Laars MagnaTherm MGH1600 Installation And Operation Instructions Manual

Laars MagnaTherm MGH1600 Installation And Operation Instructions Manual

Modulating boiler & water heater
Table of Contents

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Installation and Operation Instructions
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler and heater installation and maintenance. Improper installation and/or operation
could create carbon monoxide gas in flue gases which could cause serious injury, property damage, or
death. Improper installation and/or operation will void the warranty.
If the information in these instructions is
not followed exactly, a fire or explosion
may result causing property damage,
personal injury or death.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from
a neighbor's 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 gas
supplier.
Installation and
Operation Instructions for
M
Modulating Boiler
Model MGH1600
1,600 MBTU/h
Model MGH2000
1,999 MBTU/h
Model MGH2500
2,499 MBTU/h
Model MGH3000
3,000 MBTU/h
Model MGH3500
3,500 MBTU/h
Model MGH4000
4,000 MBTU/h
WARNING
T
AGNA
HERM
Water Heater
Model MGV1600
1,600 MBTU/h
Model MGV2000
1,999 MBTU/h
Model MGV2500
2,499 MBTU/h
Model MGV3000
3,000 MBTU/h
Model MGV3500
3,500 MBTU/h
Model MGV4000
4,000 MBTU/h
Assurez-vous de bien suivres les instructions
données dans cette notice pour réduire au
minimum le risque d'incendie ou d'explosion ou
pour éviter tout dommage matériel, toute blessure
ou la mort.
Ne pas entreposer ni utiliser d'essence ou ni
d'autres vapeurs ou liquides inflammables dans
le à proximité de cet appareil ou de tout autre
appareil.
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
• Ne pas tenter d'allumer d'appareils.
• Ne touchez à aucun interrupteur. Ne pas vous servir
des téléphones dans le bâtiment où vous vous trovez.
• Appelez immédiatement votre fournisseur de
gaz depuis un voisin. Suivez les instructions du
fournisseur.
• Si vous ne pouvez rejoindre le fournisseur de
gaz, appelez le sservice des incendies.
L'installation et l'entretien doivent être assurés par
un installateur ou un service d'entretien qualifié ou
par le fournisseur de gaz.
Document 1276D
®
AVERTISSEMENT

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Summary of Contents for Laars MagnaTherm MGH1600

  • Page 1 Installation and Operation Instructions Document 1276D Installation and Operation Instructions for AGNA HERM ® Modulating Boiler Water Heater Model MGH1600 Model MGV1600 1,600 MBTU/h 1,600 MBTU/h Model MGH2000 Model MGV2000 1,999 MBTU/h 1,999 MBTU/h Model MGH2500 Model MGV2500 2,499 MBTU/h 2,499 MBTU/h Model MGH3000 Model MGV3000...
  • Page 2: Table Of Contents

    LAARS Heating Systems Table of Contents Section 6 – WATER CONNECTIONS, MGH Section 1 - GENERAL INFORMATION MGH System Piping: Hot Supply Introduction ............1 Connections ............ 19 Safety Notes ............. 1 MGH Cold Water Make-Up ......19 1.3 Model Nomenclature / Identification ....2 MGH Freeze Protection........19...
  • Page 3 MagnaTherm Boilers and Water Heaters Section 11 – MAINTENANCE Section 9 – NAVIGATING THE TOUCH SCREEN 11.1 System Maintenance........70 The Touch Screen ..........46 11.2 Maintenance Notes .........70 Using the Touch Screen ........46 9.3 Verification Process for Safety-Related 11.2.1 Burner ............. 70 Parameters ............48 11.2.2 Modulating Gas Valve/ Venturi ......70 While Operating - Checking Individual 11.2.3 Controller ............71...
  • Page 4 LAARS Heating Systems...
  • Page 5: Section 1 - General Information

    Please read this manual completely before proceeding with the installation. If you have any questions regarding this equipment, please consult the LAARS Heating Systems factory, or a local factory representative. Many operating problems are caused by improper installation. Touch...
  • Page 6: Model Nomenclature / Identification

    MagnaTherm units must be installed in X - “H” STAMP (MGH) accordance with the procedures detailed in this W - “HLW” STAMP (MGV) manual, or the LAARS Heating Systems warranty (13) Revision will be voided. The installation must conform to 1 = First...
  • Page 7: Unit Overviews ( All Sizes )

    MagnaTherm Boilers and Water Heaters Page 3 Unit Overviews The next 3 pages give a visual reference to the basic component locations of the LAARS MagnaTherm. Blower Manual gas valve Touch Screen Heat Exchanger Condensing Unit Power Pack Air Intake and...
  • Page 8 Page 4 LAARS Heating Systems Blower Manual gas valve Touch Screen Heat Exchanger Condensing Unit Air Intake and Filter Power Pack Water Outlet Water Inlet Vent Condensate Trap Models 2500 and 3000...
  • Page 9 MagnaTherm Boilers and Water Heaters Page 5 Blower Manual gas valve (hidden behind main gas valve) Touch Screen Heat Exchanger Condensing Unit Air Intake and Filter Water Outlet Power Pack Water Inlet Vent Condensate Trap Models 3500 and 4000...
  • Page 10: Dimensions

    Page 6 LAARS Heating Systems Dimensions Model Inches (cm ) Inches (cm ) 1600 29.3 (75 ) 79.8 (203 ) 38 (96 ) 57.5 (147 ) 49.8 (126 ) 4.8 (12 ) 60.8 (154 ) 2.6 (7 ) 8.4 (21 ) 68.4 (1...
  • Page 11: Unpacking

    MagnaTherm Boilers and Water Heaters Page 7 Unpacking Note - When located on the same wall, the MagnaTherm combustion air intake terminal must be The MagnaTherm is shipped in a single crate. installed a minimum of 12” ( below the exhaust 30cm) Remove all packing and tie-down materials.
  • Page 12: Section 3 - Venting And Combustion Air

    Page 8 LAARS Heating Systems Section 3 VENTING AND COMBUSTION AIR Combustion Air MagnaTherm boilers and water heaters must have commencing within 12” (300 mm) of the top and provisions for combustion and ventilation air in one commencing within 12” (300 mm) of the accordance with the applicable requirements for bottom, of the enclosure shall be provided.
  • Page 13: Ducted Combustion Air

    The combustion air can be taken through the wall, or including but not limited to, ANSI Z223.1/NFPA 54, through the roof. LAARS offers accessories to use CSA B149.1, CSAB149.2 and ULC S636. Failure with ducted air systems, as shown in Table 3.
  • Page 14: Common Venting

    (1.5m). LAARS offers accessories to use with supplier’s recommended installation techniques. horizontal and vertical exhaust vent systems, as If these are not available, refer to the LAARS shown in Table 5 recommendations for the material used. (Place in section 3.1) NOTE: For Category IV boilers, have horizontal 3.2.1...
  • Page 15: Locating The Vent And Combustion Air Terminals

    Locate the vent terminal so that vent gases An exhaust vent terminal must be installed. If an cannot enter the building through doors, exhaust vent terminal is not available with the windows, gravity inlets or other openings. certified vent system, LAARS suggests the use of...
  • Page 16 Page 12 LAARS Heating Systems U.S. Installations (see note 1) Canadian Installations (see note 2) A= Clearance above grade, veranda, porch, 12 inches (30 cm) 12 inches (30 cm) deck, or balcony See note 6 See note 6 B= Clearance to window or door that may be Direct vent only: 12 inches (30 cm);...
  • Page 17: Side Wall Combustion Air Terminal

    MagnaTherm Boilers and Water Heaters Page 13 to damage by accident or vandalism. It must be at least 7 feet ( 2.1 m) above a public walkway. Locate the combustion air terminal so that it cannot be blocked by snow. The National Fuel Gas Code requires that it be at least 12 inches (30 cm) above grade, but the installer may determine it should be higher, depending upon...
  • Page 18: Vertical Vent Terminal

    Page 14 LAARS Heating Systems 3.3.4 Vertical Combustion Air Terminal When combustion air is taken from the roof, a field- supplied rain cap or an elbow arrangement must be used to prevent entry of rain water. The opening on the end of the terminal must be at least 12” (30 cm)
  • Page 19: Common Vent Test

    MagnaTherm Boilers and Water Heaters Page 15 When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. Au moment du retrait d’une chaudiére existante, les At the time of removal of an existing boiler, the mesures suivantes doivent être prises pour chaque following steps shall be followed with each appliance...
  • Page 20: Outdoor Installation

    Page 16 LAARS Heating Systems (Place in section 3.5) Model 1600 Model 2000 Model 2500 Model 3000 Model 3500 Model 4000 Air intake screen for unit placed outdoors CA0011904 CA011901 CA011901 CA011902 CA0011903 CA0011903 Vent terminal for unit placed outdoors...
  • Page 21 Actual ID: 2.067 2.469 3.068 4.026 5.047 Length (ft) Capacity in Cubic Feet of Gas per Hour 4,020 6,400 11,300 23,100 41,800 MagnaTherm Boilers and Water Heaters Page 17 2,760 4,400 7,780 15,900 28,700 2,220 3,530 6,250 12,700 23,000 1,900 3,020 5,350 10,900...
  • Page 22: Magnatherm Boiler Flow And Head Requirements

    4000 34.5 52.0 70.0 Sizing Data Page 18 LAARS Heating Systems Input Rate Output Rate Gas Pipe Water Pipe Size (NPT) (NPT) Section 5 1600 1599 1512 WATER FLOW REQUIREMENTS 2000 1999 1883 Boiler Water Flow Requirements 2500 2499 2374...
  • Page 23: Mgh System Piping: Hot Supply Connections

    Components required by local codes must be Do not use automotive antifreeze. To help prevent properly installed. freezing, LAARS recommends the use of inhibited The MagnaTherm’s efficiency is higher with glycol concentrations between 20% and 35% glycol. lower return water temperatures. Therefore, to...
  • Page 24: Mgh Suggested Piping Schematics

    Page 20 LAARS Heating Systems Different glycol products may provide varying The condensate drain must be installed to prevent degrees of protection. Glycol products must the accumulation of condensate. When a condensate be maintained properly in a heating system, or pump is not used, the tubing must continuously they may become ineffective.
  • Page 25 MagnaTherm Boilers and Water Heaters Page 21 Low temp. radiant zone Space heating zone circuits Space heating zone circuit Air vent System pump 4 pipe dia. max. 4 pipe dia. max. 4 pipe dia. max. Water feed controls 4 pipe dia. max. Note - This drawing is a schematic representation of a piping style,...
  • Page 26 Page 22 LAARS Heating Systems Note - This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Low temp. radiant zone Low temp. radiant zone...
  • Page 27 MagnaTherm Boilers and Water Heaters Page 23 Space heating Note - zone circuits This drawing is a schematic representation of a piping style, and is not intended to be used as a working installation drawing. Local code requirements must be met. Low temp.
  • Page 28 Page 24 LAARS Heating Systems Space heating zone circuits High temp. space heating zone circuit Space heating zone circuit Air vent 4 pipe dia. max. 4 pipe dia. max. Water feed controls Expansion tank 4 pipe dia. max. Common piping must be sized for the combined water ow of all the boilers.
  • Page 29: Mgv Water Quality

    MagnaTherm Boilers and Water Heaters Page 25 Section 7 - WATER CONNECTIONS 7.2 MGV Suggested Piping Schematics Figure 11 through Figure 13 show suggested piping MGV UNITS configurations for MGV boilers. These diagrams are only meant as guides. All components or piping 7.1 MGV Water Quality required by local code must be installed.
  • Page 30: Mgv Cold Water Make-Up

    Page 26 LAARS Heating Systems event of pressure relief. Install a diaphragm-type 7.5 MGV Freeze Protection expansion tank, flow check, and shutoff valves If installing outdoors in a location that may where needed or as required by code. experience freezing temperatures, precautions must...
  • Page 31: Mgv Water Flow

    MagnaTherm Boilers and Water Heaters Page 27 Building return NOTES: NOTE: This drawing shows 1. Locate the MGV DHW sensor suggested piping configuration and or remote aquastat well valving. Check with local codes and in lower 1/3 of tank. ordinances for additional requirements. Cold water 2.
  • Page 32: Section 8 - Electrical Connections

    24 Volt Transformer. The 120 plate for appropriate voltage and current ratings. volt and 24 volt outputs of either transformer are As a common industry practice, LAARS has color protected with resettable fuses mounted in the top coded the single and three phase wires.
  • Page 33: Pump Connections And Operation

    MagnaTherm Boilers and Water Heaters Page 29 Model 1600 2000 ø ø ø ø ø ø Voltage 208 3 480 3 600 3 208 3 480 3 600 3 Nominal 15.1 Current 17.7 22.6 11.3 12.7 Table 14. Electrical Data Model 2500 / 3000 3500 / 4000...
  • Page 34: Control Panel Layout

    Page 30 LAARS Heating Systems 8.4 Control Panel Layout PART NO. CA0099 KM004400 E2339800 E2346100 KM004300 A0014300 A0014300 E0086800 30N7050 PARTS LIST ITEM NO. PART NO. DESCRIPTION CA0099 VARI-PRIME PRINTED CIRCUIT BOARD KIT KM004400 AUTO-RESET HIGH LIMIT CONTROL E2339800 TOUCH SCREEN...
  • Page 35 MagnaTherm Boilers and Water Heaters Page 31...
  • Page 36: Wiring Diagrams

    Page 32 LAARS Heating Systems THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE PROPRIETARY TO LAARS HEATING SYSTEMS CO. AND SHALL NOT BE REPRODUCED, TRANSFERRED TO OTHER DOCUMENTS, USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY LAARS HEATING SYSTEMS CO.
  • Page 37 FRACTIONS 1/8" DIMENSIONS ARE IN INCHES. SHIELDED VTB6 DECIMALS .XX .03 24VAC POWER DIGITIZED CABLE DECIMALS .XXX .010 TITLE: VTB1 P/N LAARS-1 ANGLES 1 DIAGRAM, WIRING/BLOCK, MGT APPROVALS (OPTIONAL) MATERIAL: DRAFT JAT 1/22/15 ENGR INTENDED SIZE: SOFTWARE DWG. NO: REV.
  • Page 38 LAARS Heating Systems Page 34 THIS DOCUMENT AND THE INFORMATION CONTAINED HEREIN ARE PROPRIETARY TO LAARS HEATING SYSTEMS CO. AND SHALL NOT BE REPRODUCED, TRANSFERRED TO OTHER DOCUMENTS, USED OR DISCLOSED TO OTHERS FOR MANUFACTURING OR ANY OTHER PURPOSE EXCEPT AS SPECIFICALLY AUTHORIZED IN WRITING BY LAARS HEATING SYSTEMS CO.
  • Page 39 DECIMALS .X FRACTIONS 1/8" DIMENSIONS ARE IN INCHES. SHIELDED VTB6 DECIMALS .XX 24VAC POWER DIGITIZED CABLE DECIMALS .XXX .010 TITLE: VTB1 P/N LAARS-1 ANGLES DIAGRAM, WIRING/BLOCK, MGT (OPTIONAL) APPROVALS MATERIAL: DRAFT 4/19/13 ENGR INTENDED SIZE: SOFTWARE DWG. NO: REV. E23512...
  • Page 40: High Voltage Wiring Diagrams

    LAARS Heating Systems Page 36 8.6 High Voltage Wiring Diagrams Figure 17. High voltage wiring diagram MGT 1600 110V...
  • Page 41 MagnaTherm Boilers and Water Heaters Page 37 Figure 18. High voltage wiring diagram MGT 1600 220V...
  • Page 42 Page 38 LAARS Heating Systems Figure 19. High voltage wiring diagram MGT 2000 110V...
  • Page 43 MagnaTherm Boilers and Water Heaters Page 39 Figure 20. High voltage wiring diagram MGT 2000 220V...
  • Page 44 Page 40 LAARS Heating Systems 120V N 120V N 120V H 120V H Figure 21. High voltage wiring diagram MGT 2000 - 4000 three phase...
  • Page 45: Ladder Diagrams

    MagnaTherm Boilers and Water Heaters Page 41 8.7 Ladder Diagrams Figure 22. MGT 1600 110V ladder diagram...
  • Page 46 LAARS Heating Systems Page 42 Figure 23. MGT 1600 220V ladder diagram...
  • Page 47 MagnaTherm Boilers and Water Heaters Page 43 Figure 24. MGT 2000 110V ladder diagram...
  • Page 48 Page 44 LAARS Heating Systems Figure 25. MGT 2000 220V ladder diagram...
  • Page 49 MagnaTherm Boilers and Water Heaters Page 45 Figure 26. Three-Phase Ladder Diagram...
  • Page 50: Section 9 - Navigating The Touch Screen

    Page 46 LAARS Heating Systems Section 9 NAVIGATING THE TOUCH SCREEN The home screen shows a picture of the MagnaTherm controller. The color of the controller depends on the status of the MagnaTherm, as shown below. Color Status Control Icon...
  • Page 51 MagnaTherm Boilers and Water Heaters Page 47 To change some parameters, a password is required. The control system includes three levels of password Screen Menu Icons protection: OEM Password Setup and parameter changes available only to the factory. Installer Password Setup and parameter changes There are several icons at the top of the Touch made when the system is Screen Menus (and most of the other screens) that...
  • Page 52: Verification Process For Safety-Related Parameters

    Page 48 LAARS Heating Systems Menu 6. Parameter Safety Warning Menu 4. Login Required WARNING The screen used to Login is similar to the Keyboard Changing safety parameters should only be screen. conducted by experienced, licensed boiler operators and mechanics. Hazardous burner conditions can...
  • Page 53 MagnaTherm Boilers and Water Heaters Page 49 Menu 8. Safety Parameter Reset When the process is complete, the system will tell you to reset the control system. The Reset button is located on the front of the controller. You must press the Reset button within 30 Figure 29.
  • Page 54: Parameters

    Page 50 LAARS Heating Systems Menu 12. Status Summary Screen Menu 10. Status Summary Screen Notice the four buttons at the bottom of each Press the Configure button to start a Status Summary screen: configuration session for the controller. • Configure – Allows an installer to change some of the setup parameters used by the system.
  • Page 55: Setting The Date And Time On The System Display

    MagnaTherm Boilers and Water Heaters Page 51 Setting the Date and Time on the System Display The display includes an internal clock, which keeps Press the Display Setup button at the bottom track of the date and time. This setting is important, of the screen.
  • Page 56: Configuration Menus (All)

    Page 52 LAARS Heating Systems 9.7 Configuration Menus The following sections give overviews of each configuration sub menu. 9.7.1 System Identification & Access Menu 18. Home Screen To navigate to the Configuration Menu Screen, first touch the controller icon on the home screen to access the Status Summary screen,...
  • Page 57: Ch - Central Heat Configuration

    MagnaTherm Boilers and Water Heaters Page 53 9.7.6 Demand Priority Configuration A factory supplied Outdoor air temperature sensor is used with the Outdoor Reset and Warm Weather Shutdown features. Wiring For single boiler operation, the outdoor sensor will be connected to TB1-21A and 22A. For Lead Lag operation of multiple boilers, the outdoor sensor will be connected to TB1-21A and 22A on the Slave Boiler, and the system sensor (supplied with boiler)
  • Page 58: Statistics Configuration

    Page 54 LAARS Heating Systems 9.7.11 Stack Limits The controller in the Magnatherm energizes the appropriate pump contacts when it receives a call for heat. Once the call for heat is satisfied, the pumps will remain on for the defined pump overrun time.
  • Page 59: Burner Control Ignition

    MagnaTherm Boilers and Water Heaters Page 55 9.7.14 Burner Control Ignition 9.7.16 Sensor Configuration The Pilot test hold function allows the installer to set the pilot flame to the required pressures listed in Table The outdoor temperature can be read from 16, without turning on the Main valve. With a call for the outdoor sensor that is shipped with the heat enabled the unit will start the normal sequence of MagnaTherm, or from an Envirocom outdoor sensor...
  • Page 60: Lead Lag Slave Configuration

    Page 56 LAARS Heating Systems 9.7.17 Lead Lag Slave Configuration Caution About Lead/Lag Operation - You should set the Modbus addresses before If an installation includes two or more boilers, they you connect the Modbus wiring. If the wiring may be set up for “Lead/Lag” operation. One boiler is attached before the Modbus addresses on will be set up as the “Master”, and the others will...
  • Page 61 MagnaTherm Boilers and Water Heaters Page 57 Number of boilers Base load value installed Low demand - The first boiler in sequence fires at less than 65% Demand increases - Once the first boiler reaches 50%, the second boiler switches on, and Table 15.
  • Page 62 Page 58 LAARS Heating Systems You will be prompted to sign in. This can be done by pressing the ‘LOCK’ symbol at the top right Select ‘Configure’. type in ‘LNT’ and press OK. Then you can select Slave Enable. Select ‘Enable slave for built-in Lead Lag master’ .
  • Page 63: Lead Lag Master Configuration

    MagnaTherm Boilers and Water Heaters Page 59 9.7.18 Lead Lag Master Configuration Wiring Connections for Lead/Lag - Now you can make the Modbus wiring connections Then set up the Master controller by going to the Lead between the units. The controller in each boiler Lag Master boiler and opening up the Lead Lag Master includes two wiring terminals for the Modbus system, Configuration in that boilers Configuration Menu.
  • Page 64 Minimum Boiler Water Temp 40F - 180F Outdoor Reset Config DHW Enable Enabled DHW Config Enable / Disable Page 60 LAARS Heating Systems Sensor Only STAT Terminal Auto:DHW (S6) or Demand Switch Auto: DHW (S6) or EnviroCOM DHW DHW Config Sensor Only...
  • Page 65 CH Frost Protection Enable Enabled Enable / Disable Frost Protection Config DHW Frost Protection Enable Enabled Enable / Disable Frost Protection Config Lead Lag Frost Protection Enable Enabled MagnaTherm Boilers and Water Heaters Page 61 Frost Protection Config Enable / Disable Lead Lag Frost Protection Rate 0% - 100% Frost Protection Config...
  • Page 66 Lead Lag Master Config- Lead Rotation Time 0 min 0 sec - 1080 hrs 0 min 0 sec (7 days) Adv Settings-Algorithms Page 62 LAARS Heating Systems Lead Lag Master Config- Base Load Common 20% - 100% Adv Settings-Rate Allocation Parameter Name...
  • Page 67: Connections To A Building Automation System

    Modbus ports. The Modbus wiring must be completed according to the diagrams shown below. If alternate communication protocols are desired, LAARS offers “gateways” to allow BACnet, LON, and other communications protocols. For additional information on setting up Modbus and other communication protocols, contact the factory.
  • Page 68: Vari-Prime Flow Control System

    Page 64 LAARS Heating Systems 9.10 Vari-Prime If Main Gas valve is “OFF” AND a call for heat is “TRUE” then the PCB overrides the PID control Vari-Prime is a variable pump control that is and runs the pump output at 100% (10 VDC, or 20 standard equipment on all MGH boilers.
  • Page 69: Combustion Setup Procedure

    MagnaTherm Boilers and Water Heaters Page 65 9.11 – Combustion Setup Procedure In this section, we will explain how to set up the gas valve so the boiler will run efficiently at both the High Fire and Low Fire conditions. Required tools: Screwdrivers, Torx bits, Allen Wrench Set, Combustion Analyzer WARNING...
  • Page 70 Page 66 LAARS Heating Systems MagnaTherm is equipped with a zero governing, negative regulator valve. The valve throttle should be adjusted only at high fire, and the offset adjustment is only to be done at low fire. From the “Home” screen touch the control icon, then touch, Diagnostics.
  • Page 71 MagnaTherm Boilers and Water Heaters Page 67 Model Gas Type High Fire CO Low Fire CO Pressure Differential Natural 9.0% ± 0.2 0.25% lower than high fire CO 0.5” to 1.2” wc* 1,600 Propane 10.0% ± 0.2 0.25% lower than high fire CO 0.5”...
  • Page 72: Section 10 - Initial Startup Instructions

    Page 68 LAARS Heating Systems Section 10 INITIAL STARTUP INSTRUCTIONS 10.1 Filling the Boiler System Ensure the system is fully connected. Close all 12. Close the make-up water valve. Check the bleeding devices and open the make-up water strainer in the pressure reducing valve for valve.
  • Page 73: Initial Operation

    MagnaTherm Boilers and Water Heaters Page 69 10.2 Initial Operation Caution The initial setup must be checked before the unit is If any odor of gas is detected, or if the gas put into operation. Problems such as failure to start, burner does not appear to be functioning rough ignition, strong exhaust odors, etc.
  • Page 74: Section 11 - Maintenance

    11.1 System Maintenance 11.2 Maintenance Notes Do the following once a year: Use only genuine LAARS replacement parts. Lubricate all the pumps in the system, per the instructions on the pump. Inspect the venting system for obstruction or Caution leakage. Periodically clean the screens in the...
  • Page 75: Controller

    MagnaTherm Boilers and Water Heaters Page 71 11.2.5 Flame Sensor mixer. Disconnect the four flange bolts connecting the gas manifold pipe to the gas valve. Remove the The flame sensor is a single rod system. The electrical connections to the gas valve. Remove minimum flame signal that will allow the unit to fire the bolts connecting the fuel/air mixer flange to the is 0.8 volts.
  • Page 76: Heat Exchanger Tubes

    Page 72 LAARS Heating Systems exchanger may restrict the flue passages. To place the unit back in operation, install all removed components in the reverse order. Be If black carbon soot buildup on the heat exchanger sure all gaskets are in place as the components is suspected, disconnect the electrical supply to are installed.
  • Page 77: Section 12 - Troubleshooting

    MagnaTherm Boilers and Water Heaters Page 73 Section 12 TROUBLESHOOTING Lockout will appear in an orange bar across the bottom of the screen. If you tap the orange bar, 12.1 Lockouts, Holds, and Alerts the system will present more information about The control system on the MagnaTherm responds to the Lockout.
  • Page 78 Page 74 LAARS Heating Systems 3. Press the long Yellow Alert or Yellow Lockout Bar (the long bar will be a long Grey ‘History’ Bar if not currently in Alert or Lockout). Menu 33. Lockout History 4. You can see more detailed information of an alert Menu 31.
  • Page 79: Troubleshooting Table

    MagnaTherm Boilers and Water Heaters Page 75 12.2 Troubleshooting Table This table includes a listing of the fault codes that may be displayed. Some of these can be corrected by changing a parameter, while other conditions are more complicated, and will require a service technician. The first column lists the code number that will appear at the beginning of the Lockout or Hold message in the orange bar at the bottom of the screen.
  • Page 80 Page 76 LAARS Heating Systems Code Description Lockout Procedure or Hold Internal fault: Internal fault Invalid burner control state flag 1. Reset module 2. If fault repeats, replace module. Internal fault: Internal fault Safety relay drive cap short 1. Reset module 2.
  • Page 81 MagnaTherm Boilers and Water Heaters Page 77 Code Description Lockout Procedure or Hold Internal fault: Internal fault Static flame ripple 1. Reset module 2. If fault repeats, replace module. Internal fault: Internal fault Flame rod shorted to ground detected 1. Reset module 2.
  • Page 82 Page 78 LAARS Heating Systems Code Description Lockout Procedure or Hold AC input phases reversed 1. Check the module and display connections. 2. Check the module power supply and make sure that both frequency and voltage meet the specifications. 3. On 24 VAC applications, assure that J4 terminal 10 and J8 terminal 2 are connected together.
  • Page 83 MagnaTherm Boilers and Water Heaters Page 79 Code Description Lockout Procedure or Hold Outlet high limit H or L 1. Check wiring and correct any possible errors. 2. Replace the outlet high limit. 3. If previous steps are correct and fault persists, replace the module.
  • Page 84 Page 80 LAARS Heating Systems Code Description Lockout Procedure or Hold Internal Fault: A2D mismatch. Internal Fault. 1. Reset module. 2. If fault repeats, replace module. Internal Fault: Exceeded VSNSR Internal Fault. voltage tolerance 1. Reset module. 2. If fault repeats, replace module.
  • Page 85 MagnaTherm Boilers and Water Heaters Page 81 Code Description Lockout Procedure or Hold Flame lost in run 1. Check main valve wiring and operation - correct any errors. 2. Check the fuel supply. 3. Check fuel pressure and repeat turndown tests. 4.
  • Page 86 Page 82 LAARS Heating Systems Code Description Lockout Procedure or Hold Fan speed failed during preignition H or L 1. Check wiring and correct any potential wiring errors. 2. Check the VFDs (Variable-speed Fan Drive) ability to change speeds. 3. Change the VFD 4.
  • Page 87 MagnaTherm Boilers and Water Heaters Page 83 Code Description Lockout Procedure or Hold Purge fan switch OFF H or L 1. Purge fan switch is off when it should be on. 2. Check wiring and correct any errors. 3. Inspect the Purge Fan switch J6 terminal 3 and its connections.
  • Page 88 Page 84 LAARS Heating Systems Code Description Lockout Procedure or Hold Block intake ON 1. Check wiring and correct any errors. 2. Inspect the Block Intake Switch to make sure it is working correctly. 3. Reset and sequence the module.
  • Page 89 MagnaTherm Boilers and Water Heaters Page 85 Code Description Lockout Procedure or Hold Invalid DHW (Domestic Hot Water) 1. Return to Configuration mode and recheck high limit enable setting selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3.
  • Page 90 Page 86 LAARS Heating Systems Code Description Lockout Procedure or Hold Invalid lightoff rate setting 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module.
  • Page 91 MagnaTherm Boilers and Water Heaters Page 87 Code Description Lockout Procedure or Hold Invalid Prepurge time setting 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. Invalid Purge rate proving setting 1.
  • Page 92 Page 88 LAARS Heating Systems Code Description Lockout Procedure or Hold Invalid Flame threshold setting 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module.
  • Page 93: Diagnostic Tests And Input/Output Indicators

    MagnaTherm Boilers and Water Heaters Page 89 Code Description Lockout Procedure or Hold Invalid DHW (Domestic Hot Water) 1. Return to Configuration mode and recheck connector type setting selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3.
  • Page 94: Lead/Lag Slave Diagnostics

    Page 90 LAARS Heating Systems Menu 38. Analog I/O Screen Menu 41. Lead/Lag Diagnostics Press the button for Diagnostic Tests. The Use the left- and right-arrows to see all of the Modulation test allows you to change the columns in the display.
  • Page 95: Control Snapshot

    MagnaTherm Boilers and Water Heaters Page 91 To use this function, select the parameter you want to track from the pull-down list. The system will present a graph that tracks that variable. To see the graph for the currently-selected function, press the View button.
  • Page 96: Section 13 - Replacement Parts

    General Information To order or purchase parts for the LAARS MagnaTherm Appliance, contact your nearest LAARS dealer or distributor. If they cannot supply you with what you need, contact Customer Service. (See the back cover for addresses, and for telephone and fax numbers.)
  • Page 97: Component Illustrations, Parts Lists, And Part Numbers

    MagnaTherm Boilers and Water Heaters Page 93 13.2 Component Illustrations, Parts Lists, and Part Numbers 13.2.1 Frame and Jacket Assembly, Part Numbers Frame and Jacket Assembly 1600 2000 2500 3000 3500 4000 Item # Description Part No. Part No. Part No. Part No.
  • Page 98 Page 94 LAARS Heating Systems DETAIL A Final Assembly Final Assembly...
  • Page 99: Final Assembly

    Hinge mounting bracket, right 20N3164 20N3164 30N3051 30N3051 40N3164 40N3164 Panel, right, rain splatter 30N3053 30N3053 30N3053 30N3053 40N3050 40N3050 Panel, left, rain splatter 30N3054 30N3054 30N3054 30N3054 40N3050 40N3050 MagnaTherm Boilers and Water Heaters Page 95 Bracket, hinge brace 30N3055 30N3055 30N3055...
  • Page 100: Waterway Outlet Assembly

    Panel, center rear 16N3020 20N3020 30N3020 30N3020 40N3020 40N3020 Panel, lower rear 16N3021 20N3021 25N3021 30N3021 40N3021 40N3021 Page 96 LAARS Heating Systems Panel, right 20N3036 20N3036 30N3036 30N3036 40N3036 40N3036 Strut, upper panel support 30N3043 30N3043 30N3043 30N3043 30N3043 30N3043...
  • Page 101: Blower Assy, Model 1600

    MagnaTherm Boilers and Water Heaters Page 97 13.2.4 Blower Burner Assembly, Part Numbers (Model 1600)
  • Page 102: Blower Assy, Model 2000

    Plate, rear panel, gas pipe Plate, rear panel, gas pipe 20N3034 30N3034 20N3034 30N3034 30N3034 30N3034 30N3034 30N3034 30N3034 30N3034 30N3034 30N3034 Page 98 LAARS Heating Systems Door, right Door, right 20N3100 20N3100 20N3100 20N3100 30N3100 30N3100 30N3100 30N3100 40N3100 40N3100 40N3100 40N3100...
  • Page 103: Blower Assy, Models 3500 & 3000

    Item # Description Item # Description Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. Part No. Heat Exchanger Heat Exchanger R16N2070 R20N2070 R30N2070 R16N2070 R30N2070 R20N2070 R40N2070 R30N2070 R40N2070 R30N2070 R40N2070...
  • Page 104 Page 100 LAARS Heating Systems PART NUMBER DESCRIP 40N5068 STAND 40N5070 S2125300 GASKET, AF-12 BLOWER INTAKE, M " 6 T " F2037700 WASHER, THICK FLAT, 3/8, STEEL, ZI " 2 40N6021 GAS TRAIN ASSEMBLY, CSD-1...
  • Page 105: Blower Assy, Models 3500 & 4000

    Flame sensor W2014900 W2014900 W2014900 W2014900 Gasket, blower outlet flange S2125600 S2125600 S2125200 S2125200 MagnaTherm Boilers and Water Heaters Page 101 Venturi / Air intake assembly A2123300 A2123300 30N5092 30N5092 Gasket, blower intake 20N5095 20N5095 S2125300 S2125300 Flow sensor, diff pressure A2121601 A2121601 Blower...
  • Page 106 Page 102 LAARS Heating Systems Gas Train Assembly (Models 1600, 2000, 2500 and 3000)
  • Page 107: Gas Train Assembly, Models 1600 Thru 3000

    Blower A2120900 A2120900 O-Ring S2124800 S2124800 Adapter 1/4" tube x 1/8" female P2090200 P2090200 MagnaTherm Boilers and Water Heaters Page 103 Blower tube 40N5077 40N5077 Gasket, burner S2124600 S2124600 Ignitor, hot surface W2013900 W2013900 Sight glass RF0044800 RF0044800 Flame sensor W2014900 W2014900 13.2.8 Gas Train Assembly, Part Numbers...
  • Page 108: Gas Train Assembly, Models 3500 & 4000

    Page 104 LAARS Heating Systems 70-236 PIPE PLUG, MA W2000300 VALVE, MANUA S2123500 WASHER, SEA P2089600 ADAPTER, FEMALE P2089300 ADAPTER, 1/4 TUB Gas Train Assembly (Models 3500 and 4000) 40N6040 GAS TRA 40N6031 GAS TRAIN V2022300 VALVE Manual/QTY. BOM Tabl...
  • Page 109 Flange, adjustable shutter V2023200 V2022400 V2022000 V2022000 Nipple, 1-1/2" x close P0015500 P0019100 P0019100 Nipple, 3/8"x3" P2090500 P2090500 P2090500 P2090500 MagnaTherm Boilers and Water Heaters Page 105 Tee, 3/8x3/8x3/8 P2090600 P2090600 P2090600 P2090600 Bushing, reducing, 3/8x1/8 P2090700 P2090700 P2090700 P2090700 Union P0030700 P0030700...
  • Page 110 Page 106 LAARS Heating Systems Control Panel Assembly...
  • Page 111: Control Panel Assembly

    V2022300 NAT Valve, Gas, Dungs V2021200 V2021200 PROP Washer, Sealing,1/8 BSPP Fitting Dungs S2123500 S2123500 MagnaTherm Boilers and Water Heaters Page 107 Adapter, Fem to Male, 1/8 FNPT X 1/8 ISO P2089600 P2089600 Valve, Manual, Brnz, 1/8 MNPTx1/8 FNPT W2000300 W2000300 Adapter, 1/4"...
  • Page 112: Distribution Box Assemblies

    Page 108 LAARS Heating Systems 13.2.11 Distribution Box Assemblies and Part Numbers AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODEL1600)
  • Page 113 MagnaTherm Boilers and Water Heaters Page 109 AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODEL 2000)
  • Page 114 Page 110 LAARS Heating Systems AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODELS 2500 AND 3500)
  • Page 115 MagnaTherm Boilers and Water Heaters Page 111 AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODELS 3000 AND 4000)
  • Page 116 Customer Service and Product Support: Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.3355 Headquarters: 1869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • Fax 905.366.0130 www.LAARS.com Litho in U.S.A. © LAARS Heating Systems 1504 Document 1276D...

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