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GAS-FIRED COPPER BOILERS FOR
HYDRONIC HEATING AND HOT WATER SUPPLY
INSTRUCTION MANUAL
• Installation
MODELS:
• Operation
VB/VW-500, 750 AND 1000
• Maintenance
SERIES 200/201
• Limited Warranty
WARNING: If the information in this
manual is not followed exactly, a fire or
explosion may result causing property
damage, personal injury or loss of life.
— Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
— WHAT TO DO IF YOU
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SAFE INSTALLATION, USE AND SERVICE The proper installation, use and servicing of this boiler is extremely important to your safety and the safety of others. Many safety-related messages and instructions have been provided in this manual and on your boiler to warn you and others of a potential injury hazard. Read and obey all safety messages and instructions throughout this manual. It is very important that the meaning of each safety message is understood by you and others who install, use, o
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GENERAL SAFETY 3
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DIMENSION AND CAPACITY DATA Minimum clearances to combustibles: • 4” (102mm) rear • 0” (0mm) top & sides • 6” (152mm) vent FIGURE 1. T ABLE 1. - GAS AND ELECTRICAL CHARACTERISTICS Manifold Pressure Maximum Supply Pressure Minimum Supply Pressure Model Type of Gas Inches W.C. kPa Inches W.C. kPa Inches W.C. kPa VB/VW-500, 750, 1000 NATURAL -2 to -3.5 -.5 to .9 14 3.44 4.0 2.0 VB/VW-500, 750, 1000 PROPANE -2 to -3.5 -.5 to .9 14 3.44 8.0 2.0 Minimum Pressures must be maintained during all
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CAPACITY AND FLOW DATA TABLE 3. RECOVERY CAPACITIES. T emperature Rise - °F (°C) Input Output Model Water Rating Rating 40 60 80 90 100 120 140 No. Flow Btu/hr Btu/hr (22) (33) (44) (90) (56) (67) (78) GPH 1,268 845 634 563 507 423 362 VW-500 500,000 421,500 LPH 4,797 3,198 2,399 2,132 1,919 1,599 1,371 GPH 1,901 1,268 951 845 761 634 543 VW-700 750,000 633,750 LPH 7,196 4,797 3,598 3,198 2,878 2,399 2,056 GPH 2,535 1,690 1,268 1,127 1,014 845 724 VW-1000 1,000,000 845,000 LPH 9,595 6,397 4,79
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CONTENTS SAFE INSTALLATION, USE AND SERVICE ...........................................2 Horizontal Installtion Requirements ......................................................17 GENERAL SAFETY......................................................................................3 Direct Vent Installation Requirements .................................................19 DIMENSION AND CAPACITY DATA .........................................................4 INSTALLATION REQUIREMENTS FOR THE COMMO
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doors open to ventilate, then call your gas supplier or GROUNDING INSTRUCTIONS service agent. Keep area clear until a service call has This boiler must be grounded in accordance with the National been made. Electrical Code and/or local codes. Boiler is polarity sensitive; correct wiring is imperative for proper operation. At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical This boiler must be connected to a grounded metal, permanen
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CONTROL COMPONENTS flue of the unit is restricted or blocked. The BFS is a normally closed THE CONTROL SYSTEM switch that opens when positive pressure is placed on the switch because of any restriction to the exhaust venting. If the BFS is The control system consists of four basic components: activated check and clear any obstructions causing the restriction. 1) Modulation Control Board (MCB); 2) Power Distribution Board (PDB); 3) V ariable Frequency Dri
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Temperature Probe allows a boiler to sense the actual water WATER TEMPERATURE LIMIT CONTROLS temperature inside the storage tank or hydronic heating loop. The boiler will modulate its firing rate in response to the actual system temperature and load conditions. The control system displays the temperature sensed from the Remote T emperature Probe as the “T ank” temperature on the default Temperatures screen. QUAD THERMISTOR PROBE When connecting up to 4 boilers to a single
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The Discharge Pipe: This ASME-rated valve has a discharge capacity that exceeds maximum • Shall not be smaller in size than the outlet pipe size of the valve, or boiler input rating and a pres sure rating that does not exceed maximum have any reducing couplings or other restrictions. working pres sure shown on boiler rating plate. In addition, a CSA • Shall not be plugged or blocked. design-cer tified and ASME -rat ed t empera t ure and pressure (T &P ) relief valve must be instal
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UNCONFINED SPACE In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for com bustion. I f t h e u n c o n fi n e d s p a c e i s w i t h i n a b u i l d i n g o f t i g h t c o n s t r u c t i o n ( b u i l d i ngs u s i ng t he f o l l o w i ng c o n s t r u c t i o n: wea t h er s t r i p pi ng , h e a v y i n s u l at i o n , c a u l k i n g, v a p o r b a r r i e r , e t c . ) , a i r f o
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f o r t h e o p e n i n g s t h at p r o v i d e f r e s h a i r i n t o c o n fi n e d s p a c e s OUTDOOR AIR THROUGH TWO HORIzONTAL DUCTS only. Do not refer to these illustrations for the purpose of vent installation. See Venting Installation on page 18 for complete venting installation instructions. OUTDOOR AIR THROUGH TWO OPENINGS FIGURE 9C. The confined space should be provided with two permanent horizontal ducts, one commencing within 12 inches (300 m
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The confined space should be provided with two permanent AIR FROM OTHER INDOOR SPACES openings, one commencing within 12 inches (300 mm) of the top and one commencing within 12 inches (300 mm) of the bottom of the enclosure. See Figure 9E. Each opening should communicate directly with an additional room(s) of sufficient volume so that the combined volume of all spaces meets the criteria for an Unconfined Space. Each opening should have a minimum free area of
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v v TERMINATION CLEARANCES SIDEWALL POWER VENT POWER VENT (using room air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION D E L B VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED V X Figure 9F. Vent terminal clearances for “Power Vent” installations. Power Vent configurations use room air for combustion. 1 2 1 2 CANADIAN INSTALLATIONS US INSTALLATIONS CANADIAN INSTALLATIONS US INSTALLATIONS Clearance to each side 3 feet (91 cm) within a Clearance above grade
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v v TERMINATION CLEARANCES SIDEWALL DIRECT VENT DIRECT VENT (using outdoor air for combustion) EXTERIOR CLEARANCES FOR SIDEWALL VENT TERMINATION D E L B VENT TERMINAL AIR SUPPLY INLETAREA WHERE TERMINAL IS NOT PERMITTED V X Figure 9G. Vent terminal clearances for “Direct Vent” installations. Direct Vent configurations use outdoor air for combustion. 1 2 1 2 CANADIAN INSTALLATIONS US INSTALLATIONS CANADIAN INSTALLATIONS US INSTALLATIONS Clearance to each side Clearance above grade, 3 feet (91 c
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VENTING 2. Through-the-Wall Termination (TWT) - horiz ontal vent termination directly through an outside wall, see Figure 11A. 3. Horizontal Direct Vent - using TWT to exhaust flue prod ucts and PVC piping to bring combus tion air to the boiler from the outside, see Figures 12 and 12C. 4. Vertical Direct Vent - using a vertical vent termination to exhaust flue products and PVC piping to bring combustion air to the boiler from outside, see Figures 12A and 12B. GENERAL EX
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4. Maintain a minimum of 6 feet (2.0m) separation between VENTING SUPPORTS the air intake and the exhaust terminals. Care must be taken in the installation of the venting system that adequate support is maintained throughout the installation process. HORIzONTAL INSTALLTION REQUIREMENTS When extending more than 10 feet (3.0m) vertically , vertical support ® 1. The vent system must terminate with a AL 29-4C Vent kits are required once every 10 feet (3.0m) o
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NOTES: If the exhaust vent terminal is within 10’ (3.0m) of a wall or parapet, it must extend a minimum of 2’ (610mm) above the wall or parapet. Joints are not joined to show vent pipe orientation. FIGURE 11. VERTICAL TERMINATION. NOTES: Joints are not joined to show vent pipe orientation. FIGURE 11A. HORIzONTAL THROUGH THE WALL TERMINATION (TWT). 18
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1. The Air-Intake System (AIS) must ter minate with the venting DIRECT VENT INSTALLATION REQUIREMENTS equipment pro vided with the boiler, Refer to the parts list for required direct vent parts. Follow the guidelines in the “HORIZONTAL INSTALLATION REQUIREMENTS” section for the exhausting of flue 2. T he AI T shall not be locat ed less t han 3 f eet (1. 0m) below products. any exhaust vent within 10 feet (3.0m), see “HORI ZONT A
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NOTE: Joints are not joined to show vent pipe orientation. CAUTION Direct venting into dead air spaces such as alleys, atriums, and inside corners can cause recirculation of flue gases. Recirculation of flue gases will cause sooting, premature failure of the heat exchanger and icing of the combustion air intake during severe cold weather. To prevent the recirculation of flue gases, maintain as much distance as possible between the combustion air intake and the exhaust vent terminal. FI
