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INSTALLATION
Disconnect the
condensate pipe
Fill the trap
with water
Fig. 12 Water Filling of Condensate System
− The installation must have provisions for suitable drainage
or collection of the condensate exiting the boiler traps.
− The condensate water shall be discharged at atmospheric
pressure, by dripping into a suitable drain, and shall be
neutralized prior to draining per local/national codes.
− The condensate drain tube must pitch away from the boiler
(1/4" slope per foot minimum) and must never reduce its
diameter downstream.
− Never use copper pipes or other material not intended
for the specific purpose, because the acidic nature of
the condensate will cause a rapid deterioration of the
unsuitable piping and/or exposed components.
− Check that the condensate drain pipe is adequately sloping
towards the discharge point avoiding high points, which
can inhibit the flow of the condensate. The condensate
pipe must be installed in such a way so as to avoid the
freezing of any liquid.
9
WARNING: Verify condensate disposal / neutralization is in
accordance 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
polypropylene for condensate drain piping (Fig. 12). DO NOT use
carbon steel or copper components.
Fig. 13 Condensate Drain and Relief Valves Manifold Locations
Fill the syphon
with water from
the top of the
vertical flue
manifold
BEFORE
connecting the
vent piping
Vertical Flue
Manifold
Syphon
Condensate Drain
(1" PVC adapter included)
Relief Valves Manifold
(2 5" NPT adapter included)
4.12 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. 9.
9
WARNING: Never use matches, candles, flames or other
sources of ignition to check for gas leaks.
9
CAUTION: Many of the soaps used for gas pipe bubble-leak
testing are corrosive to metals. Therefore, piping must be
rinsed thoroughly with clean water after leak checks have
been completed.
NOTE: All gas piping must be arranged so that it does not interfere
with the removal of any covers, inhibit service and/or maintenance,
or restrict access between the unit and walls, or another unit.
− Prior to installation, all pipes should be de-burred and
internally cleared of any scale, metal chips, oil, water or
other foreign particles. Do not install any flexible connectors
or unapproved gas fittings. Piping must be supported only
from the floor, ceiling or walls, 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
prevent 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
supply piping.
− Installation of a union fitting at the appliance gas line
connection is required for ease of service.
4.12.1 Gas Supply Specifications
The gas supply input specifications to the unit for Natural Gas are
as follows:
− The maximum 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, and maintain the recommended minimum
gas pressure at 8" w.c. while operating the burners at
maximum capacity.
4.12.2 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.
18
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