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The procedure for filling the traps and syphon with water is shown
on the Fig. 10:
Disconnect the
condensate pipe
Fill the trap
with water
Fig. 10 Water Filling of Condensate System
− The installation must have provisions for suitable drainage
or collection of the condensate out of the boiler traps.
− The condensate water shall be discharged at atmospher-
ic pressure, by dripping into a suitable drain, and shall be
neutralized prior to draining per local codes.
− The condensate drain tube must pitch away from the boiler
(1/4" slope per foot) and must never reduce its diameter
downstream.
− Never use copper pipes or of other material not intended
for the specific purpose, because the action of condensate
will cause a rapid deterioration.
− Check that the condensate drain pipe is adequately sloping
towards the discharge point avoiding high points, which
can inhibit the flow of condensate. The condensate pipe
must be installed in such a way so as to avoid the freezing
of the liquid.
9
WARNING: Verify condensate disposal / neutralization is in ac-
cordance with local, state and federal regulations.
If a floor drain is not available, a condensate pump can be used to
remove the condensate to drain. The maximum condensate flow
rate is 23.8 GPH for Array AR 3000 and 31.7 GPH for Array AR 4000.
The drain line must be removable for routine maintenance.
9
CAUTION: Use PVC, CPVC, stainless steel, aluminum or polypro-
pylene for condensate drain piping (Fig. 10). DO NOT use car-
bon or copper components.
Fig. 11 Condensate Drain and Relief Valves Manifold Locations
2.11 Gas supply piping
Array AR 3000 and AR 4000 boilers contain a 2 inch NPT gas inlet
connection on the top of the unit as shown in Fig. 7.
9
Fill the syphon
with water from
the top of the
9
vertical flue
manifold
BEFORE to
connect the
vent piping
NOTE: All gas piping must be arranged so that it does not interfere
with removal of any covers, inhibit service/maintenance, or re-
strict access between the unit and walls, or another unit.
Vertical Flue
Manifold
Syphon
2.11.1 Gas Supply Specifications
The gas supply input specifications to the unit for Natural Gas are
as follows:
2.11.2 Manual Gas Shutoff Valve
A manual shut-off valve must be installed in the gas supply line
upstream of the boiler. Maximum allowable gas pressure to the
boiler is 20" W.C.
Condensate
Drain
Relief Valves
Manifold
11
WARNING: Never use matches, candles, flames or other sourc-
es of ignition to check for gas leaks.
CAUTION: Many of the soaps used for gas pipe leak testing are
corrosive to metals. Therefore, piping must be rinsed thor-
oughly with clean water after leak checks have been com-
pleted.
− Prior to installation, all pipes should be de-burred and in-
ternally cleared of any scale, metal chips or other foreign
particles. Do Not install any flexible connectors or unap-
proved gas fittings. Piping must be supported from the
floor, ceiling or walls only and must not be supported by
the unit.
− A suitable piping compound, approved for use with natural
gas, should be used. Any excess must be wiped off to pre-
vent clogging of components.
− To avoid unit damage when pressure testing gas piping,
isolate the unit from the gas supply piping. At no time
should the gas pressure applied to the unit exceed 20" W.C.
Leak test all external piping thoroughly using a soap and
water solution or suitable equivalent. The gas piping used
must meet all applicable codes.
− A sediment trap / drip leg must be installed on the gas sup-
ply piping.
− Installation of a union at the appliance gas line connection
is required for ease of service.
− The maximum static pressure to the unit must not exceed
20" W.C.
− The gas supply piping and pressure to the unit must be
of sufficient capacity to provide 3030 cfh for AR 3000 and
4040 cfh for AR 4000, while maintaining the recommended
minimum gas pressure at 8" W.C. for burners operating at
maximum capacity.
INSTALLATION
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