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SBR-I-S Rev C
Installation & Service Manual
Models: 45,000 - 260,000 Btu/hr
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.
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Summary of Contents for Solution CBN045
- Page 1 SBR-I-S Rev C Installation & Service Manual Models: 45,000 - 260,000 Btu/hr 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.
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Page 2: Table Of Contents
Boiler Operating Temperature Control ......34 RATINGS ................5 Room Thermostat or Remote Thermostat Connection ..34 THE SOLUTION -- HOW IT WORKS........6-8 Auxiliary Device Connection to Terminal Strip ....34 1. DETERMINE BOILER LOCATION Pump Wiring for a Heating Boiler ........35 Location of Unit .............. -
Page 3: Please Read Before Proceeding
Installation & Service Manual Please read before proceeding Improper installation, adjustment, alteration, This is a gas appliance and should be installed WARNING NOTICE service or maintenance can result in severe by a licensed electrician and/or certified gas supplier. Service must be performed by a personal injury, death, or substantial property damage. - Page 4 Installation & Service Manual Please read before proceeding To minimize the possibility of serious WARNING personal injury, fire, or damage to your appliance, never violate the following safety rules: 1. Boilers are heat producing appliances. To avoid damage or injury, do not store materials against the appliance or the vent-air intake system.
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Page 5: Ratings
3. Use only the vent materials and methods specified in the Installation and Service Manual. 4. The Solution is orificed for operation up to 2000 feet altitude. The ap pli ance will be derated 4% per 1000 feet above 2000 feet el e va tion. Consult the factory for Figure A High Altitude Label Location installations above 2000 feet elevation. -
Page 6: The Solution - How It Works
Installation & Service Manual The Solution - How it works... 16. Sight Glass Control panel cover The control panel cover provides access to the thermostat, ignition The sight glass provides a view of the burner surface, burner flame, module, and transformer. - Page 7 Installation & Service Manual The Solution - How it works... (continued) Models 45,000 - 90,000 Btu/hr Front View Models 45,000 - 90,000 Rear View Models 45,000 - 90,000 Left Side (inside unit) Models 45,000 - 90,000 Right Side (inside unit)
- Page 8 Installation & Service Manual The Solution - How it works... Models 135,000 - 260,000 Btu/hr Front View Models 135,000 - 260,000 Btu/hr Rear View Models 135,000 - 260,000 Btu/hr Right Side (inside unit) Models 135,000 - 260,000 Btu/hr Left Side (inside unit)
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Page 9: Determine Boiler Location
Installation & Service Manual Determine boiler location Location of unit Recommended Service Clearances: Left - 24” Front - 24” 1. Locate the appliance so that if water connections should leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. -
Page 10: Combustion And Ventilation Air
Installation & Service Manual Determine boiler location Combustion ventilation requirements for conventionally vented appliances Provisions for combustion and ventilation air must be in accordance with, Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes. - Page 11 Installation & Service Manual Determine boiler location (continued) Under no circumstances should the room CAUTION where the appliance is installed ever be under a negative pressure. Particular care should be taken where exhaust fans, attic fans, clothes dryers, compressors, air handling units, etc., may take away air from the appliance.
- Page 12 Installation & Service Manual Determine boiler location TABLE - 1B MINIMUM RECOMMENDED COMBUSTION AIR SUPPLY TO EQUIPMENT ROOM *Outside Air from *Outside Air from **Inside Air from 2 Openings Directly from 2 Ducts Delivered from 2 Ducts Delivered from *Outside Air from Input Outdoors Outdoors...
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Page 13: Venting
Installation & Service Manual Venting A Conventional Negative Draft TABLE - 2A Venting System VENT PIPE SIZES The negative draft in a conventional vent in stal la tion must Input Btu/hr Flue Size be within the range of a negative 0.02 to 0.05 inches 45,000 4"... - Page 14 Installation & Service Manual Venting Locate appliance as close as possible to a chimney or gas vent. (e) Test for spillage at the draft hood/relief opening after 5 minutes of main burner operation. Use the flame of Avoid long horizontal runs of the vent pipe, 90° el bows, a match or candle, or smoke from a cigarette, cigar or reductions and restrictions.
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Page 15: Vertical Vent Termination Clearances
Installation & Service Manual Venting (continued) Vertical Vent Termination Clearances 10' OR LESS 10' OR LESS 10' OR LESS CHIMNEY 2' MIN 2' MIN 3' MIN 2' MIN 3' MIN RIDGE CHIMMEY WALL OR CHIMMEY PARAPET Figure 2-2_Vent Termination from Peaked Roof 10' or Figure 2-4_Vent Termination from Flat Roof 10' or Less from Ridge Less from Parapet Wall... -
Page 16: Masonry Chimney Installation
Installation & Service Manual Venting Masonry Chimney Installation The in duced draft fan MUST also be equipped with a prov ing switch, properly interlocked into the ap pli ance’s con trol circuit A masonry chimney must be properly sized for the installation to prove fan operation before the main burn ers are allowed of a gas fired appliance. -
Page 17: Automatic Vent Damper
Installation & Service Manual Venting (continued) Automatic Vent Damper VENT DAMPER This heating boiler is design certified for use with the automatic vent damper (FIG. 15) part number printed on the boiler’s rating plate. A vent damper must be installed on all residential heating boilers with inputs of less than 300,000 Btu/hr to comply with minimum efficiency requirements. -
Page 18: Gas Connections
Installation & Service Manual Gas connections Gas Supply Gas Pressure Test Verify that the appliance is supplied with the type gas The appliance must be disconnected from the gas supply spec i fied on the rating plate. This appliance is orificed for piping system during any pressure testing of that system at operation up to 2000 feet altitude. -
Page 19: Gas Piping
Installation & Service Manual Gas connections (continued) TABLE - 3E GAS PIPING SIZE CHART Nominal Length of Pipe in Straight Feet Maximum Iron Pipe Capacity of Pipe Size in Thousands of Inches Btu/hr per hour for gas pressures of 13.5 Inches Water Column (0.5 PSIG) or less and a pressure... -
Page 20: Gas Manifold Pressure Adjustment Procedure
Immediately : Adjustment fitting is plas tic and may require slightly repair any leaks found in the gas train greater turning force than a metal fitting. -
Page 21: Checking Gas Supply Pressure
IMPORTANT Turn on gas supply at the manual valve, turn on L.P. gas gas system, leak test all gas connections with a soap solution while main burners at tank if required. are operating. Im me di ate ly repair any Turn the power “ON”... -
Page 22: Combination Gas Valves
Installation & Service Manual Gas connections Combination Gas Valves Venting of Combination Gas Valves PRESSURE REGULATOR ADJUSTMENT The combination gas valve regulator used on all WIRING TERMINALS (UNDER CAP SCREW) mod els is equipped with an integral vent limiting orifice. The vent limiter ensures that the volume of gas emitted from the valve does not exceed the maximum safe leak age rate allowed by agency OUTLET... -
Page 23: Water Connections Relief Valve
Installation & Service Manual Water connections Relief Valve Water Flow Switch (if equipped) FLOW SWITCH RELIEF VALVE Figure 4-2_Water Flow Switch - Top Connections Figure 4-1_Relief Valve A water flow switch is available as a factory sup plied option on This appliance is supplied with a relief valve(s) sized in all heating boilers (see FIG. -
Page 24: Low Water Cutoff (If Equipped)
Installation & Service Manual Water connections Low Water Cutoff (if equipped) Typical Heating Boiler Installations A hot water boiler installed above radiation level must be General Plumbing Rules provided with a low water cutoff device either as part of the unit or installed at the time the boiler is installed. An Check all local codes. -
Page 25: Piping Of The Boiler System
Installation & Service Manual Water connections (continued) Piping of the Boiler System Inspect the liquid level in the expansion tank. The system must be full and under normal operating The drawings in this section (see FIG’s 4-7 thru 4-11) show pressure to ensure proper water level in the expansion typical heating boil er piping installations. - Page 26 Installation & Service Manual Water connections Circulator Pump Requirements Hot water pip ing must be supported by suitable hangers or floor stands, NOT by the boiler. Copper pipe systems will be This is a low mass, high efficiency hot water boil er which subject to considerable expansion and con trac tion.
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Page 27: Performance Loop
FIG. 4-3. If removal of the performance loop is NOTICE necessary, consult the manufacturer for 120V a Solution Without a Performance Loop SUPPLY (KIT30068). Failure to install the system sensor can WARNING cause operation problems such as nuisance high limit trips. -
Page 28: Low Temperature Bypass Requirements
Flow rate can be determined by measuring the temperature rise through the boiler. It is acceptable for the Solution boiler to be installed in a full The basic guide for minimum flow in this boiler is based on flow application, as long as the following requirements are a 40°F temperature rise in most in stal la tions. -
Page 29: Primary / Secondary Piping
MAKE UP WATER SYSTEM SUPPLY SENSOR SEPARATOR SYSTEM CIRCULATOR FROM SYSTEM SYSTEM NOT TO EXCEED 12" APART BALL VALVE (TYPICAL) BOILER EXPANSION CIRCULATOR TANK DRAIN POINT (TYPICAL) Y-STRAINER (RECOMMENDED) UNION (TYPICAL) TEMPERATURE / PRESSURE DRAIN GAUGE PRESSURE RELIEF VALVE SOLUTION BOILER... - Page 30 SYSTEM SUPPLY SENSOR SEPARATOR SYSTEM CIRCULATOR FROM SYSTEM SYSTEM NOT TO EXCEED 12" APART BALL VALVE LOW TEMPERATURE BYPASS (TYPICAL) BOILER EXPANSION CIRCULATOR TANK DRAIN POINT (TYPICAL) Y-STRAINER (RECOMMENDED) UNION (TYPICAL) TEMPERATURE / PRESSURE DRAIN GAUGE PRESSURE RELIEF VALVE SOLUTION BOILER...
- Page 31 Installation & Service Manual Water connections (continued) Primary / Secondary Piping Figure 4-6_Multiple Boilers Zoned with Circulators ZONE #1 ZONE #1 ZONE CIRCULATORS (TYPICAL) PRESSURE PRESSURE ZONE #2 ZONE #3 ZONE #4 ZONE #2 ZONE #3 ZONE #4 REDUCING VALVE GAUGE BACKFLOW PREVENTER...
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Page 32: Full System Flow
Figure 4-7_Single Boiler Full System Flow PRESSURE REDUCING VALVE PRESSURE BACKFLOW GAUGE PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SEPARATOR SYSTEM CIRCULATOR FROM SYSTEM SYSTEM BALL VALVE (TYPICAL) EXPANSION TANK Y-STRAINER (RECOMMENDED) UNION (TYPICAL) TEMPERATURE / PRESSURE DRAIN GAUGE PRESSURE RELIEF VALVE SOLUTION BOILER... - Page 33 BACKFLOW GAUGE PREVENTER MAKE UP WATER SYSTEM SUPPLY SENSOR SEPARATOR SYSTEM CIRCULATOR FROM SYSTEM SYSTEM BALL VALVE (TYPICAL) 3-WAY VALVE W/BYPASS PIPE EXPANSION TANK BOILER CIRCULATOR Y-STRAINER (RECOMMENDED) UNION (TYPICAL) TEMPERATURE / PRESSURE DRAIN GAUGE PRESSURE RELIEF VALVE SOLUTION BOILER...
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Page 34: Electrical Connections
Connection to Terminal Strip A field supplied powered venter or powered louver/damper may be connected to the Solution boiler via a terminal strip located A room thermostat or remote temperature control may be on the left side of the unit, see FIG. 5-1, inset B. -
Page 35: Pump Wiring For A Heating Boiler
Installation & Service Manual Electrical connections (continued) Pump Wiring for a Heating Boiler Temperature Adjustment Operating Temperature Control The heating boiler circulating pump must be pur chased locally. The max i mum load for the pump switched by the The temperature controller is pre-set at the internal pump relay must not exceed 1 HP. -
Page 36: Maximum Set Point Determination
Installation & Service Manual Electrical connections Maximum Set Point Determination High-Fire Offset The temperature control operates a two-stage firing system. The maximum set point for the control is factory set. Boilers The two stages are High-Fire and Low-Fire. High-Fire operates can be set to 240°F max. - Page 37 Installation & Service Manual Electrical connections (continued) Outdoor Air Temperature Sensor Ground the cable shield at the connection NOTICE to the boiler temperature control only. Do The outside air temperature sensor will only be used for not ground the shielded cable at the sensor boiler systems.
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Page 38: Outdoor Air Reset Option
Installation & Service Manual Electrical connections Outdoor Air Reset Option If the outdoor design and boiler design temperatures are known, the Ratio setting can be calculated using the following formula: For boilers ordered with the Outdoor Air Reset option, there Ratio = (boiler design temperature - operator set point) is an additional control (FIG. -
Page 39: Blocked Vent And Flame Roll-Out / Flame Interlock Switch
Installation & Service Manual Electrical connections (continued) Blocked Vent and Flame Roll-Out / Flame OUTER AIR Interlock Switch DEFLECTOR UPPER FRONT JACKET PANEL DETAIL A FLAME ROLL-OUT SWITCH / INTERLOCK SWITCH BLOCKED VENT SWITCH LOWER FRONT INVERTED TO SHOW RESET JACKET PANEL UNDERNEATH HEX FILLER BRACKET... -
Page 40: Startup Initial Startup
Installation & Service Manual Start-up Initial Start-up Verify that properly sized combustion Follow the Lighting Instructions on the label applied to the ven ti la tion air openings are provided and not obstructed appliance. in any way. A. On boilers with the system pump delay option, the operating temperature control will energize Check carefully for gas leaks. -
Page 41: Safety Shutoff Test For Spark Ignition Pilot System
Installation & Service Manual Start-up (continued) Operating Instructions To Turn Off Gas to Appliance Set the thermostat to the OFF position. STOP! Read the safety information first. Turn off all electric power to the appliance if service is to Remove the control panel door. be performed. -
Page 42: Intermittent Pilot Spark Ignition System (M9)
50°F the pump relay will turn antifreeze. OFF. A solution of 50% propylene glycol will pro vide maximum Location - Heating boilers must be located in a room protection of approximately -30°F. having a temperature safely above freezing [32°F(0°C)]. -
Page 43: Maintenance
Installation & Service Manual Maintenance Maintenance and annual startup Table 7A_Service and Maintenance Schedules Service technician Owner maintenance (see the following pages for instructions) (see the User’s Information Manual for instructions) • Check appliance area General: • Check pressure/temperature • Address reported problems gauge Daily •... -
Page 44: Address Reported Problems
Installation & Service Manual Maintenance Follow the service and maintenance procedures given throughout this manual and in component literature WARNING shipped with the appliance. Failure to perform the service and maintenance could result in damage to the appliance or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage. -
Page 45: Check Expansion Tank
Installation & Service Manual Maintenance (continued) Check Expansion Tank Following installation, the valve lever must WARNING be operated AT LEAST ONCE A YEAR to 1. Expansion tanks provide space for water to move in ensure that waterways are clear. Certain and out as the heating system water expands due to naturally occurring mineral deposits may temperature increase or contracts as the water cools. -
Page 46: Combustion Air
Installation & Service Manual Maintenance Check All Wiring Combustion Air This ap pli ance uses an atmospheric combustion process. 1. Inspect all wiring, making sure wires are in good condition Combustion air is provided to the burners by the gas injection and securely attached. -
Page 47: Inspection And Cleaning
Installation & Service Manual Maintenance (continued) Inspection and Cleaning Avoid breathing dust and contact with skin and eyes. • Use NIOSH certified dust respirator (N95). This j. Check the heat exchanger surface for sooting. The type of respirator is based on the OSHA requirements for external surfaces of the copper tubes should be free of cristobalite time... -
Page 48: Review With Owner
IMPORTANT OUTER AIR gas system, leak test all gas connections DEFLECTOR with a soap solution while main burners UPPER FRONT are operating. Im me di ate ly repair any JACKET PANEL leak found in the gas train or re lat- ed components. -
Page 49: Troubleshooting
Installation & Service Manual Troubleshooting Troubleshooting Guide: M9 Solution Boilers Step 1: Check continuity on the spark Check for an open Is the spark cable. Check for 24 VAC on sensor. If no open ignitor sparking? the 24v terminal (gray wire) sensor, make sure on the ignition module. -
Page 50: Diagrams
Installation & Service Manual Diagrams Schematic Diagram - M9 Unit Wiring Diagram - M9 Unit 45,000 - 260,000 Btu/hr Models 45,000 - 260,000 Btu/hr Models... - Page 51 Notes...
- Page 52 Revision A (ECO #C03746) initial release. Revision B (ECO #C06868) update the pressure drop chart (Table 4C) to reflect the correct models and change out the reference to the two blues wires to SYS/TANK contacts under System Sensor on page 36 (ECR03727).
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