Laars MagnaTherm MGH1600 Installation And Operation Instructions For
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Laars MagnaTherm MGH1600 Installation And Operation Instructions For

Modulating boiler/water heater, 1,600/1,999/2,499/3,000/3,500/4,000 mbtu/h
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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 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.
Installation and
Operation Instructions for
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
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
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 êtes.
• 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 1276J

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Summary of Contents for Laars MagnaTherm MGH1600

  • Page 1 Installation and Operation Instructions Document 1276J Installation and Operation Instructions for 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 3,000 MBTU/h 3,000 MBTU/h...

  • Page 2: Table Of Contents

    LAARS Heating Systems Table of Contents SECTION 1 General Information SECTION 7 Water Connections Introduction ............1 Water Quality ..........30 Warranty ............1 Suggested Piping Schematics ......30 1.C Model Identification ........... 1 Piping Requirements ........30 Safety Notes ............. 2 Water Flow............
  • Page 3 MagnaTherm Boilers and Water Heaters SECTION 13 Replacement Parts ....100 9.H.15 Burner Control Ignition ........67 13.A General Information ........100 9.H.16 System Configuration ........67 13.B Component Illustrations, Parts Lists, and Part Numbers ........101 9.H.17 Sensor Configuration ........67 13.B.1 F rame and Jacket Assy, Part Numbers ..101 9.H.18 L ag (Slave) Configuration ......
  • Page 4 LAARS Heating Systems...

  • Page 5: A Introduction

    SECTION 1 General Information Rating Plate Introduction This manual includes information which will help you to install, operate, and maintain the Laars Heating Systems MagnaTherm. Please read this manual completely before proceeding with the installation. If you have any questions regarding this equipment, please contact Laars Heating Systems, or your local Laars representative.

  • Page 6: D Safety Notes

    Page 2 LAARS Heating Systems Safety Notes Safety Notes are used thoughout this manual to bring attention to the presence of hazards with various risk levels and to off er important information concering the life of this product. There are 3 basic types.
  • Page 7 Page 3 MagnaTherm Boilers and Water Heaters WARNING NOTE: All installations must be made in accordance with 1) American National Standard Z223.1/NFPA54-Latest Electrical Shock Hazard Edition “National Fuel Gas Code” or Electrical shock can cause severe injury, death or 2) CSA B149.1 “Natural Gas and Propane Installation property damage.

  • Page 8: E Unit Overviews

    LAARS Heating Systems Page 4 Unit Overviews The next 3 pages give a visual reference to the basic component locations of the unit. Control Panel Blower Manual Gas Valve Spark Generator Rating Plate (on outside of panel) On all models, the Control Panel hinges forward for easy access to wiring and to the heat exchanger.
  • Page 9 Page 5 MagnaTherm Boilers and Water Heaters Control Panel Blower Manual Gas Valve Spark Generator Rating Plate. (on outside of panel) Touch Screen Heat Exchanger Condensing Unit Field Gas Supply Electrical Connections Drain Air Intake and Filter Power Pack Main Power Connections Water Outlet Water Inlet...
  • Page 10 LAARS Heating Systems Page 6 Blower Manual Gas Valve (hidden behind main gas valve) Spark Generator Rating Plate. (on outside of panel) Touch Screen Control Panel Heat Exchanger Condensing Unit Gas Supply Air Intake and Filter Field Main Power Electrical...

  • Page 11: Dimensions

    Page 7 MagnaTherm Boilers and Water Heaters 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 ) 2000 29.3 (75 )

  • Page 12: G Unpacking And The Installation Kit

    LAARS Heating Systems Page 8 Unpacking and the Installation Kit This unit is shipped in a single crate. Carefully disassemble the crate and inspect the unit for any damage during shipping. Included in the crate and yet outside of the unit is the ‘Installation Kit’ box.

  • Page 13: Section 2 Locating The Unit

    Page 9 MagnaTherm Boilers and Water Heaters SECTION 2 Locating the Unit WARNING Locating the unit If installing outdoors in a location that may This unit may be installed indoors or outdoors. If experience freezing temperatures, provisions installing outdoors in a location that may experience must be made to protect the unit from freeze freezing temperatures, precautions must be taken to damage.
  • Page 14 Page 10 LAARS Heating Systems See Table 1 for Suggested Service Top INCHES SURFACE Clearances Front Left Side Right Side Back Top, 1600 & 2000 Top, 2500 & 3000 Top, 4000 Table 1. Suggested Service Clearances SURFACE INCHES Front Left Side...

  • Page 15: Section 3 Venting And Combustion Air

    Page 11 MagnaTherm Boilers and Water Heaters SECTION 3 Venting and Combustion Air General Venting General Venting This unit requires a special venting system. Refer Do not mix venting suppliers and models in venting This product requires a special venting system. Refer to venting supplier’s instructions for complete parts list and method to venting supplier’s instructions for complete parts systems.

  • Page 16: B Combustion Air

    Page 12 LAARS Heating Systems Combustion Air Boilers and water heaters must have provisions for shall communicate directly, or by ducts, with the combustion and ventilation air in accordance with the outdoors or spaces that freely communicate with applicable requirements for Combustion Air Supply the outdoors.

  • Page 17: Ducted Combustion Air

    Page 13 MagnaTherm Boilers and Water Heaters Venting Other methods of introducing combustion and WARNING ventilation air are acceptable, providing they conform Selection of improper vent materials for to the requirements in the applicable codes listed installations that are installed in closets, or will be above.

  • Page 18: Common Venting

    Page 14 LAARS Heating Systems 3.D.1 Common Venting This unit can be common vented, however, the All installations must be done following the vent common venting must be a professionally designed supplier’s recommended installation techniques. If and approved system. See Document 1396.

  • Page 19: E Locating The Vent & Comb Air Terminals

    Page 15 MagnaTherm Boilers and Water Heaters Class II venting systems are further classified into four temperature ratings as follows: Up to and including 65°C / 149°F Up to and including 90°C / 194°F Up to and including 110°C / 230°F and Up to and including 135°C / 275°F Flue Gas Sampling Port - It is also the responsibility of the installer to ensure...
  • Page 20 Page 16 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 21: Side Wall Combustion Air Terminal

    Page 17 MagnaTherm Boilers and Water Heaters 3.E.3 Vertical Vent Terminal When the unit is vented through the roof, the vent must extend at least 3 feet (0.9 m) above the point at which it penetrates the roof. It must extend at least 2 feet (0.6 m) higher than any portion of a building within a horizontal distance of 10 feet (3.0 m), and high enough above the...

  • Page 22: Common Vent Test

    Page 18 LAARS Heating Systems At the time of installation of the side wall vented gas fueled appliance, the installing plumber or gas-fitter shall observe that a hard-wired carbon monoxide detector with an alarm battery back-up is installed on the floor level where the gas appliance is to be installed.

  • Page 23: G Outdoor Installation

    Page 19 MagnaTherm Boilers and Water Heaters 3. Dans la mesure du possible, fermer toutes les 3. Insofar as is practical, close all building doors portes et les fenêtres du bâtiment et toutes les and windows and all doors between the space in portes entre l’espace où...

  • Page 24: Section 4 Gas Supply And Piping 4.A Gas Supply And Piping

    Page 20 LAARS Heating Systems SECTION 4 Gas supply and Piping Gas Supply and Piping All Installations must conform to the National Fuel Natural Gas LP (propane) Gas Code ANSI Z223.1/NFPA54, and/or local codes. In Canada, the installation must conform to the latest 4.0 IN - W.C.
  • Page 25 2,220 3,530 6,250 12,700 1,900 3,020 5,350 10,900 1,680 2,680 4,740 9,660 Page 21 MagnaTherm Boilers and Water Heaters 1,520 2,430 4,290 8,760 1,400 2,230 3,950 8,050 1,300 2,080 3,670 7,490 The following are gas line sizing examples from the National Fuel Gas Code. Size your gas lines properly, 1,220 1,950 3,450...

  • Page 26: Section 5 Water Flow Requirements

    4000 34.5 52.0 70.0 Page 22 LAARS Heating Systems SECTION 5 Water Flow Requirements Boiler Flow and Head Requirements Boiler Water Flow Requirements Temperature Rise in °F 25°F 30°F 35°F 40°F Model Model Flow Flow Flow Flow Head Loss Head Loss...

  • Page 27: Water Heater Flow And Head Requirements

    Page 23 MagnaTherm Boilers and Water Heaters Water Heater Flow and Head Requirements Water Flow Requirements (for water heater submittal) Water Hardness Allowable pH: 6.5 to 9.5 1-10 grains per gallon Model Flow Rate Temp Rise Headloss Flow Rate Temp Rise Headloss Flow Rate Temp Rise...

  • Page 28: Section 6 Water Connection Boilers

    Page 24 LAARS Heating Systems SECTION 6 Water Connection Boilers System Piping: Hot Supply Connections NOTE: This unit must be installed in a closed pressure system with a minimum of 12 psi (82.7 required by the authority having jurisdiction, must be kPa) static pressure at the boiler.

  • Page 29: D Condensate Drain Trap

    Page 25 MagnaTherm Boilers and Water Heaters specific products, maintenance of solutions, and set a condensate pump is not used, the tubing must up according to your particular conditions. continuously slope downward toward the drain with no spiraling. The following manufacturers offer glycols, inhibitors, and anti foamants that are suitable for use in the Connect a 3/4”...
  • Page 30 Page 26 LAARS Heating Systems 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.
  • Page 31 Page 27 MagnaTherm Boilers and Water Heaters 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.
  • Page 32 Page 28 LAARS Heating Systems 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. radiant zone...
  • Page 33 Page 29 MagnaTherm Boilers and Water Heaters 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 34: Section 7 Water Connections

    Page 30 LAARS Heating Systems SECTION 7 Water Connections Suggested Piping Schematics Water Quality Figure 14 through Figure 16 show suggested piping configurations for water heaters. These diagrams Water heaters must be installed in water conditions are only meant as guides. All components or piping of 15 gpg hardness or less, with a pH range of 6.5...
  • Page 35 Page 31 MagnaTherm Boilers and Water Heaters 7.5 Freeze Protection tank, flow check, and shutoff valves where needed or as required by code. If installing outdoors in a location that may The piping should be installed so that each pump experience freezing temperatures, precautions supplies flow only to the heater to which it is must be taken to prevent water in the heat...

  • Page 36: E Water Flow

    Page 32 LAARS Heating Systems NOTE: This drawing shows suggested piping configuration and valving. Optional location for EXPANSION COLD WATER SUPPLY Check with local codes and TANK ordinances for additional requirements. BUILDING RETURN Location of pump Check valve Location of pump...

  • Page 37: Section 8 Electrical Connections 8.A Installation Warnings

    Page 33 MagnaTherm Boilers and Water Heaters SECTION 8 Electrical Connections WARNING Installation Warnings The unit must be electrically grounded in accordance with the requirements of the authority CAUTION having jurisdiction or, in the absence of such requirements, with the latest edition of the National The supply voltage to this unit must not be Electrical Code, ANSI/NFPA 70, in the U.S.

  • Page 38: C Pump Connections And Operation

    Page 34 LAARS Heating Systems Pump Connections and Operation The controller in this unit energizes the appropriate 7.4 amps, and an appropriately sized contactor pump contacts when it receives a call for heat. Once must be supplied and installed by a qualified the call for heat is satisfied, the pumps will remain on technician to ensure proper pump operation.

  • Page 39: D Field Wiring

    Page 35 MagnaTherm Boilers and Water Heaters Both units are shown with outside panels removed for full servicing. Field Junction Box Electrical for Main Power Connections. Connections At the front of the unit. Available Electrical Raceway Available Knockouts for System Sensor and/or modbus,...

  • Page 40: E Field Connections For Single Unit Installs

    Page 36 LAARS Heating Systems Field Connections for 15 BOILER PUMP H Single unit installations 16 BOILER PUMP N 17 SYSTEM PUMP H 18 SYSTEM PUMP N 19 DHW PUMP H Power for Field Connections must be 20 DHW PUMP N...

  • Page 41: G Control Panel Layout

    Page 37 MagnaTherm Boilers and Water Heaters Control Panel Layout CONN CONN CONN 15 BOILER PUMP H 16 BOILER PUMP N 17 SYSTEM PUMP H 18 SYSTEM PUMP N 19 DHW PUMP H 20 DHW PUMP N 21 OUTDOOR/SYS 22 OUTDOOR/SYS 23 ANALOG 24 ANALOG + 25 TT...

  • Page 42: H Building Automation System Connections

    Page 38 LAARS Heating Systems Lead Unit Building Automation System Connections This commercial unit can be controlled and monitored with a Gateway BAS using the included Modbus ports. Doc# 4236. The Gateway Modbus Control (H2354400) for BACnet MS/TP, BACnet/IP, Modbus TCP/IP, Metasys N2 and LonWorks.

  • Page 43: I Lead Lag Connections

    Page 39 MagnaTherm Boilers and Water Heaters Lag Unit/s Lead Lag Connections This commercial unit can be connected in Lead Lag up to a total of 8 units (controllers). One as the Lead control and up to 7 more as the Lag controllers. For Lead Lag Connections, COM2 A, B, and C must be connected together AND the MB2 A.

  • Page 44: J Wiring Diagrams

    Page 40 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 45 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 1 (OPTIONAL) APPROVALS MATERIAL: DRAFT JAT 1/22/15 ENGR INTENDED SIZE: SOFTWARE DWG. NO: REV. AL 1/22/15...
  • Page 46 LAARS Heating Systems Page 42 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 47 FROM ENCLOSURE DECIMALS .X FRACTIONS 1/8" DIMENSIONS ARE IN INCHES. SHIELDED VTB6 DECIMALS .XX 24VAC POWER DIGITIZED CABLE DECIMALS .XXX .010 P/N LAARS-1 TITLE: VTB1 ANGLES DIAGRAM, WIRING/BLOCK, MGT (OPTIONAL) APPROVALS MATERIAL: DRAFT 4/19/13 ENGR INTENDED SIZE: SOFTWARE DWG. NO: REV.

  • Page 48: K High Voltage Wiring Diagrams

    LAARS Heating Systems Page 44 High Voltage Wiring Diagrams Figure 24. High voltage wiring diagram Model 1600, 120V...
  • Page 49 MagnaTherm Boilers and Water Heaters Page 45 Figure 25. High voltage wiring diagram Model 1600, 208V Single Phase...
  • Page 50 LAARS Heating Systems Page 46 8.K High Voltage Wiring Diagrams (continued) Figure 26. High voltage wiring diagram Model 1600, 240V...
  • Page 51 Page 47 MagnaTherm Boilers and Water Heaters Figure 27. High voltage wiring diagram Model 2000, 120V...
  • Page 52 LAARS Heating Systems Page 48 8.K High Voltage Wiring Diagrams (continued) 120V N 120V N 120V H 120V H Figure 28. High voltage wiring diagram Model 2000, 208V Single Phase...
  • Page 53 Page 49 MagnaTherm Boilers and Water Heaters Figure 29. High voltage wiring diagram Model 2000, 240V...
  • Page 54 Page 50 LAARS Heating Systems 8.K High Voltage Wiring Diagrams (continued) 120V N 120V N 120V H 120V H Figure 30. High voltage wiring diagram Model 2000 - 4000 three phase...

  • Page 55: L Ladder Diagrams

    MagnaTherm Boilers and Water Heaters Page 51 Ladder Diagrams Figure 31. Model 1600 120V ladder diagram...
  • Page 56 LAARS Heating Systems Page 52 8.L Ladder Diagrams (continued) Figure 32. Model 1600, 208V, 1 Phase, ladder diagram...
  • Page 57 MagnaTherm Boilers and Water Heaters Page 53 Figure 33. Model 1600 240V ladder diagram...
  • Page 58 LAARS Heating Systems Page 54 8.L Ladder Diagrams (continued) Figure 34. Model 2000, 208V, 1 Phase, ladder diagram...
  • Page 59 Page 55 MagnaTherm Boilers and Water Heaters Figure 35. Model 2000, 120V ladder diagram...
  • Page 60 Page 56 LAARS Heating Systems 8.L Ladder Diagrams (continued) Figure 36. Model 2000, 240V ladder diagram...
  • Page 61 Page 57 MagnaTherm Boilers and Water Heaters Figure 37. Three-Phase Ladder Diagram...

  • Page 62: Section 9 Navigating The Touchscreen

    Page 58 LAARS Heating Systems SECTION 9 Navigating the Touchscreen Touch Screen Open the front panel to access the Touch Screen Figure 38. To access the Touch Screen Figure 40. With Front Doors Open. The Touch Screen The Touch Screen is visible behind a protective...

  • Page 63: C Screen Menu Icons

    Page 59 MagnaTherm Boilers and Water Heaters To change some parameters, a password is required. The control system includes three levels of password protection: OEM Password Setup and parameter changes available only to the factory. Installer Password Setup and parameter changes made when the system is installed, and some diagnostic and troubleshooting functions.

  • Page 64: D Verification Process For Safety Related Parameters

    Page 60 LAARS Heating Systems The verification process allows the user to confirm that all the changes made are correct and that there have not been any inadvertent changes made. When you start to change a parameter that is related to safety, the system will present a warning which looks like this: Menu 4.

  • Page 65: E Checking Individual Parameters

    Page 61 MagnaTherm Boilers and Water Heaters Reset Menu 8. Safety Parameter Reset Figure 41. Reset Button on Controller 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. The system will present a listing for each You must press the Reset button within 30 group of parameters that need verification...

  • Page 66: F Configuring Parameters

    Page 62 LAARS Heating Systems Menu 12. Status Summary Screen Menu 10. Status Summary Screen Notice the four buttons at the bottom of each 3. Press the Configure button to start a Status Summary screen: configuration session for the controller.

  • Page 67: G Setting The Date And Time

    Page 63 MagnaTherm Boilers and Water Heaters Setting the Date and Time on the System Display Press the Display Setup button at the bottom The display includes an internal clock, which keeps of the screen. track of the date and time. This setting is important, because log entries for Lockouts and Alerts include time listings.

  • Page 68: H Configuration Menus

    Page 64 LAARS Heating Systems ConfigurationMenus The following sections give overviews ofeachconfigurationsubmenu. 9.H.1 SystemIdentification&Access Menu 18. Home Screen To navigate to the Configuration Menu Screen, first touch the controller icon on the home screen to This menu will display information regarding...

  • Page 69: Dhw - Domestic Hot Water Configuration

    Page 65 MagnaTherm Boilers and Water Heaters Connect the outdoor reset sensor as descibed in is used with the Outdoor Reset and Warm Weather Section 8.D Shutdown features. From this menu you will be able to enable/disable Wiring the Warm Weather Shutdown feature and adjust the For single boiler operation, the outdoor sensor will set point.

  • Page 70: Pump Configuration

    Page 66 LAARS Heating Systems 9.H.8 PumpConfiguration 9.H.11 High Limits 9.H.9 8.5.8 PumpConfiguration The outlet high limit can be adjusted using the The controller in this unit energizes the appropriate installer password. After a change is made, the pump contacts when it receives a call for heat.

  • Page 71: Delta T Limits

    Page 67 MagnaTherm Boilers and Water Heaters 9.H.13 Delta T Limits- sequence of operation to light the pilot only. Once pilot pressure has been properly set, the installer must disable call for heat and turn this feature “OFF”. The next time a call for heat is supplied the unit will light normally.

  • Page 72: Lag (Slave) Configuration

    Page 68 LAARS Heating Systems 9.H.18 Lag (Slave) anyoneunitdoesnotrunsignificantlylonger Configuration than the others. The Lead Lag controller tracks the run times for all of the units, and uses this About Lead Lag Operation - to calculate the starting order for the units. This Units = Boilers or Water Heaters.
  • Page 73 Page 69 MagnaTherm Boilers and Water Heaters Number of Base load value boilers installed Low demand - The first boiler in sequence fires at less than 65% Demand increases - Once the first boiler reaches 65%, the second boiler switches on, and Table 21.
  • Page 74 Page 70 LAARS Heating Systems 9.H.18 L ag(Slave)Configuration(continued) Select ‘Configure’. type in ‘LNT’ and press OK. Then you can select Slave Enable. Select ‘Enable Slave for built-in Lead Lag Master’ . Then select OK Then select a Modbus address (number) for that unit.

  • Page 75: Lead (Master) Configuration

    Page 71 MagnaTherm Boilers and Water Heaters 9.H.19 Lead(Master)Configuration Wiring Connections for Lead Lag - All Connections to the Lag units must be made prior to configuring the Lead unit. Now you can make the Modbus wiring Set up the Lead (Master) controller by going to connections between the units.
  • Page 76 Minimum Boiler Water Temp 40F - 180F Outdoor Reset Config DHW Enable Enabled Enable / Disable DHW Config Page 72 LAARS Heating Systems Sensor Only STAT Terminal Auto:DHW (S6) or Demand Switch DHW Config Auto: DHW (S6) or EnviroCOM DHW Sensor Only...
  • Page 77 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 Frost Protection Config Enable / Disable Page 73 MagnaTherm Boilers and Water Heaters Lead Lag Frost Protection Rate 0% - 100% Frost Protection Config...
  • Page 78 Lead Rotation Time 0 min 0 sec - 1080 hrs 0 min 0 sec (7 days) Adv Settings-Algorithms Page 74 LAARS Heating Systems Lead Lag Master Config- Base Load Common 20% - 100% Adv Settings-Rate Allocation Parameter Defaults and Ranges (continued)

  • Page 79: J C Onfiguring For A Gateway Control For Bas

    Page 75 MagnaTherm Boilers and Water Heaters  C onfiguringforaGatewayControl. (Building Automation System) Building Automation Systems Control: BACnet MS/ TP, BACnet/IP, Modbus TCP/IP, Metasys N2 and LonWorks. If communication protocols are desired, this commercial unit can be controlled and monitored through the included Modbus Ports.

  • Page 80: Kvari-Prime Flow Control System

    Page 76 LAARS Heating Systems VARI-PRIME Flow Control System ® VARI-PRIME is a variable pump control that is 5. Once the Main Gas valve is energized the PCB standard equipment on all boilers. Pump speed is will maintain pump output at 100% for 60 seconds controlled to maintain a user-chosen temperature to allow the system to stabilize.

  • Page 81: L Combustion Setup Procedure

    Page 77 MagnaTherm Boilers and Water Heaters Combustion Setup Procedure 5. From the “Configuration” menu, select the line In this section, we will explain how to set up the gas “Burner Control Ignition.” valve so the boiler will run efficiently at both the High Fire and Low Fire conditions.
  • Page 82 Page 78 LAARS Heating Systems pilot test hold. 9. This unit 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”...
  • Page 83 Page 79 MagnaTherm Boilers and Water Heaters Model Gas Type High Fire CO Low Fire CO Pressure Differential Natural 9.0% ± 0.2 .25 lower than high fire CO 0.5” to 1.2” wc* 1,600 Propane 10.0% ± 0.2 .25 lower than high fire CO 0.5”...

  • Page 84: Section 10 Initial Startup Instructions

    Page 80 LAARS Heating Systems SECTION 10 Initial startup Instructions 10.A Filling the Boiler System the expansion tank, open the tank drain, and drain to that level. Ensure the system is fully connected. Close all Shut down the entire system and vent all...

  • Page 85: B Initial Operation

    Page 81 MagnaTherm Boilers and Water Heaters WARNING 10.B Initial Operation If any odor of gas is detected, or if the gas The initial setup must be checked before the unit is burner does not appear to be functioning in a put into operation.

  • Page 86: Section 11 Maintenance

    Page 82 LAARS Heating Systems SECTION 11 Maintenance WARNING Disconnect all power to the unit before attempting 11.A System Maintenance any service procedures. Contact with electricity Do the following once a year: can result in severe injury or death. Lubricate all the pumps in the system, per the instructions on the pump.

  • Page 87: Controller

    Page 83 MagnaTherm Boilers and Water Heaters 11.B.5 Flame Sensor After the valve has been removed, reassemble in reverse order making sure to include all gaskets The flame sensor is a single rod system. The minimum and O-rings. Turn on the manual gas valves and flame signal that will allow the unit to fire is 0.8 volts.

  • Page 88: Heat Exchanger Tubes

    Page 84 LAARS Heating Systems 11.B.8 Heat Exchanger Tubes Black carbon soot buildup on the external surfaces of the heat exchanger is caused by one or more of the following; incomplete combustion, combustion air problems, venting problems or heater short cycling.

  • Page 89: Battery Back Up For Date And Time

    Page 85 MagnaTherm Boilers and Water Heaters 11.B.10 Battery Back Up for Date and Time The touchscreen does have an internal battery for back-up of the date and time settings. The battery is a CR2032 ‘coin type’ battery and has an expected service life of 6 years. If the battery needs to be replaced, there is a battery cover on the back of the touchscreen display and it can be easily reached when the Control Panel that the...

  • Page 90: Section 12 Troubleshooting

    Page 86 LAARS Heating Systems SECTION 12 Troubleshooting 12.A Lockouts, Holds, and Alerts bottom of the screen. If you tap the orange bar, The control system on this unit responds to three the system will present more information about kinds of trouble indications: the Lockout.
  • Page 91 Page 87 MagnaTherm Boilers and Water Heaters If you choose ‘LOCKOUTS’, this menu will appear. (the long bar will be a long Grey ‘History’ Bar if not currently in Alert or Lockout). Menu 34. OK, Lockouts, Alerts, or Silence. Menu 36. Lockout History Choose which history list you would like to see.

  • Page 92: B Troubleshooting Table

    Page 88 LAARS Heating Systems 12.B 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.
  • Page 93 Page 89 MagnaTherm Boilers and Water Heaters Internal fault: Safety relay test failed due to safety relay OFF Internal fault: Internal fault Safety relay test failed due to safety 1. Reset module relay not OFF 2. If fault repeats, replace module. Internal fault: Safety relay test failed due to feedback not ON...
  • Page 94 Page 90 LAARS Heating Systems Modulation fault Internal sub-system fault. Pump fault 1. Review alert messages for possible trends. Motor tachometer fault 2. Correct possible problems. 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.
  • Page 95 Page 91 MagnaTherm Boilers and Water Heaters 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. DHW (Domestic Hot Water) high limit H or L 1.
  • Page 96 Page 92 LAARS Heating Systems Pressure Sensor Fault 1. Verify the Pressure Sensor is a 4-20 ma source. 2. Check wiring and correct any possible errors. 3. Test Pressure Sensor for correct operation. 4. Replace the Pressure sensor. 5. If previous steps are correct and fault persists, replace the module.
  • Page 97 Page 93 MagnaTherm Boilers and Water Heaters Lightoff rate proving failed 1. Check wiring and correct any potential wiring errors. 2. Check VFD’s (Variable-speed Fan Drive) ability to change speeds. 3. Change the VFD 4. If the fault persists, replace the module. Purge rate proving failed 1.
  • Page 98 Page 94 LAARS Heating Systems Flame detected H or L Holds if flame detected during Safe Start check up to Flame Establishing period. Flame not detected Sequence returns to standby and restarts sequence at the beginning of Purge after the HF switch opens if flame detected during Safe Start check up to Flame Establishing period.
  • Page 99 Page 95 MagnaTherm Boilers and Water Heaters Invalid BLOWER / SPARK output setting Invalid Delta T limit enable setting Invalid Delta T limit response setting Invalid DHW (Domestic Hot Water) high 1. Return to Configuration mode and recheck selected parameters, reverify and reset module. limit enable setting Invalid DHW (Domestic Hot Water) high 2.
  • Page 100 Page 96 LAARS Heating Systems Invalid DHW (Domestic Hot Water) demand source setting Invalid Flame threshold setting Invalid Outlet high limit setpoint setting Invalid DHW (Domestic Hot Water) high limit setpoint setting 1. Return to Configuration mode and recheck Invalid Stack limit setpoint setting selected parameters, reverify and reset module.

  • Page 101: C Diagnostic Tests And Input/Output Indicators

    Page 97 MagnaTherm Boilers and Water Heaters 12.C Diagnostic Tests and Input/Output Indicators Two kinds of screens are grouped together in this section: • Detailed indications of the input and output signals • Diagnostic tests of the pumps and burner modulation Note that these functions apply to just one selected controller.

  • Page 102: D Lead Lag Diagnostics

    Page 98 LAARS Heating Systems 12.D Lead Lag Diagnostics 12.F Analysis The control system includes a diagnostic screen that The control system includes an Analysis branch lists some information on the Lag (Slave) units in the that can display the behavior over a period of time system.

  • Page 103: G Control Snapshot

    Page 99 MagnaTherm Boilers and Water Heaters 12.G Control Snapshot 12.H Operating Sequence The software allows you to take a “snapshot” of When there is a call for heat, the unit will close pump the current state of the controller, including setup contacts to energize the customer supplied relay/ information and operating information.

  • Page 104: Section 13 Replacement Parts

    Page 100 LAARS Heating Systems SECTION 13 Replacement Parts Use only genuine Manufacturer replacement parts. 13.A General Information To order or purchase parts, contact your nearest manufacturers dealer or distributor. (See the back cover of this manual for the manufacturers website).

  • Page 105: B Component Illustrations, Parts Lists, And Part Numbers

    Page 101 MagnaTherm Boilers and Water Heaters 13.B Component Illustrations, Parts Lists, and Part Numbers 13.B.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 106 Page 102 LAARS Heating Systems DETAIL A DETAIL Final Assembly Final Assembly...

  • Page 107: Final Assembly, Part Numbers

    Page 103 MagnaTherm Boilers and Water Heaters Frame and Jacket Assembly 1600 2000 2500 3000 3500 4000 View from Back Item # Description Part No. Part No. Part No. Part No. Part No. Part No. Base assembly 16N1000 20N1000 30N1000 30N1000 40N1000 40N1000...

  • Page 108: Control Panel Assembly, Part Numbers

    P2090700 P2090700 P2090700 P2090700 Union P0030500 P0030700 Nipple P0053400 P2072800 Elbow P0008700 P0008700 P0008700 P0008700 Page 104 LAARS Heating Systems Nipple P0015700 P0015500 P0021200 P0021200 Nipple P2095900 P0021200 P0021200 P0021200 Nozzle Orifice, 0.2 mm P2105100 Washer, Sealing S2123500 S2123500 S2123500...

  • Page 109: Blower Burner Assembly, Part Numbers (Model 1600)

    Page 105 MagnaTherm Boilers and Water Heaters DETAIL 13.B.4 Blower Burner Assembly, Part Numbers (Model 1600) W2014100 16N5074 A2132700 Spark Generator 20N3060...

  • Page 110: Blower Burner Assembly, Part Numbers (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 106 LAARS Heating Systems Door, right Door, right 20N3100 20N3100 20N3100 20N3100 30N3100 30N3100 30N3100 40N3100 30N3100 40N3100 40N3100 40N3100...

  • Page 111: Blower Burner Assembly, Part Numbers (Models 2500 And 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 Assembly Heat Exchanger Assembly R16N2070 R20N2070 R30N2070 R16N2070 R30N2070 R20N2070 R40N2070 R30N2070 R40N2070...

  • Page 112: Blower Burner Assembly, Part Numbers (Models 3500 And 4000)

    S2123600 Plug, button, 7/8" F0032300 F0032300 F0032300 Flue Gas Sensor E2340000 E2340000 E2340000 Page 108 LAARS Heating Systems Waterway Outlet Assembly 13.B.7 Blower Burner Assembly, 1600 2000 2500 Part Numbers (Models 3500 and 4000) Item # Description Part No. Part No.

  • Page 113: Ac Distribution Box Assemblies And Part Numbers (Model 1600)

    Page 109 MagnaTherm Boilers and Water Heaters 13.B.8 AC Distribution Box Assemblies and Part Numbers (Model 1600) AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODEL1600)

  • Page 114: Ac Distribution Box Assembly And Blower Part Numbers (Model 2000)

    Page 110 LAARS Heating Systems 13.B.9 AC Distribution Box Assembly and Blower Part Numbers (Model 2000) AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS AND BLOWER (MODEL 2000)

  • Page 115: Part Numbers (Models 2500 To 4000)

    Page 111 MagnaTherm Boilers and Water Heaters SEE DETAIL A FOR PILOT TUBE PLACEMENT ETAIL A 13.B.10 AC Dist Box Assy and Blower Part Numbers (Models 2500 to 4000) AC DISTRIBUTION BOX ASSEMBLY PART NUMBERS (MODELS 2500 AND 3500) PART NUMBER DESCRIPTION 40N5068 STANDARD...

  • Page 116: Gas Train Assembly, Part Numbers (Models 1600, 2000, 2500 And 3000)

    Page 112 LAARS Heating Systems Gas Train Assembly (Models 1600, 2000, 2500 and 3000)
  • Page 117 O-Ring S2124800 S2124800 Blower A2120900 A2120900 Adapter 1/4" tube x 1/8" female P2090200 P2090200 Page 113 MagnaTherm Boilers and Water Heaters Blower tube 40N5077 40N5077 Gasket, burner S2124600 S2124600 Ignitor, hot surface W2013900 W2013900 Sight glass RF0044800 RF0044800 13.B.11 Gas Train Assembly, Part Numbers Flame sensor W2014900 W2014900...

  • Page 118: Gas Train Assembly, Part Numbers (Models 3500 And 4000)

    Page 114 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 119 Nipple P0053400 P2072800 Elbow P0008700 P0008700 P0008700 P0008700 Nipple P0015700 P0015500 P0021200 P0021200 Page 115 MagnaTherm Boilers and Water Heaters Nipple P2095900 P0021200 P0021200 P0021200 Nozzle Orifice, 0.2 mm P2105100 Washer, Sealing S2123500 S2123500 S2123500 S2123500 13.B.12 Gas Train Assembly, Part Numbers (Models 3500 and 4000) 3500 4000 Item #...

  • Page 120: Waterway Outlet Assembly, Part Numbers

    Panel, center rear 16N3020 20N3020 30N3020 30N3020 40N3020 40N3020 Panel, lower rear 16N3021 20N3021 25N3021 30N3021 40N3021 40N3021 Page 116 LAARS Heating Systems Panel, right 20N3036 20N3036 30N3036 30N3036 40N3036 40N3036 Strut, upper panel support 30N3043 30N3043 30N3043 30N3043 30N3043 30N3043...
  • Page 121 Page 117 MagnaTherm Boilers and Water Heaters Notes:...
  • Page 122 Page 118 LAARS Heating Systems Notes:...
  • Page 123 Page 119 MagnaTherm Boilers and Water Heaters Notes:...
  • Page 124 Industrial Way, Rochester, NH, USA 03867 • 603.335.6300 • Fax 603.335.3355 If the mark MUST rev Headquarters: the PMS® 300 mark, 9 Brigden Gate, Halton Hills, Ontario, Canada L7G 0A3 (905) 203-0600 Fax: (905) 636-0666 white outline. www.Laars.com Litho in U.S.A. © Laars 1810 Document 1276J...

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