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Model Numbers: Ti400 and Lx400 Version Date: 2011-04-29

ASME HEAT EXCHANGER ASSEMBLY (400) (P/N 82926-1) - INSTALLATION INSTRUCTIONS

NY Thermal Inc. Technical Assistance: 1-800-688-2575 Fax: 1-506-432-1135 www.nythermal.com

Installer Responsibilities

As the installing technician, it is your responsibility to ensure the installation is performed in accordance with the NTI Installation Instructions included with the ASME Heat Exchanger Assembly (400). Refer to facing page for Lx400 Installation Procedure. See Boiler System Preparation for instructions on de-scaling and protecting the heating system and the new heat exchanger.

Kit Contents (P/N 82926-1) � 82926 - Heat Exchanger Assembly � 82774 - Gaskets (2) � Installation Instructions (model specific)

The heat exchanger has been factory prepared for a Ti400, field modifications required for use with Lx400.

Ti 400 Installation Procedure

The new style of 400 heat exchangers has additional ports, such as the inlet sensor port on the underside of the water manifold and the flue sensor port in the front of the heat exchanger. These ports are not used on Ti400 boilers and have been plugged at the factory with a brass plug (Fig. 2) and a flue sensor (Fig. 3). Sensor wires can be snipped off (if preferred) but the sensor must remain. No field modifications are required for a Ti400 other than to replace the existing heat exchanger with the new heat exchanger and to rotate the burner door. The Ti400 Installation Procedure is as follows:

1.

Power Down - To turn off power: a) locate the Manual Gas Shutoff Valve outside the unit, b) turn the valve off, and c) shut off electrical power to the appliance. See "Lighting/Shutting Down the Appliance".

2.

Plugs - DO NOT remove brass plug or flue sensor if installing on a Trinity Ti400. 3.

Burner Door - Remove burner door on new heat exchanger, rotate to appropriate orientation, re-connect to new unit. The igniter hole in the burner door has been reamed out to accommodate a Ti400 igniter (Fig. 4).

4.

Flame Rod and Igniter - Remove and reuse the existing hot surface igniter and flame rod, install on the new burner door using screws provided and new gaskets (Fig. 1 & 4).

5.

Heat Exchanger - Disconnect boiler jacket, wires, plumbing, etc. as required. Replace the existing heat exchanger with the new heat exchanger. Secure heat exchanger in place, reattached all operational hardware.

6.

Power Up - Turn on electrical power to the appliance, then turn the Manual Gas Shutoff Valve outside the unit to the on position. See section "Lighting/Shutting Down the Appliance".

7.

Air Removal - Fill boiler with water, circulate to remove air from system prior to firing up the boiler. 8.

Flush Contaminants - At some point, cleanse and flush the heating system, see Boiler System Preparation.

9.

Leak Check - Fire up boiler, check for gas leaks while unit operating (i.e. burner doors, plugged ports).

Fig. 2 Inlet Sensor Port (Plug) Fig. 3 Flue Sensor Port (Plug) Fig. 4 New Burner Door

Fig. 1 Screws Provided

� Flush System � De-scale with

Fernox F3 � Protect with

Fernox F1

Ti400, Lx400 82926 ASME HX Assembly (400) │Trinity

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Lx 400 Installation Procedure

If the heat exchanger assembly is being installed on a Lx400 model, there are several important field modifications that need to be performed by the installing contractor during the heat exchanger replacement process. Refer to the installation procedure below and Figures 8 and 9 on the back page.

Explosion Hazard (Lx400) - The aluminum tube connecting the blower and the metallic high-vent pressure switch contains a fuel/air mixture. Refer to the Installation Procedure

below for instructions on disconnecting and reconnecting the aluminum tubing assembly. Failure to follow these instructions may result in serious injury or death.

1. Power Down - To turn off power: a) locate the Manual Gas Shutoff Valve outside the unit, b) turn the valve off, c) shut off electrical power to the appliance. See section on "Lighting/Shutting Down the Appliance".

2. Move Brass Plug - On the new heat exchanger, remove brass plug in far end of water manifold with a hex-head allen key, re-tape plug threads, and reinstall in center port (Fig. 5).

3. Disconnect High Vent Pressure Tube - Read Danger warning! On existing unit, loosen the compression fitting at the high-vent pressure switch using a 1/2" wrench to. At the blower end, support the brass fitting body with a 1/2" wrench to keep it from turning and loosen the compression fitting nut with a 9/16" wrench. Remove tubing assembly.

4. Heat Exchanger - Disconnect boiler jacket, wires, plumbing, etc. as required. Replace the existing heat exchanger with the new heat exchanger. Secure heat exchanger in place, reattached all operational hardware.

5. Re-use Burner Door - DO NOT use new burner door on Lx400 models. The new burner door has been reamed out for a Ti400 igniter, which requires a bigger mounting hole than the Lx400 igniter. For this reason, Lx400 models must re-use the existing burner door. Align holes in existing door with new insulation disk (Fig. 6), install on new heat exchanger assembly. Do not use old door if damaged. Replace if damaged with a Lx400 Burner Door, part #83949.

6. Reconnect High Vent Pressure Tube - Read Danger warning! Reconnect the metallic tube between the blower and the high-vent pressure switch using the same procedure used to disconnect the tube, where the brass fitting body at the blower is supported to ensure it remains stationary and does not rotate during reconnection.

7.

Power Up - To turn on power: a) turn on electrical power to the appliance, and b) turn the Manual Gas Shutoff Valve outside the unit to the on position. Refer to section "Lighting/Shutting Down the Appliance".

8.

Air Removal - Fill boiler with water, circulate to remove air from system prior to firing up the boiler. 9.

Flush Contaminants - At some point, cleanse and flush the heating system, see Boiler System Preparation.

10.

Leak Check - Fire up boiler, check for gas leaks while operating (i.e. burner door, tubing connections).

Fig. 5 Relocate Brass Plug Fig. 6 Re-use Burner Door Fig. 7 High Vent Tubing

Boiler System Preparation

To maintain the efficient and reliable operation of the heat exchanger and to avoid heat exchanger failure, it is critical to rid the heating system of any contaminants. Both old and new must be cleansed to remove flux, grease and carbon residue. NTI recommends using "Fernox F3 Cleaner". For retrofits, all system piping including radiators, must be cleansed of all build-up including sludge and scale. Applications with heavy limescale and sludge deposits will need a stronger cleaner, such as "Fernox DS-40 System Cleaner". Cleansing procedure and instructions included with Fernox. See Table 1-1 for list of Boiler Only water treatment and cleansers.

Failure to rid the heating system of the contaminants listed above will void your NTI warranty and may result in premature heat exchanger failure and property damage.

move brass plug to the center port

Ti400, Lx400 82926 ASME HX Assembly (400) │Trinity

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Water Heaters - The Lx400 model can be installed as a boiler or a water heater with the difference being how the appliance is plumbed and wired. DO NOT use Fernox to flush

system or heat exchanger if the Trinity Lx400 is installed as a Water Heater. Toxic chemicals used for boiler treatment shall not be introduced into the potable water system. Failure to follow instructions may result in contamination of potable water system, personal injury or damage to equipment.

Table 1-1 Boiler System Cleansers and Corrosion Inhibitors Application Fernox Product NTI Part # Description

Boiler Water Treatment F1 Protector 83448 Corrosion inhibitor.

Cleanser for new and old systems F3 Cleaner 83449 Removes flux, grease and carbon residue.

Cleanser for Retrofits DS-40 System Cleaner 83450 Removes heavy limescale and sludge deposits.

Notes: 1 Fernox products listed above are for Boilers Only. DO NOT use these products to flush or cleanse Lx400 Water Heaters.

Lighting / Shutting Down the Appliance

Read Before Proceeding - If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

A) This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. B) BEFORE OPERATING smell all around the appliance area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS: • Do not try to light any appliance. • Do not touch any electric switch. • Do not use any phone in your building. • Immediately call your gas supplier from a neighbor's phone. Follow the gas supplier's instructions. • If you cannot reach your gas supplier, call the fire department. C) Use only your hand to push in or turn the gas control knob. Never use tools. If the knob will not push in or turn by hand, don't try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion. D) Do not use this appliance if any part has been under water. Immediately call a qualified service technician to inspect the appliance and to replace any part of the control system and any gas control which has been under water.

OPERATING INSTRUCTIONS_

1. STOP! Read the safety information above very carefully. 2. Set the thermostat to lowest setting. Turn off all electric power to the appliance. 3. This appliance does not have a pilot. It is equipped with an ignition device which automatically lights the burner. Do not try to light the burner by hand. 4. Turn the manual gas valve to the OFF position. Remove front access panel. 5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas, STOP! Follow “B” in the safety information above. If you don't smell gas, go to the next step. 6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas. 7. Replace the front access panel. 8. Set thermostat to highest setting. Turn on all electric power to the appliance. 9. Ignition sequence is automatic. Combustion will occur after a brief fan purge. 10. If ignition does not occur, follow the instructions “To Turn Off Gas To Appliance” and call your service technician or gas supplier.

TO TURN OFF GAS TO THE APPLIANCE_

1. STOP! Read the safety information above very carefully. 2. Turn off all electric power to the appliance. 3. Turn the manual gas valve to the OFF position

Ti400, Lx400 82926 ASME HX Assembly (400) │Trinity

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400 Heat Exchanger Assembly

Fig. 9 Lx400 Heat Exchanger Assembly

Flue Sensor Port

Inlet Sensor Port

Fig. 8 Ti400 Heat Exchanger Assembly

Ti400 Hot Surface Igniter

The new style of 400 heat exchangers has additional ports (inlet sensor and flue sensor) which are not used on Ti400 boilers. See Lx400 Installation Procedure for required field modifications.

Lx400 Spark Igniter