and open the make up water valve Allow the syst...

Page 78: ...ill follow Each cycle will include pre purge ignitor on valve flame on and post purge Ignition will not occur because the gas is off The ignition control will lockout after a single try or a third try depending on the controller model Open the gas shutoff valve Reset the boiler control by pressing the Reset button on the control or on the display If the unit has the optional gas pressure switches ...

Page 79: ...essure Relief Valve should be inspected and tested every year 10 B Appliance Maintenance and Component Description Use only genuine replacement parts The gas and electric controls in the unit are engineered for long life and dependable operation but the safety of equipment depends on their proper functioning Only a qualified service technician should inspect the basic items listed below every year...

Page 80: ... manual gas valves and check for gas leaks Turn on the 120 Volt power Place the unit in operation following the instructions in Section 9 Once the boiler is operating check for leaks again and confirm that all fasteners are tight Check the appliance setup according to Section 9 Appliance Control The unit has an integrated control that incorporates manual reset high limit control operating temperat...

Page 81: ...e added or a short occurs during installation the integral circuit breaker may trip If this happens be sure to reset the circuit breaker before replacing the transformer The transformer is mounted underneath the control panel If the transformer must be replaced turn off the 120Vac power to the appliance Remove the transformer wires from the terminal blocks Remove the fasteners holding the transfor...

Page 82: ...This will be diverted into the separate container 11 Install all components removed in the reverse order to place the appliance back in operation Be sure all gaskets are in place as the components are installed Replace any damaged gaskets Do not reuse damaged gaskets 12 Place the appliance in operation according to the instructions in Section 10 Check all gas connections for leaks Confirm that all...

Page 83: ...ane gas or from propane to natural gas in the field Some units require the addition of a gas orifice along with proper gas valve adjustment Other units require no additional parts only proper gas valve adjustment Please contact the manufacturer for specific information regarding the gas conversion of a particular appliance If a gas conversion is performed the unit must be identified with the appro...

Page 84: ... control system is waiting for a condition to be satisﬁed No 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 11 A 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 of the cause o...

Page 85: ...s 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 4 Alert History If you choose LOCKOUTS this menu will appear Menu 5 Lockout History 4...

Page 86: ... safety data veriﬁcation L 1 Device in Conﬁguration mode and safety parameters need veriﬁcation and a device needs reset to complete veriﬁcation 2 Conﬁguration ended without veriﬁcation re enter conﬁguration verify safety parameters and reset device to complete veriﬁcation 3 If fault repeats replace module 3 Internal fault Hardware fault H Internal fault 1 Reset module 2 If fault repeats replace m...

Page 87: ...ternal fault Bias changed since heating cycle starts H 24 Internal fault Spark voltage stuck low or high H 25 Internal fault Spark voltage changed too much during ﬂame sensing time H 26 Internal fault Static ﬂame ripple 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 Flam...

Page 88: ...ault Mux pin shorted L Internal Fault 1 Reset module 2 If fault repeats replace module 61 Anti short cycle H Will not be a lockout fault Hold Only 62 Fan speed not proved H 63 Rollout switch is regarding the SAFETY CHAIN OFF Could be one of the following Flow Switch Standard Equipment Sizes 399 and Up Additional High Limit Field Supplied Optional Pressure Switch Size 399 Only Low Water Cut Off Sta...

Page 89: ...the module 79 Outlet high limit H or L 1 Check wiring and correct any possible errors 2 Replace the outlet high limit 3 If previous steps are correct and fault persists replace the module 80 DHW Domestic Hot Water high limit H or L 1 Check wiring and correct any possible errors 2 Replace the DHW high limit 3 If previous steps are correct and fault persists replace the module 81 Delta T limit H or ...

Page 90: ... 3 If previous steps are correct and fault persists replace the module 97 Internal Fault A2D mismatch L Internal Fault 1 Reset module 2 If fault repeats replace module 98 Internal Fault Exceeded VSNSR voltage tolerance L 99 Internal Fault Exceeded 28V voltage tolerance L 100 Pressure Sensor Fault H 1 Verify the Pressure Sensor is a 4 20 ma source 2 Check wiring and correct any possible errors 3 Te...

Page 91: ...he VFD 4 If the fault persists replace the module 123 Purge rate proving failed L 128 Fan speed failed during prepurge H or L 129 Fan speed failed during preignition H or L 130 Fan speed failed during ignition H or L 131 Fan movement detected during standby H 132 Fan speed failed during run H 137 ILK Interlock failed to close H 1 Check wiring and correct any possible shorts 2 Check Interlock ILK s...

Page 92: ...ts replace the module 159 Main valve OFF L 160 Ignition ON L 1 Check Ignition terminal wiring and correct any errors 2 Reset and sequence the module If fault persists replace the module 161 Ignition OFF L 164 Block intake ON L 1 Check wiring and correct any errors 2 Inspect the Block Intake Switch to make sure it is working correctly 3 Reset and sequence the module 4 During Standby and Purge measu...

Page 93: ...utton leads to Menu 8 Menu 8 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 9 Menu 9 Digital I O Screen 3 The button for Analog I O displays items that change continuously between two limits See Menu 10 Menu 10 Analog I O Screen 4 Press the button for Diagnostic Tests The M...

Page 94: ...me for several different parameters fan speed outlet temperature inlet temperature etc Menu 15 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 tracks that variable To see the graph for the currently selected function press the View button Menu 16 Trend Analysis Graph The time scale can be adjusted by pre...

Page 95: ...ir 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 begin to make the ignitor spark Once the Pre ignition timer has expired the control will open the Pilot solenoid and the Pilot Flame Establishing Period PFEP will start for 10 seconds to establ...

Page 96: ...75D1002 75D1002 Stanchion 24 Brace Front 20D1005 20D1005 85D1005 85D1005 85D1005 60D1005 85D1005 85D1005 HX Stanchion 24A Brace Rear 20D1007 20D1007 R50D1005 85D1005 85D1005 85D1005 85D1005 85D1005 HX Stanchion 25 Mounting Rail R15D1004 R30D1004 R30D1004 40D1004 R50D1004 R50D1004 75D1004 85D1004 2 2 2 2 2 2 2 2 26A Diagonal Brace 75D1006 75D1006 27 Condensate Trap Assy R20D4020 R20D4020 R50D4020 R...

Page 97: ...oiler Not Shown A2114400 A2135410 A2133621 A2133621 A2133621 Pump Optional Heater Not Shown A2135600 A2135700 A2135500 A2135420 A2135420 A2133616 A2133616 A2133616 62 Low Water Cutoff Switch CA004805 CA004805 CA004804 CA015604 RE2076500 RE2076500 RE2076500 RE2076500 63 Inlet Water Temp Sensor RE2320600 RE2320600 RE2320600 RE2320600 RE2320600 RE2320600 RE2320600 RE2320600 64 Duplex Outlet Water RE2...

Page 98: ... R50D2020 R50D2020 R50D2020 Electrical Components See Parts Illustration 8 80 Control Panel Enclosure R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 R50D7001 81 Transformer RE2108700 RE2108700 RE2108700 RE2108700 RE2108700 RE2108700 RE2108700 RE2108700 82 High Voltage Shield R50D7002 R50D7002 R50D7002 R50D7002 R50D7002 R50D7002 R50D7002 R50D7002 83 Top Panel Bracket R50D7003 R50D70...

Page 99: ...Page 99 Parts Illustration 2 Internal Components Sizes 150 199 Parts Illustration 3 Internal Components Sizes 285 600 NEOTHERM Commercial Boilers and Water Heaters ...

Page 100: ...Page 100 Parts Illustration 4 Internal Components Sizes 750 850 LAARS Heating Systems ...

Page 101: ...Page 101 Parts Illustration 5 Gas Train Components Sizes 150 500 Sizes 150 285 NEOTHERM Commercial Boilers and Water Heaters ...

Page 102: ...Page 102 Parts Illustration 6 Gas Train Components Sizes 600 850 LAARS Heating Systems ...

Page 103: ...Page 103 Parts Illustration 7 Heat Exchanger Components 68A Sizes 285 NEOTHERM Commercial Boilers and Water Heaters ...

Page 104: ... use based on the app please contact AHRI s Certification Program Admin Product Labels PMS 300 C 100 M HTML 0065BD or Generic Marketing Application PMS 300 C 100 M 42 Y 0 K 0 R 0 G 101 B 189 HTML 0065BD or Black If the mark MUST reverse out of a dark background use the PMS 300 mark or the black mark All marks have a white outline If the mark MUST rev the PMS 300 mark white outline Dimensions and s...

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