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Installation, Operation and Maintenance Instructions
Installation,
Operation and
Maintenance
Instructions for
Mighty Max
Hydronic Boilers
Model HH
Sizes 320M - 1000M
FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician,
qualified in hot water boiler 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.
WARNING
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not
use any phone in your building.
• Immediately call your gas supplier from a
nearby 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.
AVERTISSEMENT
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 ni
d'autres vapeurs ou liquides inflammables dans
le voisinage 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 dansle bâtiment où vous
vous trouvez.
• 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 2060D
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Summary of Contents for Laars Mighty Max HH1000M
- Page 1 Installation, Operation and Maintenance Instructions Document 2060D Installation, Operation and Maintenance Instructions for Mighty Max Hydronic Boilers Model HH Sizes 320M - 1000M FOR YOUR SAFETY: This product must be installed and serviced by a professional service technician, qualified in hot water boiler 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.
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Page 2: Table Of Contents
LAARS HEATING SYSTEMS Page 2 TABLE OF CONTENTS SECTION 1. SECTION 3. General Information Operating Instructions Introduction ............ 3 Start Up Requirements ........ 16 Warranty ............3 Hi-Limit checkout ......... 18 Technical Assistance ........3 Venturi and Gas Pressure Regulator System ........18 3C-1. -
Page 3: General Information
Details are specified on the 400M 399,000 339,150 back cover of this manual. 520M 520,000 442,000 Make all warranty claims to an authorized Laars 625M 625,000 531,250 representative or directly to the factory. Claims must 775M 775,000 658,750... -
Page 4: Installation Instructions
Install the Mighty Max HH boiler in accordance exists. with the procedures in this manual (or the Laars warranty may be voided), local codes, and ordinances. Locate the boiler to provide at least the... -
Page 5: Installation Of Indoor Boilers
Mighty Max Hydronic Boiler Page 5 not require the full freeze protection of a 50%/50% fireplace dampers and any other gas-burning mixture, it is beneficial to use a maximum 30% glycol appliances to their previous condition of use. solution. This mixture will protect the boiler to Any improper operation of the common venting temperatures of about 5°F (-15°C), and will serve as system should be corrected so the installation... -
Page 6: Gas Supply And Piping
Water Column arrangement. Minimum Check the rating plate to make sure the boiler is fitted for the type of gas being used. Laars Maximum boilers are normally equipped to operate below a 2000 foot (610m) altitude. Boilers equipped to Table 4. Gas Supply Pressure Requirements. - Page 7 Mighty Max Hydronic Boiler Page 7 Air Shutter Enclosure Air Shutter Enclosure Filter Air Shutter Filter Housing Enclosure Housing Filter Blower Housing Motor Blower Blower Motor Motor Automatic, Regulator Regulator Regulator Venturi Redundant Venturi Gas Valve Automatic Redundant Gas Valve Manual Gas Venturi Manual Gas...
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Page 8: Water System Requirements
The Model HH boilers must have continuous pumps or 3-way valves. This can result in a high flow through the heat exchanger when firing for temperature rise across the boiler. Laars recommends proper operation. The system pump must be capable primary-secondary pumping for all variable flow of developing sufficient pressure to overcome the systems. -
Page 9: System Pressure Requirements
Mighty Max Hydronic Boiler Page 9 2G-3. System Pressure Requirements pressure relief valve may discharge water due to expansion. An expansion tank approved for potable The Model HH boilers are designed to operate water will eliminate this condition. Follow the on closed, pressurized systems. -
Page 10: Filling The System
NOTES: Select Method 1 or 2 when using low water cutoff accessory: 10. Recheck the water level in the expansion tank. If 1. Under Method 1, the low water cutoff is furnished by Laars and shipped as a separate item for fieldinstallation. - Page 11 Mighty Max Hydronic Boiler Page 11 Category I For vertically ducted combustion air: • Combustion air intake must terminate at least 3 feet (0.91m) lower than vent termination, if it is located within a 10 foot (3.05m) radius. • Combustion air intake must be at least 1 foot (0.3m) above roof top Vertical Venting (Category I) and normal snow levels.
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Page 12: Top-To-Rear Vent Collar Conversion
LAARS HEATING SYSTEMS Page 12 Blank Plate On Adapter Plate Boiler Jacket Top Panel Top Panel Blank Plate On Vent Flue Collector Collar/Stack Blank Plate (Boiler Jacket) 1. Removal of Blank Plate and Adapter 3. Blank Plate Placement Plate From Boiler... -
Page 13: Venting
The following requirements must be used for Non-Category I venting: Slip the adapter plate over the vent collar/stack Laars specified vent pipe material (Table 6) and and install it onto the rear boiler jacket (see sizes (Table 7). Figure 9). -
Page 14: Side Wall Vent Terminal
LAARS HEATING SYSTEMS Page 14 Vent Hood 3 (0.9m) Minimum Vent Hood Vent Hood 4 (1.2) 4 (1.2) Minimum Minimum Vent Hood 7 (2.1) Minimum Above Public Walkway 6 (1.8) Above Any Outside Air Intake Within 10 (3.0) Vent Hood Vent Hood Must Be Mounted 4 (1.2) -
Page 15: Air From Room
Table 7. Plate Combustion air must be taken from out-of-doors by means of the Laars side wall terminal. Locate the terminal within 10 feet (3.0m) of the boiler vent exhaust terminal, but no closer than 3 feet (0.9m) (centerline distance). -
Page 16: Combustion Air Piping
LAARS HEATING SYSTEMS Page 16 Remove the louvered plate from the left side of Electrically interlock the pump and boiler so the the boiler. boiler cannot come on unless the pump is running. Remove the adapter plate from the shipping container. - Page 17 Mighty Max Hydronic Boiler Page 17 Figure 12. Wiring Diagram.
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Page 18: Hi-Limit Checkout
LAARS HEATING SYSTEMS Page 18 3C. Venturi and Gas Pressure Regulator Front View of Boiler System Igniter 3C-1. Overall Operation The gas control system of the Mighty Max boiler Junction is similar to that of a carburetor of a gasoline engine: a venturi pulls the gas into the combustion air stream (see Figure 14). -
Page 19: To Start Up System
Mighty Max Hydronic Boiler Page 19 Use a single, inclined manometer or digital Using the toggle switch, turn the heater off. Turn manometer with a 4.0 inch water column range. Install the heater back on and check the gas pressure shutoff valves at the gas orifice (regulator outlet) tap offset after the heater has fired. -
Page 20: Setting Temperature Controls
LAARS HEATING SYSTEMS Page 20 taps on the venturi. Gas flow is checked by evaluating Caution venturi pressures and the regulator offset pressure. This appliance is equipped with an ignition In a venturi flow system the difference between device which automatically lights the burner. - Page 21 Mighty Max Hydronic Boiler Page 21 The difference in pressure between the venturi inlet tap and the gas plenum tap (see Figure 16). This measurement is taken by connecting the positive side of the manometer to the venturi inlet tap and connecting the negative side of the manometer to the gas plenum tap.
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Page 22: Venturi Setup Procedure
LAARS HEATING SYSTEMS Page 22 By setting the gas offset pressure and gas orifice repeat steps 3-5 until the gas offset and gas differential pressure according to Table 11, the correct orifice differential pressures are according to input rate and gas to air ratio is achieved. -
Page 23: Inspection Of The Heat Exchanger
4B-1b. Internal Heat Exchanger Inspection Remove the return cover of the heat exchanger. Remove the inlet/outlet header of the heat Clean the internal surface. (Laars offers a tube exchanger. cleaning kit part no. R00100000.) Remove the return cover of the heat exchanger. -
Page 24: Filter
LAARS HEATING SYSTEMS Page 24 Other maintenance requirements include: Caution Periodic cleaning of filters, when supplied. The filter has arrows which indicate the Lubrication of moving parts (when applicable), direction of the air flow. Failure to install the with the correct type and amount of lubricant. - Page 25 Mighty Max Hydronic Boiler Page 25 Figure 20. Troubleshooting Chart.
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Page 26: Venturi And Gas Pressure Regulator System
LAARS HEATING SYSTEMS Page 26 5C-2. Electrical Troubleshooting 5B. Venturi and Gas Pressure Regulator Troubleshooting procedures should only be System performed by professional service technicians qualified in heater maintenance. 5B-1. Field Checkout Some electrical components are wired in See Section 3B “Venturi and Gas Pressure parallel, so it is necessary to troubleshoot in the order Regulator System”... -
Page 27: Parts List For Mighty Max Hh Boiler
Parts List for Mighty Max HH Boiler 20260101 (Canada) 6A. General Information 775M ..........20260200 (U.S.) To order or purchase parts for the Laars Mighty 20260201 (Canada) Max HH boiler, contact your nearest Laars contractor 1000M ..........20265600 (U.S.) or distributor. If they cannot supply you with what... - Page 28 LAARS HEATING SYSTEMS Page 28 Front View Right Side View...
- Page 29 Mighty Max Hydronic Boiler Page 29 Rear View Front View Left Side View Right Side View...
- Page 30 LAARS HEATING SYSTEMS Page 30 Item Description Part Number Item Description Part Number 16. Cover, Machined In/Out ......... 20150200 31. Panel, Back 17. Plate, Mach. Adapter 320M ............20157201 320M, 400M ..........20150302 400M ............20157202 520M, 625M, 775M ........20150306 520M ............
- Page 31 Mighty Max Hydronic Boiler Page 31...
- Page 32 6000 Condor Drive, Moorpark, CA 93021 • 805.529.2000 • FAX 805.529.5934 20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • FAX 603.335.3355 480 S. Service Road West, Oakville, Ontario, Canada L6K 2H4 • 905.844.8233 • FAX 905.844.2635 www.laars.com Litho in U.S.A. © Laars Heating Systems 0303 Document 2060D...