installation and operation instructions for mighty thermbostonheatingsupply.com/laars/laars mighty...

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 couldcreate carbon monoxide gas in flue gases which could cause serious injury, property damage, or death.Improper installation and/or operation will void the warranty.

WARNINGIf the information in this manual is not followed exactly, a fire or explosion may resultcausing 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 orany 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 gassupplier.

H01

1740

0E

Installation and OperationInstructions for

Mighty ThermHydronic Boilers

Models HH and PHSizes 500-1825

These instructions are to be stored in the pocket provided on the boiler

Installation and Operation Instructions Document 1049E

LAARS Heating Systems

TABLE OF CONTENTS

SECTION 1.General Information1A. Introduction ................................................... 31B. Boiler Identification ....................................... 31C. Flow Requirements ....................................... 31D. Variable Water Flow Systems ....................... 41E. Warning Regarding Chilled

Water Systems ............................................. 51F. Freeze Protection ......................................... 5

SECTION 2.Installation2A. Boiler Placement .......................................... 62B. Installation of Indoor Boilers .......................... 62B-1. Combustion Air Supply ................................. 62B-2. Venting ......................................................... 82C. Installation of Outdoor Boilers ....................... 92D. Gas Supply and Piping ................................. 92E. Electrical Wiring .......................................... 102F. Water Piping of System .............................. 112G. Filling Fully-Connected System................... 11

SECTION 3.Operation3A. Controls - General ...................................... 123B. Initial Start-Up ............................................. 133C. To Start Up System .................................... 133D. To Turn Off Boiler ....................................... 143E. To Shut Down System ................................ 14

SECTION 4.Maintenance

................................................................... 14

SECTION 5.Troubleshooting and Analysis ofService Problems

................................................................... 16

SECTION 6.Parts Descriptions andOrder Numbers

................................................................... 18

SECTION 7.Outdoor Parts Descriptions andOrder Numbers

................................................................... 26

SECTION 8.Optional Parts Descriptions andOrder Numbers

................................................................... 28

Mighty Therm Hydronic Boiler

SECTION 1.General Information

1A. IntroductionThis manual provides information for the

installation and operation of Laars hydronic boilers. Itis strongly recommended that all application andinstallation procedures be reviewed completely beforeproceeding with the installation. Consult the Laarsfactory, or local factory representative with anyproblems or questions regarding this equipment.Experience has shown that most problems are causedby improper installation not system design.

Some accessory items are shipped in separatepackages. Verify receipt of all items listed on thepackage slip. Inspect everything for possible damageupon delivery, and inform the carrier of any shortagesor impairments. Any such claims should be filed withthe carrier. The carrier, not the shipper, is responsiblefor shortages and damage to the shipment whethervisible or concealed.

IMPORTANT WARNING:

The model HH and PH hydronic boilers must beinstalled in accordance with the procedures outlinedin this manual. The warranty does not apply to boilersnot installed or operated in accordance with theseprocedures. Consult local building and safety codesbefore proceeding with work. The installation must

conform to the requirements of the authority havingjurisdiction or, in the absence of such requirements, tothe latest edition of the National Fuel Gas Code;ANSI Z223.1, National Electrical Code ANSI/NFPA70 and/ or in Canada CAN 1 -13149 requirement.

When required by the authority havingjurisdiction, the installation must conform toAmerican Society of Mechanical Engineers safetycodes for controls and safety devices for automaticallyfired boilers No. CSD-1, and in Canada CGA 3.3. Anymodification to the boiler, its gas controls, gasorifices, wiring or draft diverter may void the Laarswarranty. If field conditions require suchmodifications, consult factory.

1B. Boiler IdentificationConsult rating plate on the boiler. The following

example simplifies the boiler identification.

1 2 3 4 5 6PH 1670 I N 09 L

(1) Basic boiler model (see descriptions below).(2) Input rate X 1000 BTU/hr.(3) Indoor (1) or Outdoor (E) installation.(4) Gas type: Natural (N) or Propane (P).(5) Ignition system: I.I.D. (09) or continuous pilot

(16). Special option: I.I.D. (04) 115 volts.(6) Firing modes:

On/Off (C)2-stage (K)4-stage (L)Mechanical Modulation (H)Motorized Modulation (F)Motorized On/Off (R)Motorized 2-stage (T).

Model HH hydronic heating boilers. There mustbe a field installed pump to circulate water.

Model PH hydronic heating boilers are basicallythe same as the HH models except that the PH boilerscome with integrally mount pumps. Pumps are sizedfor pressure drop through the heat exchanger and shortruns of pipe for primary-secondary systems.

Laars hydronic boilers are available in twoconfigurations: an indoor version and an outdoorversion. Both are available from the factory (seeFigure 1).

1C. Flow RequirementsAll low volume hydronic boilers must have

continuous flow through the heat exchanger for properoperation. The system pump must be capable ofdeveloping sufficient pressure to overcome theFigure 1. Boiler Configuration.


Design Temperature Rise Across The Boiler

20°F 11°C 25°F 14°C 30°F 17°C 35°F 19°CIndoor Outdoor Flow H/L Flow H/L Flow H/L Flow H/LSizes Sizes GPM l/s Ft. m GPM l/s Ft. m GPM l/s Ft. m GPM l/s Ft. m

500 — 38 2.4 1.4 0.4 31 2.0 1.1 0.3 26 1.6 0.9 0.3 22 1.4 0.6 0.2— 500 41 2.6 1.7 0.5 33 2.1 1.1 0.3 27 1.7 0.9 0.3 23 1.5 0.7 0.2

600 — 49 3.1 2.3 0.7 39 2.5 1.6 0.5 32 2.0 1.1 0.3 28 1.8 0.9 0.3— 600 49 3.1 2.3 0.7 39 2.5 1.6 0.5 32 2.0 1.1 0.3 28 1.8 0.9 0.3

715 — 56 3.5 2.5 0.8 45 2.8 1.9 0.6 37 2.3 1.5 0.5 32 2.0 1.0 0.3— 715 58 3.7 3.2 1.0 47 3.0 2.2 0.7 39 2.5 1.6 0.5 33 2.1 1.1 0.3

850 — 66 4.2 3.4 1.0 53 3.3 2.5 0.8 44 2.8 2.0 0.6 38 2.4 1.4 0.4— 850 69 4.4 3.6 1.1 55 3.5 3.1 0.9 46 2.9 2.2 0.7 39 2.5 1.6 0.5

1010 — 79 5.0 4.7 1.4 63 4.0 3.4 1.0 53 3.3 2.7 0.8 45 2.8 1.9 0.6— 1010 82 5.2 5.0 1.5 66 4.2 3.6 1.1 55 3.5 3.1 0.9 47 3.0 2.2 0.7

1200 — 94 5.9 6.5 2.0 75 4.7 4.8 1.5 62 3.9 3.7 1.1 53 3.3 2.6 0.8— 1200 98 6.2 6.9 2.1 78 4.9 4.9 1.5 65 4.1 3.6 1.1 56 3.5 3.1 0.9

1430 — 112 7.1 8.9 2.7 89 5.6 6.5 2.0 74 4.7 5.0 1.5 64 4.0 3.5 1.1— 1430 117 7.4 9.5 2.9 93 5.9 6.7 2.0 78 4.9 5.0 1.5 67 4.2 3.7 1.1

1670 — * * * * 102 6.4 8.8 2.7 85 5.4 6.7 2.0 73 4.6 4.7 1.4— 1670 * * * * 109 6.9 9.1 2.8 91 5.7 6.8 2.1 78 4.9 5.0 1.5

1825 — * * * * 114 7.2 10 3.0 95 6.0 8.0 2.4 81 5.1 5.5 1.7— 1825 * * * * 119 7.5 10.4 3.2 99 6.2 8.3 2.5 85 5.4 5.7 1.7

*Consult factory for recommendations

resistance of the boiler plus the entire circulatingsystem at the designated GPM (see Table 1). Thetemperature rise across the boiler should never exceed40°F (22°C). Primary-secondary pumping is the mosteffective way to assure proper flow through the boilerresulting in longer boiler life and greater systemefficiency (see Figure 2).

1D. Variable Water Flow SystemsHeating systems using zone valves, zone pumps

or 3-way valves can experience reduced water flowthrough the boiler. This can result in an excessivewater temperature rise and unstable boiler operation.If the system water flow is variable, it must not beallowed to fall below 30% of full flow. The boilermust be equipped with staged or modulated fire withthe temperature sensor installed in the outlet water.State variable flow when ordering. Laars recommendsprimary-secondary pumping for all variable flowsystems. Primary-secondary pumping is mandatoryfor variable flow systems where minimum flows areless than 30% of full flow conditions. The boilerpump in a primary-secondary system maintainsconstant flow through the boiler even though thesystem flow is variable. In a primary-secondarysystem the pressure drop of the boiler is not added tothe system (see Figure 2).

Table 1. Flow Requirements.

A Special Note About 3-Way Water Valves3-way water valves (2 position or proportional)

are sometimes used to divert water around a boilerand control the temperature of water being supplied tothe system. Valves installed in this manner must besupplied with an end switch or some other suitablecontrol to shut off the boiler when the flow is reducedto 30%. The boiler must be supplied with staged ormodulated fire as indicated in Section 1D, VariableWater Flow Systems.

It is often possible to accomplish excellent watertemperature control without 3-way valves throughproper application of staged or modulated firingsystems. Consult the factory or local Laarsrepresentative for assistance with such systems.

System Pressure RequirementsThe model HH and PH boilers are designed to

operate on closed, pressurized systems. A minimum of12 psi should be maintained on the system whereboiler supply water temperatures are 200°F (93°C) orless. If higher temperatures are required, the minimumsystem pressure should be at least 15 psi above thewater vapor pressure corresponding to the elevatedwater temperature.

The hydronic boilers are not suitable for opensystems unless the supply water temperatures are keptbelow 180°F (82°C), and minimum of 5 psi statichead is maintained within the boiler.


1E. Warning Regarding ChilledWater SystemsWhen a boiler is connected to an air

conditioning system where the same water is used forheating and cooling, chilled water must be preventedfrom entering the boiler. When changing such asystem from cooling to heating, the chilled watershould be allowed to circulate through the building(after the chiller has been turned off) for a period long

enough for the water to warm up to at least 70°F(21°C) before the water is allowed to flow into theboiler. It is equally important to prevent hot waterfrom entering the chiller. The system shown in Figure3 is suggested to make sure that the system water isneither too hot nor too cold when a changeover fromheating to cooling, or vice versa, takes place. When aboiler is connected to heating coils located in airhandling units (where they may be exposed torefrigerated air circulation), the boiler piping systemshall be equipped with a flow control valve or otherautomatic means to prevent gravity circulation ofchilled water through the boiler. Chilled water in theboiler will create condensation on the boiler tubeswhich will drip on the burners and may extinguish thepilot.

Boilers installed in violation of either of theabove requirements may void the warranty.

1F. Freeze ProtectionBoiler installations are not recommended in

areas where the danger of freezing exists unlessproper precautions are taken for freeze protection. Thepreferred method of freeze protection is bymaintaining a mixture of no more than 50% properlyinhibited HVAC glycol. This mixture will protect theboiler to temperatures of about -35°F (-37°C). To getthe desired temperature rise across the boiler whenthis mixture is used, increase the water flow by 15%above the original recommendation. Increase the headloss requirement by 20%.

Figure 3. Boiler-Chiller Installation.

Figure 2. Typical Schematic for a Primary-Secondary System.

Suggested Wiring Diagram For Tempering System Waterat Change-over From Heating to Cooling.


SECTION 2.Installation

2A. Boiler PlacementThe boiler must be placed to provide specific

clearances on all sides for maintenance andinspection. There must also be minimum distancesmaintained from combustible surfaces. Theseclearances also apply to non-combustible materials,because the boiler requires air circulation for properoperation.

Boiler should be mounted on a level surface. Anintegral combustible flooring base is provided asstandard equipment on all outdoor models. Indoormodels can be installed on a combustible floor with aspecial base assembly which is available from thefactory, or with a base that complies with local coderequirements. See rating plate for part number of thebase assembly.

Do not install boiler on carpeting.Under the National Fuel Gas Code, ANSI

Z223.1, it is permissible to place the boiler on floorsother than non-combustible when the installationcomplies with the American Insurance Code. Figures5, 6, 7, and 8 show common installation oncombustible flooring.

2B. Installation of Indoor Boilers1. Locate the boiler to provide adequate

clearance for inspection and service on all sides(see Table 2). We recommend minimums of 24"from front (for proper access to and service ofcontrols) and 18" at water connection end. Foralcove installation, see Figure 9.

2B-1. Combustion Air Supply1. The boiler location must provide sufficient air

supply for proper combustion and ventilation ofthe surrounding area as outlined in the latestedition of ANSI standard Z223.1 and/or inCanada CAN 1 - B1 49 requirements, and anylocal codes that may be applicable. Inadequatecombustion air supply may result in incompletecombustion, sooting of the heat exchanger, andunsafe operation of the boiler.

2. (a.) In the United States, the generalrequirements specify that boiler rooms should beprovided with two permanent air supplyopenings communicating directly through thewall to outside air; one within 12 inches(305mm) of the ceiling, and the other within 12inches (305mm) of the floor. Each openingshould have a minimum free area of one squareinch per 4,000 BTUH input of the total inputrating of all appliances in the enclosed area. SeeTable 3 for recommended air supply for eachmodel. An improperly ventilated equipmentroom can get excessively hot and causeaccelerated deterioration of controls andelectrical components.

Table 2. Minimum Boiler ClearancesFrom Combustible Surfaces.

Clearance Indoor OutdoorFrom inches mm inches mmTop 30 762 unobstructWater Conn. Side 12 305 24 610Opposite Side 6 152 24 610Front Alcove UnobstructRear 8 203 24 610Vent Pipe* 6 152 —Hot Water Pipes Per Code Per Code*1" when using type B Vent (refer to Manufacturer'sInstructions

2. Install the boiler on a waterproof floor with anadequate floor drain and a 6" (152mm)minimum curb on all four sides to protect thebuilding if boiler repairs are required. Themanufacturer will not be held liable for anywater damage in connection with this boiler.

Table 3. Minimum RecommendedAir Supply to Boiler.

Boiler Each Opening*Model Sq. Inches Sq. cm

500 125 806.5600 150 967.8715 179 1154.9850 213 1374.3

1010 253 1632.41200 300 1935.61430 358 2309.81670 418 2696.91825 457 2948.6

*Net Free Area in Square Inches

Area indicated is for one of two openings; one atfloor level and one at the ceiling, so the total netfree area could be double the figures indicated.For special conditions refer to the latest edition ofANSI Z223.1.

Consult factory if not communicating directlythrough the walls with the outdoors.

Note: Check with louver manufacturers for netfree area of louvers. Correct for screenresistance to the net free area if a screen isinstalled. Check all local codes applicable tocombustion air.


(b.) In Canada, consult local building and safetycodes or, in the absence of such requirements,follow CGA requirements and/or CAN 1 - B149standard. (Table 3 does not apply).

3. Exhaust Fans or Vents: Any equipment whichexhausts air from the boiler room can deplete thecombustion air supply or reverse the naturaldraft action of the venting system.The boiler must be completely isolated and thiscould cause flue products to accumulate in theroom. Additional air must be supplied tocompensate for such exhaust. The information inTable 3 is not applicable in installations whereexhaust fans or blowers of any type are used.Such installations must be designed by qualifiedengineers.

Figure 4. Base for Combustible Floors.

Figure 5. Typical Boiler Installation on Concrete Slab.

Figure 6. Typical Boiler Installation on Raised Platform(Wood).

Figure 7. Typical Boiler Installation on Roof Using a4 x 4 Stringer.

Figure 8. Installation on Concrete Blocks or Tile.


Figure 9. Alcove Installation.

4. If a blower or fan is used to supply air to theheater room, the installer should make sure itdoes not create drafts which could causenuisance shutdowns of the pilot. If a blower isnecessary to provide adequate combustion air tothe boiler, a suitable switch or equivalent mustbe wired into the boiler control circuit to preventthe boiler from firing unless the blower isoperating.

5. The boiler must be completely isolated andprotected from any source of corrosive chemicalfumes such as trichlorethylene, perchlorethylene,chlorine, etc.

2B-2. Venting1. Laars boilers have built-in draft diverters for

natural draft operation and must not beconnected to any portion of a mechanical draftsystem under positive pressure. The flue outletmust be connected to a clear, unobstructed ventof adequate capacity ending above the highestpoint of the building with an approved vent cap.The venting system should be installedaccording to the latest edition of ANSI Z223.1and/or, in Canada, CAN1-13149 requirementand any local codes having jurisdiction.IMPORTANT NOTE: Do not use sheet metalscrews at the snap lock joints of Type B gas vents.

2. Do not weld or fasten the vent pipe to the boilerdraft hood. The weight of the stack must not reston the boiler. The draft hood and boiler top mustbe easily removable for normal boiler serviceand inspection.

3. Avoid using long horizontal runs of the ventpipe, and too many 90° elbows, reductions orrestrictions. Horizontal runs should have at leasta 1/4" rise per foot in the direction of flow. Avent connector should be supported for thedesign and weight of the material used tomaintain clearances and prevent physicaldamage and separation of joints.

4. Avoid ending heater vents near air conditioningor air supply fans. The fans can pick up exhaustflue products from the boiler and return theminside the building, creating a possible healthhazard. A minimum of 4 feet (1.2m) horizontaldistance must be maintained from electricalmeters, gas meters, and relief equipment.

5. Always use double-wall or insulated vent pipe(Type B or equivalent). In cold weather,uninsulated outside vents can chill the rising flueproducts, blocking the natural draft action of theventing system. This can create a health hazardby spilling flue products into the boiler room.

6. Avoid oversize vent piping or extremely longruns of the pipe which may cause excessivecooling and condensation. Rule of Thumb: Thetotal length of the vent, including the connectorand any offset, should not exceed 15 feet (4.6m)for every inch of vent diameter. Longer totallengths shown in venting tables are based onmaximum capacity, not condensation factors.

7. When the installation of a draft fan is necessaryin connecting a venting system to a Laars boiler,the installation should be engineered bycompetent personnel following good engineeringpractices. The draft fan supplier should beconsulted for correct size. The installationshould be in accordance with the latest edition ofANSI Z223.1 and/or, in Canada, CAN 1-B149requirement and any local codes havingjurisdiction. When a draft fan is installed, asuitable draft switch must be wired into theboiler control circuit at terminal designated“Field Interlock” to prevent firing of the boilerunless a positive draft has been established.

8. When an existing boiler is removed from acommon venting system, the common ventingsystem is likely to be too large for proper ventingof the appliances remaining connected to it.At the time of removal of an existing boiler, thefollowing steps shall be followed with eachappliance remaining connected to the commonventing system placed in operation, while the


other appliances remaining connected to thecommon venting system are not in operation.(a) Seal any unused openings in the common

venting system.(b) Visually inspect the venting system for

proper size and horizontal pitch anddetermine there is no blockage orrestriction, leakage, corrosion and otherdeficiencies which could cause an unsafecondition.

(c) Insofar as is practical, close all buildingdoors and windows and all doors betweenthe space in which the appliancesremaining connected to the commonventing system are located and other spacesof the building. Turn on clothes dryers andany appliance not connected to the commonventing system. Turn on any exhaust fans,such as range hoods and bathroomexhausts, so they will operate at maximumspeed. Do not operate a summer exhaustfan. Close fireplace dampers.

(d) Place in operation the appliance beinginspected. Follow the lighting instructions.Adjust thermostat so appliance will operatecontinuously.

(e) Test for spillage at the draft hood relief open-ing after 5 minutes of main burner operation.Use the flame of a match or candle, or smokefrom a cigarette, cigar or pipe.

(f) After it has been determined that eachappliance remaining connected to thecommon venting system properly ventswhen tested as outlined above, returndoors, windows, exhaust fans, fireplacedampers and any other gasburningappliance to their previous conditions ofuse.

(g) Any improper operation of the commonventing system should be corrected so theinstallation conforms with the latest editionof the National Fuel Gas Code, ANSIZ223.1. When resizing any portion of thecommon venting system, the commonventing system should be resized toapproach the minimum size as determinedusing the appropriate tables in Appendix Gin the National Fuel Gas Code,ANSI Z223. 1.

2C. Installation of Outdoor Boilers1. Locate the boiler to provide the minimum

clearances as listed in Table 2, “BoilerClearances.” See Service Clearance, 2 B.1.

2. Do not place the boiler in an enclosure or wallrecess. Avoid locations where wind deflection

off structures might cause a down draft. Whensuch wind conditions are possible, place theboiler at least three (3) feet (0.9m) from thestructures.

3. Never install the boiler under any kind of roofoverhang. Do not place the boiler below oradjacent to any doors, windows, louvers, grills,etc. which connect in any way with an inhabitedarea of a building. This includes other structuressuch as garages or utility rooms (see Figure 10).

Figure 10. Incorrect Outdoor Installation.

4. Although these models are AGA designedcertified for outdoor installations, suchinstallations are not recommended in areaswhere the danger of freezing exists unless properprecautions are taken for freeze protection.

CautionOutdoor installations are not recommended

in areas where the danger ofsnow blockage exists.

2D. Gas Supply and PipingReview the following instructions before

proceeding with the installation.1. Verify that the boiler is fitted for the proper type

of gas by checking the rating plate. Laars boilersare normally equipped to operate below a 2000foot (610m) altitude. Boilers equipped to operateat higher altitudes have appropriate stickers ortags attached.

2. Use the figures in Table 4 to provide adequategas piping from the gas meter to the boiler.

3. A trap (drip leg) must be provided ahead of thegas controls (see Figure 11). A manual gas


shutoff valve must also be provided for serviceconvenience and safety. Check the local codes.

4. The boiler and its individual shutoff valve mustbe disconnected from the gas supply pipingsystem during any pressure testing of that systemat test pressures in excess of 1/2 psig. The boilermust be isolated from the gas supply pipingsystem by closing its individual manual gasshutoff valve during any pressure testing of thegas supply piping system at test pressures equalto or less than 1/2 psig.

5. Provide gas supply pressure to the boiler asfollows:

Natural Gas LPG

Min. (inches Per Rating Platewater column)

Max. (inches 9 14water column)

Note: The boiler and all other gas appliancessharing the boiler gas supply line must be firing atmaximum capacity to properly measure the inlet

supply pressure. Low gas pressure could be anindication of an undersized gas meter and/orobstructed gas supply line.6. The correct burner manifold gas pressure is

stamped on the rating plate. The regulator ispreset at the factory and normally requires nofurther adjustment.

7. The gas manifold and control assembly wastested and conform to the safe lighting and otherperformance criteria specified in the latesteditions of ANSI Z21.13 and CGA 3.3 LowPressure Boiler Standard.

8. Before operating the boiler, the complete gassupply system and all connections must be testedfor leaks using a soap solution. Do not use rawflame.

CautionSince some leak test solutions (including soapand water) may cause corrosion or stresscracking, the piping must be rinsed with waterafter testing, unless it has been determinedthat the leak test solution is noncorrosive.

2E. Electrical WiringElectrical diagrams are included with the packet

provided with each unit.

WARNINGThe boiler must be electrically grounded inaccordance with the most recent edition of theNational Electrical Code, ANSI/NFPA 70. InCanada, all electrical wiring to the boiler shouldbe in accordance with the Canadian ElectricalCode, CSA C22.1 Part 1. Do not rely on thegas or water piping to ground the metal partsof the heater. Frequently, plastic pipe ordielectric unions isolate the boiler electrically.Service and maintenance personnel who workon or around the boiler may be standing on wetfloors and could be electrocuted by anunderground boiler.

1. Check boiler wiring and pump for correctvoltage, frequency and phase. If the pump circuitis other than 115V, check to see that the boiler isprovided with an appropriate transformer.

2. Wire the boiler and pump exactly as shown inthe wiring diagram supplied with the boiler.

Table 4. Gas Piping Sizes.

Distance from Gas Meteror Last Stage Regulator

Size 0-100' 100-200' 200-300'(0-30.5m) (30.5-61m) (61-91.4m)

50060071585010101200143016701825

1-1/2"1-1/2"

2"2"2"

2-1/2"2-1/2"2-1/2"2-1/2"

2"2"2"

2-1/2"2-1/2"

3"3"3"3"

2"2-1/2"2-1/2"2-1/2"

3"3"3"3"

3-1/2"Note: These figures are for Natural Gas (.65 Sp. Gr.), and arebased on 1/2" water column pressure drop. Check supplypressure with a manometer, and local code requirements forvariations. For LPG, reduce pipe diameter one size, but maintaina 1" minimum diameter. A normal number of Tees and elbowshave been taken into allowance.

Figure 11. T-Fitting Sediment Trap Installation.


3. The pump and boiler must be electricallyinterlocked so the boiler cannot come on unlessthe pump is running.

4. All field installed electrical safety devices andall field installed devices (draft switches, relays,timers, outdoor temperature reset devices, etc.)can be connected to the heater wiring at pointsshown in the wiring diagram designated “FieldInterlock.”

2F. Water Piping of System1. Be sure to provide valves at the inlet and outlet

of the boiler so it can be readily isolated forservice. A butterfly or similar type of valve isrecommended.

2. The pressure relief valve installed in the tappedopening provided in the outlet header (SeeFigure 12), must be piped, but not fastened, to adrain or floor sink. The drain pipe must be thesame size as the valve outlet and must pitchdownward from the valve.

5. Check piping diagrams with local applicableplumbing, heating and building safety codes.

6. A boiler installed above radiation level must beprovided with a low water cutoff device either aspart of the boiler or at the time of boilerinstallation.

7. Install manual and/or automatic bleeding devicesat high points in the system to eliminate air.Install a correctly sized air charger and tankdrainer, as appropriate.

2G. Filling Fully-Connected System1. Close all bleeding devices and open make-up

water valve. Allow system to fill slowly.2. If make-up water pump is employed, adjust

pressure switch on pumping system to provide aminimum of 12 psi at the highest point in theheating loop.

3. If a water pressure regulator is provided on themake-up water line, adjust the pressure regulatorto provide at least 12 psi at the highest point inthe heating loop.

4. Open bleeding devices on all radiation units atthe highest points in the piping throughout thesystem, unless automatic air bleeders areprovided at such points.

5. Run system circulating pump for a minimum of30 minutes with the boiler shut off.

6. Open all strainers in the circulating system andcheck for debris.

7. Recheck all air bleeders as described in Step 4above.

8. Check liquid level in expansion tank. With thesystem full of water and under normal operatingpressure, the level of water in the expansion tankshould not exceed 1/4 of the total, with thebalance filled with air.

9. Start up boiler according to procedure describedin Section 3B. Operate the entire system,including the pump, boiler, and radiation unitsfor one (1) hour.

10. Recheck the water level in the expansion tank. Ifthe water level exceeds 1/4 of the volume of theexpansion tank, open the tank drainer and drainto that level.

11. Shut down the entire system and vent allradiation units and high points in the systempiping as described in Step 4 above.

12. Close make-up water valve and check strainer inpressure reducing valve for sediment or debrisfrom the make-up water line. Reopen make-upwater valve.

Figure 12. Pressure Relief Valve Location.

PressureRelief Valve

Special attention must be given to relief valvesettings in installations where the boiler islocated on the ground floor of a tall building,The static pressure of the system is elevated andcould cause the relief valve to leak. Where nospecial setting of the relief valve is ordered, thefactory will furnish a 75 psi setting. Neverreduce the relief valve openings.

3. Pressure relief valve lever must be tripped atleast once a year to insure that waterways areclean. When manually operating lever, waterwill discharge through drain line. Precautionsmust be taken to avoid contact with hot waterand water damage.

4. The weight of all water and gas piping should besupported by suitable hangers or floor stands.


13. Check gauge for correct water pressure and alsocheck water level in system. If the heightindicated above the boiler insures that water is atthe highest point in the circulating loop, then thesystem is ready for operation.

14. Within three (3) days of start-up, recheck all airbleeders and expansion tank as described inSteps 4 and 8 above.

SECTION 3.Operation

3A. Controls - General1. Electronic Ignition Controls:

a. Intermittent Ignition:Pilots are automatically lit when theoperating aquastat calls for heat (System #4and #9) The unit performs its own safetycheck and opens the main valves only afterthe pilot is proven to be lit. Whenever thepilot flame is interrupted, the main gasvalve closes within 0.8 seconds.

b. Electronically Supervised Standing PilotSystem (System #16):When pilot flame fails, the ignition controlmodule responds in less than 0.8 secondsand provides 100% safety shutdown.

2. Operating Controls:a. Electrically Operating Controls:

Single, two-stage, four-stage or modulatingaquastats are provided in models HH andPH boilers to control the desired servicewater temperature. The temperaturesensing bulb is located in the boiler inlet.

b. Modu-Snap Valves (MechanicalModulation Only):These valves are furnished in addition tothe main electric gas valve. Each valve hasa remote capillary bulb immersed in a wellat the outlet header to maintain a constantoutlet temperature. Consult Table 5 fordesired temperature setting.

Figure 13. Typical Controls Locations.

Dial No. 1 2 3 4 5 6 7 8 9Temp °F 120 135 150 165 180 195 210 225 240Temp °C 49 57 66 74 82 91 99 107 116

Table 5. Modu-Snap Temperature Settings

3. High Limit Controls:The manual reset high limit switches areprovided as standard equipment on allboilers. Automatic reset switches areoptionally provided. The temperaturesensing bulb of the switch is always locatedin the boiler outlet. Burners willautomatically shut down wheneveroverheating of water occurs.


4. Flow Switch:Standard on all models: Models HH andPH, the switch is mounted in the outlet“tee” connection. The flow switch shutsdown all burners in case of pump failure.

5. Low Water Cut Off (Optional):The low water cut off automatically shutsoff boiler whenever water level dropsbelow probe. Located at boiler inlet (modelPH) and at return header (model HH).

3B. Initial Start-UpLighting: Safe lighting and other performance

criteria were met with the gas manifold and controlassembly provided on the boiler when it underwenttests specified in the ANSI Z21.13 standard.

Before placing the boiler in operation, be certainthat the boiler is filled with water and all air is purgedfrom the system. Once the boiler is connected to thegas supply, the automatic safety shutoff devices mustbe checked.1. Before beginning the tests, make sure the main

manual gas valve, and any other boiler firingvalves are in the “OFF” position.

2. Make sure the boiler’s power switch is in the“ON” position. After placing the manual pilotgas valve in the open position and resetting allsafety devices, (high limit, pressure switch, low-water cutoff, etc.) pilot(s) can be lit followingthe procedure located on the boiler rating plate.

3. Once the pilot(s) is lit and has been establishedfor five minutes, the flame failure response timeshould be checked as follows:Systems 9 and 4 - (Intermittent ignition), natural

gas only: With this system pilots are automatically litwhen the operating controls call for heat. If the pilotflame fails for any reason, the main valve is shut offwithin one second and the pilot spark ignition isinitiated until the pilot flame has been reestablished.On propane systems, unit locks out for safety. Thissequence should be checked by turning off the manualpilot gas valve, and, at the same time, monitoring theaudible sparking at the pilot burner and signalinterruption to the main valve.

CautionPropane gas is heavier than air and sinks tothe ground. Exercise extreme care in lightingthe boiler when so equipped.

System 16 - (Electronically supervised standingpilot system): Extinguish the pilot flame by placingthe manual pilot valve in the closed position, and atthe same time, begin recording the time it takes for theoutput signal from the electronic ignition control to be Figure 14. Gas Manual Valves.

interrupted. The signal interruption can be detectedeither with a test light or a voltmeter. The responsetime should never exceed one second.4. With the pilots lit, initial activation of the main

burners can be achieved by slowly opening themain valve. The result should be a smoothlighting of the main burners.

Hi-Limit Checkout :After running the boiler for a long enough

period, bring the water temperature within the rangeof the hi-limit and slowly back off the high limitsetting until the boiler shuts off. The main burnersshould reignite when the hi-limit is reset and turnedback up to its original setting. The boiler should nowrun until it shuts off automatically on operatingaquastat.

3C. To Start Up System:1. Start Up Boiler

Be certain system pump is running, then proceedas follows:a. Turn off main electrical switch.b. Turn off all manual gas valves and wait

five minutes (see Figure 14).c. Set operating control to lowest setting.d. Slowly turn manual gas valve to “ON”.e. Reset all safety valve switches (manual

reset high limit and low water cut off).


Figure 16. Main Burner Flame Pattern.

f. Open manual pilot valve. Turn on mainelectrical switch.

g. Set temperature controller to desiredtemperature. Pilot will light automaticallyto ignite main burners whenever theaquastat calls for heat.

h. For standing pilot system, press on pilotrelay knob (see Figure 15), light pilot andkeep relay knob depressed for one minutethen release. Once the pilot is lit, the poweris supplied through the aquastat to the maingas valve.

remove drain plug in the bottom of front header cover.Drain every part of system subject to freezingtemperature.

SECTION 4.Maintenance1. Lubricate the water circulating pump (see

instructions found on the pump).2. If a strainer is employed in a pressure reducing

valve or in piping, clean it every six (6) months.3. At start-up and every six (6) months thereafter,

the pilot and main burner flame should beobserved for proper performance (see Figure 16).See attached lighting and shut-down instructionsfor proper pilot flame pattern). If flame has theappearance of “sooting” tips, check for debrisnear orifices. Call serviceperson.

Figure 15. Pilot Safety Relay.

2. To set the temperature and high-limit controls:a. Set the temperature controller at the system

design temperature.b. Set the high-limit to 40-50°F above

temperature controller setting.c. Models with Mechanical Modulation

Set the temperature controller (Modu-Snapvalve) dial to the desired water temperature(see Table 5).

3. Minimum input rates:The low firing rate setting must be equal to orgreater than the specified minimum input ratingas shown on the appliance rating plate. Laars’boilers use gas valves which are factory set toprovide an input on low fire that meet or exceedthe specified minimum.

3D. To Turn Off Boiler:1. Turn off main electric switch.2. Close all manual gas valves.

3E. To Shut Down System:To shut down boiler, turn off all manual gas

valves and electrical disconnect switches. Wheneverdanger of freezing exists, shut off water supply and

4. Inspect the venting system for obstruction,leakage and corrosion at least once each year.

5. Keep boiler area clear and free from combustiblematerial, gasoline and other flammable vaporsand liquids (see Table 2 for minimumclearances).

6. Be certain all combustion air and ventilationopenings are unobstructed.

7. Check for fouling on the external surfaces of theheat exchanger every six months. (NOTE: Afterinstallation and first start-up, check the heatexchanger for fouling after the following periodsof operation: 24 hours, 7 days, 30 days, 90 days,and once every six months thereafter).Fouling on the external surfaces of the heatexchanger is caused by incomplete combustionand is a sign of combustion air and/or ventingproblems. As soon as any fouling is observed,the cause of the fouling should be corrected (seeSection 5, Troubleshooting Guide). The heatexchanger can be checked by locating a mirrorunder the burners with a flashlight. An alternatemethod is to remove the venting and top panel asnecessary to inspect from above. Also check thevent system for defects at this time.


a. If cleaning is required, shut off allelectrical and gas supply to the heater.

b. To expose the heat exchanger:

Indoor Models:Remove flue pipe, top of unit, rear upper jacket,

flue collector rear panel and heat exchanger baffles.

Outdoor Models:Remove vent top assembly, rear upper jacket,

flue collector rear panel and heat exchanger baffles.c. Remove all burners:

It is usually more convenient to remove theburner tray assembly. Disconnect sensorwire, ignition cable (or thermocouplegenerator) and pilot gas line. Disconnectmanifold inlet union(s). Remove the four(4) retaining screws. Grasp burner/pilotassembly firmly at the front. Push it back,disengaging it from the gas orifice. Lowerthe front of the burner (to avoid damagingpilot shield) then remove the burner tray.

CautionBlack carbon or green soot on a dirty heatexchanger can, under certain conditions, beignited by a random spark or open flame. Toprevent this unlikely occurrence, dampen thesoot deposits with wet brush or fine waterspray before servicing or cleaning the heatexchanger.

With a wire brush, remove soot and loose scalefrom heat exchanger. Clean fallen debris from bottomof heater. Make sure burner ports are clear and pilotassembly is free of debris.

d. Reassemble in reverse order: Be sure theheat exchanger baffles are replaced.

8. The gas and electric controls installed on boilersare engineered for both dependable operationand long life, but the safety of this equipmentcompletely depends on their proper functioning.It is strongly recommended that the basic itemsbe checked by a competent serviceperson everyyear and replaced when necessary. The basiccontrols are:a. Water temperature controls.b. Pilot safety system.c. Automatic electric gas valve(s).d. Flow sensing safety device.

9. Low water cutoffs should be inspected every six(6) months, including flushing of float types.NOTE: Warranty does not cover any damage

caused by lack of required maintenance or improperoperating practices.10. Both modulating and stage valve are adjusted at

the factory for minimum permissible rates andshould not be readjusted.


4. PRESSURE RELIEF VALVES LEAKINGINTERMITTENTLY OR STEADILY.

3. BOILER WILL NOT FIRE.

Possible Cause What To Do

A. Electric power is off. A. Check to see that main powerswitch is “ON.” Use testingdevice to trace power toboiler junction box.

B. Operating or safety control has B. Turn off power. Use continuityopened circuit to electric across terminals of eachgas valve. operating and safety control

switch up to the electric gasvalve. Replace defectivecontrol.

C. Pilot flame is out. C. Relight pilot per instruction.

D. Manual reset device has tripped. D. Follow instructions for start-up.Reset Pilot safety and allmanual reset safety switchesand reset manual safety gasvalve.

E. No gas pressure to burners. E. Trace gas line to service shutoffcock. If service cock is open,trace gas line to meter. If nopressure is present at meter,call for public utility service. Ifgas is present in boiler inlet,check pressures in followingsequence: (1) downstream frompressure regulator;(2) downstream from electric gasvalve. Replace or adjust asnecessary.

F. Electric gas valve operator is F. Disconnect wiring harness at gasburned out or shortened. valve terminals. Check continuity

to actuator coil. If open circuit orshort is indicated, replace coil oroperator.


A. Static pressure in system A. Calculate height of water inexceeds setting of relief valve. system above boiler. Install new

valve with psi setting 25% aboverequired static system workingpressure. Do not exceed 160 psi.

B. Expansion tank is waterlogged B. Drain expansion tank, then(if installed). reopen it to the system. Look for

leaks in expansion tank orfittings. Calculate requiredvolume of expansion tank inrelation to system to determine

that tank is adequate.

SECTION 5.Troubleshooting and Analysis ofService Problems1. For proper service and problem diagnosis of the

heater and heater system, the following tools arerequired:a. Gas pressure test kit with range from zero

to 14 W.C. Either a slack tub manometer oran accurate gas pressure gauge isacceptable with proper adapters which willconnect to the available fittings in the lineand on the gas valve.

b. Multi-meter with the following ranges:0 to 500 volts A.C.0 to 1000 ohms continuity.

c. Tube cleaning kit consisting of reamer,stainless steel brush, speed handle andhandle extensions.

d. Strap on digital temperature gauge to checktemperature rise.

2. In addition, the boiler should be equipped with asystem pressure gauge with proper ranges forboiler operation.


5. BOILER IS POUNDING, KNOCKING OR EMITTINGSTEAM FROM RELIEF VALVES.


A. Low or no water flow. A. This condition is usuallycaused by lack of adequateflow through boiler.Check the following:(1) Is the boiler wired intothe pump circuit so that theboiler cannot fire unlessthe pump is running?(2) Check to see that allvalves in system are opento be sure that water cancirculate through the boilerand the system.(3) If the system hasautomatic water valves (2-way or 3-way) that can cutoff the water flow throughthe boiler check to seethat they are equipped withend-switches which shutthe boiler down when thewater flow through theboiler is reduced by 70%from full flow.(4) Examine pump forclogged impeller.

B. Low or no system pressure. B. Clean strainer in pressurereducing valve. Look forclosed valve water line ora leak in the system.

C. Clogged "Y" strainer. C. Remove strainer elementand clean screen.

D. Debris from system piping is D. Remove header covers.blocking tubes. Examine all tubes and

waterways. Use newgaskets when reassembling.Clean out tubes.

E. Scale has formed in tubes. E. This is always caused bythe inflow of raw water intothe system. Clean tubeswith tube cleaning kit.Determine hardness.Check for modified flow ifnecessary.

7. WATER DRIPPING IN FIREBOX.


6. SOOT IN FLUEWAYS OR IN TUBES,OR NOXIOUS FUMES INDICATIVE

OF BAD COMBUSTION.


A. Combustion air supply to A. Check air supply opening.boiler room is inadequate. Look for debris in screen or

louvre which coverscombustion air opening, orfor material blocking theopening.

B. Stack or vent is blocked or B. Look for blocked stack andrestrictive. excessive number of elbows in

stack or excessive length ofhorizontal runs.

C. Severe down draft is causing C. Check for (1) proper vent cap onspillage of flue products into stack; (2) adequate height ofroom. stack above roof; (3) equipment

exhausting air from inside ofbuilding; and (4) properinstallation of draft diverter.

D. Gas pressure to burners is D. Check gas presssure withexcessive. Manometer, and adjust

with heater firing at full rate.

E. Boiler not fitted for the fuel E. See nameplate for correctbeing supplied. fuel.

F. Boiler installed at high F. Installations at altitudes inaltitude without proper excess of 2000 ft. abovederating. sea level are subject to

jurisdiction of the localinspection authorities.

Tub in heat exchanger has A tube failure is almost alwaysoverheated and ruptured. caused by (1) scale formation in the

tube or (2) inadequate water flowthrough the boiler.


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SECTION 6. Parts Descriptions and Order Numbers


Figure 19. Parts Identification.

NOTE:Temperature Control Wells -Inlet/Outlet Header1. Firing Mode L, K, & C -

2 Dry Wells2. Firing Mode H

A. Natural Gas Boilers & Heaters500 thru 850 - 2 Dry Wells1010 thru 1430 - 3 Dry Wells1670 thru 1825 - 4 Dry Wells

B. Propane Gas Boilers & Heaters500 thru 850 - 2 Dry Wells1010 thru 1852 - 3 Dry Wells


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40Lo

wer

Rig

ht P

anel

/Hea

tS

hiel

d W

eldm

ent

1055

4601

1055

4602

1055

4603

1055

4604

1055

4605

1055

4606

1055

4607

1055

4608

1055

4609

41M

iddl

e Fr

ont P

anel

1055

4401

1055

4402

1055

4403

1055

4404

1055

4405

1055

4406

1055

4407

1055

4408

1055

4409

42S

wee

p S

heet

, Flu

e C

olle

ctor

1053

3901

1053

3902

1053

3903

1053

3904

1053

3905

1053

3906

1053

3907

1053

3908

1053

3909

NO

TE: N

umbe

rs in

() r

epre

sent

qua

ntity

requ

ired

for e

ach

size

. Qua

ntity

is o

ne o

ther

wis

e.


Figure 20. Tile Assemblies.

LAARS Heating SystemsK

eyD

escr

iptio

nM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

No

500

600

715

850

1010

1200

1430

1670

1825

43Ig

nitio

n C

ontro

l, E

lect

roni

cE

0100

900

E01

0090

0E

0100

900

E01

0090

0E

0100

900

E01

0090

0E

0100

900

E01

0090

0E

0100

900

44Tr

ansf

orm

er, 1

1 5V

/24V

E00

8610

0E

0086

100

E00

8610

0E

0086

100

E00

8610

0E

0086

100

E00

8610

0E

0086

100

E00

8610

045

Con

trol B

ox W

eldm

ent

1054

5800

1054

5800

1054

5800

1054

5800

1054

5800

1054

5800

1054

5800

1054

5800

1054

5800

46C

ontro

l Box

Cov

er10

5472

0010

5472

0010

5472

0010

5472

0010

5472

0010

5472

0010

5472

0010

5472

0010

5472

0047

Win

g N

ut, #

8-32

F003

2100

F003

2100

F003

2100

F003

2100

F003

2100

F003

2100

F003

2100

F003

2100

F003

2100

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

48B

ase

Tile

Sup

port

Ass

y.10

5369

0110

5369

0210

5369

0310

5369

0410

5369

0510

5369

0610

5369

0710

5369

0810

5369

0949

Bur

ner,

Mai

nL0

0523

00L0

0523

00L0

0523

00L0

0523

00L0

0523

00L0

0523

00L0

0523

00L0

0523

00L0

0523

0050

Pilo

t Brk

t/Bur

ner

Wel

dmen

t(J

ohns

on P

ilot)

1052

9501

1052

9501

1052

9501

1052

9501

1052

9501

1052

9501

1052

9501

1052

9501

1052

9501

(Hon

eyw

ell P

ilot)

1052

9502

1052

9502

1052

9502

1052

9502

1052

9502

1052

9502

1052

9502

1052

9502

1052

9502

51P

ilot B

urne

r (Jo

hnso

n)St

andi

ng P

ilot,

Nat

W00

3470

0W

0034

700

W00

3470

0W

0034

700

W00

3470

0W

0034

700

W00

3470

0W

0034

700

W00

3470

0P

ilot B

urne

r (H

oney

wel

l)St

andi

ng P

ilot,

Nat

W00

3580

0W

0035

800

W00

3580

0W

0035

800

W00

3580

0W

0035

800

W00

3580

0W

0035

800

W00

3580

052

Pilo

t Bur

ner (

John

son)

Stan

ding

Pilo

t, P

ropa

neW

0034

600

W00

3460

0W

0034

600

W00

3460

0W

0034

600

W00

3460

0W

0034

600

W00

3460

0W

0034

600

Pilo

t Bur

ner (

Hon

eyw

ell)

Stan

ding

Pilo

t, P

ropa

neW

0034

400

W00

3440

0W

0034

400

W00

3440

0W

0034

400

W00

3440

0W

0034

400

W00

3440

0W

0034

400

53P

ilot B

urne

r (Jo

hnso

n)IID

Pilo

t, N

atW

0034

500

W00

3450

0W

0034

500

W00

3450

0W

0034

500

W00

3450

0W

0034

500

W00

3450

0W

0034

500

Pilo

t Bur

ner (

Hon

eyw

ell)

IID P

ilot,

Nat

W00

3430

0W

0034

300

W00

3430

0W

0034

300

W00

3430

0W

0034

300

W00

3430

0W

0034

300

W00

3430

054

Gas

Man

ifold

Wel

dmen

t (si

ngle

)10

5259

0110

5259

0210

5259

0310

5259

0410

5259

0510

5259

0610

5259

0710

5259

0810

5259

0955

Orif

ice,

Nat

, Gas

L005

0700

L005

0700

L005

0700

L005

0700

L005

0700

L005

0700

L005

0700

L005

0700

L005

0700

(22)

(26)

(30)

(36)

(42)

(50)

(60)

(70)

(76)

56O

rific

e, P

ropa

ne -

9" W

.C.

L003

2900

L003

2900

L003

2900

L003

2900

L003

2900

L003

2900

L003

2900

L003

2900

L003

2900

(22)

(26)

(30)

(36)

(42)

(50)

(60)

(70)

(76)

57M

anifo

ld C

over

Pla

t Ass

y.10

5529

0110

5529

0210

5529

0310

5529

0410

5529

0510

5529

0610

5529

0710

5529

0810

5529

0958

Bur

ner,

Ant

i Rot

atio

n B

rkt (

left)

1052

5301

1052

5302

1052

5303

1052

5304

1052

5305

1052

5306

1052

5307

1052

5308

1052

5309

59B

urne

r, A

nti R

otat

ion

Brk

t (rig

ht)

1054

2701

1054

2702

1054

2703

1054

2704

1054

2705

1054

2706

1054

2707

1054

2708

1054

2709

60B

urne

r Tie

Dow

n B

rack

et (l

eft)

1052

5701

1052

5702

1052

5703

1052

5704

1052

5705

1052

5702

1052

5703

1052

5704

1052

5704

(2)

(2)

(2)

1052

5705

61B

urne

r Tie

Dow

n B

rack

et (r

ight

)10

5420

0110

5420

0210

5420

0310

5420

0410

5420

0510

5420

0210

5420

0310

5257

0410

5257

04

62Va

lve,

Man

ual,

Gas

, Nat

ural

V00

0420

0V

0004

200

V00

0420

0V

0004

200

V00

0430

0V

0004

300

V00

0430

0V

0004

300

V00

0430

0

63Va

lve,

Man

ual,

Gas

, Pro

pane

V00

0480

0V

0004

800

V00

0480

0V

0004

800

V00

0420

0V

0004

200

V00

0430

0V

0004

300

V00

0430

0

NO

TE: N

umbe

rs in

() r

epre

sent

qua

ntity

requ

ired

for e

ach

size

. Qua

ntity

is o

ne o

ther

wis

e.


Key

Des

crip

tion

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elN

o50

060

071

585

010

1012

0014

3016

7018

2564

Saf

ety

Gas

Val

ve, O

n-O

ff,Tw

o St

age

(Nat

)V

0046

600

V00

4660

0V

0046

00V

0046

00V

0046

700

V00

4670

0V

0046

700

V00

4670

0V

0046

800

65S

afet

y G

as V

alve

, On-

Off,

Two

Stag

e (P

ro)

V00

4660

0V

0046

600

V00

4660

0V

0046

600

V00

4660

0V

0046

600

V00

4670

0V

0046

700

V00

4670

0

66Va

lve,

Gas

, Ope

ratin

g / R

eg.

On-

Off,

Tw

o St

age

(Nat

)V

0051

200

V00

5120

0V

0051

200

V00

5120

0V

0051

300

V00

5130

0V

0051

300

V00

5140

0V

0051

400

67Va

lve,

Gas

, Ope

ratin

g / O

n-O

ffTw

o St

age

(Pro

)V

0054

800

V00

5480

0V

0054

800

V00

5480

0V

0054

800

V00

5480

0V

0054

900

V00

5490

0V

0054

900

68Va

lve,

Pilo

t, G

as, M

anua

lW

0002

100

W00

0210

0W

0002

100

W00

0210

0W

0002

100

W00

0210

0W

0002

100

W00

0210

0W

0002

100

69Tu

be A

ssem

bly,

Cop

per

1053

4701

1053

4702

1053

4703

1053

4704

1053

4705

1053

4706

1053

4707

1053

4708

1053

4709

70Tu

be A

ssem

bly,

Cup

ro-n

icke

l10

5537

0110

5537

0210

5537

0310

5537

0410

5537

0510

5537

0610

5537

0710

5537

0810

5537

09

71S

crew

, Cap

, 1/2

" - 1

3 x

4 1/

2"F0

0287

00F0

0287

00F0

0287

00F0

0287

00F0

0287

00F0

0287

00F0

0287

00F0

0287

00F0

0287

00

72S

crew

, Cap

, 1/2

" - 1

3 x

2 1/

4"F0

0231

00F0

0231

00F0

0231

00F0

0231

00F0

0231

00F0

0231

00F0

0231

00F0

0231

00F0

0231

00

73S

crew

, Cap

, 1/2

" - 1

3 x

1 1/

2"F0

0133

00F0

0133

00F0

0133

00F0

0133

00F0

0133

00F0

0133

00F0

0133

00F0

0133

00F0

0133

00

74W

ashe

rF0

0114

00F0

0114

00F0

0114

00F0

0114

00F0

0114

00F0

0114

00F0

0114

00F0

0114

00F0

0114

00

75P

lug,

Sq.

Hd.

, 1 “

NP

TP

0033

000

P00

3300

0P

0033

000

P00

3300

0P

0033

000

P00

3300

0P

0033

000

P00

3300

0P

0033

000

76P

lug,

1/2

" NP

TP

0026

900

P00

2690

0P

0026

900

P00

2690

0P

0026

900

P00

2690

0P

0026

900

P00

2690

0P

0026

900

77N

ippl

e, B

rass

, 3/4

" x 2

"P

0025

300

P00

2530

0P

0025

300

P00

2530

0P

0025

300

P00

2530

0P

0025

300

P00

2530

0P

0025

300

78Va

lve,

Pre

ss, R

elie

f 3/4

" -75

PSI

A00

6360

0A

0063

600

A00

6360

0A

0063

600

A00

6360

0A

0063

600

A00

6360

0A

0063

600

A00

6360

0

79Te

mp/

Pre

ss G

auge

A00

7900

0A

0079

000

A00

7900

0A

0079

000

A00

7900

0A

0079

000

A00

7900

0A

0079

000

A00

7900

0

80Fl

ow S

witc

h (in

door

)E

0013

100

E00

1310

0E

0013

100

E00

1310

0E

0013

100

E00

1310

0E

0013

100

E00

1310

0E

0013

100

(out

door

)E

0013

000

E00

1300

0E

0013

000

E00

1300

0E

0013

000

E00

1300

0E

0013

000

E00

1300

0E

0013

000

81N

ippl

e, 2

" x c

l. - G

aIv

P00

3850

0P

0038

500

P00

3850

0P

0038

500

——

——

——

——

——

——

——

——

——

——

82N

ippl

e, 2

1/2

" x 3

" GaI

v—

——

——

——

——

——

——

——

—P

0022

000

P00

2200

0P

0022

000

P00

2200

0P

0022

00

83R

ed. T

ee, 2

x 2

x 1

, GaI

vP

0028

500

P00

2850

0P

0028

500

P00

2850

0—

——

——

——

——

——

——

——

——

——

—R

ed. T

ee, 2

1/2

x 2

1/2

x 1

, GaI

v—

——

——

——

——

——

——

——

—P

0055

900

P00

5590

0P

0055

900

P00

5590

0P

0055

900

84P

ump

Rot

atin

g A

ssem

bly

See

Cur

rent

Doc

umen

t 204

0 Fo

r Pum

p R

equi

rem

ents

85P

ump

Hou

sing

1026

1501

1026

1501

1026

1501

1026

1501

1026

1501

1026

1501

1026

1501

1026

1501

1026

1501

86G

aske

t, P

ump

Hou

sing

S00

2460

0S

0024

600

S00

2460

0S

0024

600

S00

2460

0S

0024

600

S00

2460

0S

0024

600

S00

2460

0

87P

ump

Ada

pter

1036

4200

1036

4200

1036

4200

1036

4200

1036

4200

1036

4200

1036

4200

1036

4200

1036

4200

88S

crew

, Hex

Hd.

1/2

- 1

3 x

1 3/

4F0

0092

00F0

0092

00F0

0092

00F0

0092

00F0

0092

00F0

0092

00F0

0092

00F0

0092

00F0

0092

0

NO

TE: N

umbe

rs in

() r

epre

sent

qua

ntity

requ

ired

for e

ach

size

. Qua

ntity

is o

ne o

ther

wis

e.


eyD

escr

iptio

nM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

No

500

600

715

850

1010

1200

1430

1670

1825

89P

lug,

3/4

, Sq.

Hd.

P00

2700

0P

0027

000

P00

2700

0P

0027

000

P00

2700

0P

0027

000

P00

2700

0P

0027

000

P00

2700

090

Pip

e E

xten

sion

1/2

" Fem

ale

Pip

e E

xten

sion

1/2

" Mal

eP

0072

300

P00

7230

0P

0072

300

P00

7230

0P

0072

300

P00

7230

0P

0072

300

P00

7230

0P

0072

300

91B

affle

, Diff

user

1033

8400

1033

8400

1033

8400

1033

8400

1033

8400

1033

8400

1033

8400

1033

8400

1033

8400

92B

urne

r Tra

y, II

D, 2

Sta

ge, S

GL

Sec

t. M

anifo

ld (N

at)

1055

0601

1055

0602

1055

0603

1055

0604

1055

0605

1055

0606

1055

0607

1055

0608

1055

0609

93B

urne

r Tra

y, S

t. P

ilot,

2 St

age,

SG

L, S

ect.

Man

ifold

(Pro

)10

5296

0110

5296

0210

5296

0310

5296

0410

5296

0510

5296

0610

5296

0710

5296

0810

5296

0994

Bur

ner T

ray,

I I D

, 4 S

tage

,Sp

lit M

anifo

ld (N

at)

1055

0701

1055

0702

1055

0703

1055

0704

1055

0705

1055

0706

1055

0707

1055

0708

1055

0709

95B

urne

r Tra

y, S

t. P

ilot,

4 St

age,

Split

Man

ifold

(Pro

)10

5503

0110

5503

0210

5503

0310

5503

0410

5503

0510

5503

0610

3303

0710

3305

0810

3305

0996

Bur

ner T

ray,

IID

, Mec

h. M

od.

Split

Man

ifold

(Nat

)10

5507

0110

5507

0210

5507

0310

5507

04—

——

——

——

——

—97

Bur

ner T

ray,

I I D

, Mec

h. M

od.,

3 &

4 S

ect.

Man

ifold

(Nat

)—

——

——

——

—10

5512

0110

5512

0210

5512

0310

5512

0410

5512

0598

Bur

ner T

ray,

St.

Pl.

Mec

h.M

od. S

pIt.

Man

ifold

(Pro

)10

5503

0110

5503

0210

5503

0310

5503

04—

——

——

——

——

—99

Bur

ner T

ray,

St.

Pl.,

Mec

h.M

od.,

3 S

ect.

Man

ifold

(Pro

)—

——

——

——

—10

5505

0110

5505

0210

5505

0310

5505

0410

5505

0510

0C

ombi

natio

n G

as V

alve

,V

0059

600

V00

5960

0V

0059

600

V00

7040

0V

0070

400

V00

7040

0—

——

——

—4

Stag

e, (N

at)

(2)

(2)

(2)

(2)

(2)

(2)

101

Saf

ety

Gas

Val

ve, 4

Sta

ge (N

at)

——

——

——

——

——

——

V00

4670

0V

0046

800

V00

4680

010

2O

pera

ting/

Reg

. Gas

Val

ve,

4 St

age

(Nat

)—

——

——

——

——

——

—V

0051

300

V00

5130

0V

0051

300

(2)

(2)

(2)

103

Com

bina

tion

Gas

Val

ve,

V00

7080

0V

0070

800

V00

7080

0V

0070

900

V00

7090

0V

0070

900

V00

7090

0—

——

—4

Stag

e, (P

ro)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

104

Saf

ety

Gas

Val

ve,

4 St

age,

(Pro

)—

——

——

——

——

——

——

—V

0046

700

V00

4670

010

5O

pera

ting/

Reg

. Gas

Val

ve,

4 St

age

(Pro

——

——

——

——

——

——

——

V00

5490

0V

0054

900

(2)

(2)

106

Mod

usna

p G

as V

alve

, (H

H &

PHV

0045

100

V00

4510

0V

0045

100

V00

4510

0—

——

——

——

——

—O

nly)

, Mec

h. M

od. (

Nat

& P

ro)

V00

7110

0V

0071

100

V00

7110

0V

0071

100

V00

7110

0V

0071

100

V00

7110

0V

0071

100

V00

7110

0(3

)(3

)(3

)N

(4) &

P(3

)N

(4) &

P(3

)10

7O

pera

ting/

Reg

. Gas

Val

ve,

Mec

h. M

od. (

Nat

)V

0047

600

V00

4760

0V

0047

600

V00

4760

0V

0047

700

V00

4770

0V

0047

700

V00

4780

0V

0047

800

108

Ope

ratin

g/R

eg. G

as V

alve

,V

0054

800

V00

5480

0V

0054

800

V00

5480

0V

0054

800

V00

5480

0V

0054

900

V00

5490

0V

0054

900

Mec

h. M

od. (

Pro

)N

OTE

: Num

bers

in (

) rep

rese

nt q

uant

ity re

quire

d fo

r eac

h si

ze. Q

uant

ity is

one

oth

erw

ise.


Figure 21. Outdoor Parts.


eyD

escr

iptio

nM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

No

500

600

715

850

1010

1200

1430

1670

1825

1To

p P

anel

Ass

embl

y10

6607

0110

6607

0210

6607

0310

6607

0410

6607

0510

6607

0610

6607

0710

6607

0810

6607

09

2R

ear

Win

dshi

eld

1065

8101

1065

8102

1065

8103

1065

8104

1065

8105

1065

8106

1065

8107

1065

8108

1065

8109

3U

pper

Rea

r Lou

ver S

hiel

d10

6571

0110

6571

0210

6571

0310

6571

0410

6571

0510

6571

0610

6571

0710

6571

0810

6571

09

4R

ear P

anel

Upp

er10

6587

0110

6587

0210

6587

0310

6587

0410

6587

0510

6587

0610

6587

0710

6587

0810

6587

09

5G

ap C

losu

re-S

ide

1066

0200

1066

0200

1066

0200

1066

0200

1066

0200

1066

0200

1066

0200

1066

0200

1066

0200

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

6G

ap C

losu

re-M

iddl

e10

6601

0010

6601

0010

6601

0010

6601

0010

6601

0010

6601

0010

6601

0010

6601

0010

6601

00

7Lo

wer

Rea

r Pan

el A

ssem

bly

1066

0501

1066

0502

1066

0503

1066

0504

1066

0505

1066

0506

1066

0507

1066

0508

1066

0509

8R

ear E

nd P

anel

Lft.

& R

t.10

6577

0010

6577

0010

6577

00(2

)10

6577

0010

6577

0010

6577

0010

6577

0010

6577

0010

6577

00(2

)(2

)(2

)(2

)(2

)(2

)(2

)(2

)(2

)

9Lo

wer

Rea

r Shi

eld

Inne

r10

6599

0110

6599

0210

6599

0310

6599

0410

6599

0510

6599

0610

6599

0710

6599

0810

6599

09

10R

ear B

ase

Ext

ensi

on10

6585

0110

6585

0210

6585

0310

6585

0410

6585

0510

6585

0610

6585

0710

6585

0810

6585

09

11G

as T

rain

Inte

rface

Pla

te20

0502

0020

0502

0020

0502

0020

0502

0020

0502

0020

0502

0020

0502

0020

0502

0020

0502

00

12Fr

ont E

nd P

anel

1065

7500

1065

7500

1065

7500

1065

7500

1065

7500

1065

7500

1065

7500

1065

7500

1065

7500

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

13Fr

ont B

ase

Ext

ensi

on10

6597

0110

6597

0210

6597

0310

6597

0410

6597

0510

6597

0610

6597

0710

6597

0810

6597

09

14D

oor

1066

0801

1066

0802

1066

0803

1066

0804

1066

0805

1066

0806

1066

0807

1066

0808

1066

0809

(2)

(2)

(2)

(2)

(2)

15Fr

ont

Win

dshi

eld

1065

9101

1065

9102

1065

9103

1065

9104

1065

9105

1065

9106

1065

9107

1065

9108

1065

9109

16Fr

ont P

anel

Upp

er10

6589

0110

6589

0210

6589

0310

6589

0410

6589

0510

6589

0610

6589

0710

6589

0810

6589

09

17Fl

ue P

anel

Fro

nt10

6595

0110

6595

0210

6595

0310

6595

0410

6595

0510

6595

0610

6595

0710

6595

0810

6595

09

18Fl

ue P

anel

Rea

r10

6593

0110

6593

0210

6593

0310

6593

0410

6593

0510

6593

0610

6593

0710

6593

0810

6593

09

19R

ain

Shi

eld-

Con

trol B

ox10

6604

0010

6604

0010

6604

0010

6604

0010

6604

0010

6604

0010

6604

0010

6604

0010

6604

00(N

ot s

how

n)

NO

TE: N

umbe

rs in

() r

epre

sent

qua

ntity

requ

ired

for e

ach

size

. Qua

ntity

is o

ne o

ther

wis

e.

SECTION 7. Outdoor Parts Descriptions and Order Numbers


Key

Des

crip

tion

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elM

odel

Mod

elN

o50

060

071

585

010

1012

0014

3016

7018

25

See

Part

s Ill

ustr

atio

n O

n Pa

ge 2

1

5R

ear P

anel

, Flu

e C

olle

ctor

1066

1701

1066

1702

1066

1703

1066

1704

1066

1705

1066

1706

1066

1707

1066

1708

1066

1709

6R

ear P

anel

, Flu

e C

olle

ctor

Ext

.10

6618

0110

6618

0210

6618

0310

6618

0410

6618

0510

6618

0610

6618

0710

6618

0810

6618

09

7Fr

ont S

uppo

rt, F

lue

Col

lect

or10

6621

0110

6621

0210

6621

0310

6621

0410

6621

0510

6621

0610

6621

0710

6621

0810

6621

09

8Ti

le C

over

, Fro

nt &

Rea

r10

6615

0110

6615

0210

6615

0310

6615

0410

6615

0510

6615

0610

6615

0710

6615

0810

6615

09(2

)(2

)(2

)(4

)(4

)(4

)(4

)(4

)(4

)

10B

affle

, Hea

t Exc

hang

er10

6677

0110

6677

0210

6677

0310

6677

0410

6677

0510

6677

0610

6677

0710

6677

0810

6677

09(7

)(1

4)(1

4)(1

4)(1

4)(2

8)(2

8)(2

8)(1

4)

41M

iddl

e Fr

ont P

anel

1066

2001

1066

2002

1066

2003

1066

2004

1066

2005

1066

2006

1066

2007

1066

2008

1066

2009

42S

wee

p S

heet

Flu

e10

6622

0110

6622

0210

6622

0310

6622

0410

6622

0510

6622

0610

6622

0710

6622

0810

6622

09C

olle

ctor

48B

ase

Tile

Sup

port

1060

2301

1060

2302

1060

2303

1060

2304

1060

2305

1060

2306

1060

2307

1060

2308

1060

2309

69Tu

be A

ssem

bly,

Cop

per

1066

5901

1066

5902

1066

5903

1066

5904

1066

5905

1066

5906

1066

5907

1066

5908

1066

5909

70Tu

be A

ssem

bly,

Cup

ro-N

icke

l10

6704

0110

6704

0210

6704

0310

6704

0410

6704

0510

6704

0610

6704

0710

6704

0810

6704

09

NO

TE: N

umbe

rs in

() r

epre

sent

qua

ntity

requ

ired

for e

ach

size

. Qua

ntity

is o

ne o

ther

wis

e.

Pump Rotating Sections and Repair Parts

Electrical OptionsAutomatic Reset Temp. Limit Switch .......................................................................................................................E0014400Manual Reset High Gas Pressure Switch ...............................................................................................................E0023300Manual Reset Low Gas Pressure Switch ................................................................................................................E0023500Outdoor Reset, On/Off 1:1 Reset Ratio ..................................................................................................................E0067600Outdoor Reset, Two Stage, 1:1 Reset Ratio ...........................................................................................................E0084200Outdoor Reset, Two Stage, 1:1.5 Reset Ratio ........................................................................................................E0081900Low-water Cut-off, Electronic, Manual Reset ..........................................................................................................E2075100

Gas valve types and sizes vary with different boiler models, with different fuels and with different firing options. For service and replacement,copy exact number from nameplate giving manufacturer’s name and pipe size.

Energy Management Monitor (EM2)STANDARD COMPONENTS

Description Part No.On/Off Auto Switch E0109200Time Delay Relay, 24 VAC E2077700

OPTIONAL EQUIPMENTDescription Part No.Remote Aquastat, 110-240F E0014400Immersion Well E0025900Note: The Remote Aquastat and the Immersion Well, whenrequired, should be ordered separately.

SECTION 8. Optional Parts Descriptions and Order Numbers

H011

7400

E

Standard PH Model Pumps (Armstrong 1050)PH Model Part Number Description

500-850 A2000700 1/3 hP with 3-1/2" Impeller



Optional PH Model Pumps (B&G 1522)PH Model Part Number Description


850-1010 A0047100 1/3 hP with 4" Impeller


Standard Pump Replacement Parts(for standard Armstrong 1050 pumps only)Description Part Number

Coupler Assembly A2010500

Shaft & Bearing Module A2010100

Mechanical Seal Assembly A2010000

Impeller for A2000700 (3-1/2") A2010200

Impeller for A2000800 (4-14") A2010301

Impeller for A2000900 (5-1/4") A2010302

Motor Assembly A2010303

800.900.9276 • Fax 800.559.1583 (Customer Service, Service Advisors)20 Industrial Way, Rochester, NH 03867 • 603.335.6300 • Fax 603.335.33551869 Sismet Road, Mississauga, Ontario, Canada L4W 1W8 • 905.238.0100 • Fax 905.366.0130www.Laars.com Litho in U.S.A. © Laars Heating Systems 0805 Document 1049E

installation and operation instructions for mighty thermbostonheatingsupply.com/laars/laars mighty...

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