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CB-CW(E)-i&s-06
INSTALLATION AND SERVICE MANUAL
HYDRONIC HEATING BOILERS and
DOMESTIC WATER HEATERS
495,000 - 2,065,000 Btu/hr MODELS
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 SMELL
GAS
• Do not try to light any
appliance.
•Do not touch any
WARNI
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Hydronic Heating Boilers and Domestic Water Heaters Table of Contents Table of Contents Installation with a Chilled Water System . . . . . . . . . . .26 General Product Information . . . . . . . . . . . . . . . . . . . . . . . . .3 Special Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Boiler Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27 Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 Boiler Bypass Requirements
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Installation and Service Manual tube may be caused by too much water velocity through GENERAL PRODUCT the tubes and is not covered by the appliance manufacturer's warranty (see System Temperature Rise INFORMATION Chart on page 26 for flow requirements). Special Instructions SAFETY INFORMATION This manual supplies information for the installation, operation The information contained in this manual is intended for use and servicing of the appliance. Read and understand this manual by qualified pr
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Hydronic Heating Boilers and Domestic Water Heaters 3. Boilers and water heaters are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-air intake system. Use proper care to avoid unnecessary contact (especially children) with the appliance and vent-air intake components. Follow all clearances from combustibles contained in this manual. 4. Never cover your unit, lean anything against it, store trash or debris near it, stand on it or
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Installation and Service Manual PRODUCT IDENTIFICATION Front View Rear View Figure 1 – Front and Rear View 5
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Hydronic Heating Boilers and Domestic Water Heaters Clearances from Combustible INSTALLATION Construction This unit meets the safe lighting performance criteria with the Maintain minimum specified clearances for adequate gas manifold and control assembly provided, as specified in operation. Allow sufficient space for servicing pipe the ANSI standards for gas-fired units, ANSI Z21.13/CSA 4.9 connections, pump and other auxiliary equipment, as well as and ANSI Z21.10.3/CSA 4.3. the unit. See ratin
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Installation and Service Manual base for combustible floor installation. Install unit over a base CAUTION: A mechanical room operating of hollow clay tiles or concrete blocks from 8" to 12" thick and under a negative pressure may experience a extending at least 24" beyond the unit sides. Place tiles or down draft in the flue of a boiler which is not blocks so that the holes line up horizontally to provide a clear firing. The cold outside air pulled down the flue passage through the tiles or b
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Hydronic Heating Boilers and Domestic Water Heaters Check this filter every month and replace when it becomes INSTALLATION dirty. The filter size is 12" x 16" x 1" (30.5cm x 40.6cm x Continued 2.5cm) . You can find this commercially available filter at any home center or HVAC supply store. Freeze Protection for a Heating Installing Combustion Air Filter Boiler System (if required) 1. Use only properly diluted inhibited glycol antifreeze To install the filter(s), remove the combustion air inle
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Installation and Service Manual Combustion Air Options CAUTION: Under no circumstances should the mechanical room ever be under a negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., take away air from the unit. 1. Outside Combustion Air, No Ducts You can direct outside combustion air to this unit using either one or two permanent openings. One Opening The opening must have a minimum free area of one squa
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Hydronic Heating Boilers and Domestic Water Heaters VENTING INSTALLATION Continued General Information You must supply adequate combustion and ventilation air to this unit. You must provide minimum clearances for the vent terminal from adjacent buildings, windows that open, and building openings. Follow all requirements set forth in the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CAN/CGA Standard B149 Installation Code for Gas Burning Appliances an
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Installation and Service Manual You must locate the air inlet termination elbow at least 12" (30cm) above the roof or above normal snow levels. Keep the vent cap clear of snow, ice, leaves, and debris to avoid blocking the flue. Figure 12 - Vent Termination from Flat Roof 10' or Less from Parapet Wall Figure 10 - Vent Termination from Peaked Roof - 10' or Less From Ridge IMPORTANT: Vent terminations are not shown in Figures 10, 11, 12, and 13. Make sure all vertical vents are installed with ve
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Hydronic Heating Boilers and Domestic Water Heaters 2. Outdoor Installation Venting INSTALLATION This option uses the installation of special air inlet and vent Continued caps on the unit. See page 13 for venting details. All units are shipped from the factory equipped for TABLE - B conventional negative draft venting. All other optional vent Flue Pipe Sizes systems require the installation of specific vent kits and venting materials. The following is a detailed explanation of Input Flue the i
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Installation and Service Manual Flue Outlet Piping 1. Conventional Negative Draft With this venting option, you must use Type-B double-wall (or Venting equivalent) vent materials. Vent materials must be listed by a nationally-recognized test agency for use as vent materials. IMPORTANT: Before installing a venting system, Make the connections from the unit vent to the outside stack as follow all venting clearances and requirements direct as possible with no reduction in diameter. Use the found in
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Hydronic Heating Boilers and Domestic Water Heaters Inspection of a Masonry Chimney INSTALLATION A masonry chimney must be carefully inspected to determine Continued its suitability for the venting of flue products. A clay-tile-lined 4. Turn on clothes dryers and any other appliances not chimney must be structurally sound, straight and free of connected to the common venting system. Turn on any misaligned tile, gaps between liner sections, missing sections exhaust fans, such as range hoods and b
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Installation and Service Manual Flue gas condensate can freeze on exterior walls or on the vent Outdoor Vent/Air Inlet Location cap. Frozen condensate on the vent cap can result in a blocked Keep venting areas free of obstructions. Keep area clean and free flue condition. Some discoloration to exterior building or unit of combustible and flammable materials. Maintain a minimum surfaces can be expected. Adjacent brick or masonry surfaces clearance of 3" (76mm) to combustible surfaces and a minimu
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Hydronic Heating Boilers and Domestic Water Heaters Gas Piping INSTALLATION To safely operate this unit, you must properly size the gas Continued supply piping. See TABLES- F, G, & H for piping and fitting requirements. Gas pipe size may be larger than heater connection. CONNECTING TO GAS The gas connection for models 495,000 to 745,000 Btu/hr is SUPPLY 1 1/4" NPT and on models 985,000 to 2,065,000 Btu/hr the gas connection to these units is 2" NPT. Only supply the gas type specified on the unit
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Installation and Service Manual The combination gas valves have an integral vent limiting device and does not require venting to atmosphere outside the COMBINATION VALVE building. The unit will not operate properly if the reference hose is removed or a vent to atmosphere is installed. DOWNSTREAM TEST VALVE Optional gas controls may require routing of bleeds and vents to the atmosphere outside the building when required by local codes. TO BURNERS ADDITIONAL VALVES BASED Connecting Gas Piping to U
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Hydronic Heating Boilers and Domestic Water Heaters not required to have vent or relief lines piped to the outdoors. INSTALLATION The termination of the vent limited opening on the Continued combination gas valve/regulator complies with the safety code requirements of CSD-1, CF-190(a) as shipped from the Water heater models do not have downstream test valves, but appliance manufacturer without the installation of additional the rest of the gas train is represented by Figure 19. vent lines. Combi
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Installation and Service Manual 9. If gas pressure is out of range, contact your gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control. 10. If gas supply pressure is within normal range, remove the gas manometer and replace the pressure tap fittings in the gas control as indicated in the following steps. 11. Turn the power switch to the “OFF” position. 4 12. Turn gas valve knob to the “OFF” position. 3 13.
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Hydronic Heating Boilers and Domestic Water Heaters 12. If adjustment is necessary, remove the regulator cover screw INSTALLATION on the gas valve. Note: If the gas valve under adjustment is Continued located on a manifold assembly monitored by an igniter, the unit may shut down and recycle when the regulator cover screw is removed. This is normal. 13. Turn the regulator adjustment screw “clockwise” to raise the regulator gas pressure. Turn the regulator adjustment screw “counterclockwise” to lo
