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Installation & Service Manual

Models: 45,000 - 260,000 Btu/hr

This manual supplies information for the installation,
operation, and 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 in severe
personal injury, death, or substantial property damage.

WARNING:

Save this manual for future reference.

SBR-I-S Rev C

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Summary of Contents for CBN045

Page 1: ...and 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 in severe personal injury death or substantial property damage WARNING Save this manual for future reference SBR I S Rev C ...

Page 2: ...earances 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 Pressure Adjustment Procedure 20 Checking Gas Supply Pressure 21 Combination Gas Valves 22 4 WATER CONNECTIONS Relief Valve 23 Water Flow Switch if equipped 23 Low Water Cutoff if equipped 24 Typica...

Page 3: ...used 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 equipment check for signs of shipping damage Pay particular attention to parts accompanying the appliances which may show signs of being hit or otherwise being mishandled Verify total number of pieces ...

Page 4: ...all 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 having jurisdiction shall be consulted before installations are made In the absence of such requirements the installation shall conform to the latest edition of the National Fuel Gas Code ANSI Z223 ...

Page 5: ...llations above 2000 feet elevation 5 Ratings have been confirmed by the Hydronics Section of AHRI Maximum allowed working pressure is located on the rating plate NOTICE Installation Service Manual Other Specifications Boiler Water Content Gallons Water Connections Gas Connections Vent Size Note 3 0 87 1 1 2 1 2 4 0 91 1 1 2 1 2 5 0 91 1 1 2 1 2 5 0 95 1 1 2 1 2 6 0 99 1 1 2 3 4 7 1 02 1 1 2 3 4 7 ...

Page 6: ...res 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 energizes the pump on a call for heat 15 Relief valve The relief valve is a safety device that ensures the maximum pressure of the appliance is not exceeded 16 Sight Glass The sight glass provides a vi...

Page 7: ...dels 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 17 15 5 4 20 Installation Service Manual 7 ...

Page 8: ...orks 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 8 15 17 5 4 20 22 21 9 14 25 23 11 3 3 7 18 12 24 6 ...

Page 9: ...ated 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 a minimum clearance of not less than 18 46cm above the floor The appliance must be located or protected so that it is not subject to physical damage by a moving vehicle 5 DO NOT install this applia...

Page 10: ...gs 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 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 ceiling Figure 1 4_Combustion Air Through Ducts 2 If combustio...

Page 11: ...essure 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 of any flammable vapors that may ignite or chemical fumes which may becorrosivetotheappliance Commoncorrosivechemicalfumes which must be avoided are fluorocarbons and other halogenated compounds...

Page 12: ...ubic 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 when the water heater is installed in a space with a volume NO LESS than 50 cubic feet per 1 000 Btu hr of all installed gas fired appliances Buildings MUST NOT be of Tight Construction Tight Const...

Page 13: ...ventional 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 appliance the connection from the vent to the chimney or vent termination on the outside of the building MUST be made with listed Type B double wall or equivalent vent connectors and must be direct as ...

Page 14: ...n 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 to the common venting system are located and other spaces of the building Turn on clothes dryers and any other appliances not connected to the common venting system Turn on any exhaust fans such as ...

Page 15: ...y 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 terminate below grade The bottom of the vent terminal shall be located at least 12 inches 30cm above grade To avoid a blocked vent condition keep the vent cap clear of snow ice leaves debris etc Flue gases w...

Page 16: ...Venting 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 vertical or sidewall vent termination for an induced draft fan MUST be installed per the recommendations of the fan manufacturer and provide proper clearances from any combustion or ventilation openi...

Page 17: ...zardous 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 in an open position when appliance main burners are operating The part number for the automatic vent damper required on this heating boiler is printed on the rating plate Vent damper regulation...

Page 18: ...al 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 system during any pressure testing of that system at a test pressure in excess of 1 2 PSIG 3 5kPa 2 The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve d...

Page 19: ...ions 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 standards and practices Reference FIG 3 1 for a typical installation Install Piping to Control 1 The gas line should be a separate line direct from the meter unless the existing gas line is of sufficient cap...

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 6 Turn gas valve control knob to ON position 7 Set the thermostat s to call for heat 8 Observe gas regulator pressure when all burners are firing See Table 3B Manifold Pressure page 18 for proper reg...

Page 21: ...ide 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 disconnect switch 13 Turn gas valve control knob to OFF position 14 Shut off gas supply at the manual valve in the gas piping to the appliance If fuel supply is L P Gas shut off gas supply at the tan...

Page 22: ...r 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 260 000 Btu hr boilers M9 are equipped with a two stage burner control system Each unit has a combination gas valve to control the gas supply to the burners The combination valve consists of a gas regulator...

Page 23: ...ater 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 jumper between the X and B terminals on the terminal strip This wiring connection installs the flow switch in the 24 VAC safety circuit to prove water flow before main burner ignition A flow switch ins...

Page 24: ...e 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 air vent must be located close to the boiler outlet and there should be a minimum distance between the cold water feed and the system purge valve 1 Close all drain cocks and air vents 2 Open the makeu...

Page 25: ...Ft 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 3 180 000 147 600 29 7 5 1 14 9 1 6 9 9 0 7 7 4 0 4 215 000 176 300 17 0 1 3 11 8 0 8 8 9 0 4 260 000 213 200 21 5 2 1 14 3 0 9 10 7 0 5 Piping of the Boiler System The drawings in this section see FIG s 4 ...

Page 26: ...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 operate continuously while the boiler is firing Pump selection is critical to achieve proper operation A pump should be selected to achieve proper system design water temperature rise A heat exchanger pres...

Page 27: ...mance 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 loop as long as the following requirements are met 1 The boiler is piped to the system in primary secondary fashion 2 The system setpoint is 140 F or higher 3 The boiler circulating pump is sized for t...

Page 28: ...of 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 the bypass Closing this discharge valve forces water through the bypass Start boiler adjustment with the bypass valve in the full open position and the boiler discharge valve half open A small amount o...

Page 29: ...NSION 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 DRAIN Y STRAINER RECOMMENDED Figure 4 4_Primary Secondary Piping of a Single Boiler 4 Water connections continued 29 Installation Service Manual ...

Page 30: ...ESSURE 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 TO SYSTEM SYSTEM SUPPLY SENSOR DRAIN Y STRAINER RECOMMENDED LOW TEMPERATURE BYPASS Primary Secondary Piping 4 Water connections 30 Installation Service Manual ...

Page 31: ...SSURE 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 TYPICAL FLOW CHECK VALVE SYSTEM SUPPLY SENSOR WHEN USED RECIRCULATION LOOP AQUASTAT RELIEF VALVE Y STRAINER RECOMMENDED MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 12 APART BOILER 2 LEADER 1 4 Wate...

Page 32: ...GE 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_Single Boiler Full System Flow Full System Flow 4 Water connections 32 Installation Service Manual ...

Page 33: ...ARATOR 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 ...

Page 34: ...ure 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 boiler The room thermostat should be installed on an inside wall away from the influences of drafts hot or cold water pipes lighting fixtures televisions sun rays or fireplaces Follow the manufacture...

Page 35: ...CE 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 If lower return water temperatures are required follow the instructions for Low Temperature Bypass Requirements see page 28 Locating Temperature Control Remove the control panel door on the front of ...

Page 36: ... the temperature 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 equipped with one inlet water temperature sensor A system sensor is also provided for use as a remote system sensor Boilers with the outdoor air reset option also have an outside air te...

Page 37: ...te 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 pointing up in an area where condensation can occur 7 Use shielded wiring to connect the sensor to the control when the possibility of an electrically noisy environment exists Shielded cable is recom...

Page 38: ...or as high as 1 5 1 Selecting the 0 5 1 ratio will increase the set point 0 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature Selecting the 1 5 1 ratio will increase the set point 1 5 for every 1 0 drop in outdoor air temperature up to the maximum set point temperature If the outdoor design and boiler design temperatures are known the Ratio setting can be calc...

Page 39: ...hes 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 burner gas supply wait for the boiler to cool then press the red reset to return the boiler to operation Oper ation of a blocked vent and or flame roll out interlock switch usually indicates a problem ...

Page 40: ...onnections 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 and ventilation air openings are provided and not obstructed in any way 7 Check carefully for gas leaks 8 Read the appliance s safety warnings lighting instructions and check out procedure carefully ...

Page 41: ...esired 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 Off Gas to Appliance 1 Set the thermostat to the OFF position 2 Turn off all electric power to the appliance if service is to be performed 3a 45 000 135 000 Btu hr models rotate the gas control knob on...

Page 42: ...of 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 if required 1 Use only properly diluted inhibited glycol antifreeze designed for hydronic systems Inhibited propylene glycol is recommended for systems where incidental contact with drinking water i...

Page 43: ...rs 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 maintenance see the User s Information Manual for instructions Daily Check appliance area Check pressure temperature gauge Monthly Check vent piping Check relief valve Periodically Test low water cutoff if use...

Page 44: ...g 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 procedure found in Section 3 Gas Connections Check all piping for leaks WARNING WARNING WARNING WARNING CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause i...

Page 45: ...e 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 inspect the boiler relief valve as directed could result in unsafe pressure buildup which can result in severe personal injury death or substantial property damage WARNING Following installation the...

Page 46: ...gas 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 proper burner operation Check frequently to be sure the flow of combustion and ventilation air to the unit is not obstructed When the main burners light observe the burner flame Flames should be ligh...

Page 47: ...ght 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 from burners and bottom of the finned tubes with a stiff bristle brush Dirt may also be removed from burner ports by rinsing the burner thoroughly with water Drain and dry burners before re installi...

Page 48: ... 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 the end of the first 45 days of operation and again at the end of 90 days of operation If no scale accumulation is observed inspections can be made at the end of each six months of operation IMPORTANT Upon com...

Page 49: ...ress 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 wires on the vent damper plug V and P on the terminal strip auto reset high limit No Check voltage to and from the transformer No Check incoming 120 VAC Check for an open sensor If no open sensor make ...

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: ...the pressure drop chart Table 4C to reflect the correct models and change out the reference to the two blues wires to SYS TANK contacts under System Sensor on page 36 ECR03727 Revision C ECO C09691 reflects the update of ASME and AHRI logos on page 5 SBR I S Rev C 1 12 ...

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