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Laars NeoTherm NTH Installation And Operation Instructions Manual

Manual is about: Modulating Boiler Sizes 399-850 MBTU/h, Water Heater Sizes 399-850 MBTU/h

Summary of NeoTherm NTH

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    Installation and operation instructions document 1252b h2355200b warning 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 vicin...

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    Laars heating systems section 1 - general information 1.1 introduction ....................................................... 1 1.2 modelidentification ........................................... 1 1.3 applianceoverview .......................................... 2 1.4 warranty ........................

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    N eo t herm boilers and water heaters section 9 - first start-up and adjustment instructions 9.1 fillingtheboilersystem ................................. 50 9.2 firstoperation ................................................ 50 9.3 adjustingthedifferentialand manifoldpressure ..........................

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    Laars heating systems.

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    Page 1 n eo t herm boilers and water heaters section 1 - general information warning neotherm units must be installed in accordance with the procedures detailed in this manual, or the laars heating systems warranty will be voided. The installation must conform to the requirements of the local jurisd...

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    Page 2 laars heating systems figure1-locationofcomponents,sizes80–105 figure2-locationofcomponents,sizes150-210 exhaust vent connection gas connection user control interface heat exchanger gas valve venturi air/ gas blower pressure relief valve water inlet water outlet air inlet connection drain val...

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    Page 3 n eo t herm boilers and water heaters figure4-locationofcomponents,size399 figure3-locationofcomponents,size285 exhaust vent connection air inlet connection gas connection user control interface heat exchanger gas valve venturi air/ gas blower exhaust vent connection gas connection user contr...

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    Page 4 laars heating systems figure6-locationofcomponents,size600 figure5-locationofcomponents,size500 exhaust vent connection pressure relief valve air pressure switch user control interface heat exchanger manual shutoff gas valve venturi gas valve exhaust vent connection gas connection pressure re...

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    Page 5 n eo t herm boilers and water heaters figure7-locationofcomponents,sizes750and850 water inlet water outlet air inlet drain valve condensate trap air/ gas blower pressure relief valve user control interface heat exchanger exhaust vent connection venturi gas valve gas connection manual shutoff ...

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    Page 6 laars heating systems figure8-contentsofshippingpackage 1.4 warranty laars heating systems’ neotherm appliances are covered by a limited warranty. The owner should complete the warranty registration at www.Laars.Com. All warranty claims must also be made at www.Laars.Com. Or to an authorized ...

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    Page 7 n eo t herm boilers and water heaters figure9-dimensiondrawing,sizes80-850 dimensions are nominal and are shown in inches, cm. * neotherm is shipped with adapters for the air and vent that accept stan- dard pipe of the proper size and type. A b c d e f g j k m n size in cm in cm in cm in cm i...

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    Page 8 laars heating systems section 2 - locating the appliance 2.1 generalinformation the neotherm unit is designed for indoor installations only. The appliance should be located to provide clearances on all sides for maintenance and inspection. It should not be located in an area where leakage of ...

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    Page 9 n eo t herm boilers and water heaters method 1: two permanent openings, one commencing within 12” (300mm) of the top and one commencing within 12” (300mm) of the bottom, of the enclosure shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that ...

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    Page 10 laars heating systems other methods of introducing combustion and ventilation air are acceptable, providing they conform to the requirements in the applicable codes listed above. In canada, consult local building and safety codes or, in absence of such requirements, follow can/csa b149. Duct...

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    Page 11 n eo t herm boilers and water heaters all installations should be done following the vent supplier’s recommended installation techniques. If manufacturer’s instructions are not available for the material used, follow the laars recommendations. The vent pipe must pitch upward, toward the vent...

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    Page 12 laars heating systems neotherm and shown in the unpacking section, be installed. Be sure to install and terminate both vent and combustion air pipes per the venting and combustion air section of the neotherm instructions. 3.3 locatingventandcombustionair terminals sidewallventterminal the ap...

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    Page 13 n eo t herm boilers and water heaters *when vent terminal is less than 10 feet (3m) horizontally from a forced air inlet, the terminal must be at least 3 feet (0.9m) above the air inlet. (us only) figure12-combustionairandventthroughsidewall u.S.Installations(seenote1) canadianinstallations(...

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    Page 14 laars heating systems 1. Installation of carbon monoxide detectors 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 l...

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    Page 15 n eo t herm boilers and water heaters section 4 - gas supply and piping gas piping should be supported by suitable hangers or floor stands, not the appliance. Review the following instructions before proceeding with the installation. 1. Verify that the appliance is fitted for the proper type...

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    Page 16 laars heating systems sched 40 metal pipe capacity for 1.50 specific gravity undiluted propane nominal pipe size @ 11” w.C. Inlet and 0.5” w.C. Pressure drop size 1/2” 3/4” 1” 1-1/4” 1-1/2” 2” length maximum capacity in thousands of btu per hour 20 200 418 787 1616 2422 4664 40 137 287 541 1...

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    Page 17 n eo t herm boilers and water heaters neotherm’s efficiency is higher with lower return water temperatures. Therefore, to get the most of low return temperature with multiple boilers, pipe as shown in figures 17-19. Neotherm ntv models 150-500 can be ordered with or without a pump included. ...

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    Page 18 laars heating systems 6a.3condensatedrain a condensate drain trap is built into the neotherm unit. Connect a 3/4” pvc pipe between the drain connection and a floor drain (or a condensate pump if a floor drain is not accessible). The condensate drain must be installed so as to prevent accumul...

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    Page 19 n eo t herm boilers and water heaters figure15-hydronicpiping—singleboiler,zoningwithcirculators.

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    Page 20 laars heating systems figure16- hydronicpiping—singleboiler,lowtempradiantspaceheating usinglowlossheaderandzonevalves.

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    Page 21 n eo t herm boilers and water heaters figure17-hydronicpiping—multipleboilers,zoningwithcirculators.

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    Page 22 laars heating systems figure18-hydronicpiping—multipleboilerswithindirectdhwtankpipedfromsystemloop.

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    Page 23 n eo t herm boilers and water heaters figure19-hydronicpiping—multipleboilers,reversereturn,multi-tempzones,zoningwithcirculators.

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    Page 24 laars heating systems figure20-hydronicpiping—heatingzoneswithindirectdhwtankpipedwithzonepumps the indirect dhw tank is piped directly off of the boiler. The boiler pump must shut down during dhw operation..

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    Page 25 n eo t herm boilers and water heaters figure21-hydronicpiping,multipleboilerswithindirectdhwoffofoneboiler the boiler pump must shut down during dhw operation..

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    Page 26 laars heating systems 6b.2pipingrequirements water piping should be supported by suitable hangers and floor stands. Do not support piping with the appliance. Due to expansion and contraction of copper pipe, consideration should be given to the type of hangers and supports used. Rigid hangers...

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    Page 27 n eo t herm boilers and water heaters 6b.3coldwatermake-up the cold water make-up may be connected to the tank or to the inlet of the boiler as shown in figures 22-25 . Install back flow preventers and shut offs where needed or required by code. Pipe sizes may have to be increased to accomod...

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    Page 28 laars heating systems figure23-dhwpiping,oneheater,twoverticaltanks notes: 1. Optional cwmu & recirc. Line location. 2. Locate ntv dhw sensor or remote aquastat well in lower 1/3 of tank. 3. Back flow preventer may be required - check local codes. 4. Thermal expansion tank may be required - ...

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    Page 29 n eo t herm boilers and water heaters figure24-dhwpiping,twoheaters,oneverticaltank figure25-dhwpiping,twoheaters,twoverticaltanks notes: 1. Optional cwmu & recirc. Line location. 2. Locate ntv dhw sensor or remote aquastat well in lower 1/3 of tank. 3. Back flow preventer may be required - ...

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    Page 30 laars heating systems section 7 - the user interface 7.1 abouttheuserinterface the user interface of the neotherm used on this unit has two main parts: • the ‘display’ area and • the ‘buttons’ the user interface displays operating and setup information sent from the neotherms electronic burn...

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    Page 31 n eo t herm boilers and water heaters 7.2 navigatingtheuserinterface navigating into the display area menus is as easy as it looks. The info/install button will be the primary button that you will use to start, and the ok button is what you press to select and approve the parameters that you...

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    Page 32 laars heating systems quick start this menu gives you an easy way to check or change the most common set- tings on the unit: • ch setpoint • dhw setpoint • outdoor reset • low water temperature • maximum outdoor temperature • minimum outdoor temperature • adjustable high limit • adjustable l...

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    Page 33 n eo t herm boilers and water heaters fig.29–changingavalue • the current setting for the setpoint appears in the box at the top of the screen. In this example, this is 182°f. • the numbers near the left edge of the screen show the allowable range for this value. In this case, the setpoint c...

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    Page 34 laars heating systems installer level settings that might affect the safe operation of the unit can only be changed by a trained technician who enters a password. These include setup and parameter changes made when the system is installed, and some diagnostic and troubleshooting functions. T...

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    Page 35 n eo t herm boilers and water heaters section 8a - quick start menu section 8 is divided into three parts. Section 8a includes instructions for using the quick start menu. Section 8b covers basic installation and wiring. Section 8c includes more detailed setup instructions and wiring diagram...

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    Page 36 laars heating systems section 8b - basic installation and wiring section 8 is divided into three parts. Section 8a includes instructions for using the quick start menu. Section 8b covers basic installation and wiring. Section 8c includes more detailed setup instructions and wiring diagrams. ...

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    Page 37 n eo t herm boilers and water heaters caution the supply voltage to the neotherm unit must not be disconnected, except for service or isolation, or unless otherwise instructed by procedures outlined in this manual. To signal a call for heat, use the 24v field interlock, as shown in the wirin...

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    Page 38 laars heating systems 8c.1 24vactransformer withintegralcircuitbreaker 24vac is supplied by a transformer mounted underneath the control panel. All 24vac power is supplied through a circuit breaker that is part of the transformer. The transformer is then connected to terminal blocks 3 and 4 ...

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    Page 39 n eo t herm boilers and water heaters • as the temperature begins to rise above 32°f, the outdoor reset function causes the setpoint to be lowered. At these warmer temperatures, the heating load on the system is not as great, so the system does not have to reach as high a temperature to hand...

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    Page 40 laars heating systems then go to “ch configuration.” select “outdoor reset configuration.” set the value on the line for “min. Boiler water temp.” if your system has more than one boiler, and is controlled using the lead/ lag function – how to get there: from the “home” screen, press “i” to ...

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    Page 41 n eo t herm boilers and water heaters dhw temperature setting - regardless of the type of dhw setup, the setpoint adjustment is made the same way. How to get there: from the “home” screen, press “i” to go to “info/ install.” choose “advanced setup,” then go to “dhw setpoint.” hydronic heatin...

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    Page 42 laars heating systems boiler pump interrupt function - the boiler pump interrupt feature is used in some applications when the boiler is being used for both hydronic and domestic hot water heating. The interrupt jumper is used to turn off the boiler pump during a domestic hot water demand. F...

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    Page 43 n eo t herm boilers and water heaters notice that, when a boiler is operating as part of a lead/lag system, it does not use the normal ch setpoint – it uses the special ll ch setpoint on the lead/lag master. The unit acting as the lead/lag master decides which boiler is assigned to start fir...

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    Page 44 laars heating systems caution you should set the modbus addresses before you connect the modbus wiring. If the wiring is attached before the modbus addresses on the controls are changed, there will be multiple controls with the same address, and the system will not work. Warning if the modbu...

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    Page 45 n eo t herm boilers and water heaters wiring connections for lead/lag - now you can make the modbus wiring connections between the units. The controller in each boiler includes two wiring terminals for the modbus system, labeled “mb1” and “mb2.” mb1 has the wiring connections to the user int...

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    Page 46 laars heating systems 8c.10optionalfieldconnections terminal block 8 (tb8) in the control panel can be used for connecting optional components, such as low water cutoffs, flow switches, additional high limits and other field-supplied devices that must be interlocked with the boiler. These ar...

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    Page 47 n eo t herm boilers and water heaters 8c.12 ladderandwiringdiagrams (see figures 43 through 45.) warning when servicing the controls, label all wires prior to disconnection. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing. Figure43-ladderdiag...

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    Page 48 laars heating systems figure44-wiringdiagram,allsizes(withstandardemeadisplay)h2354300b bo ile r pu m p gn d bl k w h g n x 01 1 2 3 12 11 10 9 8 7 6 5 4 7 6 5 4 x 07 1 2 3 8 pressur e switch br o r/ w h br or/wh n c c o m therm o -f use (on some models ) gy/w h mb 1 mb 2 ec o m b a v d c b ...

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    Page 49 n eo t herm boilers and water heaters figure45-wiringdiagram,allsizes-withoptionalfull-colortouchscreenh2355400b bo ile r pu m p gn d bl k w h g n co m 2 24vac 24v co m 1 2 3 4 5 6 7 8 to tb4 -1 to tb3 -1 co m 1 bl /g n y/ g n pressur e switch br o r/ w h br or/wh n c c o m mb 1 mb 2 ec o m ...

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    Page 50 laars heating systems ready for operation. 14. Prime the condensate trap with water. (this is not required for nth 600, 750, and 850 units.) 15. Refer to local codes and the make-up water valve manufacturer’s instructions as to whether the make-up water valve should be left open or closed. 1...

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    Page 51 n eo t herm boilers and water heaters 3. Observe all warnings on the operating instructions label and turn on the gas and electrical power to the appliance. 4. The neotherm unit will begin the start sequence. The blower and pump will energize for the pre-purge period, then the ignition seque...

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    Page 52 laars heating systems 600 750,850 figure46- neothermgasvalves 80–285 500 399 inlet gas pressure high fire co 2 adjustment (under cap) gas pressure tap low fire co 2 adjustment outlet gas pressure inlet gas pressure low fire co 2 adjustment high fire co 2 adjustment (under cap) outlet gas pre...

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    Page 53 n eo t herm boilers and water heaters 9.4 shuttingdowntheneothermunit 1. Turn off the main electrical disconnect switch. 2. Close all manual gas valves. 3. If you think the neotherm unit might freeze, drain it. All water must be removed from the heat exchanger, or damage from freezing may oc...

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    Page 54 laars heating systems section 10 maintenance warning disconnect all power to the appliance before attempting any service. Contact with electricity can result in severe injury or death. 10.1systemmaintenance do this once a year, unless otherwise noted. 1. Lubricate the system water-circulatin...

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    Page 55 n eo t herm boilers and water heaters the control. If control replacement is required, turn off all power to the appliance and shut off all manual gas valves to the appliance. Remove the front door to the appliance and the plastic bezel and the control panel. Remove all wire connections from...

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    Page 56 laars heating systems transformerwithintegralcircuitbreaker the appliance has a 24vac transformer with integral 4 amp circuit breaker installed to supply the control voltage required for the appliance. The transformer is sized to provide power for the neotherm unit only, and should not be us...

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    Page 57 n eo t herm boilers and water heaters nt size (mbtu) kit number 80 ca006201 105 ca006202 150 ca006203 199 ca006204 210 ca006204 285 ca006205 399 ca008600 500 ca008600 600 ca008600 750 ca008600 850 ca008600 table16a-propanegasconversionkits nt size (mbtu) kit number 80 ca006206 105 ca006206 1...

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    Page 58 laars heating systems section 11 - operating details and troubleshooting 11.1 normalstartupandinitialization when power to the unit is turned on, the controller will automatically go through a startup and initialization procedure. At first the interface will display some information about th...

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    Page 59 n eo t herm boilers and water heaters 11.5 anti-short-cycle(asc) because the neotherm unit is a modulating boiler, and its input will decrease when there is a reduction in the heating load, short cycling is greatly reduced. If the heating load drops below the minimum input of the boiler for ...

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    Page 60 laars heating systems 12.2 parts list si ze si ze si ze si ze si ze si ze si ze si ze si ze si ze item d escription nth 80 nth 105 nth 150 nth 210 nth 285 nth 399 nth 500 nth 600 nth 750 nth 850 ntv 150 ntv 199 ntv 285 ntv 399 ntv 500 ntv 600 ntv 750 ntv 850 jacket components – see figure 63...

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    Page 61 n eo t herm boilers and water heaters si ze si ze si ze si ze si ze si ze si ze si ze si ze si ze item d escription nth 80 nth 105 nth 150 nth 210 nth 285 nth 399 nth 500 nth 600 nth 750 nth 850 ntv 150 ntv 199 ntv 285 ntv 399 ntv 500 ntv 600 ntv 750 ntv 850 23 cantilevered base r15d1002 r15...

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    Page 62 laars heating systems si ze si ze si ze si ze si ze si ze si ze si ze si ze si ze item d escription nth 80 nth 105 nth 150 nth 210 nth 285 nth 399 nth 500 nth 600 nth 750 nth 850 ntv 150 ntv 199 ntv 285 ntv 399 ntv 500 ntv 600 ntv 750 ntv 850 49 high gas pressure switch — — — — — — r50d5014 ...

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    Page 63 n eo t herm boilers and water heaters si ze si ze si ze si ze si ze si ze si ze si ze si ze si ze item d escription nth 80 nth 105 nth 150 nth 210 nth 285 nth 399 nth 500 nth 600 nth 750 nth 850 ntv 150 ntv 199 ntv 285 ntv 399 ntv 500 ntv 600 ntv 750 ntv 850 69a gasket set rs2109100 rs210910...

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    Page 64 laars heating systems figure50-jacketcomponents optionaltouchscreenuserinterfacekit(km50d7130).

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    Page 65 n eo t herm boilers and water heaters figure51a-internalcomponents,sizes80–210 figure51b-internalcomponents,sizes285–600

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    Page 66 laars heating systems figure51c-internalcomponents,sizes750-850

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    Page 67 n eo t herm boilers and water heaters figure52a-gastraincomponents,sizes80-500

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    Page 68 laars heating systems figure52b-gastraincomponents,sizes600-850

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    Page 69 n eo t herm boilers and water heaters figure53-heatexchangercomponents.

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    Page 70 laars heating systems figure54-electricalcomponents.

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    Page 71 n eo t herm boilers and water heaters appendixa- software control functions this table includes a listing of all of the control functions that can be used by the operator or installer. Functions that require a password are indicated in the second column. Name pw? Function how to get there ad...

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    Page 72 laars heating systems name pw? Function how to get there demand switch (ch) - set to “stat terminal.” info/ advanced setup/ ch configuration dhw pump control y the boiler pump can be turned on manually, or it can be set to operate automatically. Info/ test/ manual pump operation info/ advanc...

  • Page 77

    Page 73 n eo t herm boilers and water heaters name pw? Function how to get there max. Outdoor temp. (ch) - used with outdoor reset – this is the maximum outdoor temperature at which the outdoor reset feature will be active. Above this point, the low water temp. Will be used as the setpoint. Quick st...

  • Page 78

    Page 74 laars heating systems name pw? Function how to get there off hysteresis (dhw) - when producing domestic hot water – the control system will not shut off the boiler until the temperature at the system sensor rises to the dhw setpoint plus a hysteresis value (normally about 10°f). Info/ advanc...

  • Page 79

    Page 75 n eo t herm boilers and water heaters name pw? Function how to get there pump exercise interval y the system can be set to exercise the pumps at set intervals. Enter a non-zero value to turn on the function. Info/ advanced setup/ system config./ pump config. Pump exercise time y if the pump ...

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    Page 76 laars heating systems appendixb- error messages this table includes a listing of the faults that might be generated by the controller, and displayed on the operator interface. Some of these can be corrected by an installer changing a parameter, while other conditions are more complicated, an...

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    Page 77 n eo t herm boilers and water heaters 12 internal fault: safety relay drive cap short h internal fault 1. Reset module 2. If fault repeats, replace module. 13 internal fault: pii (pre-ignition interlock) shorted to ilk (interlock) h or l internal fault 1. Reset module 2. If fault repeats, re...

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    Page 78 laars heating systems 27 internal fault: flame rod shorted to ground detected h internal fault 1. Reset module 2. If fault repeats, replace module. 28 internal fault: a/d linearity test fails h internal fault 1. Reset module 2. If fault repeats, replace module. 29 internal fault: flame bias ...

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    Page 79 n eo t herm boilers and water heaters 63 lci (limit control input) off (safety chain open) h 1. Check wiring and correct any faults. 2. Check interlocks connected to the lci to assure proper function. 3. Reset and sequence the module; monitor the lci status. 4. If code persists, replace the ...

  • Page 84

    Page 80 laars heating systems 94 header sensor fault h 1. Check wiring and correct any possible errors. 2. Replace the header sensor. 3. If previous steps are correct and fault persists, replace the module. 95 stack sensor fault h 1. Check wiring and correct any possible errors. 2. Replace the stack...

  • Page 85

    Page 81 n eo t herm boilers and water heaters 108 flame lost in run l 1. Check main valve wiring and operation - correct any errors. 2. Check the fuel supply. 3. Check fuel pressure and repeat turndown tests. 4. Check ignition transformer electrode, flame detector, flame detector siting or flame rod...

  • Page 86

    Page 82 laars heating systems 132 fan speed failed during run h 1. Check wiring and correct any potential wiring errors. 2. Check the vfds (variable-speed fan drive) ability to change speeds. 3. Change the vfd 4. If the fault persists, replace the module. 137 ilk (interlock) failed to close h 1. Che...

  • Page 87

    Page 83 n eo t herm boilers and water heaters 159 main valve off l 1. Check the main valve terminal wiring and correct any errors. 2. Reset and sequence the module. If fault persists, replace the module. 160 ignition on l 1. Check ignition terminal wiring and correct any errors. 2. Reset and sequenc...

  • Page 88

    Page 84 laars heating systems 187 invalid dhw (domestic hot water) high limit enable setting l 1. Recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. 188 invalid dhw (domestic hot water) high limit response se...

  • Page 89

    Page 85 n eo t herm boilers and water heaters 204 invalid ntc sensor type setting l 1. Recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. 205 invalid outlet high limit response setting l 1. Recheck selected p...

  • Page 90

    Page 86 laars heating systems 222 unconfigured outlet high limit setpoint setting l 1. Recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. 223 unconfigured stack limit setpoint setting l 1. Recheck selected pa...

  • Page 91

    Page 87 n eo t herm boilers and water heaters 237 invalid dhw (domestic hot water) connector type setting l 1. Recheck selected parameters, reverify and reset module. 2. If fault repeats, verify electrical grounding. 3. If fault repeats, replace module. 238 invalid stack connector type setting l 1. ...

  • Page 92

    H2355200b 800.900.9276 • fax 800.559.1583 (customer service and product support) 20 industrial way, rochester, nh 03867 • 603.335.6300 • fax 603.335.3355 1869 sismet road, mississauga, ontario, canada l4w 1w8 • 905.238.0100 • fax 905.366.0130 www.Laars.Com printed in u.S.A. © laars heating systems 1...