INSTALLATION OPERATION AND SERVICE MANUAL Dynaforce® Series GAS FIRED COMMERCIAL CONDENSING STAINLESS STEEL TUBE BOILERS HYDRONIC HEATING Models; DRH300, 350 400, 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000, 4500, 5000 H HOT WATER HEATER Models; DRW300, 350 400, 500, 600, 800, 1000, 1200, 1400, 1600, 1800, 2000, 2500, 3000, 3500, 4000, 4500, 5000 HLW WARNING: If the information in these instructions is not followed exactly, a fire or explosion may result causing property damage, personal injury or death Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS o Do not try to light any appliance, o Do not touch any electrical switch; do not use any phone in your building, o Immediately call your gas supplier from a neighbour’s phone. Follow the gas supplier’s instructions, o If you cannot reach your gas supplier, call the fire department. Qualified installer, service agency or the gas supplier must perform installation and service. To the Installer: After installation, these instructions must be given to the end user or left on or near the appliance. To the End User: This booklet contains important information about this appliance. Retain for future reference. 6226 Netherhart Road, Mississauga, Ontario, L5T 1B7 99-0171 Rev. 0.7 Table of Contents PART 1 GENERAL INFORMATION............................................................................................................................... 1 1.1 INTRODUCTION ............................................................................................................................................. 1 1.2 SPECIAL INSTRUCTIONS TO OWNER ............................................................................................................. 1 1.3 CHECKING EQUIPMENT ................................................................................................................................. 1 1.4 HOW IT OPERATES (SEQUENCE OF OPERATION) .......................................................................................... 1 1.4.1 HEAT TRANSFER PROCESS ............................................................................................................................. 2 1.4.2 END OF SEQUENCE ........................................................................................................................................ 2 1.5 CODES ............................................................................................................................................................ 3 1.6 WARRANTY .................................................................................................................................................... 3 1.7 REMOVAL OF EXISTING APPLIANCE .............................................................................................................. 3 1.8 BOILER ROOM OPERATING CONDITION ....................................................................................................... 4 1.9 CLEARANCE FROM COMBUSTIBLE MATERIAL............................................................................................... 4 1.10 INSTALLATION PROCEDURE AND LOCATION OF UNIT .................................................................................. 5 PART 2 VENTING ........................................................................................................................................................ 7 2.1 GENERAL VENTING GUIDE ............................................................................................................................ 7 2.1.1 CATEGORY II AND CATEGORY IV VENTING .................................................................................................... 7 2.1.2 VENTING GUIDELINES FOR CATEGORY IV VENTING...................................................................................... 7 2.1.3 APPROVED VENTING MATERIALS .................................................................................................................. 8 2.1.4 VENT TERMINATION CLEARANCES ................................................................................................................ 8 2.1.5 INLET CAP FOR ROOFTOP TERMINATION ..................................................................................................... 8 2.1.6 LOCATION OF A ROOFTOP AIR INLET AND VENT CAPS ................................................................................. 9 2.1.7 AIR INLET DAMPER ........................................................................................................................................ 9 2.1.8 MASONARY CHIMNEY INSULATIONS ............................................................................................................ 9 2.1.9 VERTICAL VENTING TERMINATION ............................................................................................................... 9 2.1.10 COMBINED COMBUSTION AIR INLET ............................................................................................................ 9 2.1.11 DRAIN TEE ................................................................................................................................................... 10 2.2 CONVENTIONAL VENTING (INDOOR) INSTALLATIONS ................................................................................ 10 2.2.1 AIR REQUIRED FOR COMBUSTION AND VENTILATION ............................................................................... 10 2.2.2 EXHAUST FANS ............................................................................................................................................ 11 2.3 OUTDOOR VENTING .................................................................................................................................... 11 2.4 SIDEWALL VENTING .................................................................................................................................... 11 2.4.1 SIDEWALL VENT TERMINAL & SIDEWALL INTAKE AIR TERMINAL ............................................................... 11 2.4.2 LOCATION OF A SIDEWALL VENT TERMINATION ........................................................................................ 11 2.4.3 LOCATION OF A SIDEWALL AIR INLET TERMINAL ....................................................................................... 12 2.4.4 LENGTH OF AIR INLET PIPE .......................................................................................................................... 12 PART 3 GAS CONNECTION ....................................................................................................................................... 12 3.1 GAS CONNECTION ....................................................................................................................................... 12 3.2 GAS PIPING .................................................................................................................................................. 13 3.3 INSTALL PIPING............................................................................................................................................ 13 3.4 AIR/GAS RATIO VALVE ................................................................................................................................. 13 3.5 DIFFERENTIAL AIR PRESSURE (DR2000 – DR5000) ...................................................................................... 14 3.6 GAS MANIFOLD DIFFERENTIAL PRESSURE ADJUSTMENT (DR2000 – DR5000) ........................................... 14 3.7 CHECKING GAS SUPPLY PRESSURE .............................................................................................................. 15 3.7.1 Regulated Gas Supply Pressures for Dynaforce® Boilers & Water Heaters ................................................ 15 3.8 CHECKING DIFFERENTIAL AIR AND GAS PRESSURES (DR2000 – DR5000) .................................................. 15 3.9 GAS TRAIN AND CONTROLS ........................................................................................................................ 16 3.10 VENTING OF GAS VALVES AND PRESSURE SWITCHES ................................................................................ 16 3.11 BURNER ....................................................................................................................................................... 16 PART 4 WATER CONNECTION .................................................................................................................................. 17 4.1 FREEZE PROTECTION ................................................................................................................................... 17 4.2 WARNING REGARDING CHILLED WATER AND HEATING COIL SYSTEMS .................................................... 17 4.3 INLET AND OUTLET CONNECTIONS ............................................................................................................. 18 4.4 MINIMUM PIPE SIZE REQUIREMENTS ......................................................................................................... 18 4.5 HEAT EXCHANGER ....................................................................................................................................... 18 4.6 LOW WATER TEMPERATURE SYSTEMS ....................................................................................................... 18 4.7 INSTANTANEOUS WATER HEATER .............................................................................................................