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Solution 000 - 260, Installation And Service Manual

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Solution 000 - 260 Installation And Service Manual Download Page 33

Installation & Service Manual

33

SOLUTION

BOILER

BACKFLOW

PREVENTER

PRESSURE
REDUCING VALVE

PRESSURE

GAUGE

TEMPERATURE / PRESSURE

GAUGE

AIR
SEPARATOR

EXPANSION

TANK 

BALL VALVE

(TYPICAL)

UNION

(TYPICAL)

PRESSURE
RELIEF VALVE

MAKE UP WATER

FROM

SYSTEM 

BOILER
CIRCULATOR

SYSTEM
CIRCULATOR

TO

SYSTEM

SYSTEM SUPPLY
SENSOR 

DRAIN

Y-STRAINER

(RECOMMENDED)

3-WAY VALVE W/BYPASS PIPE

Figure 4-8_

Single Boiler Full System Flow with Low Temperature Bypass

Full System Flow

4  

Water connections 

(continued)

Summary of Contents for 000 - 260

Page 1: ...nd servicing of the appliance It is strongly recommended that this manual be reviewed completely before proceeding with an installation Perform steps in the order given Failure to comply could result...

Page 2: ...arances 15 Masonry Chimney Installation 16 Inspection of a Masonry Chimney 16 Automatic Vent Damper 17 3 GAS CONNECTIONS Gas Supply 18 Gas Pressure Test 18 Gas Connection 18 Gas Piping 19 Gas Manifold...

Page 3: ...ed by too much water velocity through the tubes and is not covered by the manufacturer s warranty see Boiler Flow Rates and Temperature Rise for flow requirements Checking equipment Upon receiving equ...

Page 4: ...ll be installed in accordance with those installation regulations in force in the local area where the installation is to be made These regulations shall be carefully followed in all cases Authorities...

Page 5: ...tions above 2000 feet elevation 5 Ratings have been confirmed by the Hydronics Institute Section of AHRI Maximum allowed working pressure is located on the rating plate NOTICE Installation Service Man...

Page 6: ...es adequate flow to operate the unit 13 Pilot not shown The pilot is a spark ignition device used to light a pilot flame which in turn is used to light the main burners 14 Pump relay The pump relay en...

Page 7: ...els 45 000 90 000 Left Side inside unit Models 45 000 90 000 Right Side inside unit Models 45 000 90 000 Rear View The Solution How it works continued 11 22 14 23 21 25 9 16 7 18 12 6 24 1 10 19 8 3 1...

Page 8: ...rks Models 135 000 260 000 Btu hr Left Side inside unit Models 135 000 260 000 Btu hr Right Side inside unit Models 135 000 260 000 Btu hr Rear View Models 135 000 260 000 Btu hr Front View 10 1 19 3...

Page 9: ...d in a residential garage and in adjacent spaces that open to the garage and are not part of the living space of a dwelling unit must be installed so that all burners and burner ignition devices have...

Page 10: ...s see FIG 1 3 a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm2 per kW This opening must be located within 12 30 cm of the floor b Ventilation air open...

Page 11: ...e Particular care should be taken where exhaust fans attic fans clothes dryers compressors air handling units etc may take away air from the appliance The combustion air supply must be completely free...

Page 12: ...feet per 1 000 Btu hr input Buildings MUST NOT be of Tight Construction For buildings of Tight Construction provide air openings into the building from outside No combustion air openings are needed wh...

Page 13: ...ntional Negative Draft Vertical Venting TABLE 2A VENT PIPE SIZES Input Btu hr Flue Size 45 000 4 75 000 5 90 000 5 135 000 6 180 000 7 215 000 7 260 000 8 On a conventionally vented negative draft app...

Page 14: ...and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected...

Page 15: ...from or 1 foot 30cm above any door window or gravity air inlet into any building Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent can not terminat...

Page 16: ...enting The induced draft fan MUST also be equipped with a proving switch properly interlocked into the appliance s control circuit to prove fan operation before the main burners are allowed to fire A...

Page 17: ...s condition such as an explosion or carbon monoxide poisoning could result The damper position indicator must be in a visible location with access for service following installation The damper must be...

Page 18: ...l Gas LP Gas 45 000 3 5 10 0 9 2 5 75 000 2 4 7 0 9 2 5 90 000 180 000 3 5 10 0 9 2 5 215 000 260 000 3 5 10 0 9 2 5 Gas Pressure Test 1 The appliance must be disconnected from the gas supply piping s...

Page 19: ...ons must be made with pipe joint compound resistant to the action of liquefied petroleum and natural gas All piping must comply with local codes Tubing installations must comply with approved standard...

Page 20: ...c for Natural gas models and 10 w c for L P gas models 4 Remove the pressure regulator adjustment cap screw on the gas valve See FIG 3 3 for location 5 Turn the power ON at the main disconnect switch...

Page 21: ...de proper gas pressure to the control 11 If the gas supply pressure is within the specified range proceed with the following steps to return the appliance to service 12 Turn the power OFF at the main...

Page 22: ...ter complies with the safety code requirements of CSD 1 CF 190 a as shipped from the manufacturer without the installation of additional vent lines Two Stage Burner Control System The 45 000 thru 260...

Page 23: ...ter Flow Switch Top Connections A water flow switch is available as a factory supplied option on all heating boilers see FIG 4 2 The flow switch should be wired between terminals X and B Remove the ju...

Page 24: ...boiler and on the suction side of the pump 6 Support all water piping Placing the Boiler in Operation Filling the System All air must be purged from the system for proper operation An air scoop and a...

Page 25: ...t hd 45 000 36 900 7 4 0 6 3 7 0 2 2 5 0 2 1 9 0 2 75 000 61 500 12 3 1 3 6 2 0 4 4 1 0 3 3 1 0 2 90 000 73 800 14 9 1 4 7 4 0 5 5 0 0 3 3 7 0 2 135 000 110 700 22 3 3 2 11 1 1 2 7 4 0 6 5 6 0 3 180 0...

Page 26: ...ts This is a low mass high efficiency hot water boiler which must have adequate flow for quiet efficient operation The boiler circulating pump must be field supplied The boiler circulator pump must op...

Page 27: ...ance loop is dedicated to the unit and does not affect the building s system or primary secondary flow characteristics and will not circulate the building It is acceptable to remove the performance lo...

Page 28: ...f combustion from condensing in most installations The bypass should be fully sized with a balancing valve to allow for proper adjustment A valve must also be provided on the boiler discharge after th...

Page 29: ...SION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE DRAIN POINT TYPICAL MAKE UP WATER FROM SYSTEM 12 NOT TO EXCEED APART BOILER CIRCULATOR SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR...

Page 30: ...SSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE DRAIN POINT TYPICAL MAKE UP WATER FROM SYSTEM 12 NOT TO EXCEED APART BOILER CIRCULATOR SYSTEM CIRCULATOR...

Page 31: ...SURE RELIEF VALVE DRAIN POINT TYPICAL MAKEUP WATER HOT WATER OUT BOILER CIRCULATOR BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE EXPANSION TANK ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE CIRCULATORS...

Page 32: ...E AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE MAKE UP WATER FROM SYSTEM SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED Figure 4 7...

Page 33: ...RATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICAL PRESSURE RELIEF VALVE MAKE UP WATER FROM SYSTEM BOILER CIRCULATOR SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED 3...

Page 34: ...re after each set point adjustment to ensure proper operation Room Thermostat or Remote Thermostat Connection to Terminal Strip A room thermostat or remote temperature control may be connected to the...

Page 35: ...E The temperature controller is pre set at the factory with test settings You may need to adjust the settings to meet your specific needs WARNING Return water temperatures must not be less than 140 F...

Page 36: ...re control shuts the unit off If the High Fire Offset knob is set to 0 or 1 the delay will be 10 seconds if set to 2 or above the delay will be 120 seconds Boiler Application Standard boiler units are...

Page 37: ...e temperature sensor wiring near welding equipment 5 Make sure good mechanical connections are made to the sensor any interconnecting wiring and the controller 6 Do not mount sensor with leadwire end...

Page 38: ...s control over the reset ratio to be used during Outdoor Air Reset The allowable ratios are as low as 0 5 1 or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 for every 1 0...

Page 39: ...es are located in the controls compartment and in the relief opening of the boiler s built in draft hood Each switch has a red reset button In the event the system has actuated to shut off the main bu...

Page 40: ...nnections are tight and the appliance and piping system have been properly filled 5 Ensure that discharge from the relief valve has been piped to a floor drain 6 Verify that properly sized combustion...

Page 41: ...sired setting 11 Re install the control panel door 12 If the appliance will not operate follow the instructions To Turn Off Gas To Appliance and call your service technician or gas supplier To Turn Of...

Page 42: ...the front header and one from the outlet side of the front header on the heat exchanger Blow all water out of the heat exchanger e Drain pump and piping Freeze Protection for a Heating Boiler System...

Page 43: ...s Perform start up checkout and performance verification per Section 6 Start up If combustion or performance indicate need Clean heat exchanger Remove and wash burners ANNUAL START UP Owner maintenanc...

Page 44: ...water may also cause severe property damage 1 Inspect all water and gas piping and verify to be leak free 2 Look for signs of leaking lines and correct any problems found 3 Check gas line using the p...

Page 45: ...unless the valve and its components are physically removed and inspected This inspection must only be conducted by a plumbing contractor or authorized inspection agency not by the owner Failure to re...

Page 46: ...injection pressure into the venturi of the burners The burners do not have an adjustable air shutter Adequate combustion air must be supplied to the room where the appliance is installed to ensure pro...

Page 47: ...ht black smudge is normal with some types of gases If abnormal soot deposits are present the heat exchanger must be cleaned and the cause of the soot problem corrected Proceed as follows k Remove soot...

Page 48: ...o be sure that no sediment or scale accumulates on the heat transfer surfaces Inspection plugs are located at both ends of the heat exchanger Inspection plugs should be removed and tubes inspected at...

Page 49: ...ess the reset button Yes Is there 24 VAC tan wire on the 4 pin connector plug on the temperature controller Yes Check each of the following for an open X and B on the terminal strip purple and gray wi...

Page 50: ...50 Installation Service Manual Schematic Diagram M9 Unit 45 000 260 000 Btu hr Models Wiring Diagram M9 Unit 45 000 260 000 Btu hr Models 9 Diagrams...

Page 51: ...51 Notes...

Page 52: ...Revision A ECO C03746 initial release SBR I S Rev A 5 10...

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