INSTRUCTION MANUAL For installation, use and maintenance for the 5-41-5 MODELS: BMS & BTS Direct Vent Space / Water Heater These instructions MUST be read prior to installation and left near the appliance when the installation is completed. 120601 Text complies with minimum size requirements. U.S.A.
SAFETY INSTRUCTIONS WARNING: If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or death. Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance. WHAT TO DO IF YOU SMELL GAS 2 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 neighbors phone.
SAFETY INSTRUCTIONS These instructions must be read prior to installation. If the information in these instructions is not followed exactly, a fire or explosion may result, causing property damage, personal injury, or death. Hazards and Your Safety - Hot Water Can Scald! Water temperature over 125°F can cause severe burns instantly, or death from scalds.
GENERAL INFORMATION This instruction manual refers to two types of heaters, the BMS and the BTS. BMS - this appliance is a wall mounted, direct vent space/water heater BTS - this appliance is a self standing floor model, direct vent space/water heater Each type of heater can be of two different input power rating; a 10/20 or 15/29; 10/20 has an input power rating of 87,000 (31.
TABLE OF CONTENTS 3.3.3 Radiant heating installation ........................................................................... 12 ................................................................................................................................ 12 3.3.4 Used of glycol ................................................................................................ 12 ...............................................................................................................................
GENERAL LAYOUT of the main components of model BMS A = Flue discharge B = Air intake Coaxial discharge 6 Figure 1 - BMS Front view Split discharge
GENERAL LAYOUT of the main components of model BMS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Figure 2 - BMS Side and top views Central heating supply Central heating return Gas inlet Domestic hot water outlet Cold water inlet Flue gas discharge fan Automatic air vent Thermostat bulb pocket Gas valve service switch Instrument panel Temperature-pressure gauge Failure lamp indicator Ignition and detection electrodes Burner Gas manifold Exchanger shell cl
GENERAL LAYOUT of the main components of model BTS 8 Figure 3 - BTS Front view
GENERAL LAYOUT of the main components of model BTS 9 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Central heating supply Central heating return Gas inlet Domestic hot water outlet Cold water inlet Flue gas discharge fan Automatic air vent Thermostat bulb pocket -Instrument panel Temperature-pressure gauge Failure lamp indicator Ignition and detection electrodes Burner Gas manifold -Gas valve High limit thermostat Power and circulator pump switches Figure 4 - BTS side view 20 21 22 23 24 25 26 27 28
A INSTALLATION INSTRUCTIONS 1 Operating and adjusting the output to the radiation system The COSMOGAS heater can be installed in any domestic or light commercial building where the maximum BTU/H required is not greater than 84,000 BTU/H. The unit has a internal mixing valve (heating side only) that can be adjusted to regulate the supply water temperature delivered to the heating system. The heating system will not receive any water unless the water temperature inside of the heater is at a minimum of 140°F.
A INSTALLATION INSTRUCTIONS template to facilitate proper installation alignments (See figure 5 below). Clearances installation for The figures 5A and 5B show the proper distances to keep from any obstacle pertaining to the support bracket (2) or to the wall. The procedure for installing the BMS is as follow: 1) - Take the support bracket (2) and choose a position with proper clearances, as per Figures 5A & 5B. A minimum clearance of 40 (100mm) is required from the front of the heater.
A INSTALLATION INSTRUCTIONS 3.2 Safety Relief Valve An ASME approved safety relief valve, (set at 30 psi), must be installed in a vertical position on the outlet side of the central heating system, and as close as possible to the heater. There must be no valves between the safety relief valve and the heater. Manually operate the safety relief valve at least once a year to ensure proper operation.
The heaters thermostat can be regulated to provide domestic hot water between 100°F and 180°F. Water temperature over 125°F can cause severe burns instantly. Since it is required that the heater water temperature reach above 140°F in order for the heating system side of the unit to operate, it is imperative that a mixing valve be installed external of the heater to further regulate the temperature of the domestic hot water (See figures 23, 25, 26, 27 and 28).
A INSTALLATION INSTRUCTIONS 3.6 Gas Supply (cont.) Length of Gas Pipe 10' 20' 30' 40' 50' 75' 100' 150' Additional length to be added for each bend or tee 14 Capacity of Gas Pipe Size in MBTUH 1/2" 132 92 73 63 1.3' 3.7 Room Thermostat Connection This is installed by removing the electrical junction box cover indicated in fig.6, (see fig.1 and 3, item 26), and connecting the two wires of the room thermostat, or zone valve control thermostat, to the low voltage terminals, (figure 6, item B).
A INSTALLATION INSTRUCTIONS 15 Figure 6A - Installation of the electrical supply cable on the model BMS a) Remove or loosen screw (2) b) Pop- out the passage tunnel for the supply cable. Pass the supply cable through the passage (1) c) Connect the supply cable to the junction box d) Tighten screw (2); e) Re-insert the passage tunnel into its position (4). f) Feed wire to junction box and connect as shown in Figure 6.
A INSTALLATION INSTRUCTIONS 4 VENTING SYSTEMS 16 This heater can be fitted with either a concentric or split type venting system. Particular attention must be taken when installing the vent pipes that go through the wall to the outside. It must always be possible to carry out routine maintenance operations of the flue. The vent pipe must be installed in such a way that it can be removed, if needed, in the future. Hence, a suitable sheath should be prepared in which to insert the vent pipe.
A INSTALLATION INSTRUCTIONS blocked, the heater will not receive enough air for combustion and the burner would fail to ignite.
A INSTALLATION INSTRUCTIONS N = This position shall be respected O = Discharge grid P = Intake grid 4.2 Split Flue 18 The split flue vent system (two separate pipes) can be extended (on the discharge side only) up to a total length of 20 ft (6 m). Changes in direction can be obtained by using 90° and 45° elbows. If they are installed, there will be a loss of draught equal to 3ft (1 m) and 1 1/2ft (0.5 m) of straight pipe, respectively. This is valid only for pipes and elbows manufactured by Cosmogas s.
A INSTALLATION INSTRUCTIONS P/N 62617168. Split vent kit. This kit is for take the air from the room where the heater is installed, and discharge the flue outside from the building. The pipe of discharge is length 2.5ft.. If you need extensiones or elbows or other accessories, refer to figures R, S and T. This kit can be used for heaters model BMS and BTS. P/N 62617174. Coaxial Vent & Elbow Kit. This kit is for taking and discharging air from/ to the outside of the building.
A INSTALLATION INSTRUCTIONS Besides the kits COSMOGAS has a series of accessories, that in conjonction with the kits, give the installer the possibility of many configuration of flue discharge and/or air intake. See exemples to the figures O, P, Q, R, S, T, U and V. Please remember that these configurations are only examples, and that many other possibilities exist.
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A INSTALLATION INSTRUCTIONS Figure L Some exemples of vent make with the kits predisposed by COSMOGAS P/N 62617168, P/N 62617174 e P/N 62617175.
A INSTALLATION INSTRUCTIONS 24 Figure O Figure P Some exemples of vent make with some accessories (Figure O and P) or with the combination of a kit P/N 62617174 and some accessories #13 and #5 (Figure Q).
A INSTALLATION INSTRUCTIONS Figure R Figure S Figure T 25 Some exemples of vent make with some accessories for split and a kit for split. In all figures (R, S and T) we have used a kit 62617168 in combination with accessories for split system.
A INSTALLATION INSTRUCTIONS Some exemples of vent make with a 3 commercial pipe. In the figure U we have a BMS heater, with elbow raccord #9, and with a kit #23 for to connect your 3 pipe. In the figure V, we have a BTS heater with with an straight raccord #16 and with a kit #23 for to connect your 3 pipe.
A INSTALLATION INSTRUCTIONS Wall A - Securing screws B - Discharge pipe C - Intake pipe D - Discharge grid E - Intake grid Figure 7 - Top view of BMS heater Figure 9 -Concentric flue (Coaxial) pipe position. For BMS model 39,8" (1010) > 4" (100) 27 A Condensate drainage pipe fitting B Condensate drainage tap Figure 8 - Side view of BMS heater Figure 10- Example of air intake and flue gas discharge through the roof.
A INSTALLATION INSTRUCTIONS A B C D E F G 28 Chimney Washer Discharge pipe Split system elbow Clamp with seal Insulation Condensing trap Figure 11 - Example of discharge to a chimney for a BMS model Figure 13 - Example of air intake through an outside wall, (without intake pipe), and discharge to a chimney. For BMS model A Condensate drainage pipe fitting B Condensate drainage tap Figure 12 - Example of air intake without intake pipe and discharge of flue gases through the roof.
A INSTALLATION INSTRUCTIONS 1 Wall 2 Sheat 1 2 3 4 5 Wall Sheat Discharge pipe Washer Intake pipe 3 Discharge pipe 4 Washer Figure 16 - Discharge with coaxial flue without intake pipe. For BTS model Figure 15 - Discharge with coaxial flue for BTS model 29 Figure 17 - Example of air intake and flue gas discharge through the roof.
A INSTALLATION INSTRUCTIONS Figure 19 - Example of air intake without intake pipe and discharge of flue gases through the roof. For model BTS. 30 A = Condensate discharge Figure 18 - Example of air intake through an outside wall, (without intake pipe), and discharge to a chimney. For model BTS. Figure 20 - Example of air intake through an outside wall, (without intake pipe), and discharge through the same wall. For model BTS.
A INSTALLATION INSTRUCTIONS 4.7 Water Connections for Model BMS Each heater contains a kit of accessories to help the installer make the water connections. An example of these connections and all the accessories supplied with the heater is shown on the drawing below: Pos.
19) Line voltage cable (not provided) 20) Fitting for block cable 21) Hot water outlet 22) Cold water inlet 23) Gas supply 24) Central heating supply 25) Central heating return 32 1) Ball valve (not provided) 2) Domestic hot water flow selector 3) Mixing valve (not provided) 4) ASME T-P relief valve (not provided) 5) Connections (not provided) 6) By-pass valve (not provided) 7) Domestic drain cock (not provided) 8) ASME pressure relief valve 9) Heating drain cock (not provided) 10) Domestic Hot water conn
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 Cosmogas combi Heating drain cock Sanitary drain cock Gas cock Safety relief valve By-pass valve Domestic relief valve Radiator Automatic feed Back-flow preventer Gas inlet Mixing valve Cold water inlet Recirculating pump Recirculating thermostat or timer Recirculating return line Hot water outlet Cold water outlet A INSTALLATION INSTRUCTIONS 33 Figure 23 - Two (BMS or BTS model) heaters installation with domestic hot water recirculating system
Ambassador Safety relief valves Heating drain cocks Ball valves Gas cocks Back-flow preventer Supplementary expansione tank Manometer Gas supply Cold water inlet 11 Supply and return for central heating 12 Supply and return for eventual indirect water heater P1 Pump for central heating P2 Pump for indirect water heater VICGeneral automatic gas valve 34 1 2 3 4 5 6 7 8 9 10 A INSTALLATION INSTRUCTIONS Figure 24 - Three or more (BMS or BTS models) heaters installation with connection for indirect water h
A INSTALLATION INSTRUCTIONS 35 1 Ambassador 2 Safety relief valves 3 Heating Drain cock 4 Plate heat exchanger 5 Three ways valve 6 Floor protection thermostat set to 104°F (40°C) 7 Supplementary pump 8 Air vent 9 Radiant heating 10 Gas cock 11 Automatic feed 12 Back flow preventer 13 14 15 16 17 18 19 20 21 22 Pressure gauge Additional expantion tank Relief valve Domestic relief valve Sanitari drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet Figure 25 - Example of (B
A INSTALLATION INSTRUCTIONS 36 1 2 3 4 5 6 7 Safety relief valve By-pass valve Heating drain cock Radiators Gas cock Automatic feed Domestic relief valve 8 9 10 11 12 13 14 Back-flow preventer Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas supply Figure 26 - Example of (BMS or BTS model) heater installation for radiators
A INSTALLATION INSTRUCTIONS 37 1 2 3 4 5 6 7 8 9 10 11 Ambassador Safety relief valve Heating drain cock Pressure disconnector Flow checks Optional ball valve to isolate heater Supply piping to zones Gas cock Automatic feed Optional ball valve Back-flow preventer 12 13 14 15 16 17 18 19 20 21 22 Added system pump Optional ball valve Tees with drains to bleed zones Return piping from zones Domestic relief valve Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet
A INSTALLATION INSTRUCTIONS 38 1 2 3 4 5 6 7 8 9 10 Ambassador Safety relief valve Heating drain cock By-pass valve Optional ball valve to isolate heater Supply piping to zones Gas cock Automatic feed Ball valve Back-flow preventer 11 12 13 14 15 16 17 18 19 20 21 Zone valves Optional ball valve Tees with drains to bleed zones Return piping from zones Domestic relief valve Sanitary drain cock Mixing valve Flow restrictor Hot water outlet Cold water inlet Gas inlet Figure 28 - Zoning with zone valves -
A INSTALLATION INSTRUCTIONS 5 REGULATING THE DOMESTIC HOT WATER The heater temperature control knob is adjusted to its lowest temperature position when shipped from the factory. Prior to starting heater, it should be adjusted to a starting point of 120°F as shown on the thermostat. After installing the space/water heater, it is necessary to regulate the flow rate of the domestic hot water so as to give a 75°F rise. For this function, you need to use a flow meter and a thermometer.
1 2 3 4 5 6 7 8 9 10 Domestic hot water priority thermostat Power switch Circulator pump switch High limit thermostat Transformer Electrical junction box Ground connections Circulator pump Flue gas discharge fan Detection electrode 40 11 12 13 14 15 16 17 18 19 Ignition electrode Ignition module Failure lamp indicator Gas valve service switch (Only for BMS) Gas valve Pressure switch Heater temperature control Low water cutoff Electrical control board A INSTALLATION INSTRUCTIONS 7 WIRING DIAGRAMS If an
DL1 DL2 DL3 DL4 DL5 DL6 DL7 DL8 r1 1 2 3 4 5 Heater temperature lamp control Low water cutoff lamp control NC (Normally Close) pressure switch lamp control NO (Normally Open) pressure switch lamp control Gas valve lamp control Room thermostat lamp control Ignition module lamp control Transformer lamp control Resistor 780 Ohm Fuse Power switch Pilot light of power switch High limit thermostat Circulator pump 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Domestic hot water priority thermostat Circulator pump switc
A INSTALLATION INSTRUCTIONS External transformer 115V Thermostat Thermostat zone 1 zone 2 External transformer 115V 24V COSMOGAS Combi 24V N L COSMOGAS Combi 1 N L Thermostat 2 3 Taco zone valves TT 12 TT 12 65 43 65 65 43 Thermostat L N COSMOGAS combi 43 External pump End switch Motor R-845 End switch Motor External Wiring schematic useing circulators and R-845 relays for multi zone system 115VAC External pump R-845 115VAC T87F thermostat TT 12 R-845 115VAC T87F thermostat
B OPERATING AND MAINTENANCE INSTRUCTIONS for BMS Qualified personnel must carry out installation, calibration or alterations to the gas apparatus, or to convert it from one gas type to another. Conversion kits are available, (optional).
B OPERATING AND MAINTENANCE INSTRUCTIONS for BMS 9.4 Summer-Winter Mode By means of the circulator pump switch, (fig.33, item 3), you can change over from the summer to the winter mode, as explained below. In the summer, the switch is turned off, allowing the production of domestic hot water only. In the winter or whenever central heating is required, the circulator pump switch must be turned on. 9.5 Adjusting Central Heating 44 This is done by turning the central heating regulation knob 2 (fig.
C OPERATING AND MAINTENANCE INSTRUCTIONS for BTS Qualified personnel must carry out installation, calibration or alterations to the gas apparatus, or to convert it from one gas type to another. Conversion kits are available, (optional). 10 - BTS model - INSTRUCTIONS FOR USE 5 Heater temperature control knob 7 Failure lamp indicator 8 Temperature-pressure gauge 1 Power switch 3 Circulator pump switch 4 High limit thermostat reset button Figure 34 - Instrument panel for model BTS 10.
C OPERATING AND MAINTENANCE INSTRUCTIONS fot BTS 10.4 Summer-Winter Mode By means of the circulator pump switch, (fig.34, item 3), you can change over from the summer to the winter mode, as explained below. In the summer, the switch is turned off, allowing the production of domestic hot water only. In the winter or whenever central heating is required, the circulator pump switch must be turned on. 10.5 Adjusting Central Heating 46 This is done by turning the central heating regulation knob 21 (fig.
D TROUBLESHOOTING Troubleshooting Sequence of Operation to Light the Burner 5J=HJ Turn power switch to the ON position Switch diode should be lit ! No Yes Turn the heater temperature control clockwise (should hear a click) No Is the pressure switch at the NC position ?. Yes DL1, DL2, DL3 and DL8 are lit No The fan will start Yes The pressure switch switches from NC to NO, only if there is a 0.3 inWC pressure change. - Check for power between terminals 17 and 18 (see fig.
D TROUBLESHOOTING Troubleshooting Sequence of Operation for a Call for Heat The pump switch is in winter mode No Is the heater temperature (shown on gauge) up to 140°F (60°C) ?. Yes Is the room thermostat calling for heat ?. No Yes DL6 lamp diode is lit Turn the central heating regulation knob to the maximum setting. Is the pump running ?. No Yes 48 Are the radiators hot ?. No Yes The light of the pump-switch is not on.
D TROUBLESHOOTING PROBLEMS CAUSES CHECKS (IF NECESSARY) REMEDIES (IF NECESSARY) the pilot light of power switch is off there isnt electrical supply check the electrical supply level the fuse doesnt work check the fuse replace the fuse the power switch is off check that the power switch is on turn the power switch on the power switch doesnt work check the power switch operating replace the power switch pilot light of power switch doesnt check the pilot light of power switch work operating
E IMPORTANT INFORMATION FOR THE CUSTOMER The technician will explain to the customer how the heater works and how to operate it. The customer must neither replace nor repair any parts. The user must call in a licensed authorized technician to carry out necessary routine maintenance on the heater at least once a year, before it is used for central heating.
F SPARE PARTS 51 Spare parts are available from your local authorized wholesale distributor. For a location of the one nearest you call Embassy Industries, Inc. at 631-694-1800.
G TECHNICAL FEATURES TABLE 1 52
G TECHNICAL FEATURES Curves of residual head for central heating system 53
NOTES 54
NOTES 55
FOR TECHNICAL SUPPORT CALL: Embassy Industries, Inc. 300 Smith Street Farmingdale, NY 11735 PH - 631-694-1800 Fax - 631-694-1832 www.embassyind.com sales@embassyind.com (For emergencies after 5 pm please call 413-348-7822) MANUFACTURED BY: COSMOGAS s.r.l. Via L. da Vinci 16 - 47014 MELDOLA (FC) ITALY info@cosmogas.com www.cosmogas.
