Installation & Service Manual Models: 497 - 2067: - What To Do If You Smell Gas

CBX-CWX-I-S_100160893_2000001309_Rev J
Installation & Service Manual

Models: 497 - 2067
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.
-- This water heater MUST NOT be installed

in any location where gasoline or flammable
vapors are likely to be present.
-- WHAT TO DO IF YOU SMELL GAS

•Do not try to light any appliance.
•Do not touch any electric switch; do not
use any phone in your building.
•Immediately call your gas supplier from a
near by phone. Follow the gas supplier’s
instructions.
• If you cannot reach your gas supplier, call
the fire department.
•Installation and service must be performed
by a qualified installer, service agency, or
the gas supplier.
WARNING:
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.
Save this manual for future reference.
Contents
HAZARD DEFINITIONS ..................................................... 2 Terminal Strip Connection Options ............................. 40-41
PLEASE READ BEFORE PROCEEDING ...................... 3-4 Temperature Controls
SAFETY INFORMATION ................................................... 4 Temperature Adjustment ............................................ 41
THE COPPER-FIN -- HOW IT WORKS.......................... 5-7 Outdoor Reset Option ................................................. 42
RATINGS ........................................................................ 8-9 Temperature Control Sensors ............................... 43-44
1. DETERMINE UNIT LOCATION Hot Surface Ignition System ............................................ 45
Locating the Unit .............................................................. 10 Operation and Diagnostic Lights ...................................... 46
Indoor Clearances from Combustible Construction ........ 10 6. STARTUP
Freeze Protection ........................................................ 11-12 Operating and Safety Instructions .................................... 47
Prevent Combustion Air Contamination ...................... 11-13 Check Water Chemistry ................................................... 48
Combustion Air Options .............................................. 14-15 Freeze Protection (when used) ........................................ 48
2. VENTING Fill and Test Water System .............................................. 49
General Venting Information ....................................... 16-17 Purge Air from Water System .......................................... 49
Vent System Options Check for Gas Leaks / Thermostat Circuit(s)................... 50
Conventional Negative Draft Venting .................... 18-21 Check Vent and Air Piping ............................................... 50
Masonry Chimney Installation and Inspection ............ 19 Placing the Boiler in Operation ........................................ 50
Outdoor Installation Options .................................. 22-23 7. DOMESTIC WATER HEATERS
3. GAS CONNECTIONS General............................................................................. 51
Connecting to Gas Supply ............................................... 24 Water Velocity Control ..................................................... 51
Gas Pressure Test ........................................................... 24 Pipe Size Requirements
Gas Piping ........................................................................ 24 Typical Water Heater Piping w/ Storage Tank ........... 52
Gas Connections / Gas Train and Controls ..................... 25 Single Water Heater Piping w/Two Storage Tanks ... 53
Combination Gas Valves.................................................. 26 Multiple Water Heater Piping w/One Storage Tank ... 54
Checking Gas Supply Pressure .................................. 26-27 Multiple Water Heater Piping w/Multi. Storage Tanks . 55
Gas Manifold Pressure Adjustment ............................ 27-28 Water Chemistry............................................................... 56
4. WATER CONNECTIONS Circulating Pump/ Performance ....................................... 56
Inlet & Outlet Connections ............................................... 29 Heat Exchanger ............................................................... 57
Relief Valve ...................................................................... 29 Potable Hot Water Temperature Controls........................ 57
Heating Boiler Installations.......................................... 29-31 Location of Cold Water Supply Piping Connections ........ 58
Low Temperature Return Water Systems........................ 32 High Water Temperature Limit Control ............................ 59
Primary/Secondary Piping of a Single Boiler.............. 33 Optional Relief Valve........................................................ 59
Primary/Secondary Piping of Multiple Boilers ............ 34 Thermal Expansion and Cathodic Protection................... 59
Boiler w/Low Temperature Bypass Piping .................. 35 8. MAINTENANCE
Primary/Secondary Piping with Buffer Tank ............... 36 Burner Flames .................................................................. 60
Installation with a Chilled Water System .......................... 37 Burner Removal and Cleaning Procedures ................ 60-61
Typical Heating Boiler Installations .................................. 37 Adjusting Differential Air Pressure .............................. 61-62
Boiler Flow Rate / Bypass Requirements ................... 37-38 Servicing a Hot Surface Igniter / Ignition Module ............ 63
Temperature/Pressure Gauge and Water Treatment ...... 38 Sequence of Operation Overview ............................... 63-64
5. ELECTRICAL CONNECTIONS 9. GLOSSARY & NOTES .......................................... 65-67
Connecting to Electrical Supply ....................................... 39 10. DIAGRAMS ........................................................... 68-71
Line Voltage Connections ........................................... 40 Revision Notes .................................................. Back Cover
EMS Connections ............................................................ 40
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk
levels or to important information concerning the life of the product.
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or
DANGER serious injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or
WARNING serious injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or
CAUTION moderate injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
CAUTION avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but
NOTICE not related to personal injury or property damage.
2
Please read before proceeding

Special instructions
This is a gas appliance and should be installed 
Apply enough water to the combustion chamber
NOTICE lining to prevent airborne dust.
by a licensed electrician and/or certified gas
supplier. Service must be performed by a  Remove the combustion chamber lining from the
qualified service installer, service agency or appliance and place it in a plastic bag for disposal.
the gas supplier.
• NIOSH stated First Aid:
WARNING If the information in these instructions is
not followed exactly, a fire or explosion may Eye: Irrigate immediately.
result causing property damage, personal Breathing: Fresh air.
injury, or death.
WARNING The combustion chamber insulation in this
This appliance MUST NOT be installed in appliance contains ceramic fiber material.
any location where gasoline or flammable Ceramic fibers can be converted to cristobalite
vapors are likely to be present, unless the in very high temperature applications.
installation is such to eliminate the probable The International Agency for Research on
ignition of gasoline or flammable vapors. Cancer (IARC) has concluded, “Crystalline
Improper installation, adjustment, silica in the form of quartz or cristobalite
WARNING
alteration, service or maintenance can from occupational sources is carcinogenic
cause injury or property damage. Refer to humans (Group 1).” Normal operating
to this manual for assistance or additional temperatures in this appliance are below the
information, consult a qualified installer, level to convert ceramic fibers to cristobalite.
service agency or the gas supplier. Abnormal operating conditions would have
to be created to convert the ceramic fibers in
Checking equipment – this appliance to cristobalite.
Upon receiving equipment, check for signs of shipping damage. The ceramic fiber material used in this
Pay particular attention to parts accompanying the appliances appliance is an irritant; when handling
which may show signs of being hit or otherwise being or replacing the ceramic materials it is
mishandled. Verify total number of pieces shown on packing advisable that the installer follow these safety
slip with those actually received. In case there is damage or a guidelines.
shortage, immediately notify the carrier.
Do not use this appliance if any part has been under water.
Warranty –
The possible damage to a flooded appliance can be extensive Factory warranty (shipped with unit) does not apply to units
and present numerous safety hazards. Any appliance that improperly installed or improperly operated.
has been under water must be replaced.
The ceramic fiber material used in this Experience has shown that improper installation or system
NOTICE design, rather than faulty equipment, is the cause of most
appliance is an irritant; when handling or
replacing the ceramic materials it is advisable operating problems.
that the installer follow these safety guides.
1. Excessive water hardness causing a lime/scale build-up in
REMOVAL OF COMBUSTION CHAMBER LINING OR the copper tube is not the fault of the equipment and is
BASE PANELS: not covered under the manufacturer’s warranty (see
 Avoid breathing dust and contact with skin Water Treatment and Water Chemistry).
and eyes.
2. Excessive pitting and erosion on the inside of the copper
• Use NIOSH certified dust respirator (N95). tube may be caused by too much water velocity through
This type of respirator is based on the OSHA the tubes and is not covered by the manufacturer’s
requirements for cristobalite at the time this warranty (see Boiler Flow Rates and Temperature Rise for
document was written. Other types of flow requirements).
respirators may be needed depending on the job
site conditions. Current NIOSH recommendations
can be found on the NIOSH website at
http://www.cdc.gov/niosh/homepage.html.
NIOSH approved respirators, manufacturers, and
phone numbers are also listed on this website.
• Wear long-sleeved, loose fitting clothing, gloves, 3
and eye protection.
Please read before proceeding

Safety information
Owner warning – WARNING
To minimize the possibility of serious
personal injury, fire or damage to your
The information contained in this manual is intended for use unit, never violate the following safety
by qualified professional installers, service technicians, or gas rules.
suppliers.
1. This unit is only for use with the type of gas indicated on the
Consult and follow all local Building and rating plate.
NOTICE
Fire Regulations and other Safety Codes that
apply to this installation. Consult local gas 2. If you smell gas
utility company to authorize and inspect all • shut off gas supply
gas and flue connections. • do not try to light any appliance
A gas appliance that draws combustion air from the equipment • do not touch any electrical switch; do not use any phone
room where it is installed must have a supply of fresh air in your building
circulating around it during burner operation for proper gas • immediately call your gas supplier from a neighbor’s
combustion and proper venting. phone. Follow the gas supplier’s instructions
• if you cannot reach your gas supplier, call the fire
Should overheating occur or the gas supply
WARNING department
fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead, 3. Boilers and water heaters are heat producing appliances. To
shut off the gas supply at a location external avoid damage or injury, do not store materials against the
to the appliance. appliance or the vent-air intake system. Use proper care
Boiler water – to avoid unnecessary contact (especially children) with the
appliance and vent-air intake components.
• Thoroughly flush the system to remove debris. Use 4. Never cover your unit, lean anything against it, store trash
an approved pre-commissioning cleaner (see Start-Up or debris near it, stand on it or in any way block the flow of
fresh air to your unit.
Section), without the boiler connected, to clean the system
and remove sediment. The high-efficiency heat exchanger 5. UNDER NO CIRCUMSTANCES MUST FLAMMABLE
can be damaged by build-up or corrosion due to sediment. MATERIALS SUCH AS GASOLINE OR PAINT THINNER
NOTE: Cleaners are designed for either new systems or BE USED OR STORED IN THE VICINITY OF THIS
APPLIANCE, VENT-AIR INTAKE SYSTEM OR ANY
pre-existing systems. Choose accordingly. LOCATION FROM WHICH FUMES COULD REACH
THE APPLIANCE OR VENT-AIR INTAKE SYSTEM.
Freeze protection fluids –
6. Appliance surfaces become hot during operation. Be careful
• NEVER use automotive antifreeze. Use only inhibited not to touch hot surfaces. Keep all adults, children, and
propylene glycol solutions, which are specifically animals away from operation of the hot unit. Severe burns
formulated for hydronic systems. Ethylene glycol is can occur.
toxic and can attack gaskets and seals used in hydronic 7. You must take adequate care to prevent scald injury when
systems. storing water at elevated temperatures for domestic use.
Codes – 8. This unit must have an adequate supply of fresh air during
The equipment shall be installed in accordance with those operation for proper gas combustion and venting.
installation regulations in force in the local area where the 9. Make sure all exhaust venting is properly installed and
installation is to be made. These shall be carefully followed in all maintained. Improper venting of this unit could lead to
cases. Authorities having jurisdiction shall be consulted before increased levels of carbon monoxide.
installations are made. In the absence of such requirements, the 10. Do not use this boiler if any part has been under water.
installation shall conform to the latest edition of the National Immediately call a qualified service technician to replace
Fuel Gas Code, ANSI Z223.1. Where required by the authority the boiler. The possible damage to a flooded boiler can
having jurisdiction, the installation must conform to American be extensive and present numerous safety hazards. Any
Society of Mechanical Engineers Safety Code for Controls and appliance that has been under water must be replaced.
Safety Devices for Automatically Fired Boilers, ASME CSD-1. 11. Do not alter this unit in any way. Any change to this unit or
All boilers conform to the latest edition of the ASME Boiler its controls can be dangerous.
and Pressure Vessel Code, Section IV. Where required by the
authority having jurisdiction, the installation must comply with
the Canadian Gas Association Code, CAN/CGA-B149.1 and/
or B149.2 and/or local codes. This appliance meets the safe
lighting performance criteria with the gas manifold and control
assembly provided, as specified in the ANSI standards for gas-
fired hot water boilers, ANSI Z21.13 and gas water heaters,
ANSI Z21.10.3.
4
The Copper-fin - How it works...

1. Heat exchanger 16. Low voltage connection board
The heat exchanger allows system water to flow through specially The low voltage connection board provides a location to tie in
designed tubes for maximum heat transfer. The glass lined all of the low voltage contacts to the appliance. This is where most
headers and copper fined tubing are encased in a jacket that of the external safety devices are connected to the unit such as
contains the combustion process. the louver proving switch.
2. Inner combustion chamber door 17. Front doors - upper and lower
The inner combustion chamber door is a galvanized steel door which The front doors provide access to the gas train as well as the
allows access for service, maintenance, and removal of the blower, burners and other key components for service and
heat exchanger from inside the combustion chamber. maintenance.
3. Blower 18. Hot surface igniter (HSI)
The blower pulls in air and injects air into the individual burners The hot surface igniter is a device that is used to ignite the
along with gas from the gas manifold where the mix is burned in air/gas mixture as well as monitor the performance of the flame
the combustion chamber. during operation. This device acts as a flame sense electrode.
4. Gas valve 19. Flame inspection window (sight glass)
The gas valve allows the proper amount of gas to pass into the The flame inspection windows, located on either side of the
burner for combustion. The gas valve is biased with pressure from appliance, allow for visual inspection of the burners and flame
the combustion chamber to assist in regulation of the gas flow. during operation.
5. System / tank temperature sensor (not shown) 20. Gas shut off valve (downstream test cock)
When connected, this sensor can be used as a system sensor or a The downstream test cock (when supplied) is in the gas train to ensure
tank sensor.
complete shut off of the gas to the burner in case of
6. Inlet temperature sensor maintenance, inspection, or testing of the valve.
This sensor monitors inlet water temperature. If selected as
the controlling sensor, the appliance will maintain the set point 21. Manual high limit
temperature based on the reading at this sensor. Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting (field
7. Temperature and pressure gauge (boiler only) adjustable), it will break the control circuit, shutting the
The temperature and pressure gauge monitors the outlet
appliance down.
temperature of the appliance as well as the system water
pressure. 22. Relief valve
The relief valve is a safety device that ensures the maximum
8. Diagnostic display pressure of the appliance is not exceeded. Boilers operate on
The diagnostic display consists of six (6) lamps used to show all
pressure only and are shipped from the factory at a rating of
the major steps of operation and control malfunctions.
50 PSI. Water heaters operate on temperature and pressure and
9. Burner are shipped standard as 150 PSI and 210°F (98.9°C).
The burner is a ported stainless steel construction which uses a gas
air mix to operate at a fixed input. Banks of burners are turned on 23. Power switch
or off to vary the firing rate. The power switch is used to engage and disengage power to the
appliance on the 120 VAC circuit.
10. Water outlet (system supply)
The water outlet is a pipe connection that supplies water to the 24. Air pressure switch
system with connections for a flow switch (see #25), a relief valve The air pressure switch is a safety device which ensures proper
(see #22), and a temperature and pressure gauge (boilers only) blower operation. The air pressure switch is wired in series with
(see #7). the low voltage control circuit in such a way that if the fan does not
11. Water inlet (system return) engage or shuts down prematurely the device will break the
The water inlet is a pipe connection that receives water from the control circuit and the unit will shut down.
system and delivers it to the heat exchanger. 25. Flow switch
12. Gas supply pipe The flow switch is a safety device that ensures flow through the
The gas supply pipe on this appliance is 1 1/4'' diameter (Models heat exchanger during operation. This appliance is low mass and
497 - 747) and 2" diameter (Models 987 - 2067) NPT. Please should never be operated without flow. The flow switch makes
reference the National Fuel Gas Code charts for connection contact when flow is detected and allows the unit to operate. If
details. flow is discontinued during operation for any reason the flow
13. Two-Stage Electronic Temperature Control switch will break the control circuit and the unit will shut down.
The electronic temperature control provides two-stage (high / low 26. Drain port(s)
fire) operation by monitoring system demand. Location from which the heat exchanger can be drained.
14. Air intake 27. Manual shutoff valve (not shown)
Fresh air for combustion is drawn through a filter provided at the Manual valve used to isolate the unit from the gas supply.
air intake, located at either the rear or right side of the appliance.
28. Flue pipe
15. Line voltage terminal strip A pipe like enclosure that is placed over an appliance to improve
The line voltage terminal strip provides a location to connect
natural upward convection of heat and thereby increase the
all of the line voltage (120 VAC) contact points to the unit.
dissipating ability of the appliance.
5
The Copper-fin - How it works...
12 17 14 28
22
25
26
17
Models 497 - 747 Front View Models 497 - 747 Rear View
21
13
16 6
4
7
15
23
8 2
18 10
24
20 11 1
19
9
Models 497 - 747 Right Side (inside unit) Models 497 - 747 Left Side (inside unit)
6
The Copper-fin - How it works... (continued)
28
12 17 14
25
22
7
26
17
Models 987 - 2067 Rear View

Models 987 - 2067 Front View
21
13 3
6
16
4
15
23
24 7
8
18
10
20 11
1
19
Models 987 - 2067 Right Side (inside unit) Models 987 - 2067 Left Side (inside unit)
7
Ratings
Copper-fin Other Specifications

AHRI Rating
Net Vent Size

Model Number Gross AHRI Boiler Water
Input MBH Output Ratings Water Gas
Content
MBH Water, Connections Connections (Note 3)
(Note 4) MBH
Gallons
Note: Change “N” to
“L” for L.P. gas models.
Min Max (Note 1) (Note 2)
CBN497 250 495 401 349 1.9 2" 1 1/4" 6"
CBN647 350 645 522 454 2.0 2" 1 1/4" 8"
CBN747 350 745 603 524 2.4 2" 1 1/4" 8"
CBN987 360 985 798 694 3.3 2 1/2" 2" 10"
CBN1257 720 1255 1017 884 3.5 2 1/2" 2" 12"
CBN1437 720 1435 1162 1010 3.7 2 1/2" 2" 12"
CBN1797 720 1797 1454 1264 4.1 2 1/2" 2" 14"
CBN2067 990 2065 1673 1455 4.3 2 1/2" 2" 14"
NOTICE Maximum allowed working pressure is located on the rating plate.
Notes:
1. The ratings are based on standard test procedures HIGH ALTIT

ITUDE
LABEL
prescribed by the United States Department of Energy.
2. Net AHRI ratings are based on net installed radiation of

sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
3. Copper-fins require special gas venting. Use only the vent

materials and methods specified in the Installation and
Service Manual.
4. The Copper-fin is orificed for operation up to 2000

feet altitude. The appliance will be derated 4% per 1000
feet above 2000 feet elevation. Consult the factory for
installations above 2000 feet elevation. Figure A High altitude label location_boiler
5. Ratings have been confirmed by AHRI.
8
Ratings (continued)
LOW LEAD CONTENT HLW
Copper-fin Specifications
Model Number
Input Water Water Connections Gas Connections Vent Size
MBH Content Gallons
Note: Change “N” to
(Note 1)
“L” for L.P. gas models
CWN497 495 1.9 2" 1 1/4" 6"
CWN647 645 2.0 2" 1 1/4" 8"
CWN747 745 2.4 2" 1 1/4" 8"
CWN987 985 3.3 2 1/2" 2" 10"
CWN1257 1255 3.5 2 1/2" 2" 12"
CWN1437 1435 3.7 2 1/2" 2" 12"
CWN1797 1795 4.1 2 1/2" 2" 14"
CWN2067 2065 4.3 2 1/2" 2" 14"
NOTICE Maximum allowed working pressure is located on the rating plate.
Notes:
1. Copper-fins require special gas venting. Use only

HIGH ALTITUDE
the vent materials and methods specified in the LABEL
Installation and Service Manual.
2. The Copper-fin is orificed for operation up to 2000

feet altitude. The appliance will be derated 4% per
1000 feet above 2000 feet elevation. Consult the
factory for installations above 2000 feet elevation.
Figure B High altitude label location_water heater
9
1 Determine unit location

Installation Indoor clearances from combustible
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 the
operation. Allow sufficient space for servicing pipe
ANSI standards for gas-fired units. ANSI Z21.13/CSA 4.9 and
connections, pump and other auxiliary equipment, as well
ANSI Z21.10.3/CSA 4.3.
as the unit. See rating plate for specific service clearance
requirements.
Locating the unit
1. Maintain all clearances from combustible construction
Right Side 3'' (7.5 cm)
when locating unit. See Clearances from Combustible
Construction, this page.
Rear 3'' (7.5 cm) (3'' min. from any surface)*
2. Locate the unit so that if water connections should
leak, water damage will not occur. When such locations Left Side 6'' (15 cm) (24'' (0.61 m) suggested for
cannot be avoided, install a suitable drain pan that service)
is well-drained under the unit. The pan must not
restrict combustion air flow. The appliance Front Alcove* (30'' (0.76m) suggested for service)
manufacturer is not responsible for water damage in
connection with this unit, or any of its components. Top 3'' (7.5 cm)
3. Install indoor units so that the ignition system Flue 1'' (25.4 mm)
components are protected from any water while
operating or during service. Hot Water Pipes 1'' (25.4 mm)
4. Appliances located in a residential garage and in
adjacent spaces that open to the garage and are not *An Alcove is a closet without a door. Thirty-six inches (36")
part of the living space of a dwelling unit must be to rear required for outdoor installation.
installed so that all burners and burner ignition devices
have a minimum clearance of not less Note: No additional clearance is needed on the right side
than 18'' (46cm) above the floor. The of the unit for the observation port. An observation port is
appliance must be located or protected so that it is located on both the right and left side of the unit.
not subject to physical damage by a moving vehicle.
Figure 1-1_Indoor clearances from combustible
5. DO NOT install this appliance in any location where
construction
gasoline or flammable vapors are likely to be present.
6. The appliance must be installed on a level surface. 3" 3"
MIN MIN
7. Models 497 - 747 are approved for installation on
REAR TOP
combustible flooring using the approved combustible floor
kits (reference Table 1A). Models 987 - 2067 are approved
for installation on combustible flooring. Do not install
appliances directly on carpeting.
8. For outdoor models, you must install an optional vent
kit. Instructions for mounting the vent kit are included
in the venting section. Do not install outdoor models
directly on the ground. You must install the outdoor
unit on a concrete, brick, block, or other
non-combustible pad. Outdoor models have additional
special location and clearance requirements. See
Outdoor Installation Venting, page 22. A wind proof 3"
MIN
cabinet protects the unit from weather. 6" RIGHT SIDE
MIN
LEFT SIDE
30"
MIN
FRONT
10
1 Determine unit location (continued)
TABLE 1A Outdoor boiler installation

COMBUSTIBLE FLOOR KITS Adequate hydronic system antifreeze must be used. A snow
Model Kit Number screen should be installed to prevent snow and ice accumulation
497 100136977 around the unit or its venting system.
647 100136978 Shut-down and draining

747 100136979 If for any reason, the unit is to be shut off, the following
precautionary measures must be taken:
Freeze protection
1. Shut off gas supply.
Although these units are CSA International design- 2. Shut off water supply.
certified for outdoor installations, such installations are not
recommended in areas where the danger of freezing exists. You must 3. Shut off electrical supply
provide proper freeze protection for outdoor installations, units 4. Drain the unit completely. Remove one threaded plug
installed in unheated mechanical rooms or where temperatures or bulbwell from the inlet side of the front header and
may drop to the freezing point or lower. If freeze protection is one from the outlet side of the front header on the heat
not provided for the system, a low ambient temperature alarm is exchanger. Blow all water out of the heat exchanger
recommended for the mechanical room. Damage to the unit by (see FIG.'s 1-2A and 1-2B).
freezing is non-warrantable.
5. Drain pump and piping.
Anytime the temperature measured at any of the sensors
(except the outside air temperature sensor) drops below 40°F, the Figure 1-2A_Drain the unit_Models 497 - 747
control turns on the pump contact and the alarm relay. The
pump will shut off when both sensors are above 50°F.
Pump operation
This unit is equipped with a pump delay of 30 seconds. If
continuous operation of the pump is desired, the pump must
be electrically connected to another circuit. Connection of
the pump to this unit will provide intermittent pump delay
operation.
Location
Locate indoor boilers and water heaters in a room having a tem-
perature safely above freezing [32°F (0°C)].
A mechanical room operating under a negative

CAUTION
draft pressure may experience a down draft DRAIN PLUG
in the flue of a boiler when it is not firing.
The cold outside air pulled down the flue Figure 1-2B_Drain the unit_Models 987 - 2067
may freeze a heat exchanger. This condition
must be corrected to provide adequate freeze
protection.
Hydronic systems anti-freeze
Freeze protection for a heating boiler or hot water supply boiler
using an indirect coil can be provided by using hydronic system
antifreeze. Follow the appliance manufacturers instructions. Do
not use undiluted or automotive type antifreeze.
DRAIN PLUG
DR G (2X)
11

Freeze Protection for a Heating Boiler Combustion and Ventilation Air
System (if required)
Provisions for combustion and ventilation air must be
Do not use undiluted or automotive type in accordance with Section 5.3, Air for Combustion and
WARNING
anti-freeze. Ventilation, of the latest edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition of CAN/CGA-B149
1. Use only properly diluted inhibited glycol Installation Code for Gas Burning Appliances and Equipment,
anti-freeze designed for hydronic systems. Inhibited or applicable provisions of the local building codes.
propylene glycol is recommended for systems where
Provide properly-sized openings to the equipment room to
incidental contact with drinking water is possible.
assure adequate combustion air and proper ventilation when
2. A solution of 50% antifreeze will provide the unit is installed with conventional venting or sidewall
maximum protection of approximately -30°F. venting.
3. Follow the instructions from the antifreeze
manufacturer. Quantity of antifreeze required is *Outside air openings shall directly communicate with the
based on total system volume including outdoors. When combustion air is drawn from the outside
expansion tank volume. through a duct, the net free area of each of the two openings
must have twice (2 times) the free area required for Outside
4. Glycol is denser than water and changes Air/2 Openings. The above requirements are for the boiler
the viscosity of the system. The addition only; additional gas fired appliances in the equipment room
of glycol will decrease heat transfer and will require an increase in the net free area to supply adequate
increase frictional loss in the boiler and combustion air for all appliances.
related piping. A larger pump with more
capacity (15% to 25% more) may be required
to maintain desired flow rates and
prevent a noise problem in a glycol system.
5. Local codes may require a back flow preventer or

actual disconnect from city water supply when
antifreeze is added to the system.
TABLE 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
*Outside Air from Inside Air from Inside Air from
2 Openings Directly from *Outside Air from 2 Ducts Delivered from 2 Ducts Delivered from
Model
Outdoors 1 Opening Directly Outdoors Interior Space
Number
Top Bottom from Outdoors, in2 Top Bottom Top Bottom
Opening, in2 Opening, in2 Opening, in2 Opening, in2 Opening, in2 Opening, in2
497 125 125 167 250 250 500 500
(806 cm2) (806 cm2) (1077 cm2) (1613 cm2) (1613 cm2) (3226 cm2) (3226 cm2)
647 163 163 217 325 325 650 650
(1052 cm2) (1052 cm2) (1400 cm2) (2097 cm2) (2097 cm2) (4194 cm2) (4194 cm2)
747 188 188 250 375 375 750 750
(1213 cm2) (1213 cm2) (1613 cm2) (2420 cm2) (2420 cm2) (4839 cm2) (4839 cm2)
987 248 248 330 495 495 990 990

(1600 cm2) (1600 cm2) (2129 cm2) (3194 cm2) (3194 cm2) (6388 cm2) (6388 cm2)
1257 315 315 420 630 630 1260 1260

(2032 cm2) (2032 cm2) (2710 cm2) (4065 cm2) (4065 cm2) (8130 cm2) (8130 cm2)
1437 360 360 480 720 720 1440 1440
(2323 cm2) (2323 cm2) (3097 cm2) (4646 cm2) (4646 cm2) (9291 cm2) (9291 cm2)
1797 450 450 600 900 900 1800 1800
(2903 cm2) (2903 cm2) (3871 cm2) (5807 cm2) (5807 cm2) (11614 cm2) (11614 cm2)
2067 518 518 690 1035 1035 2070 2070
(3342 cm2) (3342 cm2) (4452 cm2) (6678 cm2) (6678 cm2) (13356 cm2) (13356 cm2)
12
Figure 1-3_Combustion air filter_ Models 497 - 747 Figure 1-4_Combustion air filter_ Models 987 - 2067
During construction the air filter should be checked more frequently to ensure it does not become clogged
NOTICE with construction dirt and debris.
Sustained operation of an appliance with a clogged burner may result in nuisance operational problems,
CAUTION bad combustion, and non-warrantable component failures.
Combustion air filter

This unit has a standard air filter located at the combustion air inlet. This filter helps ensure clean air is used for the
combustion process. Check this filter every month and replace when it becomes dirty. The filter size on Models 497 - 747 is
12" x 12" x 1" (30.5cm x 30.5cm x 2.5cm) and 16" x 16" x 1" (40.6cm x 40.6cm x 2.5 cm) on Models 987 - 2067. You can find
these commercially available filters at any home center or HVAC supply store.
13

Combustion Air Options Two Openings
The combustion air opening must have a minimum free area
Under no circumstances should a mechanical of one square inch per 4000 Btu input (5.5cm2 per kW). You
CAUTION must locate this opening within 12'' (30cm) of the bottom of
room ever be under a negative pressure.
Particular care should be taken when exhaust the enclosure.
fans, clothes dryers, compressors, air handling The ventilation air opening must have a minimum free area
units, etc., take away air from the inlet. of one square inch per 4000 Btu input (5.5cm2 per kW). You
must locate this opening within 12'' (30cm) of the top of the
This unit has four combustion air options. enclosure.
1. Outside Combustion Air, No Ducts
Figure 1-6_Outside combustion air, two openings
You can direct outside combustion air to this unit using either
one or two permanent openings (see FIG. 1-5).
One Opening
The opening must have a minimum free area of one square
inch per 3000 Btu input (7 cm2 per kW). You must locate this
opening within 12'' (30 cm) of the top of the enclosure.
Figure 1-5_Outside combustion air single opening
2. Outside Combustion Air, Using Ducts

You can direct outside combustion air to this unit using two air
ducts to deliver the air to the boiler room.
Each of the two openings must have a minimum free area of one
square inch per 2000 Btu input (11cm2 per kW).
Figure 1-7_Outside combustion air, using ducts
14
3. Combustion Air from an Interior Space Exhaust Fans

You can direct combustion air to this unit using air from an
Any fan or equipment which exhausts
adjoining interior space. You must provide two openings from WARNING
air from the boiler room may deplete the
the boiler room to the adjoining room. Each of the two openings
combustion air supply and/or cause a
must have a net free area of one square inch per 1000 Btu input
down draft in the venting system. Spillage
(22cm2 per kW), but not less than 100 square inches (645cm2).
of flue products from the venting system
into an occupied living space can cause
a very hazardous condition that must be
Figure 1-8_Combustion air from an interior space corrected immediately. If a fan is used to
supply combustion air to the boiler room,
the installer must make sure that it does not
cause drafts which could lead to nuisance
operational problems with the boiler.
All dimensions are based on net free area in square inches.

Metal louvers or screens reduce the free area of a combustion air
opening a minimum of approximately 25%. Check with louver
manufacturers for exact net free area of louvers. Where two
openings are provided, one must be within 12'' (30 cm) of the
ceiling and one must be within 12'' (30 cm) of the floor of the
equipment room. Each opening must have a minimum net free
area as specified in TABLE 1B, page 12. Single openings shall be
installed within 12'' (30 cm) of the ceiling.
CAUTION The combustion air supply must be

completely free of any flammable vapors
that may ignite or chemical fumes which
may be corrosive to the appliance. Common
corrosive chemical fumes which must be
avoided are fluorocarbons and other
halogenated compounds, most commonly
present as refrigerants or solvents, such as
Freon, trichlorethylene, perchlorethylene,
chlorine, etc. These chemicals, when
burned, form acids which quickly attack
the heat exchanger finned tubes, headers,
flue collectors, and the vent system. The
result is improper combustion and a non-
warrantable, premature unit failure.
15
2 Venting
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 and Equipment or applicable local building codes. Vent installations for connection to gas vents or chimneys
must be in accordance with Part 7, “Venting of Equipment” of the above-mentioned standards.
NOTICE Examine the venting system at least once each year. Check all joints and vent pipe connections for tightness.
Also check for corrosion or deterioration. If you find any problems, correct them at once.
DANGER Failure to use correct venting materials can result in loss of life from flue gas spillage into working or living
space.
Venting support
Support horizontal portions of the venting system to prevent sagging. Provide an upward slope of at least 1/4 inch per foot
(21mm/m) on all horizontal runs from the unit to the vertical flue run or to the vent terminal on sidewall venting installations.
Do not use an existing chimney as a raceway if another appliance or fireplace is vented through the chimney. A water heater shall
not be connected to a chimney flue serving a separate appliance designed to burn solid fuel. The weight of the venting system must
not rest on the unit. Provide adequate support of the venting system. Follow all local and applicable codes. Secure and seal all vent
connections. Follow the installation instructions from the vent material manufacturer.
Vertical vent termination clearances and location

The vent terminal should be vertical and exhaust outside the building at least 2 feet (0.61m) above the highest point of the roof
within a 10 foot (3.05m) radius of the termination.
The vertical termination must be a minimum of 3 feet (0.91m) above the point of exit.
A vertical termination less than 10 feet (3.05m) from a parapet wall must be a minimum of 2 feet (0.61m) higher than the parapet
wall.
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 2-2_Vent termination from peaked roof - 10 ft. or

Figure 2-1_Vent termination from peaked roof - 10 ft. or
more from ridge
less from ridge
Vent terminations are not shown in FIG.’s 2-1 thru 2-4. Make sure all vertical vents are installed with vent
NOTICE
terminations recommended by the vent manufacturer.
16
2 Venting (continued)
Figure 2-3_Vent termination from flat roof - 10 ft. or Figure 2-4_Vent termination from flat roof - 10 ft. or more
less from parapet wall from parapet wall
Units which are shut down or will not operate may experience freezing due to convective air flow in flue
CAUTION
pipe, through the air inlet, or from negative pressure in the equipment room. In cold climates, operate pump
continuously to help prevent freezing of boiler water. Provide proper freeze protection. See Freeze Protection,
page 48.
TABLE 2A
FLUE PIPE SIZES
MODEL FLUE SIZE MODEL FLUE SIZE

497 6'' 1257 12''
647 8'' 1437 12''
747 8'' 1797 14''
987 10'' 2067 14''
Installer may increase diameter one pipe size for ease of installation, if needed.
Vent system options Barometric damper location

Vent System Options Any venting system option that requires a barometric
This fan-assisted Category 1 unit has two venting options. damper must adhere to the following directions for optimum
performance. The preferred location for the barometric damper
1. Conventional Negative Draft Venting
is in a tee or collar installed in the vertical pipe rising from the
This option uses a vertical rooftop flue termination. unit’s flue outlet. The barometric damper MUST NOT be
Combustion air is supplied from the mechanical room. installed in a bull head tee installed on the unit’s flue outlet.
See page 15 for detailed information. The tee or collar containing the barometric damper should
2. Outdoor Installation Venting be approximately three feet vertically above the connection to
This option uses the installation of special air inlet and the unit’s flue outlet. This location ensures that any positive
vent caps on the unit. velocity pressure from the unit’s internal combustion fan is
dissipated and the flue products are rising due to buoyancy
All units are shipped from the factory equipped for generated from the temperature of the flue products. Adjust
conventional negative draft venting. All other optional vent the weights on the damper to ensure that draft is maintained
systems require the installation of specific vent kits and venting within the specified ranges.
materials. The following is a detailed explanation of the
installation requirements for each venting system, components
used and part numbers of vent kits for each model.
17
2 Venting
1. Conventional negative draft Negative draft
venting The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper
Before installing a venting system, follow
NOTICE operation. Make all draft readings while the unit is in stable
all venting clearances and requirements
operation (approximately 2 to 5 minutes).
found in the Venting, General Information
section, page 16. Connect the flue vent directly to the flue outlet opening on
the top of the unit. No additional draft diverter or barometric
Figure 2-5_Conventional negative draft vertical venting damper is needed on single unit installations with a dedicated
with combustion air louvers stack and a negative draft within the specified range of 0.02
to 0.08 inches w.c. If the draft in a dedicated stack for a single
unit installation exceeds the maximum specified draft, you
must install a barometric damper to control draft. Multiple unit
installations with combined venting or common venting with
other Category I negative draft appliances require each boiler
to have a barometric damper installed to regulate draft within
the proper range.
Do not connect vent connectors serving appliances vented by
natural draft (negative draft) to any portion of a mechanical
draft system operating under positive pressure. Connecting to a
positive pressure stack may cause flue products to be discharged
into the living space causing serious health injury.
Flue outlet piping

The negative draft in a conventional vent installation must be
within the range of 0.02 to 0.08 inches w.c. to ensure proper
On a conventionally vented, negative draft appliance, the operation. Make all draft readings while the unit is in stable
connection from the vent to the chimney or vent termination operation (approximately 2 to 5 minutes).
on the outside of the building MUST be made with listed Type
"B" double wall (or equivalent) vent connectors and must be Connect the flue vent directly to the flue outlet opening on
direct as possible with no reduction in diameter. To properly the top of the unit. No additional draft diverter or barometric
size all double wall vent connectors and stacks, use the venting damper is needed on single unit installations with a dedicated
tables in the latest edition of the National Fuel Gas Code, ANSI stack and a negative draft within the specified range of 0.02 to
Z223.1, in Canada, the latest edition of CGA Standard B149 0.08 inches w.c.
Installation Code for Gas Burning Appliances and Equipment.
The Type "B" vent and accessories, such as firestop spacers, Common venting systems
thimbles, caps, etc., MUST be installed in accordance with the You can combine the flue with the vent from any other negative
manufacturer's listing. The vent connector and firestop must draft, Category I appliance. Using common venting for multiple
provide correct spacing to combustible surfaces and seal to the negative draft appliances requires you to install a barometric
vent connector on the upper and lower sides of each floor or damper with each unit. This will regulate draft within the
ceiling through which the vent connector passes. proper range. You must size the common vent and connectors
from multiple units per the venting tables for Type-B double-
Any vent materials used must be listed by a nationally recognized wall vents in the latest edition of the National Fuel Gas Code,
test agency for use as vent material. ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.
Common venting systems may be too large when an existing
unit is removed.
18
Common venting systems may be too large when an existing Masonry chimney installation
unit is removed.
A masonry chimney must be properly sized for the installation
At the time of removal of an existing appliance, the following of a high efficiency gas-fired appliance. Venting of a high
steps shall be followed with each appliance remaining connected efficiency appliance into a cold or oversized masonry chimney
to the common venting system placed in operation, while other can result in operational and safety problems. Exterior masonry
appliances remaining connected to the common venting system chimneys, with one or more sides exposed to cold outdoor
are not in operation. temperatures, are more likely to have venting problems.
1. Seal any unused opening in the common venting system. The temperature of the flue products from a high efficiency
appliance may not be able to sufficiently heat the masonry
2. Visually inspect the venting system for proper size and structure of the chimney to generate proper draft. This will
horizontal pitch. Make sure there is no blockage or result in condensing of flue products, damage to the masonry
restriction, leakage, corrosion and other unsafe conditions. flue/tile, insufficient draft and possible spillage of flue products
3. If possible, close all building doors and windows. Close all into an occupied living space. Carefully inspect all chimney
doors between the space in which the appliances remaining systems before installation.
connected to the common venting system are located and Venting of high efficiency appliances into a
other building spaces. CAUTION
masonry chimney without a sealed stainless
4. Turn on clothes dryers and any other appliances not steel liner can result in operational and safety
connected to the common venting system. Turn on any problems. Any breaks, leaks, or damage to
exhaust fans, such as range hoods and bathroom exhausts, the masonry flue/tile will allow spillage of
so they will operate at maximum speed. Do not operate a the positive pressure flue products from the
summer exhaust fan. chimney. These flue products can easily
escape into an occupied living space causing
5. Close fire place dampers.
a health hazard. If there is any doubt about
6. Place in operation the unit being inspected. Follow the the condition of a masonry chimney, or
lighting instructions. Adjust thermostat so unit will operate its acceptability for use after insertion of
continuously. a corrosion resistant liner system, consult
7. Test for spillage at the draft hood/relief opening after 5 with local code officials.
minutes of main burner operation. Use the flame of a match
or candle, or smoke from a cigarette, cigar or pipe. Inspection of a masonry chimney
8. After making sure that each appliance remaining connected A masonry chimney must be carefully inspected to determine
to the common venting system properly vents when tested its suitability for the venting of flue products. A clay-tile-
as above, return doors, windows, exhaust fans, fireplace lined chimney must be structurally sound, straight and free of
dampers and other gas burning appliances to their previous misaligned tile, gaps between liner sections, missing sections of
conditions of use. liner or any signs of condensate drainage at the breaching or
clean out. If there is any doubt about the condition of a masonry
9. Correct any improper operation of the common venting
chimney, it must be relined with a properly-sized and approved
system so that the installation conforms to the latest edition
chimney liner system.
of the National Fuel Gas Code, ANSI Z223.1, in Canada,
the latest edition of CAN/CGA-B149 Installation Code for Vertical vent termination clearances and
Gas Burning Appliances and Equipment. When resizing any
location
portion of the common venting system, resize to approach
the minimum size as determined using the appropriate Follow all vertical venting termination information for
tables of the latest edition of the National Fuel Gas Code, clearances and location under Vertical Vent Termination
ANSI Z223.1, in Canada, the latest edition of CAN/ Clearances and Location, page 16.
CGA-B149 Installation Code for Gas Burning Appliances
and Equipment.
19
2 Venting
Figure 2-6 Other than Direct Vent Terminal Clearances
Table 2B Other than Direct Vent Terminal Clearances

Canadian Installations¹ US Installations²
Clearance above grade, veranda, porch,
A= 12 in (30 cm) 12 in (30 cm)
deck, or balcony
6 in (15 cm) for appliances < 10,000 Btuh
(3 kW), 12 in (30 cm) for appliances >
Clearance to window or door that may 4 ft (1.2 m) below or to side of opening; 1 ft
B= 10,000 Btuh (3 kW) and < 100,000 Btuh
be opened (300 mm) above opening
(30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
Clearance to permanently closed * *
C=
window
Vertical clearance to ventilated soffit * *
located above the terminal within a
D=
horizontal distance of 2 ft (61 cm) from
the center line of the terminal.
* *
E= Clearance to unventilated soffit
* *
F= Clearance to outside corner
* *
G= Clearance to inside corner
Clearance to each side of center line * *

H= extended above meter / regulator
assembly
20
Table 2B Other than Direct Vent Terminal Clearances (continued)
Above a regulator within 3 ft (91 cm) *

Clearance to service regulator vent horizontally of the vertical center line of the
I=
outlet regulator vent outlet to a maximum vertical
distance of 15 ft (4.5 m)
6 in (15 cm) for appliances < 10,000 Btuh 4 ft (1.2 m) below or to side of opening; 1 ft
Clearance to nonmechanical air supply (3kW), 12 in (30 cm) for appliances > (300 mm) above opening
J= inlet to building or the combustion air 10,000 Btuh (3 kW) and < 100,000 Btuh
inlet to any other appliance (30 kW), 36 in (91 cm) for appliances >
100,000 Btuh (30 kW)
Clearance to a mechanical air supply 6 ft (1.83 m) 3 ft (91 cm) above if within 10 ft (3 m)
K=
inlet horizontally
Clearance above paved sidewalk or 7 ft (2.13 m)† 7 ft (2.13 m)
L= paved driveway located on public
property
Clearance under veranda, porch, deck, 12 in (30 cm)‡ *
M=
or balcony
* Clearance in accordance with local installation codes and the requirements of the gas supplier.
† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family dwellings
and serves both dwellings.
‡ Permitted only if veranda, porch, deck, or balcony is fully open on a minimum of two sides beneath he floor.
NOTES:
1) In accordance with the current CSA B149.1, Natural Gas and Propane Installation Code
2) In accordance with the current ANSI Z223.1/NFPA 54, National Fuel Gas Code
21
2 Venting
2. Outdoor installation venting
Before installing a venting system, follow Multiple outdoor unit installations require
NOTICE NOTICE
all venting clearances and requirements 48'' (1.22m) clearance between each vent
found in the Venting, General Information cap. Locate the outdoor cap at least 48''
section, page 16. (1.22m) below and 48'' (1.22m) horizontally
from any window, door, walkway or gravity
Only install outdoor models outdoors
WARNING air intake.
and only use the vent caps supplied by
the appliance manufacturer. Personal Locate the unit at least 10 feet (3.05m) away
injury or product damage may result if from any forced air inlet.
any other cap is used or if an outdoor Locate the unit at least 3 feet (0.91m) outside
model is used indoors. Properly install all any overhang.
covers, doors and jacket panels to ensure
proper operation and prevent a hazardous Clearances around outdoor installations can
condition. change with time. Do not allow the growth
of trees, shrubs or other plants to obstruct
Units are self-venting and can be used outdoors when installed the proper operation of the outdoor vent
with the optional outdoor caps. These caps mount directly system.
to the unit and cover the flue outlet and combustion air inlet
openings. No additional vent piping is required. A minimum of 3 feet must be maintained
CAUTION at all times from outdoor air vent cap
Combustion air supply must be free of contaminants (see
surfaces to combustible construction and/or
Combustion and Ventilation Air, page 12). To prevent
materials.
recirculation of the flue products into the combustion air inlet,
follow all instructions in this section.
Do not install in locations where rain from
Outdoor vent/air inlet location CAUTION building runoff drains will spill onto the
unit.
Keep venting areas free of obstructions. Keep area clean and
free of combustible and flammable materials. Maintain a
minimum clearance of 3'' (76mm) to combustible surfaces and
36" clearance to the rear of the unit for outdoor installations.
To avoid a blocked air inlet or blocked flue condition, keep
the air inlet, flue outlet and drain slot clear of snow, ice, leaves,
debris, etc.
Do not install outdoor models directly on
CAUTION
the ground. You must install the outdoor
unit on a concrete, brick, block, or other
non-combustible pad.
Do not locate unit so that high winds

CAUTION
can deflect off of adjacent walls, buildings
or shrubbery causing recirculation.
Recirculation of flue products may cause
operational problems, bad combustion or
damage to controls. Locate unit at least
3 feet (0.91m) from any wall or vertical
surface to prevent wind conditions from
affecting performance.
22
3'
3'
3' 3'
3'
3'
3'
3'
Figure 2-7_Outdoor vent cap installed on Models Figure 2-8_Outdoor vent cap installed on Models
497 - 747 987 - 2067
Outdoor vent kit

The optional outdoor vent kit is available from the appliance manufacturer. The outdoor kit part numbers are listed by unit size. See
Table 2C for kit numbers.
You can install the outdoor vent cap and combustion air inlet panel(s) on the unit (see FIG.’s 2-7 and 2-8).
TABLE 2C
Outdoor Vent Kits
Kit* Kit*
Model
w/ Pump Cover without Pump Cover
497 100163798 100163789
647 100163799 100163790
747 100163799 100163790
987 100163822 100163809
1257 100163830 100163829
1437 100163823 100163810
1797 100163780 100163781
2067 100163780 100163781
* These kits include an outdoor vent cap, air inlet hood(s), and gasket.
23
3 Gas connections
Connecting to gas supply Gas piping
Verify that the appliance is supplied with the type of gas specified To safely operate this unit, you must properly size the gas
on the rating plate. This appliance is configured for operation supply piping. See Tables 3B through 3D for piping and
up to 2000 feet altitude. Consult factory for installations above fitting requirements. Gas pipe size may be larger than heater
2000 feet elevation. connection.
Inlet gas pressure: Measured at the inlet pressure tap on the The gas connection for Models 497 - 747 is 1 1/4'' NPT and on
appliance gas manifold. The pressure tap is located upstream of Models 987 - 2067 the gas connection to these units is 2'' NPT.
the combination gas valve(s). For ease of service, install a union.
Install a manual main gas shutoff valve, outside of the unit gas
See Table 3A for maximum and minimum inlet pressures. Do connection within six feet of the unit in accordance with the
not exceed the maximum. Minimum inlet pressure is for the requirements of the National Fuel Gas Code, ANSI Z223.1.
purpose of input adjustment.
You must provide a sediment trap (drip leg) in the inlet of the
TABLE 3A gas connection to the unit.
INLET GAS PRESSURE
It is the installer’s responsibility to supply
NATURAL LP NOTICE the sediment trap (drip leg).
MODEL Max. Min. Max. Min.
w.c. w.c. w.c. w.c. The combination gas valves have an integral vent limiting
device and do not require venting to atmosphere, outside the
497 - 2067 14'' 4.5'' 14.0'' 8.0'' building. The unit will not operate properly if the reference hose
is removed or a vent to atmosphere is installed.
Manifold pressure: The gas regulator on the unit’s
Optional gas controls may require routing of bleeds and vents
combination gas valve is adjustable to supply proper manifold
to the atmosphere, outside the building when required by local
pressure for normal operation.
codes.
If an inline high gas pressure regulator is
NOTICE
used, it MUST BE of the lockup type and Figure 3-1_Gas line connection
be located a minimum of 10 feet from the
appliance. Failure to do so may result in USE WRENC
NCH
insufficient gas volume supplied to the TO HOLD
SUPPLY PIPE
appliance.
COUPLING 8"
If you must adjust regulator pressure, follow the instructions UNION
UN MIN
under Gas Manifold Pressure Adjustment on page 27. Do not
increase regulator pressure beyond specified pressure setting.
MANU
NUAL MAIN
Gas pressure test SHUT OFF
VALVE
VA
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 (3.5 kPa).
2. The appliance must be isolated from the gas supply

piping system by closing a manual shutoff valve during
NIPPLE
any pressure testing of the gas supply piping system at
test pressures equal to or less than 1/2 PSIG (3.5 kPa). CAP
3. The appliance and its gas connection must be leak

tested before placing it in operation.
24
3 Gas connections (continued)
Gas connection TABLE 3B

All gas connections must be made with pipe joint compound SUGGESTED GAS PIPE SIZE FOR
resistant to the action of liquefied petroleum (L.P.) and natural SINGLE UNIT INSTALLATIONS
gases. All piping must comply with local codes and ordinances.
Distance from Meter (in feet)
Piping installations must comply with approved standards and MODEL
practices. 0 - 50 51 - 100 101 - 200 201- 300 301- 500
1. Make sure gas line is a separate line direct from the meter 497 1 1/4'' 1 1/4'' 1 1/2'' 2'' 2''
unless the existing gas line is of sufficient capacity. Verify 647 1 1/4'' 1 1/2'' 2'' 2'' 2 1/2''
pipe size with your gas supplier. 747 1 1/2'' 2'' 2'' 2 1/2'' 2 1/2''
2. Use new, properly threaded black iron pipe free from 987 2'' 2'' 2 1/2'' 2 1/2'' 3''
chips. If you use tubing, make sure the ends are cut 1257 2'' 2 1/2'' 2 1/2'' 3'' 3''
square, deburred and clean. Make all tubing bends smooth
1437 2 1/2'' 2 1/2'' 3'' 3'' 3 1/2''
and without deformation. Avoid flexible gas connections.
Internal diameter of flexible lines may not provide unit with 1797 2 1/2'' 3'' 3'' 3 1/2'' 3 1/2''
proper volume of gas. 2067 2 1/2'' 3'' 3'' 3 1/2'' 4''
For each elbow or tee, add equivalent straight pipe to total length from Table 3C.
3. Install a manual main gas shutoff valve at the unit’s gas inlet,
outside of the unit.
4. Run pipe or tubing to the unit’s gas inlet. If you use tubing, TABLE 3C
obtain a tube to pipe coupling to connect the tubing to the FITTINGS TO EQUIVALENT STRAIGHT PIPE
unit’s gas inlet. Diameter
5. Install a sediment trap in the supply line to the unit’s gas Pipe 3/4 1 1 1/4 1 1/2 2 3 4 5
inlet (see FIG. 3-1). (inches)
Equivalent
6. Apply a moderate amount of good quality pipe compound
length of
(do not use Teflon tape) to pipe only, leaving two end 2 2 3 4 5 10 14 20
Straight Pipe
threads bare.
(feet)
7. Remove seal over gas inlet to unit.
Water heater models do not have downstream test valves, but
8. Connect gas pipe to inlet of unit. Use wrench to support gas the rest of the gas train is represented by FIG. 3-2.
manifold on the unit.
9. For L.P. gas, consult your L.P. gas supplier for expert
installation. Figure 3-2_Gas train drawing
10. Ensure that all air is completely bled from the gas line before
starting the ignition sequence. Start up without properly 497 MODEL
bleeding air from the gas line may require multiple reset
COMBINATION
functions of the ignition control module to achieve proper VALVE
ignition.
Do not have any open flame in proximity to
WARNING the gas line when bleeding air from the gas
line. Gas may be present. DOWNSTREAM COMBINATION
VALVE 2067 MODEL
TEST VALVE
Gas train and controls

TO BURNERS
The gas train and controls assembly DOWNSTREAM
NOTICE TEST VALVE
provided on this unit have been tested under
the applicable American National Standard
TO BURNERS
to meet minimum safety and performance
criteria such as safe lighting, combustion
and safety shutdown operation.
25
3 Gas connections
Combination gas valves Checking gas supply pressure
These units fire in multiple stages of burner input. Each stage
Use the following procedure to check gas supply pressure.
of burner operation has a combination gas valve(s) to cycle
the gas supply on and off and regulate gas to the burners. Each 1. Turn the main power switch to the “OFF” position.
combination valve consists of a gas regulator and two valve seats
to meet the requirements for redundant gas valves. The valve 2. Turn gas valve knobs to the “OFF” position.
has a gas control knob that must remain in the open position
3. Shut off gas supply at the field-installed manual gas cock in
at all times when the unit is in service. The gas control valve the gas piping to the unit. If fuel supply is L.P. gas, shut off
has pressure taps located on the inlet and discharge sides of the gas supply at the tank.
valve. Manifold pressure is adjusted using the regulator located
on the valve. A manifold gas pressure tap for each burner 4. Remove the 1/8'' hex plug, located on the “inlet” side of the
stick is located on the discharge side of the valve. The manifold gas valve (FIG. 3-3). You may also use a tapping on the
pressure is preset at the factory and adjustment is not usually field-installed main manual gas cock or gas piping. Install a
required. If you must adjust regulator pressure, follow the fitting in the inlet pressure tapping suitable to connect to a
instructions under Gas Manifold Pressure Adjustment, page 27. manometer or magnehelic gauge. Range of scale should be
14'' w.c. or greater to check inlet pressure.
Venting of combination gas valves
5. Turn on gas supply at the manual gas cock, turn on L.P. gas
The combination gas valve/regulator used on all units is at the tank if required.
equipped with an integral vent limiting orifice per ANSI Z21.78.
The vent limiter ensures that the volume of gas emitted from 6. Turn the power switch to the “ON” position.
the valve in the event of a failed gas diaphragm does not exceed
the maximum safe leakage rate allowed by agency requirements. 7. Turn the gas valve knobs to the “ON” position. Set the
electronic temperature control or thermostat to call for
Combination gas valve/regulators equipped with integral vent heat.
limiters are not required to have vent or relief lines piped to
8. Observe the gas supply pressure as all burners are firing.
the outdoors. The termination of the vent limited opening on Ensure that inlet pressure is within the specified range.
the combination gas valve/regulator complies with the safety See Connecting To Gas Supply, page 24 for minimum and
code requirements of CSD-1, CF-190(a) as shipped from the maximum gas supply pressures.
appliance manufacturer without the installation of additional
vent lines. 9. If gas pressure is out of range, contact gas utility, gas
supplier, qualified installer or service agency to determine
necessary steps to provide proper gas pressure to the
control.
TABLE - 3D
Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour
(based on .60 specific gravity, 0.30" w.c. pressure drop)
Pipe Length of Pipe in Straight Feet
Size
(Inches) 10 20 30 40 50 60 70 80 90 100 125 150 175 200
1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A
3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A
1 514 353 284 243 215 195 179 167 157 148 131 119 109 102
1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209
1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313
2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602
2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960
3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700
4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460
26
3 Gas connections (continued)
10. If gas supply pressure is within normal range, remove the Gas manifold pressure adjustment
gas manometer and replace the pressure tap fittings in the
gas control as indicated by the following steps. The gas valves are referenced to the fan
NOTICE
pressurized chamber by a hose connected
11. Turn power switch to the “OFF” position.
from the vent of the gas valve regulator
12. Turn gas valve knob to the “OFF” position. to the chamber pressure tap located on
the front inside portion of the jacket.
13. Shut off gas supply at the manual gas cock in the gas piping Reference the drawings in this section for
to the unit. If fuel supply is L.P. gas, shut off gas supply at component and connection points for
the tank. pressure measurement. The referenced
chamber pressure must be subtracted from
14. Remove the manometer and related fittings from the “inlet the manifold pressure to obtain actual net
side of the gas valve, replace 1/8'' hex plug in the gas valve manifold pressure for normal operation.
and tighten.
A manometer or magnahelic gauge legible
15. Turn on the gas supply at the manual valve, turn on L.P. gas in 0.1'' increments up to 10 inches w.c. is
at the tank if required. required to check and adjust the manifold
pressure. The regulator cover screw on the
16. Turn the power switch to the “ON” position. gas valve must be in place and tight for the
unit to operate properly.
17. Turn the gas valve knob to the “ON” position.
18. Set the electronic temperature control or thermostat to call 1. Remove the thumbscrew that fastens the control panel
for heat. access door and remove the door.
After completing any testing on the gas 2. Turn the power switch located in the lower left corner
WARNING behind the control panel access door to the “O” or “OFF”
system, leak test all gas connections. Apply
a soap/water solution to all gas connections position.
while main burners are operating. Bubbles
forming indicate a leak. Repair all leaks at 3. Remove the top front jacket access panels to access the gas
once. Do not operate this unit with a leak in valve(s).
the gas train, valves or related piping. 4. Locate the reference hose on the first gas valve which goes
Check burner performance by cycling the system while you from the vent fitting on the gas valve to the barbed fitting
observe burner response. Burners should ignite promptly. on the deck of the unit (see FIG. 3-4).
Flame pattern should be stable, see Burner Flames in the
5. Remove the flexible cap from the barbed fitting on the “tee”
Maintenance section of this manual. Turn system off and allow
located in this line and hook one side of the manometer, or
burners to cool, then cycle burners again to ensure proper
(-) side of a magnahelic gauge, to this “tee”. Retain this cap
ignition and flame characteristics.
for future use.
Figure 3-3_Measuring gas supply pressure at combination 6. Remove the 1/8'' hex plug from the manifold pressure tap
gas valve on the gas valve (see FIG. 3-4). Retain plug for future use.
SUPPLY INLET
PRESSURE TAP
7. Install a fitting in this tap that is suitable for connection of
a hose to a manometer, or (+) side of a magnahelic gauge
INLET (see FIG. 3-4).
8. Turn the power switch to the “I” or “ON” position.
9. Push the reset button(s) for the ignition control(s), if

necessary.
10. Set the temperature control to call for heat (see Setting
Temperature Control, page 41).
11. Once the unit is firing, the manometer/magnahelic will

reflect the net manifold gas pressure. Compare this reading
OUTLET to the respective value in Table 3E for Natural Gas or
GAS Propane Gas.
VALVE
CONTROL
KNOB
27
3 Gas connections
12. If adjustment is necessary, remove the regulator 15. Read the value on the manometer/magnahelic and
cover screw on the gas valve. Note: If the gas valve compare it to the values in TABLE- 3E.
under adjustment is located on a manifold assembly
monitored by an igniter, the unit may shut down and 16. Repeat this adjustment procedure for each gas valve as
recycle when the regulator cover screw is removed. necessary to adjust to the proper manifold gas pressure.
This is normal.
17. Remove hoses, replace and tighten plugs and caps
13. Turn the regulator adjustment screw “clockwise” to when complete.
raise the regulator gas pressure. Turn the regulator
18. Replace top front upper jacket access panels and
adjustment screw “counterclockwise” to lower the
control panel door in reverse order.
regulator gas pressure.
19. If proper ignition and burner operation is not
14. Replace the regulator cover screw and make sure it is
achieved after checking gas supply pressure, see
tight for proper operation.
Cleaning and Maintenance, page 61 for Combustion
Air Fan Adjustment. Follow the procedure to adjust
the combustion air fans as necessary.
Figure 3-4_Measuring manifold gas pressure

PRESSURE
REGULATOR
CHAMBER
ADJUSTMENT
MANIFOLD PRESSURE
(UNDER CAP
PRESSURE SCREW)
INLET TEE
OUTLET
MANOMETER GAS TO BARBED

VALVE FITTING
CONTROL
KNOB
TABLE 3E
Net Manifold Pressure
Regulator Pressure Less
Front Chamber Pressure
MODEL Nat. Gas LP
497 - 747 1.8'' w.c. --
987 - 2067 1.2'' w.c. --
497-2067 -- 4.6'' w.c.
28
4 Water connections
Inlet and outlet connections Water flow switch
For ease of service, install unions on the water inlet and water A water flow switch is factory installed in the outlet piping on
outlet of the unit. The connection to the unit marked “Inlet” all heating boilers and water heaters. The flow switch must
on the header should be used for return from the system. The prove water flow before a trial for ignition can begin. The flow
connection on the header marked “Outlet” is to be connected to switch requires a minimum flow of 15 - 18 GPM on Models
the supply side of the system. 497 - 747 and 26 GPM on Models 987 - 2067 to make the flow
switch and start burner operation. A water flow switch meets
Figure 4-1_Water Connections_Models 497 - 797
most code requirements for a low water cutoff device on boilers
2" NPT
requiring forced circulation for operation.
WATER
Low water cutoff

INLET
(if equipped)
E
AG
2" NPT If this boiler is installed above radiation level, a low water
WATER cutoff device must be installed at the time of boiler installation.
OUTLET
IM An electronic low water cutoff is available as a factory supplied
E W option on all models. The low water cutoff should be inspected

every 6 months.
N
D Heating boiler installations
E E Piping of the boiler system
N
The drawings in this section show typical boiler piping
INSPECTION installations, see FIG.’s 4-5 through 4-8. Before beginning
PLUGS the installation, consult local codes for specific plumbing
requirements. The installation should provide unions and
Figure 4-2_Water Connections_Models 987 - 2067 valves at the inlet and outlet of the boiler so it can be isolated
2-1/2" NPT
for service. An air separation device must be supplied in the
WATER installation piping to eliminate trapped air in the system.
INLET
Locate a system air vent at the highest point in the system.
The system must also have a properly sized expansion tank
2-1/2" NPT
WATER installed. Typically, an air charged diaphragm-type expansion
OUTLET tank is used. The expansion tank must be installed close to the
boiler and on the suction side of the system pump to ensure
proper operation. A water meter to monitor makeup water is
recommended. Makeup water volume should not exceed 5%
of total system per yearInstall a Y-strainer or equivalent multi-
purpose strainer just before the boiler pump at the inlet of the
heat exchanger. This item is used to remove system debris from
older hydronic systems and to protect newer systems.
The boiler system should not be operated
INSPECTION
CAUTION
PLUGS
at less than 12 PSIG(83 kPa) (Non-metallic
system piping must have an oxygen barrier
Relief valve to be considered a closed loop).
Hot water piping must be supported by suitable hangers or floor
This unit is supplied with a relief valve(s) sized in accordance stands, NOT by the boiler. Copper pipe systems will be subject
with ASME Boiler and Pressure Vessel Code, Section IV to considerable expansion and contraction. Rigid pipe hangers
(“Heating Boilers”). The relief valve(s) is installed in the vertical could allow the pipe to slide in the hanger resulting in noise
position and mounted in the hot water outlet. No valve is to be transmitted into the system. Padding is recommended on rigid
placed between the relief valve and the unit. To prevent water hangers installed with a copper system. The boiler pressure
damage, the discharge from the relief valve shall be piped to a relief valve must be piped to a suitable floor drain. See the Relief
suitable floor drain for disposal when relief occurs. No reducing Valve section on this page.
couplings or other restrictions shall be installed in the discharge
A leak in a boiler “system” will cause the
line. The discharge line shall allow complete drainage of the CAUTION
“system” to intake fresh water constantly,
valve and line. Relief valves should be manually operated at
which will cause the tubes to accumulate a
least once a year.
lime/scale build up. This will cause a non-
CAUTION Avoid contact with hot discharge water. warrantable failure.
29
4 Water connections
Water connections (heating boilers only) Circulator pump specifications
Inlet and outlet water connections on Models 497 - 747
1. Maximum operating pressure for the pump must exceed
have 2'' NPT and on Models 987 - 2067 the inlet and outlet
system operating pressure.
connections are 2 1/2'' NPT.
2. Maximum water temperature should not exceed the
Field installed reducing bushings must not nameplate rating.
CAUTION
be used to reduce below the pipe diameters
of the models listed above. 3. Cast iron circulators may be used for closed loop systems.
Any reduction in pipe size may decrease flow resulting in high 4. A properly sized expansion tank must be installed near the
water temperatures, boiler noise, flashing to steam, and non- boiler and on the suction side of the pump.
warrantable heat exchanger damage.
Circulator pump operation (heating boilers only)
The boiler may be installed with a primary/secondary piping
The boiler pump must run when the boiler is firing. Separate
system provided to the boiler. It is important to guarantee that
supply circuits can be provided or the two circuits (pump
adequate flow is provided to properly dissipate heat from the
and controls) can be combined for connection to one circuit,
boiler and also ensure that flow through the boiler does not
properly sized for both.
exceed the maximum recommended flow rate of 55 GPM for
Models 497 - 747 and 90 GPM for Models 987 - 2067 for a boiler Pump delay operation
equipped with a copper heat exchanger.
A pump delay operation feature is provided. The boiler’s
Boiler circulator requirements circulating pump will cycle on at each call for heat, before the
burner fires. The pump will continue to operate while the
This is a low mass, high efficiency hot water boiler which
burner is firing. The pump will run for a minimum 30 second
must have adequate flow for quiet, efficient operation. Pump
period after the temperature set point is satisfied. This timing
selection is critical to achieve proper operation. A pump should
will remove any of the residual heat from the combustion
be selected to achieve proper system design water temperature
chamber before turning the pump off. See the wiring diagram
rise. Pipe diameter and length are critical to ensure proper flow
in Section 10 of this manual.
through the boiler. A System Temperature Rise Chart (Table 4B
on page 32) is provided to assist in proper pump selection. This
table provides GPM and boiler head-loss at various temperature
rises for each model based on Btu/hr input. Temperature rise
is the difference in boiler inlet temperature and boiler outlet
temperature while the boiler is firing at full rate.
Example: The boiler inlet temperature is 160°F (71.1°C) and
the boiler outlet temperature is 180°F (82.2°C). This means that
there is a 20°F (11.1°C) temperature rise across the boiler. The
boiler temperature rise is visible in the Operator Interface on the
boiler’s front control panel.
Figure 4-3_Heat exchanger pressure drop chart_ Figure 4-4_Heat exchanger pressure drop chart_
Models 497- 747 Models 987 - 2067
Pressure Drop Chart

Models 497 - 747 MODELS 987 - 2067
12
PRESSURE DROP IN FEET HEAD
10
8
2
0
80
75
70
60
65
55
50
45
40
30
20
10
FLOW IN GALLONS PER MINUTE
30
4 Water connections (continued)
Pump Maintenance: Inspect the pump every six (6) months Minimum boiler water temperatures
and oil as necessary. Use SAE 30 non-detergent oil or lubricant
Inlet water temperatures below the specified minimum of
specified by the pump manufacturer.
140°F (60°C) can excessively cool the products of combustion
The boiler is recommended for installation in a primary/ resulting in condensation on the heat exchanger. Condensation
secondary piping system. This type of system uses a separate on the heat exchanger can cause operational problems, bad
boiler circulating pump to supply flow to and from the boiler combustion, sooting, flue gas spillage and reduced service life
only. The secondary pump is sized based on the head loss of the of the related components. See the Low Temperature Bypass
boiler and related pipe and fittings in the secondary loop only. Requirements section for boiler system applications below the
minimum specified temperature.
A properly sized primary system pump provides adequate flow
to carry the heated boiler water to radiation, air over coils, Low system water volume
etc. The fittings that connect the boiler to the primary system System run time is very important to the overall operating
should be installed a maximum of 12 inches (0.30m) (or 4 pipe efficiency of the boiler. Short cycling of the boiler creates
diameters) apart to ensure connection at a point of zero pressure problems with condensation in the vent stack, condensation on
drop in the primary system. There should be a minimum of the heat exchanger, system temperature spikes, and mechanical
10 pipe diameters of straight pipe before and after the boiler component failures. To prevent short cycling of the boiler, it
secondary loop connections to prevent turbulent flow at the is important to limit the boiler cycles to six or fewer per hour.
secondary loop connections. The secondary loop piping to and
from the boiler must have a fully ported ball valve installed in A buffer tank is an effective way to enhance a small system load
both the supply and return side piping. The ball valves must and increase heating system efficiency (see FIG. 4-8 on page 36
be fully ported having the same inside diameter as the installed of this manual). Buffer tanks add water volume to the system
piping. The ball valve in the piping supplying water to the boiler and act as a flywheel to absorb the additional Btu’s provided by
will only be used as a service valve. The ball valve installed in the boiler when only a single zone of a large system is calling
the discharge from the boiler back to the primary system will be for heat.
used to adjust boiler flow and temperature rise to ensure proper
To calculate the proper buffer tank size for a multiple zone
performance.
system:
The boiler primary piping system must have a circulator
installed in the main system loop to carry the heated boiler (Run Cycle) (Output - Minimum System Load)
water to the point of use in the main system. (Temp. Rise) (8.33) (60 Min.)
Multiple boilers may also be installed with a primary/secondary
CFN2067
manifold system. Multiple boilers should be connected to the
common manifold in reverse return to assist in balancing flow Min. Load = 100,000 Btu/Hr
to multiple boilers.
Min. Boiler Output = 850,000 Btu/Hr
The installer must ensure that the boiler has adequate flow Cycle Time = 10 Min
without excessive temperature rise. Low system flow can result
in overheating of the boiler water which can cause short burner Temp. Rise = 38
cycles, system noise, relief valve discharge and in extreme cases, (10)(850,000 – 100,000) / (38)(8.33)(60) = 395 Gallons
a knocking flash to steam. These conditions indicate the need
to increase boiler flow to and from the boiler. This is generally
accomplished by either increasing the size of the boiler pump or
by increasing the diameter of the piping that connects the boiler
to the primary system. A larger diameter pipe reduces head loss
and increases flow.
At no time should the system pressure be less
CAUTION
than 12 PSIG.
Do not allow the flow in the primary loop to

CAUTION
drop lower than the flow in the secondary
loop at any time during boiler operation.
Improper operation of the boiler(s) and
possible tripping of the high limits and relief
valves may occur.
31
4 Water connections
Low temperature return water systems Start boiler adjustment with the bypass valve in the full open
position and the boiler discharge valve half open. A small
Any non-condensing boiler and venting system will develop
amount of the higher temperature boiler discharge water is
operational problems when exposed to inlet water temperatures
mixed with the system water to maintain the desired lower
below 140°F. Lochinvar offers a low temperature protection
system temperature. A remote low temperature range operator
valve (LTV) that is factory preset to maintain 140°F inlet water
is recommended to control the boiler operation based on the
to the boiler regardless of the system return water temperature.
lower system temperature. (See Terminal Strip Connection
See Table 4A for available valve kits.
Options starting on page 40).
TABLE 4A
LTV VALVE KITS Radiant floor and snow melt heating
MODEL LTV VALVE KIT systems
497 - 747 100172001
987 - 2067 100172000 This type of heating boiler application operates in a low
temperature range which requires a boiler bypass as described
Be sure to install the LTV valve per the piping diagrams under the Low Temperature Bypass Requirements section. A
included with the kits. Alternatively, a bypass as shown in FIG. non-metallic rubber or plastic tubing installed in a radiant (in
4-6 may be piped into the system. This piping is like a primary/ floor) system must have an oxygen barrier to prevent oxygen
secondary boiler installation with a bypass in the secondary from entering the system through the walls of the installed
boiler piping. Inlet water temperatures below 140°F (60°C) tubing. Excessive oxygen absorption into the system will result
can excessively cool the products of combustion resulting in in an accelerated rate of corrosion causing a sludge buildup.
condensation on the heat exchanger and in the flue. This excessive corrosion will also damage the boiler and system
components. Sludge formed as the result of excessive oxygen
Condensation can cause operational problems, bad combustion, in the system can restrict water flow resulting in a premature
sooting, flue gas spillage and reduced service life of the vent boiler failure. Any boiler damage due to excessive oxygenation
system and related components. The bypass allows part of the is non-warrantable.
boiler discharge water to be mixed with the cooler boiler return
water to increase the boiler inlet temperature above 140°F
(60°C). This should prevent the products 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.
TABLE 4B
SYSTEM TEMPERATURE RISE CHART
Temperature Rise Based on Boiler Input in Btu/hr
Btu/hr 10°F T 20°F T 30°F T 40°F T 50°F T 60°F T
Input Output GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd GPM Ft/hd
497,000 400,950 80+ * 40 4.0 27 1.6 20 0.6 16 0.6 13 0.6
647,000 522,450 129+ * 52 5.1 35 3.0 26 1.2 21 0.8 17 0.6
747,000 603,450 149+ * 60 * 40 4.0 30 1.6 24 1.2 20 0.7
987,000 831,600 197+ * 80 5.2 53 2.4 40 1.4 32 1.0 27 0.8
1,257,000 1,058,000 251+ * 102+ * 68 4.3 51 2.3 41 1.6 34 1.1
1,437,000 1,209,000 288+ * 116+ * 78 6.0 58 3.7 47 2.2 39 1.7
1,797,000 1,512,000 360+ * 146+ * 97+ * 73 6.2 58 4.2 49 2.4
2,067,000 1,738,800 414+ * 168+ * 112+ * 84 8.7 67 6.0 56 4.5
+ These flow rates exceed recommended flow rates of boiler. If these system temperature rises are used, an external piping bypass must be
installed.
*These foot head calculations exceed the maximum allowable flow rate of the boiler. Requires Cupro-Nickel heat exchanger.
32
Figure 4-5_Primary/secondary piping of single boiler
COMMON MANIFOLD SIZE (Min.) COMMON MANIFOLD SIZE (Min.)

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
Number of Units GPM Number of Units GPM
(in.) (in.)
1 60 2 1 90 2 1/2
HEATING
RETURN
LOOP
Y-STRAINER
TO
FLOOR
DRAIN 12"
MAX
TO EXPANSION TANK AND
HEATING
MAKEUP WATER SYSTEM
SUPPLY
LOOP
DIR #2000548304 000
*Please note that these illustrations are meant to show system piping concept only, the installer is responsible
NOTICE
for all equipment and detailing required by local codes.
33
4 Water connections
Figure 4-6_Primary/secondary piping of multiple boilers

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
2 120 3 2 180 4
3 180 3 1/2 3 270 5
4 240 4 4 360 6
5 300 5 5 450 6
6 360 5 6 540 6
7 420 6 7 630 8
8 480 6 8 720 8
EXPANSION
PRESSURE
TANK
RELIEF
VALVE
LOW WATER
CUT-OFF
MAKE-UP
(OPTIONAL)
WATER
TO SYSTEM
AIR WATER
SEPARATOR METER
12" OR 4X SYSTEM
PIPE DIAMETERS PUMP
FROM
SYSTEM
Y-STRAINER
(TYPICAL)
SECONDARY
BOILER DIR #2000548439 00
PUMP
NOTICE
34
Figure 4-7_Boiler with low temperature bypass

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
1 60 2 1 90 2 1/2
MIXING
VALVE TO EXPANSION
TANK AND MAKEUP
Y-STRAINER WATER SYSTEM
HEATING
RETURN
LOOP
TO
FLOOR
DRAIN
12"
MAX
HEATING
SUPPLY
LOOP
DIR #2000548440 00
NOTICE
35
4 Water connections
Figure 4-8_Primary/secondary piping with buffer tank

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
2 120 3 2 180 4
3 180 3 1/2 3 270 5
4 240 4 4 360 6
5 300 5 5 450 6
6 360 5 6 540 6
7 420 6 7 630 8
8 480 6 8 720 8
PUMP
Y-STRAINER
1" TEMPERATURE (TYPICAL)
AND PRESSURE
GAUGE
AUTOMATIC AIR
ELIMINATOR/VENT
SYSTEM
OUTLET
SYSTEM COMMOM MANIFOLD

SENSOR MUST BE SIZED TO
LOCATION ACCOMMODATE COMBINED
FLOW RATE FOR
ALL BOILERS
SYSTEM
INLET
DIR #2000548442 00
BUFFER DRAIN
TANK
NOTICE
36
Installation with a chilled water TABLE - 4C

system BOILER TEMPERATURE RISE AT MAXIMUM FLOW
Temperature Rise at Full Rate Fire
Pipe refrigeration systems in parallel. Install duct coil Maximum Flow
downstream at cooling coil. Where the hot water heating Model Temperature Rise °F
boiler is connected to a heating coil located in the air handling
497 15 @ 55 GPM
units which may be exposed to refrigeration air circulation, the
boiler piping system must be equipped with flow control valves 647 20 @ 55 GPM
or other automatic means to prevent gravity circulation of the 747 23 @ 55 GPM
boiler water during the cooling cycle. 987 19 @ 90 GPM
1257 24 @ 90 GPM
The coil must be vented at the high point and hot water from the
boiler must enter the coil at this point. Due to the fast heating 1437 27 @ 90 GPM
capacity of the boiler, it is not necessary to provide a ductstat to 1797 34 @ 90 GPM
delay circulator operation. Also, omit thermostat flow checks 2067 39 @ 90 GPM
as the boiler is cold when heating thermostat is satisfied. This
provides greater economy over maintaining standby heat.
Typical heating boiler installations Boiler flow rate

General plumbing rules: Do not exceed the maximum flow rate of the
CAUTION
1. Check all local codes. heating boiler.
2. For serviceability of boiler, always install unions. TABLE - 4D
3. Always pipe pressure relief valve to an open drain. MAXIMUM WATER FLOW
4. Locate system air vents at highest point of system. CAUTION: The maximum flow rate through a water heater with
5. Expansion tank must be installed near the boiler and on the a copper heat exchanger must be set to provide and not exceed
suction side of the system pump. the following flow:
Maximum Flow for
6. Support all water piping. Model Maximum Flow CuNi Heat Exchanger
497, 647, and 747 55 GPM 75 GPM
987, 1257, 1437, 1797, and 2067 90 GPM 115 GPM
The heat exchanger is generally capable of operating within

the design flow rates of the building heating system. Should
the flow rate exceed the maximum allowable flow rate through
the boiler an external bypass must be installed. The bypass
should be fully sized with a balancing valve to allow for proper
adjustment of flow. Flow rate can be determined by measuring
the temperature rise through the boiler.
37
4 Water connections
Boiler bypass requirements Do not use petroleum based stop leak
CAUTION
The installer must ensure that the boiler is supplied with products. All system leaks must be repaired.
adequate flow without excessive temperature rise. It is The constant addition of make-up water can
recommended that this boiler be installed with a bypass in the cause damage to the boiler heat exchanger
piping if the maximum recommended flow rate is exceeded. due to scale accumulation. Scale reduces
The bypass will help to ensure that the boiler can be supplied flow and heat transfer, causing overheating
with adequate water flow. Flow rates exceeding the maximum of the heat exchanger.
recommended flow will result in erosion of the boiler tubes.
A typical bypass with a valve as shown in FIG. 4-6 will allow 6. Run the system circulating pump for a minimum of 30
control of boiler flow. minutes with the boiler turned off.
7. Open all strainers in the system and check for debris.
Temperature / pressure gauge
8. Recheck all air vents as described in step 4.
This boiler is equipped with a dial type temperature / pressure
gauge. This gauge is factory installed in the outlet side of the 9. Inspect the liquid level in the expansion tank. The system
boiler piping. The gauge has one scale to read system pressure must be full and under normal operating pressure to
and a separate scale to read water temperature in degrees ensure proper water level in the expansion tank. Ensure
Fahrenheit. The temperature / pressure gauge is provided to that diaphragm type expansion tanks are properly charged
meet code requirements. Water temperatures can be more and not water logged.
accurately monitored from the data provided in the digital 10. Start the boiler according to the operating instructions in
display in the Operator Interface. this manual. Operate the system, including the pump,
Filling the system boiler and radiation units, for one hour.
All air must be purged from the system for proper operation. 11. Recheck the water level in the expansion tank. If it exceeds
An air scoop and air vent must be located close to the boiler half the tank volume, open the tank to reduce the water
outlet and there should be a minimum distance between the level. Recheck pressure charge on diaphragm type tanks.
cold water feed and the system purge valve. 12. Shut down the entire system and vent all radiation units
1. Close all drain cocks and air vents. and high points in the system.
2. Open the makeup water valve and slowly fill the 13. Close the water makeup valve and check the strainer and
system. pressure reducing valve for sediment or debris. Reopen
the water makeup valve.
3. If a makeup water pump is employed, adjust the
pressure to provide a minimum of 12 psi at the highest 14. Verify system pressure with the boiler pressure gauge
point in the system. If a pressure regulator is also before beginning regular operation.
installed in the line, it should be adjusted to the same 15. Within three days of startup, recheck and bleed all air
pressure. vents and the expansion tank using these instructions.
4. Close all valves. Purge one circuit at a time as follows: Water treatment
A. Open one circuit drain valve and let the water
drain for at least five minutes. Ensure that In hard water areas, water treatment should be used to reduce
there are no air bubbles visible in the water the introduction of minerals to the system. Minerals in the
stream before closing the drain valve. water can collect in the heat exchanger tubes and cause noise on
B. Repeat this procedure for each circuit. operation. Excessive build up of minerals in the heat exchanger
can cause a non-warrantable failure.
5. Open all valves after all circuits have been purged.
Make sure there are no system leaks.
38
5 Electrical connections
Connecting to electrical supply WARNING
ELECTRICAL SHOCK HAZARD – For your
safety, turn off electrical power supply before
This unit is wired for 120 VAC service. The unit, when making any electrical connections to avoid
installed, must be electrically grounded in accordance with possible electric shock hazard. Failure to do
the requirements of the authority having jurisdiction or in so can cause severe personal injury or death.
the absence of such requirements, with the latest edition of
Label all wires prior to disconnection when
the National Electrical Code ANSI/NFPA No. 70. When CAUTION
the unit is installed in Canada, it must conform to the servicing controls. Wiring errors can cause
CAE C22.1, Canadian Electrical Code, Part 1 and/or local improper and dangerous operation.
Electrical Codes.
TABLE 5A
AMP DRAW DATA
1. Use only Type-T wire [63°F (35°C) rise] on all wiring
between the unit and field-installed devices. Approximate
Model Controls Fan Total Amps @
2. Enclose line voltage wire exterior to the unit in approved 120 VAC
conduit or approved metal-clad cable. 497 4.6 3.4 8.0
3. The pump must run continuously when the unit is 647 4.6 3.4 8.0
being fired (water heaters must use the pump delay if
747 4.6 3.4 8.0
the pump is to be cycled. See Freeze Protection, page 11
when cycling the pump). Water heaters use the 987 4.6 3.4 8.0
pump delay as standard in accordance with ASHRAE 1257 4.6 3.4 8.0
90.1 requirements. 1437 4.6 3.8 8.4
4. To avoid serious damage, do not energize the unit until the 1797 4.6 3.8 8.4
system is filled with water. 2067 4.6 3.8 8.4
5. Provide the unit with proper overload protection.
Do not block access to the electrical
NOTICE cover plate when installing electrical
conduit.
Figure 5-1_Control panel location

TWO STAGE IGNITION
THERMOSTAT MODULE
CONNECTION
BOARD
MANUAL
RESET
GROUND HIGH LIMIT
SCREW
TERMINAL
STRIP
24 VDC
ON/OFF COIL
24 VAC SWITCH RELAY
RELAY
39
Line voltage connections wiring connections. This remote ON/OFF control will provide
an Enable/Disable signal to the unit and allow the unit to
1. Connect 120 VAC power wiring to the line voltage
operate based on the stage set points, until the remote ON/
terminal strip in the junction box, as shown in FIG. 5-2.
OFF signal is cancelled.
2. Provide and install a fused disconnect or service switch
Figure 5-7 shows the connections necessary to operate the
(15 AMP recommended) as required by the code (see
unit as a two-stage (High/Low Fire) boiler or water heater
FIG. 5-2).
from an Energy Management System (EMS). The actual set
3. To activate a system pump, wire as shown in FIG. 5-2. point temperatures are controlled by the EMS. The High Fire
If the motor is larger than 1 HP, you must install a Offset on the electronic temperature control in the unit must
contactor. be set to zero and the set point must be set to a value which
UNIT UNIT PUMP
L
SUPPLY
N G L
SUPPLY
N G
will function as an upper limit for proper operation under this
two-stage control from an EMS.
Figure 5-8 shows the Continuous and Intermittent terminals.
D
I
S
D
I
S
External safety devices connected to these terminals will
C
O
N
C
O
N
function to protect the unit. Devices connected to the
N N
E
C
T
E
C
T
Intermittent terminals (B1 and B2) are monitored only
when there is an active Call for Heat. Devices connected
to the Continuous terminals (A1 and A2) are monitored
continuously and will activate an alarm (if the unit is equipped
with the alarm option) anytime the safety device senses an
abnormal condition.
UNIT
PUMP
Figure 5-3_Stand-alone operation boiler
GROUND
1 + SYSTEM/TANK
SPLICE 2 + SENSOR
6 1
3 + B2 INTERMITTENT 7 2
CHASSIS 4 + B1 LIMITS
GROUND
5 + A2 CONTINUOUS 8 3
6 + A1 LIMITS
LBL20174 REV A
9 4
L
120V
N
UNIT
7 + 2 NO HIGH FIRE
SUPPLY PUMP
1 HP MAX
IMG00594 8 + 2 C ENABLE 10 5
9 + 1 NO LOW FIRE
Figure 5-2_Line Voltage Field Wiring Connections 10 + 1 C ENABLE
External EMS connection to terminal

strip for stage firing control of Figure 5-4_Stand-alone operation water heater
burners 1 + SYSTEM/TANK
This unit is equipped with a factory installed terminal strip 2 + SENSOR
6 1
for connection of an energy management system (EMS)
to the burner stages. The EMS terminal strip is located 4 + B1 LIMITS
in the unit’s control panel. Ensure that all wiring used 5 + A2 CONTINUOUS 8 3
for connection to this terminal strip is properly sized per 6 + A1 LIMITS 9 4

7 + 1 NO
the recommendations in TABLE 5A. When connecting ENABLE
8 + 1C 10 5
an EMS to this terminal strip to sequence on each stage

of burner operation, the unit’s internal thermostat or
electronic sequencer should be set as an additional high
Figure 5-5_Remote on/off boiler
limit control. This will prevent problems between the set
points of the EMS and the boiler’s internal controller.
1 + SYSTEM/TANK
Terminal strip connection options 2 + SENSOR
6 1
Figures 5-3 and 5-4 show the position of jumpers as shipped
from the factory for stand-alone operation of boilers or
4 + B1 LIMITS
water heaters. 5 + A2 CONTINUOUS 8 3
Figures 5-5 and 5-6 show connections to the terminal strip Remote 6 + A1 LIMITS 9 4
7 + 2 NO HIGH FIRE
for Remote ON/OFF control of the boiler or water heater. on/off
8 + 2 C ENABLE 10 5
The 1C-1NO jumper must be removed when making these
9 + 1 NO LOW FIRE
10 + 1 C ENABLE
40
5 Electrical connections (continued)
Figure 5-6_Remote on/off water heater Temperature control settings

There are three setting knobs on the temperature control unless
1 + SYSTEM/TANK your unit is specified as a boiler only with an outdoor air reset
2 + SENSOR
6 1
option. If your unit is a boiler only with an outdoor air reset
option, there are additional controls for this option. They are
explained under Outdoor Air Reset Option, page 42.
Remote 4 + B1 LIMITS
The three setting knobs on the temperature control are for Set
on/off
6 + A1 LIMITS 9 4 Point, Differential, and High-Fire Offset (see FIG. 5-10).
7 + 1 NO ENABLE
8 + 1C 10 5 Maximum set point
The maximum set point for the control is factory set. Boilers
are set to 230°F max., water heaters are set to 190°F max., and
Figure 5-7_Two-stage (high/low fire) boiler specialty state and local codes to 200°F.
1 + SYSTEM/TANK These maximum set points are established by not cutting/
2 + SENSOR cutting the OJ1 and OJ2 jumpers located on the right side of the
6 1
temperature controller (see FIG. 5-10). The maximum set point
3 + B2 INTERMITTENT 7 2 is determined as shown in Table 5B.
4 + B1 LIMITS
Figure 5-9_Locating temperature control
Stage 2 6 + A1 LIMITS 9 4
7 + 2 NO HIGH FIRE TEMPERATURE
CONTROL
8 + 2 C ENABLE 10 5
9 + 1 NO LOW FIRE
10 + 1 C ENABLE
Stage 1
Figure 5-8_Field installation safety devices
1 + SYSTEM/TANK
Intermittent 2 + SENSOR
6 1
Alarms
4 + B1 LIMITS
6 + A1 LIMITS 9 4
Continuous 7 + 2 NO HIGH FIRE
Alarms 8 + 2 C ENABLE 10 5
9 + 1 NO LOW FIRE
10 + 1 C ENABLE
Figure 5-10_Temperature control setting knobs
Temperature adjustment
OJ1
OJ1
Note: The temperature controller is preset at the factory with
test settings. You may need to adjust the settings to meet your
specific needs. OJ2 OJ2
Return water temperatures must not be less
WARNING
than 140°F. If lower return water temperatures
are required, follow the instructions for Low
Temperature Return Water Systems on page
32.
Locating the temperature control
The temperature control is located behind the panel on the left

front of the unit (see FIG. 5-9). Follow the steps below to access
the temperature control.
1. Loosen the knurled knob at the bottom of the control
SETPOINT HIGH-FIRE
panel cover. OFFSET
DIFFERENTIAL
2. Pull the bottom of the panel out and down to remove.
41
TABLE 5B Figure 5-11_Optional outdoor reset control

Maximum Setpoint Determination
OUTDOOR OUTDOOR
AIR AIR
Max. SHUTDOWN SENSOR
OJ1 OJ2
Setpoint SHUTDOWN
Connected Connected 230°

Cut Connected 190°
Connected Cut 200°
Cut Cut 160°
Anytime that OJ1 is the only jumper cut, a

NOTICE new overlay is required under the Set Point
knob on the temperature controller because
the scale has changed to a maximum of
190°F.
Anytime the OJ2 jumper is cut (with or
without OJ1), a new overlay is required
under the Set Point knob on the temperature
controller because the scale has changed to
a maximum of 200°F.
Setpoint
OUTDOOR RATIO
AIR
MAX
The Set Point knob specifies the target water temperature in
degrees, Fahrenheit. After the water temperature reaches the set Outdoor reset option
point, the temperature control shuts off the burners.
For boilers ordered with the Outdoor Air Reset option, there
Differential is an additional control (see FIG. 5-11). There are three setting
knobs for Shutdown, Outdoor Air Max., and Ratio. There is
The Differential specifies the number of degrees below the set
also a switch to turn the outdoor air sensor On or Off. An O.A.
point that the control will allow the water temperature to drop
Sensor is also included.
before it brings the unit back on again.
Shutdown
High-fire offset
The Shutdown knob specifies the outdoor air shutdown
The temperature control operates a two-stage firing system.
temperature at which the control would prevent the unit from
The two stages are High-Fire and Low-Fire. High-Fire operates
operating. This feature can be enabled/disabled with the O.A.
all burners while Low-Fire operates approximately one-half of
Shutdown switch.
the burners.
The High-Fire knob specifies the number of degrees below set Outdoor air max (O. A. Max)
point that the High-Fire stage shuts down. At that point, the The O. A. Max knob allows a reset up to the maximum outdoor
unit will continue to operate at the Low-Fire stage until the set air temperature specified by this knob setting. When the
point is reached. outdoor air temperature is above the specified setting, the unit
The High-Fire offset knob has settings between 0°F and 20°F. will not function in the O.A. Reset Mode, but will continue to
If set at 0°F, the High-Fire offset is disabled and the unit will run at the selected set point temperature.
operate at the High-Fire stage until the set point is reached and Note that the set point knob will now indicate the “minimum”
the temperature control shuts the unit off. boiler temperature. Target temperature is determined by the
When the High-Fire offset knob is set to 0 or 1, the unit will ratio and outdoor air temperature below the O.A. Max setting.
light at Low Fire and operate for approximately 10 seconds
before the High-Fire stage actuates. When set to 2 or above, the
unit will operate at Low Fire for approximately 2 minutes before
the High Fire stage can actuate.
42
Ratio The sensor must be connected to two wires provided on the side
of the appliance with the water connections (FIG. 5-12). It will
The Ratio knob allows the control over the reset ratio to be used
be necessary to add additional wire to reach from the appliance
during Outdoor Air Reset. The allowable ratios are as low as
to the remote water source. Use twisted pair wire or minimum
0.5:1 or as high as 1.5:1.
18 gauge wire or larger. Reference Table 5C on page 44 for a
Selecting the 0.5:1 ratio will increase the set point 0.5°F for every chart regarding distance versus wire gauge.
1.0°F 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°F for every Figure 5-12_Remote sensor for pump delay
1.0°F drop in outdoor air temperature up to the maximum set
FIELD SUPPLIED CONNECTION BOARD
point temperature (see page 41). WIRING
1 + SYSTEM/TANK
See FIG. 5-13 for an outdoor air reset chart example. 2 + SENSOR
SYSTEM/ 6 1
Temperature control sensors

TANK
SENSOR
4 + B1 LIMITS
This is a two-stage temperature control that controls the 5 + A2 CONTINUOUS 8 3
REQUIRED IN ORDER 6 + A1 LIMITS 9 4

burner ignition, pump, and alarm functions. This temperature FOR PUMP DELAY TO 7 + 2 NO HIGH FIRE
FUNCTION PROPERLY 8 + 2 C ENABLE 10 5
controller can measure up to three different sensor inputs, 9 + 1 NO LOW FIRE
depending upon how the unit is set up. They are as follows: 10 + 1 C ENABLE
1. Inlet Water Temperature Sensor

2. Multi-Purpose Temperature Sensor Boiler application
3. Outside Air Temperature Sensor Standard boiler units are shipped with two sensors; the inlet
Inlet water temperature sensor water temperature sensor and the multi-purpose temperature
sensor. The multi-purpose sensor should be used as a system
This sensor measures the inlet water temperature coming into sensor. Boilers with the outdoor air reset option also have an
the unit. outside air temperature sensor.
Multi-purpose temperature sensor Water heater application
This sensor can be used as a system sensor or a tank sensor. Water heater units are shipped with two sensors; the inlet water
Outdoor air temperature sensor temperature sensor and the multi-purpose temperature sensor
to be used as a tank sensor.
This sensor is only available on boiler units with an outdoor
air reset option. This allows you to tie boiler operation to the Placement of sensors
outdoor air temperature. As outside temperatures drop, the
control will increase the temperature setting of the boiler. Inlet temperature sensor
As outdoor temperatures rise, the control will decrease the The inlet water temperature sensor is installed by the factory
temperature to the selected set point of the boiler. You can set in new units. The sensor is an immersion style and maintains
the control to shut the boiler off when a desired outdoor air direct contact with the water.
temperature level is reached. System sensor
Remote sensor for pump delay This is used for boiler applications. This sensor will control the
This appliance is provided with a special thermostat sensor boiler operation based upon the water temperature within the
that MUST be field installed. The sensor is shipped loose in building loop.
the I & O packet. This remote mounted sensor will be the Tank sensor
primary water sensor which will inform the appliance's built- This is used in water heating applications. Place the sensor in
in thermostat control. Reading the water temperature at the the water storage tank to measure water temperature. For more
remote location is required for proper operation of the pump information on mounting the sensor, see Remote Mounting of a
delay option provided with this appliance. Sensor, page 44.
For domestic water heating, the sensor must be installed into a
bulbwell on the storage tank. For boiler and hydronic heating,
the sensor must be installed in the system piping loop. If the
appliance is controlled by a remote sequencer, the sensor must
be routed back into the appliance and placed in a bulbwell on
the inlet side of the heat exchanger.
43
Outdoor air Temperature sensor 7. Use shielded wiring to connect the sensor to the control
The outside air temperature sensor will only be used for boiler when the possibility of an electrically noisy environment
systems. The outside air sensor is optional. You must purchase exists. Shielded cable is recommended on all cable runs of
the sensor from the appliance manufacturer. The sensor comes more than 25 feet in length.
with a housing that helps protect the sensor from the elements. Ground the cable shield at the connection
Mount the air sensor housing under the eve of the roof. Make NOTICE to the boiler temperature control only. Do
sure the housing is out of direct sunlight. This will ensure that not ground the shielded cable at the sensor
the sensor will accurately read the true outdoor temperature. end.
For more information on mounting the sensor, see Remote To maintain temperature accuracy, sensor
Mounting of a Sensor. wires should be at least 18 AWG, see Table
5C.
Figure 5-13_Outdoor air reset chart example
TABLE 5C
Remote Wire Connection
Wire Gauge Max. Allowable Length
12 GA 100 FT
14 GA 75 FT
16 GA 50 FT
18 GA 30 FT
Remote mounting of a sensor

You must mount the outside air temperature sensor outside
the building. To mount remote sensors, follow the guidelines
below. Take care to correctly wire sensors to the unit. Erratic
temperature readings can be caused by poor wiring practices.
Twist the wires between the unit and the remote sensor. Turn
wires at least three or four turns per linear foot of wiring. This
provides common mode rejection of some types of electrical
interferences.
1. Do not route temperature sensor wiring with building
power wiring.
2. Do not locate temperature sensor wiring next to control
contactors.
3. Do not locate temperature sensor wiring near electric
motors.
4. Do not locate 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.
44
Hot surface ignition system Diagnostic Status Indication

The ignition module has an LED which indicates the status of the
Hot surface igniter and ignition control safety circuits. A remote Ignition Module Status indicating light
module is wired from the ignition module Status LED and mounted on
This unit has one ignition module and one hot surface igniter. the front diagnostic panel. The flashing operation of this light
indicates the diagnostic status of the ignition control module.
The status LED, mounted on the ignition module flashes a code
Figure 5-14_Hot surface igniter
sequence from the Ignition Module to indicate the status of the
ignition process. See Table 5D for the flashing diagnostic status
codes as signaled by the ignition module.
Note: Flame current is typically 2 - 6 μA
Figure 5-15_Hot surface ignition control module

The igniter is extremely fragile, be very
CAUTION
careful when removing. A faulty or damaged
hot surface igniter MUST BE replaced with
a Lochinvar PLT3400 igniter. Do not use
general purpose field replacement igniters.
Hot surface ignition control module

Ignition Module Lockout Functions
The ignition module may lockout in either a hard-lockout
condition, requiring pushing of the reset button to recycle
the control, or a soft-lockout condition which may recycle
after an approximate five-minute waiting period. This soft-
lockout condition is intended to allow self-correcting faults
to correct themselves and permit normal operation. A typical
hard-lockout fault is a flame failure condition. An ignition
module that is in a hard-lockout condition may only be reset
by pushing the reset button next to the ignition control or the
“RESET” button on the diagnostic panel on the left end of
the unit. Upon a flame failure, the reset button is only active
after the control module has completed its post-purge cycle.
Turning main power “OFF” and then “ON” or cycling the
thermostat will not reset a hard-lockout condition. Wait five
seconds after turning on main power before pushing the reset
button when the ignition module is in a hard lockout. The
ignition module will go into a soft lockout if conditions of low
air, low voltage or low hot surface igniter current are present.
A soft-lockout condition will operate the combustion air fans
for the post purge cycle and then the ignition module will
pause for approximately five minutes. At the end of this timed
pause, the ignition module will attempt a new trial for ignition
sequence. If the soft-lockout fault condition has subsided or
has been corrected at the end of the timed pause, main burner
ignition should be achieved with the resumption of the normal
trial for ignition sequence. If the control sensed fault is not
corrected, the ignition module will continue in the soft-lockout
condition. If the electronic thermostat opens during the soft-
lockout period, the ignition module will exit soft lockout and
wait for a new call for heat from the thermostat. A soft-lockout
condition may also be reset by manually cycling the thermostat
or turning the main power switch “OFF” and then “ON” after
the control sensed fault has been corrected.
45
Operation and diagnostic lights
TABLE 5E
The diagnostic control panel has up to 6 indicating and Status LED Diagnostic Codes
diagnostic lights to show all major steps of operation and
control sensed malfunctions. This panel is located on the front Code
Condition Lights
of the unit. Sequence
TABLE 5D Operation for combustion air fan before ignition

Prepurge
Status LED Diagnostic Codes on stages 1 and 2.
Code Trial for

Condition Hot surface igniter preparing to light burners.
Sequence Ignition
Constant
System OK, no faults present. Stage 1 ON Burners for stage 1 operating.
ON
Possible control fault, check power; LED may Burners for stage 2 operating.
Constant be defective, do not replace control if all Stage 2 ON
OFF operational sequences function properly, see
Trouble- Shooting Guide.
Status Remote status light for ignition module.
Low Air, check air pressure switch and hoses
One to pressure sensing points, fan, venting and Indicates flame failure on the ignition module
Flash sealing of pressurized chamber. Note: Brief Alarm and will indicate additional alarms if the alarm
flashing normal on fan start-up proving. of any failure option is purchased.
Flame without call for heat, check for a gas

Two valve stuck in the open position, air, venting, Figure 5-16_Operation / diagnostic lights
Flashes burners and the combustion process. Fan will
remain on.
Lockout due to flame failure, push reset

button on the diagnostic panel after correcting
Three ignition problem. Initial heater start up
Flashes without properly bleeding air from the gas
line may require multiple reset functions to
achieve proper ignition.
Igniter failure, igniter will not maintain a

Four minimum 2.75 amp current draw, caused
Flashes by low voltage, bad wiring/continuity, high
resistance or igniter failure.
Power supply problem, check for low supply

Five
voltage or transformer output less than
Flashes
18VAC.
Six
Replace ignition module, internal fault.
Flashes
46
6 Startup
Figure 6-1_Operating instructions
FOR YOUR SAFETY READ BEFORE OPERATING
WARNING: If you do not follow these instructions

exactly, a fire or explosion may result causing
property damage, personal injury or loss of life.
A. This appliance is equipped with an ignition If you cannot reach your gas supplier,
device which automatically lights the burner. call the fire department.
Do not try to light the burner by hand.
B. BEFORE OPERATING smell all around the C. Use only your hand to turn the gas
appliance area for gas. Be sure to smell next control knob. Never use tools. If the
to the floor because some gas is heavier knob will not turn by hand, don't try to
than air and will settle on the floor. repair it, call a qualified service tech-
nician. Force or attempted repair may
result in a fire or explosion.
FOR YOUR SAFETY
"WHAT TO DO IF YOU SMELL GAS"
D. Do not use this appliance if any part
has been under water. Immediately call
Do not try to light any appliance.
a qualified service technician to inspect
Do not touch any electrical switch; do not use the appliance and to replace any part
any phone in your building. of the control system and any gas con-
trol which has been under water.
Immediately call your gas supplier from a
neighbor's phone. Follow the gas supplier's
instructions.
OPERATING INSTRUCTIONS
1. STOP! Read the safety information above on 5. Push in gas control knob slightly and
this label. turn clockwise OFF
to "OFF."
2. Turn off all electric power to the appliance. ON
3. Open control access panel. NOTE: On the 36C valve, knob cannot be
turned to "OFF" unless knob is pushed in
4. This appliance is equipped with an ignition slightly. Do not force.
device which automatically lights the burner.
Do not try to light the burner by hand. 6. Wait five (5) minutes to clear out any gas.
Then smell for gas, including near the floor. If
you smell gas, STOP! Follow "B" in the safety
information above on this label. If you don't
smell gas, go to the next step".
PSI
7. Turn gas control knob counterclockwise

OFF
to "ON."
IN
ON ON
8. Replace control access panel.

OFF 9. Turn on all electric power to the appliance.
10. If the appliance will not operate, follow
GAS CONTROL KNOB the instructions "To Turn Off Gas To
Appliance" and call your service tech-
SHOWN IN THE "ON" POSITION
nician or gas supplier.
TO TURN OFF GAS TO APPLIANCE

1. Turn off all electric power to the appliance 3. Push in gas control knob slightly and
if service is to be performed. turn clockwise to "OFF". Do not
OFF
force.
ON
2. Open control access panel. 4. Replace control access panel.

LBL2084 REV D
47
6 Startup
Pre-Commissioning Cleaning Boiler water
1. Prior to fill and start-up, flush the entire heating system. Do not use petroleum based cleaning or
CAUTION sealing compounds in the boiler system.
2. Clean the entire heating system with an approved pre-
commissioning cleaner (comparable to Sentinel X300 Gaskets and seals in the system may be
or Fernox F3) in accordance with the manufacturer’s damaged. This can result in substantial
recommendation to remove debris and prolong the life of property damage.
the heat exchanger.
DO NOT use "homemade cures" or "boiler
3. Clean all water filtering devices in the system. patent medicines". Serious damage to
4. Flush the cleaning solution out of the entire system and boiler, personnel, and/or property may
refill. result.
Fill water Table 6A Boiler Water Chemistry
Check/control fill water chemistry
Conduct water quality testing prior to BOILER WATER CHEMISTRY
IMPORTANT
installing the appliance. Various solutions Specification Range
are available to adjust water quality. Dissolved Solids < 2000 ppm
The manufacturer recommends the following for properly pH Level 6.5 to 9.5
filling your boiler with the appropriate water chemistry for Chloride < 150 ppm
closed loop boilers. Good fill water quality will help extend
the life of the appliance by reducing the effects of lime scale • Monitoring pH, chlorides, TDS, and hardness
buildup and corrosion in closed loop systems. levels can prolong the life of the appliance by reducing
lime scale buildup, corrosion, and erosion. Check for
Hardness between 5 and 15 grains per gallon leaks to ensure that fresh water is not entering the
1. Consult local water treatment companies for hard water system.
areas (above 15 grains per gallon hardness). • Continual fresh makeup water will reduce boiler life.
2. Hardness levels that are above 15 grains/gallon can lead • Mineral buildup in the heat exchanger reduces heat
to lime scale buildup throughout the boiler system. If the transfer, overheats the stainless steel heat exchanger,
fill water is below 5 grains/gallons, usually due to use of a and causes failure.
water softener, it is recommended to mix in some potable
• The addition of oxygen carried in by makeup water
water at the inlet to increase the hardness of the water to
can cause internal corrosion in system components.
above 5 grains/gallons.
• Leaks in the boiler or piping must be repaired at
pH between 6.5 and 8.5 once to prevent excessive makeup water. For this
purpose, it is recommended to install a water meter
1. pH levels below 6.5 can cause an increase in the rate of
to easily check the amount of makeup water entering
corrosion. pH of 8.5 or higher can potentially cause lime
the system. Makeup water volume should not exceed
scale buildup.
5% of the total system volume per year. NOTE: When
makeup water is added, make sure the chemical
Total Dissolved Solids (TDS) less than 350 ppm
additives are added to maintain the correct level.
1. Total dissolved solids are all minerals, salts, metals, and • An approved multi-metal corrosion inhibitor
charged particles that are dissolved in water. (comparable to Sentinel X100 or Fernox F1) is
recommended at the correct concentration and in the
2. The greater the amounts of TDS present, the higher the
manner recommended by the manufacturer.
corrosion potential due to increased conductivity in the
water.
Freeze protection for a heating
Chlorine concentration less than 150 ppm boiler system (if required)
1. Do not fill boiler or operate with water containing WARNING Ethylene glycol is toxic, DO NOT use as
chlorine in excess of 150 ppm. your freeze protection. Ethylene glycol has a
sweet aroma which children and pets could
2. Filling with fresh drinking water should be acceptable. mistake as food and ingest; leading to death.
3. Do not use the boiler to directly heat swimming pool or
spa water.
48
6 Startup (continued)
1. Use glycol only if needed for freeze protection. Fill and test water system
2. Propylene glycol is the recommended freeze protection. 1. Fill system only after ensuring the water meets the
requirements of this manual.
3. Make sure to flush the boiler system before adding glycol.
4. Determine the freeze protection fluid quantity using 2. Close automatic and manual air vents and boiler drain
system water content, following the fluid manufacturer's valve.
instructions. Boiler water content is listed on page 6. 3. Fill to correct system pressure. Correct pressure will vary
Remember to include expansion tank water content. with each application.
5. Local codes may require a backflow preventer or actual a. The minimum cold water fill pressure for a system is
disconnect from city water supply. 12 psi.
b. Pressure will rise when the boiler is turned ON and
6. When using freeze protection fluid with automatic fill, it is system water temperature increases.
suggested to install a water meter to monitor water makeup.
4. At initial fill and during boiler startup and testing, check
Freeze protection fluid may leak before the water begins to
the system thoroughly for any leaks. Repair all leaks before
leak, causing the concentration to drop, which reduces the
proceeding further.
freeze protection level.
7. The freeze protection set points may be lowered when Purge air from water system
freeze protection fluid is used (see the Copper-Fin Service 1. Purge air from system:
Manual). a. Connect a hose to the purge valve (see purge/drain
valve in the piping diagrams on pages 42 through 47).
8. Consult the glycol manufacturer for details on the suggested
Route the hose to an area where water can drain and be
mix of glycol and water for the desired freeze protection
seen.
level and the de-rate effect it will have on the boiler output.
b. Close the boiler or system isolation valve between the
Test / replace freeze protection fluid purge valve and fill connection to the system.
1. For systems using freeze protection fluids, follow the fluid c. Close zone isolation valves.
manufacturer's instructions. d. Open the quick-fill valve on the cold water makeup
line.
2. Freeze protection fluid must be replaced periodically due to e. Open purge valve.
degradation of inhibitors over time. f. Open the isolation valves one zone at a time. Allow
3. It is recommended to test the glycol concentration annually water to run through the zone, pushing out the air.
and adjust within the desired set points. Run until no noticeable air flow is present. Close
Oxygen prevention the zone isolation valves and proceed with the next
zone. Follow this procedure until all zones are purged.
Eliminate all system leaks. Continual g. Close the quick-fill water valve and purge valve and
CAUTION fresh makeup water will reduce boiler remove the hose. Open all isolation valves. Watch that
life. Minerals can build up in the heat system pressure rises to correct cold-fill pressure.
exchanger, reducing heat transfer, h. After the system has operated for a while, eliminate
overheating the heat exchanger, and any residual air by using the manual air vents located
causing heat exchanger failure. throughout the system.
Dissolved oxygen can have a negative effect on the boiler i. If purge valves are not installed in the system, open the
system. Oxygen can cause iron oxide to generate iron deposits. manual air vents in the system one at a time, beginning
Oxygen may also increase the rate of corrosion on non-stainless with the lowest floor. Close the vent when water
steel parts of the system. A low pH level combined with oxygen squirts out. Repeat with remaining vents.
further enhances its corrosive effects. After boiler installation,
2. Open the automatic air vent (diaphragm-type or bladder
check for air leaks in the following areas:
type expansion tank systems only) one turn.
• Suction gasket
• Pump 3. Open other vents:
• Air valve a. Starting on the lowest floor, open air vents one at a
• O-ring gaskets time until water squirts out.
b. Repeat with remaining vents.
Precautions include installing a water meter to evaluate the
fresh water volume entering the system (should be no more 4. Refill to correct pressure.
than 5% system volume). Additional volumes of fresh water
could indicate that a leak is present.
49
6 Startup
Check for gas leaks
Before starting the boiler, and during initial Boiler operation

WARNING
operation, smell near the floor and around the 8. Verify that all adjustable points in the Operator
boiler for gas odorant or any unusual odor. Interface are set as required.
Remove the front access panel and smell the
9. Boiler should begin the start-up process for the
interior of the boiler enclosure. Do not proceed
sequence of operation.
with startup if there is any indication of a gas
leak. Use an approved leak detection solution. 10. The boiler will ignite and operate to meet the system
Repair any leaks at once. demand.
11. Ensure that inlet water temperature does not fall below
Propane boilers only – Your propane supplier
WARNING the specified minimum for the boiler.
mixes an odorant with the propane to make
its presence detectable. In some instances, the 12. As system demand is satisfied, the burner will cycle off
odorant can fade, and the gas may no longer and the combustion air blower will run for a post
have an odor. Before startup (and periodically purge operation before the boiler shuts down.
thereafter), have the propane supplier verify
the correct odorant level in the gas. Start the boiler
1. Read and follow the Lighting Instructions in FIG. 6-1, on
Check thermostat circuit(s)
page 47.
1. Disconnect the two external wires connected to the enable
terminals on the connection board. If boiler does not start correctly
2. Connect a voltmeter across these two incoming wires. 1. Check for loose connections, blown fuse or service switch
Close each thermostat, zone valve, and relay in the external off?
circuit one at a time and check the voltmeter reading across 2. Is external limit control (if used) open? Is boiler water
the incoming wires. temperature above 200°F (93.3°C)?
3. There should NEVER be a voltage reading. 3. Is thermostat set below room temperature?
4. If a voltage does occur under any condition, check and 4. Is gas turned on at meter or boiler?
correct the external wiring. (This is a common problem 5. Is incoming gas pressure less than 4 inches water column?
when using 3-wire zone valves.)
If none of the above corrects the problem, refer to the
5. Once the external thermostat circuit wiring is checked and Maintenance Section of this manual.
corrected if necessary, reconnect the external thermostat
circuit wires to the connection board. Allow the boiler to
cycle. WARNING The venting system must be installed so that
it will prevent flue gas spillage and carbon
Check vent and air piping monoxide emissions, which will result in
severe personal injury or death.
1. Inspect vent piping and air piping for signs of
deterioration from corrosion, physical damage or
sagging. Verify air piping and vent piping are intact
and correctly installed per this manual.
Placing the boiler in operation

Boiler operational checks
2. Turn the boiler main power switch to the “ON”
position.
3. Confirm the settings of the temperature control.
4. Push the reset for the low water cutoff (if equipped).
5. Ensure that maximum flow to the boiler does not exceed
55 GPM on Models 402 - 752 and 90 GPM on Models
992 - 2072. Verify by checking temperature rise while
burner is firing at 100% of rated input.
6. Install a manometer on the gas supply to the boiler and
verify minimum gas supply pressure as the burner fires at
100% of rated input.
7. Verify operation of safeties as necessary (low water
cutoff, high limit, gas pressure, etc.,).
50
7 Domestic water heaters

This section applies only to those units used to supply potable hot water for domestic use. The water heater must be installed
with a storage tank.
This section contains specific instructions for those units used to supply domestic hot water. All warnings, cautions, notes
and instructions in the general installation and service sections apply to these instructions. Water heaters are designed for
installation with a properly sized storage tank. The use of a properly sized pump and the control of water velocity, as explained
below, are important for correct operation of your water heater.
Water velocity control

TABLE 7B
To ensure proper velocity through the Temperature Rise Chart
NOTICE heat exchanger, you must regulate the
Temperature
temperature rise across the heat exchanger Model
Rise
from inlet to outlet. Do this upon initial
installation and periodically recheck. 497 15°F
647 19°F
The correct temperature rise across the
747 22°F
heat exchanger ensures proper velocity
in the tubes. This will yield long life and 987 18°F
economical operation from your hot water 1257 23°F
heater. Excessive lime build up in the 1437 26°F
tube is caused by too low velocity through
1797 32°F
the tubes. Excessive pitting or erosion in
the tube is caused by too high velocity 2067 37°F
through the tubes. Take care to measure 1. With the pump running and the water heater off,
temperature rise and maintain a velocity the inlet and outlet thermometers should read the same
as follows: temperatures. If they do not, an adjustment must be
made to your final calculation.
Initial set-up of maximum water flow
2. Turn the water heater “On” and allow time for the
On initial start-up, the maximum water flow through temperature to stabilize. Record the difference between
the heat exchanger must be manually set before normal the inlet and outlet temperatures. This difference will
operation begins. be the “temperature rise”.
3. Compare the temperature rise on the heater with the
TABLE - 7A required temperature rise in Table 7B. Should
MAXIMUM WATER FLOW adjustment be needed, proceed as follows:
If the temperature rise is too high, the water velocity is too
CAUTION: The maximum flow rate through a water heater with low. Check the following:
a copper heat exchanger must be set to provide and not exceed the 1. Check for restrictions in the outlet of the water heater.
following flow: 2. Be sure all valves are open between the water heater and
Maximum Flow for
Model Maximum Flow CuNi Heat Exchanger the tank.
497, 647, and 747 55 GPM 75 GPM 3. Check the pump to be sure it is running properly and
that the pump motor is running in the proper direction
987, 1257, 1437, 1797, and 2067 90 GPM 115 GPM (see arrow on volute housing).
4. Be sure the installed circulation pipes between the
The heat exchanger is capable of operating within the design water heater and storage tank are not less than 2 1/2'' in
flow rates required for the water heater, storage tank(s), and diameter on Models 987 - 2067.
connecting piping. Erosion of the finned copper tubes may 5. Common manifold piping for multiple unit installations
occur if the flow rate exceeds the maximum allowable flow will require larger minimum pipe sizes and tank
rate through the water heater. The maximum flow rate circulating tappings to ensure proper flow. See Table
through the water heater must be adjusted. Flow rate can 7C on page 56.
be determined by measuring the temperature rise through
If the temperature rise is too low, the water velocity is too
the water heater when it is firing at full rate input.
high. Adjust as follows:
1. Slowly throttle the valve on the outlet side of the water
heater until the temperature rise is steady at the required
temperature rise as noted in Table 7A.
2. Sustained high water velocity and low temperature rise
may result in pitting or erosion of the copper tubes in the
heat exchanger. This is a non-warrantable failure.
Temperature rise must be properly adjusted to achieve the
specified flow rate.
51

Figure 7-1_Typical water heater piping with storage tank

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
1 60 2 1/2 1 90 2 1/2
MIXING COLD
VALVE WATER
BUILDING SUPPLY
HOT WATER
SUPPLY
RELIEF
VALVE
INLET
Y-STRAINER
RELIEF
VALVE
OUTLET
BUILDING
RETURN
LOCK-TEMP
STORAGE DRAIN
TANK DIR #2000548445 00
NOTICE
52
7 Domestic water heaters (continued)
Figure 7-2_Single water heater piping with two storage tanks

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
1 60 2 1/2 1 90 2 1/2
BUILDING MIXING
HOT WATER VALVE
SUPPLY
COLD
WATER
SUPPLY
INLET
Y-STRAINER
RELIEF
VALVE
OUTLET
LOCK-TEMP DIR #2000548447 00

STORAGE
TANK
DRAIN
BUILDING
RETURN
NOTICE
53

Figure 7-3_Multiple water heater piping with a single storage tank

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
2 120 3 1/2 2 180 4
3 180 4 3 270 5
4 240 5 4 360 6
5 300 5 5 450 6
6 360 6 6 540 6
7 420 6 7 630 8
8 480 6 8 720 8
BUILDING MIXING COLD

HOT VALVE WATER
WATER SUPPLY
SUPPLY
Y-STRAINER
(TYPICAL)
RELIEF
VALVE
LOCK-TEMP MIN 4"

STORAGE COMMON
TANK MANIFOLD
SIZE
DIR #2000548448 00
DRAIN
BUILDING
RETURN
NOTICE
54
Figure 7-4_Multiple water heater piping with multiple storage tanks

Models: 497 - 747 Models: 987 - 2067
Diameter Diameter
(in.) (in.)
2 120 3 1/2 2 180 4
3 180 4 3 270 5
4 240 5 4 360 6
5 300 5 5 450 6
6 360 6 6 540 6
7 420 6 7 630 8
8 480 6 8 720 8
MIXING COLD
VALVE WATER
SUPPLY
BUILDING
HOT Y-STRAINER
WATER (TYPICAL)
SUPPLY
RELIEF
VALVE
MIN 4"
COMMON
LOCK-TEMP
MANIFOLD
STORAGE
SIZE
TANK
DRAIN DIR #2000548449 00
BUILDING
RETURN
NOTICE
55

Required temperature rise Circulating pump
Based on heating potable water with a hardness of 5 to
1. The water heater must be connected to a properly sized
20 grains per gallon and/or total dissolved solids not
pump that circulates water between the heater and
exceeding 350 ppm, see Water Chemistry, this page.
storage tank.
Water chemistry
2. The pump is sized to heater input and water hardness.
The required temperature rise and the standard pump sizing Care should be taken to size the pump correctly. See
are based on the heating of potable water with a hardness Water Chemistry, this page.
of 5 to 20 grains per gallon and a total dissolved solids not
exceeding 350 ppm. Consult the appliance manufacturer 3. The water heater is equipped with a factory-supplied
when heating potable water exceeding these specifications. pump delay system in accordance with the requirements
of the latest edition of ASHRAE 90.1.
Heating of high hardness and/or high total dissolved solids
water will require a larger circulating pump, an optional 4. Lubricate the pump to the manufacturer’s
cupro-nickel heat exchanger and a revised temperature rise recommendations. Pump damage due to inadequate
specification based on the water chemistry of the water to lubrication is non-warrantable.
be heated.
5. Standard water heaters are furnished with the following
Water with a hardness of less than 5 grains per gallon circulating pump. Mount the pump on the unit’s inlet
will usually have a low pH which can be aggressive and water connection.
corrosive causing non-warrantable damage to the heater,
pump and associated piping. Corrosion due to water
chemistry generally shows up first in the hot water system Models 497 - 747
because heated water increases the rate of corrosive chemical 1/4 HP, 120 VAC, 5.8 Amps
reactions. Models 987 - 2067
Pipe size requirements 1/2 HP, 120 VAC, 7.4 Amps
Table 7B, pipe sizing chart provides the minimum pipe size
for common manifold piping to ensure adequate flow. This pump is sized based on installation of a single storage
tank and heater in close proximity. If the number of fittings
and straight pipe exceeds the quantities shown in this section, a
larger pump will be required.
TABLE 7C
Pipe Sizing Chart The standard pump selection is based on the following pipe and
fittings from the unit to the storage tank:
497 - 747 987 - 2067
Number of Common Pipe Number of Common Pipe • 6 90° elbows • 2 ball valves
Units Size (Min.) Units Size (Min.) • 2 unions • 1 cold water tee
1 2'' 1 2 1/2'' • No more than 45
2 3'' 2 4'' feet of straight pipe.
3 3'' 3 4''
For every elbow and tee in excess of those shown
4 4'' 4 5'' NOTICE
above, deduct 5 feet from maximum allowable
5 5'' 5 6'' straight pipe in heater to tank circulating loop.
6 5'' 6 6''
56
Minimum pump performance Potable hot water temperature

This is based on heating potable water with a hardness of control settings
5 to 25 grains per gallon and/or total dissolved solids not
exceeding 350 ppm. See Water Chemistry, page 56. Domestic water temperature
TABLE 7D WARNING You must take adequate care to prevent

Water Heater Pump Applications scald injury when storing water at elevated
Flow Head temperatures for domestic use.
Pipe Water Grundfos Temp.
Model Rate Loss
Size Hardness Pump Rise
(GPM) (FT)
497 2"
5 to 15 gpg TP44PAB 55 10 15°F This unit has an adjustable temperature control to maintain the
15 to 20 gpg UP 43-110 SF 75 10 11°F desired water temperature set point. See Setting Temperature
5 to 15 gpg TP44PAB 55 10 19°F
647 2"
15 to 20 gpg UP 43-110 SF 75 10 14°F
Control, page 41, for instructions to adjust the temperature
5 to 15 gpg TP44PAB 55 10 22°F control. The temperature control is factory preset at
747 2"
15 to 20 gpg UP 43-110 SF 75 10 16°F approximately 125°F (52°C) or less. Households with small
987 2-1/2"
5 to 15 gpg TP24PAB 90 15 18°F children or invalids may require 120°F (49°C) or lower
15 to 20 gpg TP 50-160/2B 115 15 14°F temperature hot water to reduce risk of scald injury.
5 to 15 gpg TP24PAB 90 15 23°F
1257 2-1/2"
15 to 20 gpg TP 50-160/2B 115 15 18°F
1437 2-1/2"
5 to 15 gpg TP24PAB 90 15 26°F Operate this high efficiency hot water heater at a temperature
15 to 20 gpg TP 50-160/2B 115 15 21°F setting high enough to prevent condensing of the products of
5 to 15 gpg TP24PAB 90 15 32°F
1797 2-1/2" combustion on the unit’s heat exchanger or in the attached
15 to 20 gpg TP 50-160/2B 115 15 26°F
2067 2-1/2"
5 to 15 gpg TP24PAB 90 15 37°F venting system. A water temperature setting that is above the
15 to 20 gpg TP 50-160/2B 115 15 30°F dew point of the gas combustion products should prevent
condensate formation
Heat exchanger
WARNING To guard against scald injury, you must use a
On all models, header inspection plugs can be removed for properly sized thermostatic mixing valve to
field inspection and cleaning of copper tubes. The entire supply domestic hot water at temperatures
heat exchanger may be easily removed from the unit. less than 125°F (52°C).
WARNING Return water temperatures must not be less

than 140°F (60°C). If lower return water
temperatures are required, follow the
instructions for Low Temperature Return
Water Systems, page 32.
57

Storing the water at a higher temperature and thermostatically The High-Fire stage will be delayed by
NOTICE
mixing the water increases the available quantity of mixed hot approximately 10 seconds to allow a
water, greatly reducing the possibility of condensate forming soft start of the water heater.
on the heat exchanger or in the venting system and helps
prevent water born bacteria growth. When water is stored at temperatures
WARNING
above 125°F (52°C), a thermostatic
Some states may require a lower water temperature setting for mixing valve must be installed on the
specific applications. Check local codes or your gas supplier for hot water outlet from the storage tank
domestic hot water temperature requirements. to supply lower temperature water and
prevent the risk of a scald injury.
This water heater, when set at a lower
NOTICE temperature setting, is not capable
of producing hot water of sufficient
• Water temperature over 125°F (52°C)
can cause severe burns instantly or temperature for sanitizing purposes.
death from scalds.
• Children, disabled and elderly are
at highest risk of being scalded. Location of cold water supply piping
connections
• See instruction manual before
setting temperature at heating
appliance.
• Feel water before bathing or showering.
• If this appliance is used to produce Incorrect piping of the cold water supply to the system
water that could scald if too hot, may result in excessive low temperature operation
such as domestic hot water use,
adjust the outlet control (limit) or use causing condensate formation on the heat exchanger and
temperature limiting valves to obtain
a maximum water temperature of
operational problems. You must install the cold water
125°F (52°C). supply piping in the discharge piping from the heater to
the storage tank. This allows the cold water to be tempered
in the storage tank before entering the heater. See FIG.
Remember, no water heating system provides exact temperatures 7-1, on page 52, and typical installation drawings provided
at all times. Let the system operate a few days at your desired with the unit for correct piping. Higher water temperatures
settings to determine correct settings for your needs. reduce condensate formation.
1. These units are equipped with an operating temperature Should overheating occur or the gas
control. WARNING
supply fail to shut off, do not turn off
or disconnect the electrical supply to
2. The control set points are preset to a low test setting when the pump. Instead, shut off the gas
shipped from the factory. supply at a location external to the
unit.
3. Reset the temperature set points to the lowest settings which
will satisfy hot water demands, eliminate a possible
condensate problem and prevent a risk of scald injury.
4. The High-Fire Offset should normally be adjusted to “0”

when supplying potable hot water for domestic use.
5. Stage firing can be achieved by adjusting the High-Fire

Offset to any value other than zero. Typically, a setting of
3°F is 5°F is suitable for stage firing in a water heater
application. Stage firing of a potable water heater is
normally only used to replace system standby heat loss.
6. All stages of burner operation should fire when there is a

major draw from the potable hot water storage system.
This prevents possible condensate problems and ensures a
rapid recovery of the hot water used.
58
High water temperature limit control

The unit is equipped with an adjustable setting, auto-reset
high water temperature limit control. The hot water heater
temperature limit control has a maximum limit setting of
200°F (93°C). If water temperature exceeds the set point,
the limit will break the control circuit and shut down the
unit. The limit control will only be reset after the water
temperature has cooled below the set point of the limit.
The high water temperature limit control is mounted in
the outlet side of the front header. A manual reset high
water temperature limit control is available as an optional
control.
Optional relief valve

This water heater is normally supplied with a temperature
and pressure relief valve(s) sized in accordance with
applicable codes. Units may be supplied with an optional
pressure only relief valve(s). When a water heater equipped
with this optional relief valve is piped to a separate storage
vessel, the storage vessel MUST have a properly installed
temperature and pressure relief valve which complies with
local codes.
Thermal expansion
A relief valve which discharges periodically may be due
to thermal expansion in a closed system. A hot water
supply boiler installed in a closed system, such as one with
a backflow preventer or check valve installed in the cold
water supply, shall be provided with means to control
expansion. Contact the water supplier or local plumbing
inspector on how to correct this situation. Do not plug or
cap the relief valve discharge!
Cathodic protection
Hydrogen gas, which is extremely flammable, can be
produced in a hot water system that has been unused for
a long period of time (generally two weeks or more). To
prevent the possibility of injury under these conditions,
open the kitchen sink hot water faucet for several minutes
before using any electrical appliance connected to the
hot water system. If hydrogen is present, there will be an
unusual sound such as air escaping through the pipe as the
hot water begins to flow. Do not smoke or have open flames
near the faucet at this time.
59
8 Maintenance
Listed below are items that must be checked to ensure safe, Lifting Flames: The usual causes for lifting flames are over
reliable operations. Verify proper installation after servicing. firing the burner(s), excessive primary air, or high draft.
Label all wires prior to disconnection when If you observe improper flame patterns, examine the venting
CAUTION
servicing controls. Wiring errors can cause system, ensure proper gas supply, and ensure adequate supply
improper and dangerous operation. of combustion and ventilation air.
Appliance area
Flue gas passageways cleaning procedure
Keep appliance area clear and free from combustible materials,
Any sign of soot around the outer jacket, at the burners or in the
gasoline and other flammable vapors and liquids.
areas between the fins on the copper heat exchanger indicates
Water circulating pump a need for cleaning. The following cleaning procedures must
Inspect pump every six months and oil as necessary. Use SAE 30 only be performed by a qualified serviceman or installer. Proper
non-detergent oil or lubricant specified by pump manufacturer. service is required to maintain safe operation. Properly installed
and adjusted units seldom need flue cleaning.
Burner flames
All gaskets on disassembled components must
Visually check main burner flames at each start up after long NOTICE be replaced with new gaskets on reassembly.
shutdown periods or at least every six months. Burner viewports Gasket kits are available from your distributor.
are located on the right and left sides of the unit.
Check fill water meter Burner removal and cleaning
Check fill water meter for water usage. If the amount exceeds 1. Turn off main power to unit.
5% of your system volume, you could have a leak. Have
2. Turn off main manual gas shutoff to unit.
the system checked for leaks and fixed by a qualified service
technician. 3. Remove the front outer jacket panels.
Test boiler water 4. Disconnect manifold from gas train using union(s) just
below each gas valve(s).
Test boiler water. Reference the Copper-Fin Installation and
Operation Manual for guidelines. When test indicates, clean 5. Remove mounting screws from manifold mounting
system water with approved system restorer following the brackets. Pull the manifold/orifice assembly away from
manufacturer's information. burners. Repeat for each manifold assembly.
6. Remove two mounting screws from burner and slide
Figure 8-1_Flame patterns burner out toward front of unit. Use caution to prevent
WARNING: The area around the burners is hot and direct contact could result in burns! damage to burners, refractory, hot surface igniter or wiring.
NORMAL YELLOW TIP
7. Remove soot from burners with a stiff bristle brush.
Dirt may be removed from burner ports by rinsing the
A B burner thoroughly with water. Drain and dry burners
before re-installing. Damaged burners must be replaced.
When installed in a dusty and dirty location, the burners may

C D require cleaning on a 3 to 6 month schedule or as needed,
YELLOW FLAME FLAME LIFT
based on severity of contamination. Contaminants can be
The areas around the burner viewports drawn in with the combustion air. Non combustible particulate
WARNING matter such as dust, dirt, concrete dust or dry wall dust can
are hot. Direct contact with the unit could
result in burns. block burner ports and cause non-warrantable failure. The
standard inlet air filter will help eliminate dust and dirt from
Normal Flame: A normal flame is blue with slight yellow tips, entering the unit. Use extreme care when operating a unit for
has a well-defined inner cone, and displays no lifting flames. temporary heat during new construction. The burners could
require a thorough cleaning before the unit is placed in service.
Yellow Tips: The usual causes for yellow tips on the burner
flame are burner air flow blockage or partial obstruction.
Yellow Flames: The usual causes for yellow flames are primary
air flow blockage to the burner(s) or excessive gas input. Correct
this condition immediately.
60
8 Maintenance (continued)
Heat exchanger cleaning Combustion and ventilation air

1. While burners are removed, check the heat exchanger Combustion air filter
surface for sooting. If present, heat exchanger must be
cleaned and problem corrected. Proceed as follows. See Combustion Air Filter, page 13.
2. Remove gas manifold(s)/orifice assemblies as described Air flow

in steps 1 through 5 in Burner Removal and Cleaning,
Check frequently to be sure the flow of combustion and
page 60.
ventilation air to the unit is not obstructed.
3. Disconnect wiring from the hot surface igniter and
hose from the burner pressure tap. Combustion air fan
4. Remove inner jacket panel mounting screws and slide These units use a fan-assisted combustion process. These units
door assembly out toward front of the unit. Use have one fan to supply combustion air to the burners.
caution to prevent damage to the refractory and hot
surface igniter. Fan cleaning
5. Check “V” baffles and frame runners along front Check combustion air fan every six months. Clean fan as
and back edges of heat exchanger. Remove and clean if required only when installed in a dusty or dirty location. Oiling
necessary. is not required.
6. Remove soot from heat exchanger with a stiff bristle Combustion air fan adjustment
brush. Use a vacuum to remove loose soot from The combustion air fan is factory preset and should not need
surfaces and inner chamber. adjustment in most cases. Follow the steps below to adjust the
7. The heat exchanger can be removed by sliding towards fan if a continuous Low Air Status Code occurs.
the front of the unit. Once the heat exchanger is Check for proper installation and draft in the venting system.
removed from the unit, a garden hose can be used Correct as required.
to wash the tubes to ensure that all soot is removed
from the heat exchanger surfaces. Note: Do not wet the Adjusting air pressure
unit’s refractory. The following is a recommended method for setting the air
8. Ensure that all burner ports are cleaned to remove any pressure for the fan.
soot. See Burner Removal and Cleaning, page 60.
Setup procedure
9. Carefully reinstall the heat exchanger, “V” baffles, and
frame runners if removed from the unit. Note: Make To the left of the fan is an air pressure switch with a large and
sure frame runners seal securely where they contact the small tube delivering pressure from points inside the unit
front and rear compartment refractory. (see FIG. 8-2). The pressure in the large tube is the chamber
10. Carefully reinstall inner jacket panels, burners, pressure. By disconnecting the cap from the tee in the hose and
manifolds, wires and hoses. Use new gasket material to connecting it to the "(+)" side of a manometer, you can read the
ensure a proper air seal. air chamber pressure.
11. Reassemble all gas and water piping. Test for gas leaks. Upon a call for heat, the fan will run for about 90 seconds
12. Reassemble outer jacket panels. before going into soft lockout. If necessary, turn the power to
the unit OFF and then back ON again to recycle the fan.
13. Cycle unit and check for proper operation.
Note: If the unit has been firing recently, allow the unit to
Electrical cool for five minutes with the fan running before
beginning the adjustment procedure.
This unit uses a transformer to supply a low voltage control
circuit. The voltage on the secondary side should be 24 to Note: Retain the plastic cap removed from the tee for
28VAC when measured with a volt meter. Larger models reinstallation when complete.
have a 7AMP circuit breaker provided on the secondary
side of the transformer. A tripped circuit breaker indicates
a short in the 24VAC controls that must be corrected.
61
8 Maintenance
4. Adjust the air shutter until the air chamber pressure is
Figure 8-2_Air pressure switch nominally 1.35 - 1.45 inches water column. See FIG. 8-4
for installations up to 2000 feet altitude. Contact the
factory for high altitude settings.
5. Once the adjustment procedure is complete, reattach the

cap to the tee in the hose and check all tubing and wire
connections for a snug fit. Test fire the unit. Reinstall upper
panels.
Figure 8-3_Adjusting air shutter
AIR PRESSURE SWITCH
Adjustment procedure Models 497 - 1257:

1. Remove the upper front jacket panels from the unit to
access the upper chamber.
2. Locate the air shutter on the side of the fan housing

(see FIG. 8-3). Turn the adjustment screw on the air TURN THE ADJUSTMENT
SCREW ON THE AIR
shutter to open or close the shutter. Increase air shutter SHUTTER TO OPEN OR
opening to increase air pressure. Decrease air shutter CLOSE THE SHUTTER
opening to decrease air pressure.
3. Adjust the air shutter until the air chamber pressure is Figure 8-4_Combustion air adjustment with manometer
nominally 1.25 - 1.30 inches water column for Models to set differential pressures
497 - 747 and 1.35 - 1.45 inches water column for Models
987 - 1257. See FIG. 8-4 on installations up to 2000 feet
altitude. Contact the factory for high altitude pressure
settings.
4. Once the adjustment procedure is complete, reconnect

the cap to the tee in the hose and check all tubing and wire
connections for a snug fit. Test fire the unit. Reinstall upper
panels.
Adjustment procedure: Models 1437, 1797 and 2067

1. Remove the upper front jacket panels from the unit to
access the upper chamber.
2. Slightly loosen the screws that attach the fan transition box
to the metal base (see FIG. 8-5).
3. Locate the air shutter at the rear of the fan duct (see
FIG. 8-6). Move the air shutter towards the rear of the
unit to increase air pressure. Move the air shutter towards
the front of the unit to decrease air pressure.
62
8 Maintenance (continued)
Figure 8-5_Loosening the transition box screws, Ignition system checkout

Models 1437, 1797 and 2067 only 1. Turn off gas supply to unit.
2. Turn electric power on.
3. Adjust the set point on the temperature control to a
setting above water temperature or to the highest safe
setting.
4. The igniter will cycle on trial for ignition.
5. The ignition module will lock out and turn the alarm
light on.
6. Adjust the Set Point Differential and High-Fire Offset to
the desired settings.
7. Turn on gas supply.
8. Press the module reset button to reset the ignition
TRANSITION BOX SCREWS module. This is a red button beside the ignition module
or on the diagnostic panel on the header-end of the unit.
9. If ignition system fails to operate properly, repair work
Figure 8-6_Adjusting the air shutter
must be performed by a qualified service person or
installer.
Sequence of operation
DECREASE
AIR PRESSURE
Overview
This sequence of operation can be considered the order of
events in sequential order that occur after the appliance has
received a call for heat. The process begins with 120VAC
power entering the appliance and ends with the appliance
going into an idle state after completion of a successful call
for heat.
Note: The following descriptions do not include
remotely connected devices that may be
INCREASE AIR
PRESSURE connected to the appliance. Refer to the wiring
diagram for actual point to point wiring
Servicing a hot surface igniter and connections that show power delivery.
ignition module 1. The POWER switch is placed in the “ON” position.
This unit uses a proven hot surface ignition module and a 2. 120VAC power is supplied to the control transformer along
hot surface igniter. The hot surface ignition module is not with L1 and F1 on the ignition module.
repairable. Any modification or repairs will invalidate the
warranty. 3. 24VAC is supplied to the electronic temperature control,
Do not attempt to repair a faulty hot the ignition module and the adjustable high limit control.
WARNING
surface igniter or ignition module. Any
4. 24VAC is then supplied to the auxiliary limit control
modification or repairs may create
(if equipped).
hazardous conditions that result in
property damage, personal injury, fire, 5. If equipped, 24VAC is supplied to a low water cut-off and
explosion and/or toxic gases. then to the high and low gas pressure switches.
A faulty hot surface igniter or ignition module must be
6. 24VAC is supplied to the continuous alarm terminals A1
replaced with an identical part. A specification igniter
and A2 and then to the remote stage one terminal strip,
and ignition module for this specific unit is available from
1C and 1NO.
your local distributor. Do not use general purpose field
replacement ignition modules or igniters. 7. 24VAC is supplied to the electronic temperature control.
8. The electronic temperature control then calls for heat.

63
8 Maintenance
9. 24VAC is supplied to the intermittent alarm field safety Heat transfer process
contacts, B1 and B2.
28. Heated products of combustion pass over the heat
10. 24VAC is supplied to the water flow switch. exchanger transferring heat to the water.
11. 24VAC is supplied to the TH terminals on the ignition 29. The rate of flue product movement is controlled
module. by “V” baffles on the heat exchanger to maximize heat
transfer.
12. As power is applied to the TH terminals on the ignition
module, 120VAC is switched from the F2 terminal to start 30. Flue products pass into the flue collector and are
the combustion air fan at full speed on Models 497 - 747 exhausted from the unit.
and at low speed on Models 987 - 2067.
End of sequence
13. 24VAC is supplied to the C terminal of the air pressure
switch. As the low air switch makes, power is supplied to 31. Set point for the high fire on the electronic temperature
the ignition module. control is satisfied.
14. 24VAC is then supplied to the PS terminals on the ignition 32. Power to all valves is turned OFF on F9 systems and
module as the air pressure switch makes to prove fan power to the high fire gas valves is turned OFF on M9
operation. systems.
15. The combustion air fan operates for the pre-purge period. 33. The water temperature continues to rise and the set
point for low fire is satisfied (M9).
16. At the end of the pre-purge, 120VAC is applied to the hot
surface igniter and the trial for ignition light. 34. Power to the low fire gas valves is turned OFF (M9).
17. The hot surface igniter proves 1800°F (982°C) ignition 35. The combustion air fan runs for a post purge period and
temperature by current draw through the ignition module. turns OFF.
18. The ignition module supplies voltage to the MV terminals 36. The appliance is now in a Standby Mode waiting for
on to the gas valve(s). the next “call for heat”.
19. The first stage gas valve(s) opens and supplies gas to the
orifice and burner inlet to pre-mix.
20. The gas/air mixture is forced into the burner and out of the
burner ports under pressure.
21. The hot surface igniter lights the gas/air mixture and
then serves as a flame sensor to prove main burner flame by
rectification.
22. Burners are now firing for approximately 50% of the

heater’s input.
23. 24VAC is supplied from the second stage of the electronic

temperature control across the 2C and 2NO terminals on
the terminal strip on to a control to a relay.
24. The control relay switches the fan on Models 987 -

2067 to high speed and energizes the gas valves for the
remaining 50% of burner input.
25. The remaining gas valves open and supply gas to the
orifice inlet to pre-mix.
26. The gas/air mixture is forced out of the burner ports

and light by carryover from the burners currently
firing.
27. The heater is now firing at full rated input.
64
9 Glossary
Power Supply Safety Device Terminals
(AC120VAC/60Hz) The safety device terminals ensure that no power can be
120VAC/60Hz/1PH power connects to black (line) and white delivered to the ignition module unless factory/field-installed
(neutral) wires located within an electrical wiring box located safety devices such as flow switches and gas pressure switches
on the left side of the unit. A green chassis grounding wire is are closed. These safety device terminals are located below the
also provided for connection to earth ground. EMS/Sequencer/Remote Aquastat terminals located within the
electrical wiring box. Two types of connections are offered:
ON/OFF Rocker Switch Continuous terminals provide for connection of safety devices
The black line voltage wire runs directly to a single pole, single that are desired to be constantly monitored. Intermittent
throw On/Off rocker switch located behind the front cover terminals are provided for devices that are only monitored
accessible by a thumb screw. Turning ON the rocker switch during a “call for heat” cycle. Connection to either of these
delivers line voltage to the low voltage transformer and ignition terminals requires the removal of a factory-installed jumper
module. located on the terminal strip.
Note: The On/Off switch does not provide for disconnection Electronic Temperature Controller (Operator)
of power being supplied to any remotely connected A 2-stage electronic temperature controller is provided on the
devices that may be connected to the unit (i.e. pumps, unit and it serves to maintain a user selectable temperature set
louvers, power venters, etc.,). As such, it may be point. Ultimately, the temperature controller delivers 24VAC
necessary to locate and turn off power to these items to the ignition module and pressure switch when it senses heat
before attempting to service the unit. mode is desired. It also activates the pump relay. If more heat is
needed, it activates the high fire stage.
Low Voltage Supply Transformer
A 120VAC to 24VAC transformer located within the control Ignition Module
panel provides 24VAC/60Hz to many of the components located (Controlled by Electronic Temperature Controller)
on the unit. One of its 24VAC outputs (blue) is connected to a One ignition module is provided on the unit. Upon sensing the
circuit breaker and the other (yellow) is connected to chassis 24VAC delivered to it by the electronic temperature controller,
ground. the ignition module checks for a shorted pressure switch and
then, provided the air switch isn’t shorted, supplies 120VAC to
24VAC Circuit Breaker its blower output relay and waits for a pressure switch signal.
A circuit breaker is provided on Models 987 - 2067 for protection
of the low voltage supply transformer from overloads and short Two Speed Blower
circuits. The breaker is located inside the unit on the lower right (Controlled by Ignition Module and Relay Board)
corner of the control panel. Power from this breaker goes to the A single 2-speed blower on Models 987 - 2067 (single 1-speed
electronic temperature controller, ignition module and various blower on Models 497 - 747) provide combustion air to the
other components and/or options on the unit. When tripped, unit. The blower is provided with a high and low speed tap.
all factory-installed 24VAC components will lose their 24VAC The blower operates in tandem with the ignition module when
power. a call for heat signal is received. Depending upon the number of
Manual Reset High-Limit Thermostat stages in operation, the blower’s speed may increase or decrease
accordingly.
A manual reset high limit thermostat is provided as backup for
the temperature controller. This will be an adjustable dial bulb- Pressure Switch
capillary style thermostat that will trip and require resetting (Activated by Blower Turning On)
should water temperature exceed its settings. When tripped, all
controls remain powered, but 24VAC is prevented from being One pressure switch is provided to monitor the blower On/
delivered to the ignition module’s thermostat input. Off operation. Upon a call for heat, 24VAC is delivered to the
pressure switch. If the blower generates adequate air pressure,
EMS/Sequencer/Remote Aquastat Terminals the pressure switch closes to deliver 24VAC to the ignition
The EMS/sequencer/remote aquastat terminals are provided module pressure switch monitoring input terminal.
for connection of the unit to an external energy management Prepurge
system or sequencer and are located along the top edge of
the terminal strip located within the electrical wiring box. (Ignition Module Function)
In addition to providing a means to externally stage fire the
unit, these terminals also provide for remote shutdown and
override by routing through dry contacts from external devices.
Connection of the external dry contacts to these terminals
requires the removal of one or more factory installed jumpers
located on the terminal strip.
65
9 Glossary
Once the ignition module sees a 24VAC input from the Post-Purge
pressure switch, it runs the blower in order to purge the (Ignition Module Function)
combustion chamber of any unburned fuel/air mixture.
When 24VAC is removed from the ignition module’s thermostat
Trial for Ignition input, the module turns off the gas valves and maintains the
(Ignition Module Function) blower in order to allow the combustion chamber to be purged
of all combustion by-products.
Once the ignition module has completed its prepurge
period, it turns on the hot surface igniter. Once the hot Pump Delay
surface igniter’s current draw reaches a proper level, the (Electronic Thermostat Function)
ignition module begins a trial for ignition period to allow
time for the igniter to reach the ignition temperature When the electronic thermostat removes 24VAC from the
necessary to ignite the fuel/air mixture. ignition module, it continues to hold the pump relay on in order
to get the remaining heat out of the combustion chamber. The
Igniter pump then turns off to prevent the heat in the water from going
(Controlled by Ignition Module) back into the combustion chamber and up the flue.
One igniter is provided in order to ignite the fuel/air Idle

mixture and its on/off operation is controlled by the (Electronic Thermostat Function)
ignition module.
After completion of the post-purge cycle, the unit will go into
Hi-Lo Fire Relay an idle state whereby the electronic thermostat continuously
The relay serves as means to switch from low fire to high monitors the water temperature until the water temperature
fire. On Models 987 - 2067, in addition to switching drops to levels that require additional heat.
between high fire to low fire, the relay also changes the fan
speed from high for high fire to low for low fire.
Ignition
(Ignition Module Function)
Once the trial for ignition period has been completed, the
ignition module sends 24VAC to the gas valves on the low
fire stage (Stage 1). Gas valves should open and allow gas
to flow to the burners in Stage 1 being energized. The fuel/
air mixture should ignite from the hot surface igniter. Once
this voltage has been sent to the valves, the hot surface
igniter is turned off. The ignition module then monitors the
status of the flame and will either allow ignition to continue
or shut down the gas valves should flame not be proven and
proceed to a Flame Failure condition. If flame was proven
briefly during the ignition period, the module may not
proceed to Flame Failure, but rather post-purge and then
go into another trial for ignition.
Heat Transfer Process

(Gas Valves, Burner, and Heat Exchanger)
Once flame has been proven, the ignition module will hold
the gas valves open as long as there is proof of flame and a
call for heat is present. If the low fire stage cannot provide
enough heat to raise the system temperature, the electronic
temperature controller turns on the high fire stage. The high
fire stage will operate until the system water temperature
shows a gain that can be handled by low fire operation.
The high fire stage shuts off at this point. When the low-
fire stage alone produces more heat than is required, the
electronic temperature controller turns off the call for heat.
66
Notes
67
10 Diagrams
Ladder diagram
68
10 Diagrams (continued)
Ladder diagram (continued)
0987-2067 0497-747
69
10 Diagrams
Connection diagram
70
10 Diagrams (continued)
Connection diagram (continued)
71
Revision Notes: Revision A (ECO #C07390) initial release.
Revision B (ECO C09691) reflects the update of AHRI and
ASME logos on pages 8 and 9.
Revision C (ECO C12077) reflects the update of ignition timing
information on pages 40, 43, 61 and 63 as well as the update
of heat exchanger information on page54.
Revision D (ECO C12972) reflects the addition of the CSA
Low Lead Content logo.
Revision E (ECO C13163) reflects the addition of the Line
Voltage Connections section on page 38 per ECR R06420.
Revision F (ECO C16918) reflects the update of water volume
in the ratings tables on pages 8 and 9 and the correction of
Table 3D on page 24 for gas pipe sizing (R07763).
Revision G (PCP# 3000002766 / CN# 500003005) reflects a
correction to images 7-1 through 7-4 on pages 49 through 52.
SAP Numbers have been updated.
Revision H (PCP# 3000006579 / CN# 500006677) reflects
the addition of new venting category information on pages 20
through 21.
Revision J (PCP #3000021634 / CN #500011858) reflects
changes made to water chemistry information on pages 4, 29,
33-37, 48-54, 56-57, and 60.
CBX-CWX-I-S_MM# 100160893_DIR# 2000001309_Rev J
01/18

Installation & Service Manual Models: 497 - 2067: - What To Do If You Smell Gas

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CBX-CWX-I-S_100160893_2000001309_Rev J

Installation & Service Manual

WARNING: If the information in

-- This water heater MUST NOT be installed

-- WHAT TO DO IF YOU SMELL GAS

This manual supplies information for the

Please read before proceeding

Please read before proceeding

The Copper-fin - How it works...

The Copper-fin - How it works...

The Copper-fin - How it works... (continued)

Models 987 - 2067 Rear View

Copper-fin Other Specifications

Net Vent Size

CBN497 250 495 401 349 1.9 2" 1 1/4" 6"

CBN647 350 645 522 454 2.0 2" 1 1/4" 8"

CBN747 350 745 603 524 2.4 2" 1 1/4" 8"

CBN987 360 985 798 694 3.3 2 1/2" 2" 10"

CBN1257 720 1255 1017 884 3.5 2 1/2" 2" 12"

CBN1437 720 1435 1162 1010 3.7 2 1/2" 2" 12"

CBN1797 720 1797 1454 1264 4.1 2 1/2" 2" 14"

CBN2067 990 2065 1673 1455 4.3 2 1/2" 2" 14"

NOTICE Maximum allowed working pressure is located on the rating plate.

1. The ratings are based on standard test procedures HIGH ALTIT

2. Net AHRI ratings are based on net installed radiation of

3. Copper-fins require special gas venting. Use only the vent

4. The Copper-fin is orificed for operation up to 2000

LOW LEAD CONTENT HLW

CWN497 495 1.9 2" 1 1/4" 6"

CWN647 645 2.0 2" 1 1/4" 8"

CWN747 745 2.4 2" 1 1/4" 8"

CWN987 985 3.3 2 1/2" 2" 10"

CWN1257 1255 3.5 2 1/2" 2" 12"

CWN1437 1435 3.7 2 1/2" 2" 12"

CWN1797 1795 4.1 2 1/2" 2" 14"

CWN2067 2065 4.3 2 1/2" 2" 14"

NOTICE Maximum allowed working pressure is located on the rating plate.

1. Copper-fins require special gas venting. Use only

2. The Copper-fin is orificed for operation up to 2000

Figure B High altitude label location_water heater

1 Determine unit location

1 Determine unit location (continued)

TABLE 1A Outdoor boiler installation

647 100136978 Shut-down and draining

A mechanical room operating under a negative

1 Determine unit location

5. Local codes may require a back flow preventer or

987 248 248 330 495 495 990 990

1257 315 315 420 630 630 1260 1260

1 Determine unit location (continued)

Combustion air filter

1 Determine unit location

Figure 1-5_Outside combustion air single opening

2. Outside Combustion Air, Using Ducts

Figure 1-7_Outside combustion air, using ducts

1 Determine unit location (continued)

3. Combustion Air from an Interior Space Exhaust Fans

All dimensions are based on net free area in square inches.