INSTRUCTION MANUAL

For installation, use and maintenance for the

5-41-5

MODELS: BMS & BTS

Direct Vent
Space / Water Heater

Combined Appliance
For Heating and Domestic Hot Water

These instructions MUST be read prior to installation and

left near the appliance when the installation is completed.
U.S.A.

Text complies with minimum size requirements. 62403262 - R1

120601
 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

• Do not try to light any appliance.

• Do not touch any electrical switch;
do not use any phone in your building.
2 • 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.

— Installation and service must be

performed by a qualified installer, service
agency or the gas supplier.

FOR YOUR SAFETY

Do not store or use gasoline or other flammable,
combustible, or corrosive vapors and liquids
in the vicinity of this or any other appliance.
 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.
Children, disabled, and elderly are at highest risk of being scalded; see instruction manual
before setting temperature at water heater! Feel water before bathing or showering.
Temperature limiting valves are available, see manual.

If there is a smell of gas:

-Turn the gas cock off - Air the room - Do not try to light any appliances - Do not use any
phone in your building - Do not touch any electrical switch - Extinguish any flames - Call
immediately a licensed authorized technician or your local gas company - Follow the gas
supplier’s instructions - If you cannot reach your gas supplier, call the fire department.

If there is a smell of combustion products:

-Turn the unit off - Air the room - Call a licensed authorized technician.

Installation, alterations
Licensed authorized personnel must carry out the installation, calibration or alteration of the
gas apparatus. Flue gas ducts must not be modified in any way. Any replaced part or
packaging parts should never be left within reach of children. 3

Explosive products or easily inflammable products

Do not keep, use or store explosive materials or easily inflammable materials such as Gasoline,
Adhesives, Solvents, Paint Thinner, Butane, Liquefied Propane, paper, etc., near the heater.

Maintenance
The user, according to the heater’s operating instructions, has to keep the installation in
good condition and guarantee the reliable, safe operation of the heater. At least once a year
the user must call in a licensed authorized technician for routine maintenance, before using
it for central heating.

Servicing Manual
When the installation and commissioning of the system has been completed, the installer
should instruct the homeowner to save the installation manual near the heater so that service
technicians may refer to it in the future.
Caution: Label all wires prior to disconnection when servicing controls. Wiring errors can
cause improper and dangerous operation. VERIFY PROPER OPERATION AFTER SERVICING.

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.
 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 (31.6) Btu/hr (kW)
15/29 has an input power rating of 107,000 (26) Btu/hr (kW)

BMS 10/20
or
BMS 15/29
or
BTS 10/20
or
BTS 15/29

When referring to this instruction manual, be sure of which type of heater you are working
4 with. This can be verified by referring to the data plate marked “Space water heater model”
. This data plate is located on the bottom side of the BMS, or on the inside of the front door
(internal side) of the BTS.
Also verify the type of gas for which the heater is set. A label in the front of your heater states
“NATURAL GAS”, for heaters set to natural gas, or “LP GAS” for heaters set to LP gas.

TABLE OF CONTENTS
GENERAL INFORMATION .................................................................................................. 4
TABLE OF CONTENTS ....................................................................................................... 4
TABLE OF CONTENTS ....................................................................................................... 5
GENERAL LAYOUT of the main components of model BMS ........................................... 6
GENERAL LAYOUT of the main components of model BTS ............................................ 8
GENERAL LAYOUT of the main components of model BTS ............................................ 9
A INSTALLATION INSTRUCTIONS .................................................................................. 10
1 Operating and adjusting the output to the radiation system ........................................ 10
2 Location ..................................................................................................................... 10
3 Installation .................................................................................................................. 10
3.1 Installation Template ......................................................................................... 10
A INSTALLATION INSTRUCTIONS .................................................................................. 11
Clearances for installation ...................................................................................... 11
3.2 Safety Relief Valve ........................................................................................... 12
3.3.1 Installation of two heaters .............................................................................. 12
3.3.2 Installation of three or more heaters ............................................................. 12
 TABLE OF CONTENTS

3.3.3 Radiant heating installation ........................................................................... 12

................................................................................................................................ 12
3.3.4 Used of glycol ................................................................................................ 12
................................................................................................................................ 13
3.4 Domestic Hot and Cold water ........................................................................... 13
3.5 Water Hardness ............................................................................................... 13
3.6 Gas Supply ....................................................................................................... 13
3.6 Gas Supply (cont.) ............................................................................................ 14
3.7 Electrical Supply Connection ............................................................................ 14
3.8 Room Thermostat Connection ......................................................................... 14
4 VENTING SYSTEMS ................................................................................................. 16
4.1 Concentric Flue (Coaxial) ................................................................................. 16
ATTENTION !!! .............................................................................................................. 17
4.2 Split Flue ........................................................................................................... 18
4.3 Chimney Venting .............................................................................................. 18
4.5 Venting Locations - Outside Walls (Direct Venting) ......................................... 18
4.6 Kit for air intake/flue discharge ......................................................................... 18
5 REGULATING THE DOMESTIC HOT WATER ........................................................... 31
6 BURNER .................................................................................................................... 31
6.1 Changing the Gas Type .................................................................................... 31
6.2 Adjusting Gas Flow and Pressure to the Burner .............................................. 31
7 WIRING DIAGRAMS ................................................................................................. 38
9.4 Summer-Winter Mode ...................................................................................... 42
5
9.5 Adjusting Central Heating ................................................................................. 42
9.6 Manual Reset High-Limit Thermostat ............................................................... 42
9.7 Resetting the Ignition Module ........................................................................... 42
9.8 Heating Circulator Pump .................................................................................. 42
9.9 Shut-Down Procedure ...................................................................................... 42
9.10 Maintenance ......................................................................................................... 42
9.11 Draining water from the heater .............................................................................. 42
10 - BTS model - INSTRUCTIONS FOR USE ............................................................... 43
10.1 Start-Up Instructions ....................................................................................... 43
10.2 Checks Prior to Ignition .................................................................................. 43
10.3 Ignition Procedure .......................................................................................... 43
10.4 Summer-Winter Mode .................................................................................... 44
10.5 Adjusting Central Heating ............................................................................... 44
10.6 Manual Reset High-Limit Thermostat ............................................................. 44
10.7 Resetting the Ignition Module ......................................................................... 44
10.8 Heating Circulator Pump ................................................................................ 44
10.9 Shut-Down Procedure .................................................................................... 44
10.10 Maintenance ....................................................................................................... 44
10.11 Draining water from the heater ............................................................................ 44
E IMPORTANT INFORMATION FOR THE CUSTOMER ................................................... 48
F SPARE PARTS ............................................................................................................... 49
G TECHNICAL FEATURES .............................................................................................. 50
 GENERAL LAYOUT of the main components of model BMS

A = Flue discharge
B = Air intake

Coaxial discharge
Split discharge

Figure 1 - BMS Front view

GENERAL LAYOUT of the main components of model BMS

1 Central heating supply

2 Central heating return
3 Gas inlet
4 Domestic hot water outlet
5 Cold water inlet
6 Flue gas discharge fan
7 Automatic air vent
8 Thermostat bulb pocket
9 Gas valve service switch
10 Instrument panel
11 Temperature-pressure gauge
12 Failure lamp indicator
13 Ignition and detection electrodes
14 Burner
15 Gas manifold
16 Exchanger shell clamps
17 Gas valve
18 High limit thermostat 7
19 Power and circulator pump switches
20 Domestic hot water priority thermostat
21 Central heating regulation knob
22 Heater temperature control
23 Electrical control board
24 Ignition module
25 Electrical plastic cover
26 Electrical junction box
27 Expansion tank
28 Pressure switch
29 Domestic water heat exchanger
30 Heat exchanger
31 Turbulator
32 Support bracket
33 Central heating regulation valve
34 Circulator pump
35 Transformer

Figure 2 - BMS Side and top views

 GENERAL LAYOUT of the main components of model BTS

Figure 3 - BTS Front view

GENERAL LAYOUT of the main components of model BTS

1 Central heating supply 20 Domestic hot water priority thermostat

2 Central heating return 21 Central heating regulation knob
3 Gas inlet 22 Heater temperature control
4 Domestic hot water outlet 23 Electrical control board
5 Cold water inlet 24 Ignition module
6 Flue gas discharge fan 25 --
7 Automatic air vent 26 Electrical junction box
8 Thermostat bulb pocket 27 Expansion tank
9 -- 28 Pressure switch
10 Instrument panel 29 --
11 Temperature-pressure gauge 30 --
12 Failure lamp indicator 31 --
13 Ignition and detection electrodes 32 --
14 Burner 33 Central heating regulation valve
15 Gas manifold 34 Circulator pump
16 -- 35 Transformer
17 Gas valve 36 Low water cut-off
18 High limit thermostat A Flue discharge
19 Power and circulator pump switches B Air intake
Figure 4 - BTS side view
 A INSTALLATION INSTRUCTIONS

1 Operating and adjusting the installed on a metal or wood panel extending behind
the full width and depth of the appliance by at least
output to the radiation system 3”, (76.2 mm), in any direction or, if the appliance
The COSMOGAS heater can be installed in any is installed in an alcove or closet, the entire floor
domestic or light commercial building where shall be covered by the panel.
the maximum BTU/H required is not greater
than 84,000 BTU/H.
The unit has a internal mixing valve (heating side
3.1 Installation Template
only) that can be adjusted to regulate the supply ONLY model BMS is provided with an installation
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. The heater built-in
domestic hot water priority thermostat will cease
the power to the circulator until the temperature is
greater than 140°F.

2 Location
This space/water heater unit is not intended for
outdoor installation. Choose a location centralized
to the piping system along with consideration to
the vent pipe length. Additionally, you will need to
place the space/water heater so that the controls,
drain, inlet/outlet, and gas valve are easily
accessed. Also, care must be exercised when
choosing the location of this appliance, where
leakage from the safety relief valves, leakage from
related piping, or connections, will not result in
10 damage to the surrounding areas, or to the lower
floor of the building.
No valve is to be placed between the safety relief
valves and the heater. The discharge from the
temperature and pressure relief valve must be
conducted to a suitable place for disposal. No
reducing coupling or other restriction shall be
installed in the discharge line. The discharge line
should allow complete drainage of both valve and Figure 5
line.

3 Installation
The installation must conform to local codes and
ordinances or, in the absence of local codes, the
National Fuel Gas Code ANSI Z 223.1/NFPA 54 -
1984. When installed the appliance must be
electrically grounded in accordance with the
National Electrical Code, ANSI/NFPA No.70 -
1987.
For Canada, the installation should conform to CGA
B149.1 INSTALLATION CODES and/or local
installation codes.
The gas supply piping system should be tested
before the heater is connected.
The heater, (complete with all its parts: external
jacket, intake and discharge flue pipes, etc.), must
be installed leaving a distance of at least 10 cm,
(4”), from sidewalls and ceiling.
Installation of the BTS combi directly on Figure 5 - Installation template, Only
combustible flooring such as carpeting shall be for model BMS
 A INSTALLATION INSTRUCTIONS

template to facilitate proper

installation alignments (See figure
5 below).

Clearances for
installation
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.

WARNING: Please take caution

when choosing a mounting
surface for the heater. The weight
of the heater with water is
approximately 165 lbs. Make Figure 5A - Clearances for model BMS
certain that the wall can support 11
such weight.

2) Screw the bracket to the wall.

The screws MUST screwed in
correspondence of the 16" vertical
studs.

3) Place the template onto the

support bracket and make all
rough-in holes for the piping to the
heater. The hole for the coaxial
flue vent kit discharge may also
be cut at this time.

4) Install the heater on the support

bracket and secure all of the
connections.

Figure 5B - Clearances for model BTS

 A INSTALLATION INSTRUCTIONS

3.3.2 Installation of three or more

3.2 Safety Relief Valve heaters
An ASME approved safety relief valve, (set Installing three or more heaters in parallel.
at 30 psi), must be installed in a vertical Follow the schema in the figure 24
position on the outlet side of the central 3.3.3 Radiant heating installation
heating system, and as close as possible to When the heater is used in conjuction with
the heater. There must be no valves between radiant heating, it is imperative that the tubing
the safety relief valve and the heater. contains an oxygen diffusion barrier. If you
Manually operate the safety relief valve at are unsure whether or not the tubing has a
least once a year to ensure proper operation. barrier, a heat exchanger must be used to
Precaution must be taken prior to operating protect the heater from oxygen corrosion (See
the safety relief valve, to avoid contact with figure 25). This situation will also occur if the
hot water coming out of the safety relief valve heater is used on an open-loop system where
and to prevent water damege. new, cold-fill water is introduced into the
If the safety relief valve discharges system. The oxygen will remove itself from
periodically, this may be due to thermal solution and react chemically with the ferrous
expansion in a closed water supply system. components (i.e. steel), causing them to rust
Contact the water supplier or local plumbing and corrode. THIS TYPE OF FAILURE IS
inspector on how to correct this situation. Do NOT COVERED BY THE WARRANTY!
not plug the safety relief valve.

3.3 Heating Supply and Return 3.3.4 Used of glycol

The central heating supply and return pipes If glycol is used with the heater, the glycol
are marked with different colored caps, must be recognized as safe or approved by
(supply red and return blue). the United States Food and Drug
12 If there are any heating elements above Administration for food contact as listed in
heater level, it is advisable to install a check Code of Federal Regulations, title 21, part 182
valve on the supply pipe to prevent “natural of the Food Additive Regulations. Any
circulation” phenomena from occurring. additives introduced into the heating system
If the heater is to be connected to an existing must be recognized as safe by the United
system it is advisable to wash out and remove States Food and Drug Administration. If a
any deposits from inside the existing pipes, non-approved additive is used, it can
and install a filter at the lowest point to trap cause serious health problems or possibly
any additional impurities when it is running. death.The pressure of the heating system
This equipment is designed for use in a closed side of the heater must be fitted with devices
loop system. (automatic water feed/pressure reducing
Installation schematics are found in figures valve not to exceed 30 psi) arranged to
23 to 28. function automatically in order to maintain the
WARNING !!! All the schematics in figures pressure of the heating side at a level below
23 to 28 are only samplesl. Safety apparatus, that of the potable water leaving the heat
pipe diameters, and auxiliary accessories, exchanger.
must be verified by a qualified personnel only
and in accordance with the national and/or 3.4 Domestic Hot and Cold water
local codes. The domestic hot water flow restrictor must be
installed on the cold water inlet, (Refer to figure
3.3.1 Installation of two heaters 25, 26, 27 and 28).
Iinstalling two heaters in parallel. Follow the For servicing purposes, install a shut-off valve
schema in the figure 23 upstream from the cold water inlet.
The heater’s thermostat can be regulated to
provide domestic hot water between 100°F This heater has orifices which will operate at
and 180°F. Water temperature over 125°F an altitude of up to 2,000 feet. For
can cause severe burns instantly. Since it is installations in higher elevations, down-rate
required that the heater water temperature the heater by 10%.
reach above 140°F in order for the heating Install a manual gas cock outside of the
system side of the unit to operate, it is heater. Refer to Figures 1 and 3, item 3, for
imperative that a mixing valve be installed the gas inlet location of the heater.
external of the heater to further regulate Gas piping to the heater must be sufficient
the temperature of the domestic hot water to guarantee a supply of gas to meet
(See figures 23, 25, 26, 27 and 28). Failure maximum requirements. See Table 1 for
to install a domestic side mixing valve will max. and min. values of gas pressure (Back
result in severe burns! of manual).
Piping and components connected to the All piping must comply with local codes
water heater for space heating shall be and ordinances or with the National Fuel
suitable for use with potable water, and shall Gas Code, (ANSI Z223.1 NFPA No. 54),
not be connected to any heating system or whichever applies.
components previously used with a non- The appliance and its individual shutoff
potable water heating appliance. valve must be disconnected from the gas
The domestic hot water circuit needs an supply piping system during any pressure
ASME approved temperature and pressure testing of that system at test pressures
P-T relief valve, set at 150 psi and 210°F, in excess of ½ psig, (3.5 kPa).
installed as close as possible to the heater. The appliance must be isolated from the
There must be no valves between the P-T gas supply piping system by closing its
relief valve and the heater. The P-T relief individual manual shutoff valve during any
valve discharge pipe must not be pressure testing of the gas supply piping 13
restricted or plugged. system at test pressures equal to or less
than ½ psig, (3.5 kPa).
3.5 Water Hardness
In hard water areas (above 150 p.p.m), it is
recommended that a suitable water treatment
device (softener with filters) be installed.
Excessive buildup of minerals in the heat
exchanger can cause a non-warranty failure.
Water hardness can be determined by using
the standard test or by checking with your
local water authority.
Toxic chemicals, such as used for heater
treatment, should not be introduced into the
potable water used for space heating.

3.6 Gas Supply

Before making any gas connections, verify
that the heater is being supplied with same
gas type as indicated on the rating plate. The
rating plate is located on the front of the BMS,
and is located on the front door of the BTS.
 A INSTALLATION INSTRUCTIONS

3.6 Gas Supply (cont.)

Length of Gas Pipe Capacity of Gas Pipe Size in MBTUH

1/2" 3/4" 1" 1 1/4"

10' 132 278 520 1050
20' 92 190 350 730
30' 73 152 285 590
40' 63 130 245 500
50' 115 215 440
75' 93 175 360
100' 79 150 305
150' 64 120 250
Additional length
to be added for 1.3' 1.7' 2.2' 2.7'
each bend or tee

3.7 Room Thermostat Connection 3.8 Electrical Supply Connection

14 This is installed by removing the electrical The heater must be connected to a 115V
junction box cover indicated in fig.6, (see fig.1 60Hz, single phase electrical supply fused
and 3, item 26), and connecting the two wires to 15 amps,
of the room thermostat, or zone valve control Grounding is required as well as the
thermostat, to the low voltage terminals, installation of a main emergency switch
(figure 6, item B). NOTE: first remove immediately upstream from the heater.
factory installed jumper from terminals. An electrical junction box (see figures 1 and
The room thermostat must always be located 3, item 26) is provided for connections for
in a point of the house where the temperature both the line voltage of 115V 60 Hz (See
is not subject to sudden changes. figure 6 item A) , and the room thermostat
at low voltage of 24Vac (See figure 6 item
B).
A Electrical supply The cable wire of the line voltage must be
connection
B Room thermostat
insered into the heater, through the pass-
connection cable positioned in the side of the idraulic
connections (see figure 7 and 8).

Figure 6 - Connecting the room

thermostat and electrical supply
A INSTALLATION INSTRUCTIONS

15

Figure 6A - Installation of the electrical Figure 6B - Installation of the

supply cable on the model BMS electrical supply cable on the model
BTS
a) Remove or loosen screw (2)
b) Pop- out the passage tunnel for the a) Remove or loosen screw (2)
supply cable. Pass the supply cable b) Pop- out the passage tunnel for the
through the passage (1) supply cable. Pass the supply cable
c) Connect the supply cable to the through the passage (1)
junction box c) Connect the supply cable to the
d) Tighten screw (2); junction box
e) Re-insert the passage tunnel into its d) Tighten screw (2);
position (4). e) Re-insert the passage tunnel into its
f) Feed wire to junction box and position (4).
connect as shown in Figure 6. f) Feed wire to junction box and
connect as shown in Figure 6.
 A INSTALLATION INSTRUCTIONS

4 VENTING SYSTEMS vented heater must not share a chimney.

Vent exhaust terminal should be inserted into,
This heater can be fitted with either a but not beyond, inner wall of chimney.
concentric or split type venting system. Do not vent into transient pipe. Warranty will
Particular attention must be taken when be void.
installing the vent pipes that go through the CAUTION! - Take all precautionary measures
wall to the outside. It must always be possible to allow the angle of the flue to run down slightly
to carry out routine maintenance operations to the outside, NEVER rising. Anticipate for
of the flue. The vent pipe must be installed all horizontal pipes, an inclination of 1/4” per
in such a way that it can be removed, if foot toward the discharge. If a vertical pipe
needed, in the future. Hence, a suitable follows a horizontal one, place a condensation
sheath should be prepared in which to insert discharge fitting in the lowest part of the vertical
the vent pipe. Both venting systems are pipe. A condensation discharge pipefitting
suitable for venting through a wall 1” to 24” must also be used for vertical discharge pipe
thick. installations directly from the heater with a pipe
The connection of the vent air intake system whose length is more than 10”.
to the heater can turn 360°, which means in all During normal operating conditions, the
directions, making installation extremely easy. heater will have exhaust gases exiting from
To turn it just loosen the securing screws on the flue pipe. The smoke will be heavier on
the base of the vent elbow where it attaches some days than on others. This is due to
to the heater, turn to desired position, then the outdoor weather conditions (the
tighten the screws without forcing them. temperature, humidity, etc.), and is
You must place the terminal in an open area, extremely common.
and follow the following guidelines:
16 • Make certain that exhaust gas does not 4.1 Concentric Flue (Coaxial)
re-circulate back into the intake pipe.
• Never vent into a walkway or patio area, The (Coaxial) concentric vent, (air inlet and
or an alley, or otherwise public area less than flue outlet), system consists of 2 pipes: the
7ft from the ground level. This is to prevent outer one for fresh air intake, the inner pipe
anyone from walking into the vent; for flue exhaust discharge.
• Never vent over or under a window or over With optional pipe, it is possible to increase
a doorway; the overall length up to 15ft (4.5 m).
• Never install a heat saver or similar product There are also 90° concentric elbows
to capture waste heat from exhaust; available, if they are installed, there will be a
• Always have vent 1ft above ground level, loss of draught equal to that caused by 3ft,
away from shrubs and bushes. (1 m), of straight pipe.
• Follow local gas codes in your region or Connections between the various parts must
refer to National Fuel Gas Code, or Can be secured by using self-tapping screws, (see
B149.1 INSTALLATION CODES. fig.9). The vents stainless steel end terminal
• Always have vent at least 3ft from an inside must always come completely out of the outer
corner of outside walls. pipe. If for any reason the intake grid is
• Maintain at least 4ft clearance to electric,
gas meters and exhaust fans.
• Always place screens in all openings in
intake and exhaust to prevent foreign matter
from entering the heater.
• The vent terminals, (concentric, split type
exhaust), must be a minimum of 1ft above
the ground level.
• If split type vent will be venting into a
chimney, make certain that no other
appliances are vented into it. This power-
 A INSTALLATION INSTRUCTIONS
blocked, the heater will not receive enough
air for combustion and the burner would fail
to ignite. screws are used to insure that the
discharge vent tube remains in place and
not allow discharge gases to re-enter the
heater. Failure to secure the internal
ATTENTION !!! discharge tube may result in the heater
We want to remember that all accessories backfiring and causing permanent damage
in the line of the air intake and in the line of to the heat exchanger. Heaters which have
flue discharge MUST be secured with been damaged for this reason are not
screws beetween them, and MUST be covered in our limited warranty.
sealed from flue or air leakage The stainless steel (End terminal) wind
guard must fit properly and inter-lock into
PRECAUTION TO BE TAKEN slip joint of intake pipe.
WHEN INSTALLING COAXIAL It is imperative that the internal discharge
VENTING pipe first be secured in place with self-
tapping scews before attaching and
Proper assembly and installation of venting securing the external vent pipe. Also,
elbows and tubing must include the use of ensure that the two grids of the end
self-tapping screws to permanently secure terminal come completely out of the outer
in place the pipe. If the intake grid is hidden the heater
internal discharge tube. Self-tapping will not receive enough air for combustion
and would fail to ignite.

Picture # X: First, insert the vent inner pipe

into the vent elbow and tighten using self-
tapping screws
17

Picture # Y: Second,
fit the outer pipe and
secure it with proper
screws
See drawings below.

K = Screws provided
L = Inner pipe
M = Screws provided
 A INSTALLATION INSTRUCTIONS
N = This position shall be respected
O = Discharge grid
P = Intake grid through horizontal ducting.
Caution!
4.2 Split Flue The discharge pipe temperature is above
250°F while functioning, therefore it is
The split flue vent system (two separate essential that a thermal insulation
pipes) can be extended (on the discharge protection sheath be used in the wall
side only) up to a total length of 20 ft (6 m). opening.
Changes in direction can be obtained by
using 90° and 45° elbows. If they are 4.3 Chimney Venting
installed, there will be a loss of draught equal If split type vent will be venting into a chimney,
to 3ft (1 m) and 1 1/2ft (0.5 m) of straight make certain that no other appliances are
pipe, respectively. This is valid only for pipes vented into it. This power-vented heater must
and elbows manufactured by Cosmogas not share a chimney. Vent exhaust terminal
s.r.l.. should be inserted into, but not beyond, inner
If the heater is installed in a large open area wall of chimney.
such as a full basement or alcove, the Do not vent into transient pipe. Warranty
combustion air could also be supplied without will be void.
the intake pipe, (For model BMS see figures
8, 11, 12, 13 and 14 or for model BTS see
figures 16, 18, 19 and 20 for model BTS).
4.5 Venting Locations - Outside
NOTE: The heater will draw all air for Walls (Direct Venting)
combustion through the top of the unit from
the space around the heater. Ventilation The center line of the vent opening must be
18 should be adequate to provide sufficient air at least 16 1/2” above grade, outside, and at
to properly support combustion. Air for least 12” from any other building openings
combustion and room ventilation must be (doors, windows, etc.).
obtained from spaces freely communicating Make sure that vent pipe is pitcheed down
with the outdoors. Air openings to the room from the unit toward the outside wall 1/4” per
should not be obstructed. foot. This will prevent any water from running
For heaters in confined rooms, two back into the heater.
permanent openings must be provided - one 4.6 Kitlocate
Do not for airtheintake/flue
vent terminal where flue
within 12” of the ceiling and one within 12” of discharge
products could strike against building
the floor. Each opening must be at least one materials and cause corrosion.
square inch per 1,000 BTU/H heater input, For comfort for the installer, COSMOGAS
but not less than 100 square inches. These has created some flue kit, complete of all
openings must freely connect with areas the necessary components for flue
having adequate infiltration to the outside. discharge and air intake. The four kits
When all air provided is supplied from the available are as follows:
outdoors, the openings, as described above,
shall be of the size listed below for each
particular arrangement:
- All ducting shall be the same size as the
opening which it is to be connected.
- One square inch of free area per 4,000 BTU/
H of heater input for direct outdoor air supply
through an outside wall or vertical duct directly
outside.
- One square inch of free area for every 2,000
BTU/H of heater input for direct outdoor air
 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. The pipe of
discharge length is 3ft. If you need extensions,
elbows or other accessories, refer to figures
O, P and Q. This kit can be used for heaters
model BM and BTS. To discharge the flue in
vertical position you must to use a roof vent
terminal 62617070, (see figure P)
19

P/N 62617175. Coaxial Vent & Straight

Adapter Kit. This kit is for taking and
discharging air from/to the outside of the
building. The pipe of discharge length is 3ft.
If you need extensions, elbows or other
accessories, refer to figures O, P and Q. This
kit can be used for heaters model BM and
BTS. To discharge the flue in vertical position
you must to use a roof vent terminal
62617070, (see figure P)

P/N 62630046. Vent Adaptor for 3"

Discharge pipe. This kit is for to connect only
the flue discharge to a commercial 3” pipe.
This kit must be used toghether with a heater
mounted adapter P/N 62617124 or
62617060. With this configuration, the
installer is responsible for the materials used
and for the installation. In any case follow
the national or local codes..
 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.

Reference P/N Description

1 60702011 Washer for split
2 60702012 Washer for coaxial
3 61302011 Split system Roof terminal D. 80
4 62617010 Plug for flue test
5 62617049 3ft coaxial Extension
6 62617053 Split system Roof terminal D. 80
7 62617056 Split system In-Line Elbow FF 90°
8 62617058 Split system In-Line Elbow MF 90°
9 62617060 Coaxial elbow (Heater Mounted Only)
10 62617062 Split system “Viking”
11 62617063 Silicone Coupling + clamp
12 62617070 Coaxial Roof Terminal
13 62617077 In-Line Elbow 90° M/F (Coaxial)
14 62617086 3ft Extension for split system
15 62617087 Coaxial 3 ft vent, (End-Terminal only)
16 62617124 Straight coaxial Adapter (Heater mounted only)
17 62617159 In-Line Elbow 45° M/F (Coaxial)
20 18 62617168 Split vent kit
19 62617172 Coaxial 60/100 condensing trap
20 62617173 Split-vent D.80 condensing trap
21 62617174 Coaxial Vent & Elbow Kit
22 62617175 Coaxial Vent & Straight Adapter Kit
23 62630046 Vent Adaptor for 3" Discharge pipe
24 61302003 Intake grid D.80
25 61302004 Terminal vent D.80
26 62617059 In-Line elbow 45° M/F (for split)
A not available Flat for roof
B not available Condensate discharge
C not available Terminal vent for roof (3” diameter)
D not available Extension (3” diameter)
E not available Tee raccord (3” diameter)
F not available Condensate discharge with siphon (3” diameter)
G not available In-Line Elbow 90° (3” diameter)

In the following pictures, the P/N 62617062 is repeated 4 times to show all of the
possibilities that has this accessory has. It can be rotated 360° under the heater, and its
elbows can also be rotated 360° to direct air intake and flue discharge in all orientations.
A INSTALLATION INSTRUCTIONS

21
 A INSTALLATION INSTRUCTIONS

22
 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.

62617168
23
Figure M Figure N

62617174 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).

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.

26
A INSTALLATION INSTRUCTIONS

Wall

A - Securing screws
B - Discharge pipe
C - Intake pipe
D - Discharge grid
E - Intake grid

Figure 9 -Concentric flue (Coaxial)

Figure 7 - Top view of BMS heater pipe position. For BMS model

27
(100)
> 4"
(1010)
39,8"

A Condensate drainage pipe fitting

B Condensate drainage tap

Figure 10- Example of air intake and

flue gas discharge through the roof.
Figure 8 - Side view of BMS heater For BMS model
 A INSTALLATION INSTRUCTIONS

A Chimney
B Washer
C Discharge pipe
D Split system elbow
E Clamp with seal
F Insulation Figure 13 - Example of air intake
G Condensing trap
through an outside wall, (without intake
Figure 11 - Example of discharge pipe), and discharge to a chimney. For
to a chimney for a BMS model BMS model
28

A Condensate
drainage
pipe fitting

B Condensate A Chimney
drainage tap B Insulation
C Condensing trap

Figure 14 - Example of air intake through

Figure 12 - Example of air intake without an outside wall, (without intake pipe),
intake pipe and discharge of flue gases and discharge through the same wall.
through the roof. For BMS model For BMS model
A INSTALLATION INSTRUCTIONS

1 Wall 3 Discharge pipe

2 Sheat 4 Washer
1 Wall
2 Sheat Figure 16 - Discharge with coaxial flue
3 Discharge pipe without intake pipe. For BTS model
4 Washer
5 Intake pipe
Figure 15 - Discharge with coaxial flue 29
for BTS model

Figure 17 - Example of air intake and

flue gas discharge through the roof.
For BTS model
 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 Figure 20 - Example of air intake through

through an outside wall, (without intake an outside wall, (without intake pipe),
pipe), and discharge to a chimney. For and discharge through the same wall.
model BTS. 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. Description 31
1) 1/2" Gasket
2) 1/2" to 1" Connection
3) 1" Gasket
4) Domestic cold water connection
5) Domestic hot water connection
6) ASME T-P relief valve (not
provided)
7) Heating return connection
8) Heating supply connection
9) ASME pressure relief valve
10) Connections (not provided)
11) Domestic drain cock (not
provided)
12) Heating drain cock (not
provided)
13) Mixing valve (not provided)
14) By-pass valve (not provided)
15) Flow selector
16) Ball valve (not provided)
17) Fitting 1/2" NPT/Copper (not
provided)
18) Gas supply (3/4)
19) Cold water inlet
20) Hot water outlet
21) Central heating return
22) Central heating supply
 32
on the drawing below:

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)
4.8 Water Connections for Model BTS

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 connections
11) Domestic Cold water
connections 19) Line voltage cable (not provided)
12) Heating Supply connections 20) Fitting for block cable
13) Heating Return connections 21) Hot water outlet
14) 1" Gasket 22) Cold water inlet
15) 1/2" to 1" Nipple 23) Gas supply
16) 1" Nipple 24) Central heating supply
17) 1/2" Gasket 25) Central heating return
18) 1/2" Nipple (not provided)
An example of these connections and all the accessories supplied with the heater is shown
Each heater contains a kit of accessories to help the installer make the water connections.
 1 Cosmogas combi
2 Heating drain cock
3 Sanitary drain cock
4 Gas cock
5 Safety relief valve
6 By-pass valve
7 Domestic relief valve
8 Radiator

recirculating system
9 Automatic feed
10 Back-flow preventer
11 Gas inlet
12 Mixing valve
13 Cold water inlet
14 Recirculating pump
15 Recirculating thermostat or timer
16 Recirculating return line
17 Hot water outlet
18 Cold water outlet
A INSTALLATION INSTRUCTIONS

Figure 23 - Two (BMS or BTS model) heaters installation with domestic hot water
33
 34

for indirect water heater

A INSTALLATION INSTRUCTIONS

1 Ambassador
2 Safety relief valves 11 Supply and return for central
3 Heating drain cocks heating
4 Ball valves 12 Supply and return for eventual
5 Gas cocks indirect water heater
6 Back-flow preventer P1 Pump for central heating
7 Supplementary expansione tank P2 Pump for indirect water heater
8 Manometer VICGeneral automatic gas valve
9 Gas supply
10 Cold water inlet

Figure 24 - Three or more (BMS or BTS models) heaters installation with connection
A INSTALLATION INSTRUCTIONS

35

1 Ambassador 13 Pressure gauge

2 Safety relief valves 14 Additional expantion tank
3 Heating Drain cock 15 Relief valve
4 Plate heat exchanger 16 Domestic relief valve
5 Three ways valve 17 Sanitari drain cock
6 Floor protection thermostat set to 18 Mixing valve
104°F (40°C) 19 Flow restrictor
7 Supplementary pump 20 Hot water outlet
8 Air vent 21 Cold water inlet
9 Radiant heating 22 Gas inlet
10 Gas cock
11 Automatic feed
12 Back flow preventer

Figure 25 - Example of (BMS or BTS model) heater installation for radiant heating
 A INSTALLATION INSTRUCTIONS

36

1 Safety relief valve 8 Back-flow preventer

2 By-pass valve 9 Sanitary drain cock
3 Heating drain cock 10 Mixing valve
4 Radiators 11 Flow restrictor
5 Gas cock 12 Hot water outlet
6 Automatic feed 13 Cold water inlet
7 Domestic relief valve 14 Gas supply

Figure 26 - Example of (BMS or BTS model) heater installation for radiators

A INSTALLATION INSTRUCTIONS

37

1 Ambassador 12 Added system pump

2 Safety relief valve 13 Optional ball valve
3 Heating drain cock 14 Tees with drains to bleed zones
4 Pressure disconnector 15 Return piping from zones
5 Flow checks 16 Domestic relief valve
6 Optional ball valve to isolate heater 17 Sanitary drain cock
7 Supply piping to zones 18 Mixing valve
8 Gas cock 19 Flow restrictor
9 Automatic feed 20 Hot water outlet
10 Optional ball valve 21 Cold water inlet
11 Back-flow preventer 22 Gas inlet
Figure 27 - Zoning with pumps - Multizone hydronic piping. For BMS or BTS
model
 A INSTALLATION INSTRUCTIONS

38

11 Zone valves
1 Ambassador 12 Optional ball valve
2 Safety relief valve 13 Tees with drains to bleed zones
3 Heating drain cock 14 Return piping from zones
4 By-pass valve 15 Domestic relief valve
5 Optional ball valve to isolate heater 16 Sanitary drain cock
6 Supply piping to zones 17 Mixing valve
7 Gas cock 18 Flow restrictor
8 Automatic feed 19 Hot water outlet
9 Ball valve 20 Cold water inlet
10 Back-flow preventer 21 Gas inlet
Figure 28 - Zoning with zone valves - Multizone hydronic piping. For BMS or BTS model.
A INSTALLATION INSTRUCTIONS

5 REGULATING THE DOMESTIC 6.1 Changing the Gas Type

HOT WATER To convert the heater from one gas type to
The heater temperature control knob is another (NAT to LP or LP to NAT). Conversion
adjusted to its lowest temperature position kits are available at an additional cost..
when shipped from the factory. Prior to
starting heater, it should be adjusted to a 6.2 Adjusting Gas Flow and
starting point of 120°F as shown on the Pressure to the Burner
thermostat. After installing the space/water
heater, it is necessary to regulate the flow The gas pressure is calibrated in the factory.
rate of the domestic hot water so as to give If any corrections are needed use a
a 75°F rise. For this function, you need to manometer and adjust the pressure
use a flow meter and a thermometer. Place according to Table 1 (back of manual).
the flow meter, under a hot water faucet, Please refer to Figure 22, below.
closest to the heater and open the faucet Loosen the screw (B) on the bottom of the
until water temperature is stabilized. The burner and place one of the manometer tubes
difference between cold and hot water on (B). Turn the burner on and compare the
should be approximately 75°F. Increase or pressure found with the value given in Table
decrease the water flow by regulating the 1. If any adjustments are needed remove
incoming cold water to the heater with the the protection cap (A) and turn the burner
DHW flow restrictor. pressure adjustment screw until the value
In any case, it is necessary to install a given in Table 1 is reached. (Turn the screw
mixing valve external of the heater. clockwise to increase the flame and counter-
clockwise to decrease it). Tighten the screw
6 BURNER that closes the burner gas pressure (B).
39
The burner, depicted below, is made of
stainless steel and can be used with both
Natural Gas (NAT) or Propane Gas (LP).

A Burner unit fixing pin

B Manifold
C O-ring A Burner pressure adjustment screw
D Nozzle (under cap screw)
E Spacer B Burner gas pressure probe
F Tie rod C Gas control knob
G Burner unit D Inlet gas pressure probe
Fig.21 - Exploded view of the burner Figure 22 - Gas valve
 40
7 WIRING DIAGRAMS

with 18 AWG wire or its equivalent.

A INSTALLATION INSTRUCTIONS

Figure 29 - Wiring diagram. For BMS and BTS model

1 Domestic hot water priority thermostat 11 Ignition electrode
2 Power switch 12 Ignition module
3 Circulator pump switch 13 Failure lamp indicator
4 High limit thermostat 14 Gas valve service switch (Only for BMS)
5 Transformer 15 Gas valve
6 Electrical junction box 16 Pressure switch
7 Ground connections 17 Heater temperature control
8 Circulator pump 18 Low water cutoff
9 Flue gas discharge fan 19 Electrical control board
10 Detection electrode
If any of the original wire as supplied with the appliance must be replaced, it must be replaced
 A INSTALLATION INSTRUCTIONS

DL1 Heater temperature lamp control 6 Domestic hot water priority thermostat
DL2 Low water cutoff lamp control 7 Circulator pump switch
DL3 NC (Normally Close) pressure switch lamp control 8 Circulator pump switch light
DL4 NO (Normally Open) pressure switch lamp control 9 Flue gas discharge fan
DL5 Gas valve lamp control 10 Transformer
DL6 Room thermostat lamp control 11 Heater temperature control

Figure 30 - Functional wiring diagram. For BMS and BTS model

DL7 Ignition module lamp control 12 Low water cutoff
DL8 Transformer lamp control 13 Pressure switch
r1 Resistor 780 Ohm 14 Ignition and detection electrodes
1 Fuse 15 Ignition module
2 Power switch 16 Gas valve
3 Pilot light of power switch 17 Failure lamp indicator
4 High limit thermostat 18 Room thermostat connection
5 Circulator pump 19 Gas valve service switch (only for BMS)
41
 A INSTALLATION INSTRUCTIONS

External
transformer
115V 24V

Thermostat Thermostat
External
zone 1 zone 2
transformer
COSMOGAS
115V 24V N Combi
Heating Heating
L thermostat thermostat
zone 1 zone 2
COSMOGAS
Combi
1
1
Thermostat
N 2 2 1 1
L 3 3
2 2
3 3
Thermostat Taco zone valves
Heating Heating
zone zone
valve 1 valve 2

Figure 32a - Wiring diagram for taco

Figure 31a - Taco zone valves zone valves

End Zone valve 1

switch Motor
Room
42 T87F T87F T87F thermostat
thermostat thermostat thermostat zone 1
115VAC

Zone valve 2
End
switch Motor
TT 12 TT 12 TT 12 Room
R-845 R-845 R-845 thermostat
65 43 65 43 65 43 zone 2

Zone valve 3
End
switch Motor
External External External Room
pump pump thermostat
zone 3
115VAC

Thermostat Wiring schematic

useing circulators
L and R-845 relays
115VAC

N for multi zone

Thermostat 24V 115V
COSMOGAS system
combi N
External
L transformer
COSMOGAS
Combi

Figure 31b - Honeywell controls and Figure 32b - Wiring diagram for zone
circulators valves
 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).

9 - BMS model - INSTRUCTIONS FOR USE

1 Power switch
5 Heater temperature control knob
2 Central heating regulation knob
6 Gas valve service switch
3 Circulator pump switch
7 Failure lamp indicator
4 High limit thermostat reset button
8 Temperature-pressure gauge
Figure 33 - Instrument panel for model BMS
43
9.1 Start-Up Instructions the heater.
b) Check that the heater is connected properly to
Check that the system has been filled and purged. the flue, it must not be clogged. The height and
The indicator on the pressure gauge “8”, (fig.33), cross section must both be adequate.
should show 15-25 psi. To properly purge the
heater and system of air it is imperative that these 9.3 Ignition Procedure
basic instructions be followed.
The automatic feed should have a fast fill feature. a) Open the gas cock.
There must be an isolation valve installed so that b) Turn the power switch on, (fig.33, item 1).
when it is closed it will direct the incoming water c) Position the heater temperature control knob “5”
flow through the system and heater in the normal (fig.33) on 120°F. The ignition module will provoke
flow pattern and out a drain cock installed at the sparks for burner ignition for about 11 seconds.
end of the loop. If, during this length of time it does not start up
a) Attach a hose to the heating drain cock and run because there is still air in the gas line, the heater
the hose to a suitable drain. will shutdown and the indicator light of the failure
b) Open heating drain cock. lamp indicator “7” (fig.33) signaling the state, will
c) Open the automatic feed using the fast fill feature come on.
and allow the system to fill purge. On multi-zone Turn the heater temperature control knob “5”
systems, each zone must be purged separately (fig.33) to position “0” and repeat operation c). The
with the other zones shut off. ignition module will attempt a new ignition
9.2 Checks Prior to Ignition automatically. Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
valve to the appliance.
Prior to ignition, it is necessary to carry out a few
It is important, especially in the heating season, to
checks.
keep the heater temperature control knob “5”
a) Check that the appliance is electrically connected
(fig.33) on 150°F seeing as the circulator pump
to a voltage of 115V 60Hz.
starts working at 140°F. During the summer
Grounding is compulsory likewise the installation
season, if the water is hot enough, this knob can
of a switch with fuse immediately upstream from
be adjusted to a lower temperature.
 B OPERATING AND MAINTENANCE INSTRUCTIONS for BMS

Once this operation has been done and if the heater

9.4 Summer-Winter Mode does not start up or if this situation repeats often,
call a licensed authorized personnel.
By means of the circulator pump switch, (fig.33,
item 3), you can change over from the summer to 9.8 Heating Circulator Pump
the winter mode, as explained below.
In the summer, the switch is turned off, allowing The circulator pump will only start working when
the production of domestic hot water only. heater the temperature reaches approximately
In the winter or whenever central heating is 140°F and the circulator pump switch, (fig.33, item
required, the circulator pump switch must be turned 3), is in the winter position (on position).
on. Initially, the circulator pump could make noises,
which are due to pockets of air left inside the water
9.5 Adjusting Central Heating circuit; they will disappear soon without having to
do anything. In any case, check that the cap on
This is done by turning the central heating the automatic air vent, (fig, 1, item 7) is open.
regulation knob “2” (fig.33) which optimizes the
central heating system, controlling radiator 9.9 Shut-Down Procedure
temperature. It is advisable, during the in-between
seasons, (spring and autumn), when you want only To stop the supply of gas and consequently turn
warm radiators, to turn the knob to minimum. In the system off, turn heater temperature control knob
the winter you will have to turn it to maximum, “5” (fig.33) to position 0.
leaving the heater temperature control knob “5” Turn power switch “1” (fig.33) off and close the
(fig.33) on 150°F. gas cock.
If you want hotter central heating, adjust the above
knob by turning it to a higher temperature setting. 9.10 Maintenance
It is however advisable to install a room thermostat
well away from heating elements, doors and The heater requires no specific maintenance; to
44 windows. keep it in good working order, however, it is
advisable to have the flue pipe into the heat
9.6 Manual Reset High-Limit exchanger and burner cleaned at the beginning of
Thermostat each season.
To clean proceed in this order:
This device acts on the heater, turning the burner a) Remove the heater jacket, the burner, the flue
off completely if heater temperature exceeds 210°F. gas discharge fan and the turbulators.
The user can see this because the burner does b) With a plastic-bristled cylindrical brush, brush
not turn on any more even if heater temperature is the insides of the flue gas pipes and the turbulators.
low. c) Vacuum away the burnt deposits from the burner
To restore the heater to its normal functioning and from the ignition and detection electrodes.
condition, unscrew and remove the protection cap However, for this cleaning job it is necessary to
of high limit thermostat reset button “4”, (fig.33). call a licensed authorized technician.
Then press it. Use a pen or a skinny object to
manually reset (the high limit thermostat will not 9.11 Draining water from the heater
reset unless the button is completely pressed). If a) Turn off the main cold water supply valve.
the high limit thermostat continues to trigger, call a b) Open the heating drain cock.
licensed authorized personnel. c) Open heating air vents.
d) Open the sanitary drain cock.
9.7 Resetting the Ignition Module e) Open all hot water faucets to allow air to enter
into the pipes.
The ignition module, (fig.1, item 24), carries out The heater holds approximately 4 gallons of water,
numerous checks on heater functioning: on the not including the water capacity of the other system
burner and on the flame detection system. When components and piping.
the ignition module detects that one of these
components is malfunctioning, it stops the heater.
To restart, Turn the heater temperature control knob
“5” (fig.33) to position “0” and reposition it on
150°F.
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

1 Power switch 5 Heater temperature control knob

3 Circulator pump switch 7 Failure lamp indicator
4 High limit thermostat reset button 8 Temperature-pressure gauge

Figure 34 - Instrument panel for model BTS 45

10.1 Start-Up Instructions the heater.
b) Check that the heater is connected properly to
Check that the system has been filled and purged. the flue, it must not be clogged. The height and
The indicator on the pressure gauge “8”, (fig.34), cross section must both be adequate.
should show 15-25 psi. To properly purge the
heater and system of air it is imperative that these 10.3 Ignition Procedure
basic instructions be followed.
The automatic feed should have a fast fill feature. a) Open the gas cock.
There must be an isolation valve installed so that b) Turn the power switch on, (fig.34, item 1).
when it is closed it will direct the incoming water c) Position the heater temperature control knob “5”
flow through the system and heater in the normal (fig.34) on 120°F. The ignition module will provoke
flow pattern and out a drain cock installed at the sparks for burner ignition for about 11 seconds.
end of the loop. If, during this length of time it does not start up
a) Attach a hose to the heating drain cock and because there is still air in the gas line, the heater
run the hose to a suitable drain. will shutdown and the indicator light of the failure
b) Open heating drain cock. lamp indicator “7” (fig.34) signaling the state, will
c) Open the automatic feed using the fast fill come on.
feature and allow the system to fill purge. On Turn the heater temperature control knob “5”
multi-zone systems, each zone must be purged (fig.34) to position “0” and repeat operation c). The
separately with the other zones shut off. ignition module will attempt a new ignition
10.2 Checks Prior to Ignition automatically. Should overheating occur or the gas
supply fail to shut off, turn off the manual gas control
valve to the appliance.
Prior to ignition, it is necessary to carry out a few
It is important, especially in the heating season, to
checks.
keep the heater temperature control knob “5”
a) Check that the appliance is electrically
(fig.34) on 150°F seeing as the circulator pump
connected to a voltage of 115V 60Hz.
starts working at 140°F. During the summer
Grounding is compulsory likewise the installation
season, if the water is hot enough, this knob can
of a switch with fuse immediately upstream from
be adjusted to a lower temperature.
 C OPERATING AND MAINTENANCE INSTRUCTIONS fot BTS

Once this operation has been done and if the heater

10.4 Summer-Winter Mode does not start up or if this situation repeats often,
call a licensed authorized personnel.
By means of the circulator pump switch, (fig.34,
item 3), you can change over from the summer to 10.8 Heating Circulator Pump
the winter mode, as explained below.
In the summer, the switch is turned off, allowing The circulator pump will only start working when
the production of domestic hot water only. heater the temperature reaches approximately
In the winter or whenever central heating is 140°F and the circulator pump switch, (fig.34, item
required, the circulator pump switch must be turned 3), is in the winter position (on position).
on. Initially, the circulator pump could make noises,
which are due to pockets of air left inside the water
10.5 Adjusting Central Heating circuit; they will disappear soon without having to
do anything. In any case, check that the cap on
This is done by turning the central heating the automatic air vent, (fig, 4, item 7) is open.
regulation knob “21” (fig.34) which optimizes the
central heating system, controlling radiator 10.9 Shut-Down Procedure
temperature. It is advisable, during the in-between
seasons, (spring and autumn), when you want only To stop the supply of gas and consequently turn
warm radiators, to turn the knob to minimum. In the system off, turn heater temperature control knob
the winter you will have to turn it to maximum, “5” (fig.34) to position 0.
leaving the heater temperature control knob “5” Turn power switch “1” (fig.34) off and close the
(fig.34) on 150°F. gas cock.
If you want hotter central heating, adjust the above
knob by turning it to a higher temperature setting. 10.10 Maintenance
It is however advisable to install a room thermostat
well away from heating elements, doors and The heater requires no specific maintenance; to
46 windows. keep it in good working order, however, it is
advisable to have the flue pipe into the heat
10.6 Manual Reset High-Limit exchanger and burner cleaned at the beginning of
Thermostat each season.
To clean proceed in this order:
This device acts on the heater, turning the burner a) Remove the upper heater jacket, the burner, the
off completely if heater temperature exceeds 210°F. flue gas discharge fan and the turbulators.
The user can see this because the burner does b) With a plastic-bristled cylindrical brush, brush
not turn on any more even if heater temperature is the insides of the flue gas pipes and the turbulators.
low. c) Vacuum away the burnt deposits from the burner
To restore the heater to its normal functioning and from the ignition and detection electrodes.
condition, unscrew and remove the protection cap However, for this cleaning job it is necessary to
of high limit thermostat reset button “4”, (fig.34). call a licensed authorized technician.
Then press it. Use a pen or a skinny object to
manually reset (the high limit thermostat will not 10.11 Draining water from the
reset unless the button is completely pressed). If heater
the high limit thermostat continues to trigger, call a
licensed authorized personnel. a) Turn off the main cold water supply valve.
b) Open the heating drain cock.
10.7 Resetting the Ignition Module c) Open heating air vents.
d) Open the sanitary drain cock.
The ignition module, (fig.3, item 24), carries out e) Open all hot water faucets to allow air to enter
numerous checks on heater functioning: on the into the pipes.
burner and on the flame detection system. When The heater holds approximately 4 gallons of water,
the ignition module detects that one of these not including the water capacity of the other system
components is malfunctioning, it stops the heater. components and piping.
To restart, Turn the heater temperature control knob
“5” (fig.34) to position “0” and reposition it on
150°F.
D TROUBLESHOOTING

Troubleshooting Sequence of Operation to Light the Burner

5J=HJ
Turn power switch to the ON position No Verify the connections to the main electrical supply
Switch diode should be lit ! and check the fuse on the control board

Yes
The fan will not start.
Turn the heater temperature control
- Check if the DL8 diode is lit (transformer lamp control). If it is
clockwise (should hear a click) not lit, check the transformer. Turn power on and carefully
check the two terminals, 13 and 14 on the electrical control board
Is the pressure switch at the “NC” No (see fig. 29) for a minimum of 110VAC. If there is no power, check
position ?. power to the heater at the on/off switch on the front panel. Place
the leads of your meter on the outer two terminals of the power
Yes switch with the switch pushed to the “ON” position. If no power is
DL1, DL2, DL3 and DL8 are lit present, check the fuse on the electrical control board for
continuity. If there is power at the switch, verify that the high limit
thermostat is working properly by turning the power OFF and
remove one wire from terminal 6 or 7 (110 voltage side) and
No - Check for power
The fan will start check for continuity. If continuity is present, reattach the wire.
between terminals - If DL8 is lit, check if DL1 is lit. If DL1 is not lit replace the
17 and 18 (see fig. heater temperature control. If DL1 is lit, check if DL3 is lit.
Yes 29) on the control If DL3 is not lit replace the pressure switch and/or check the
board. If there is connections between the pressure switch and the electrical
no power, replace control board.
electrical control
board.

The pressure switch

switches from “NC”
to “NO”, only if there The lamp control DL4 diode is not lit. 47
is a 0.3 inWC - Check if the vent air-intake pipes are too long.
pressure change. - Check if the vent air-intake pipe has an obstruction.
No - Check if the two leads inside the fan are dirty or not attached.
- Check if flue condensation is inside the fan (in this case a
Yes condensing trap immediately up to the heater is necessary).
- Check if DL7 diode is lit. - Check if pressure switch has good connections.
DL4 is lit
If not, replace the
electrical control board.
- Check for power After 11 seconds (safety time), spark stops and gas valve closes.
Spark starts and No between 25V and 25V Failure lamp indicator becomes lit (see item 7 Fig. 33 or 34).
gas valve opens (gnd) on the ignition - Check if gas switch on front panel is at the “ON” position.
Yes module. If voltage is OK, - Check if gas valve is at the open position. To check the gas valve
and the unit doesn't for 24VAC, the power must be shut off to reset the cycle. Turn the
DL7 is lit spark, replace ignition power back on and 24VAC should be obtained during that 11
module. If there isn't second period.
any voltage, replace - Check if the inlet gas pressure is between the maximum and
control board. minimum operating ranges (see TABLE 1). Now check
manifold pressure during the 11 second cycle (see TABLE 1 for
correct manifold pressures).
No
The burner lights - Check if the electrodes (flame sensor and ignition) are correctly
positioning on the burner (3-4mm or an 1/8” from the top of the
Yes burner).
- Check if the electrodes are correctly connected to the
All diodes are lit except for Dl6. ignition module.
Spark stops and burner is lit
continuously
If the unit continuosly trips at the safety limit of 210°F (100°C), this
would indicate an excessive amount of air in the heat exchanger
or a faulty heater temperature control. Once the unit trips, the
The burner stops when heater No manual reset button must be pressed by unscrewing the black cap
reaches the set temperature
on the front panel.
A sharp narrow object must be used to completely depress the
button.
Yes

Unit is functioning properly

 D TROUBLESHOOTING

Troubleshooting Sequence of Operation for a Call for Heat

The pump switch is in winter mode

The light of the pump-switch is not on.
- Check if the heater temperature control is set at a minimum
of 140°F (60°C). If is already up to 140°F (60°C) replace the
No
Is the heater temperature (shown heater temperature control.
on gauge) up to 140°F (60°C) ?.
Yes The DL6 lamp diode is not lit.
Is the room thermostat calling for No - Check if the room thermostat is wired properly.
heat ?. - Check T-T inputs “Thermostat 24Vac” on the white junction box
attached to the heater cavity. Jump across terminals to see if
Yes the pump starts.
DL6 lamp diode is lit If it does, the problem is external of the boiler.

The pump is not running. The radiators will be cold.

Turn the central heating regulation - Check if the pump is “locked” or jammed in its position.
knob to the maximum setting. This may be due to the pump not running throughout the
summer. In this case, turn the screw on top of the pump with
flat head screwdriver to help loosen the pump impeller.
No - Check for power to the pump by checking for 110VAC
Is the pump running ?. between terminals 15 and 16 on the main electrical control
board.
Yes If pump is still not operational, remove cover on pump and
check for power between “N” and “L” terminals. If 110VAC is
obtained, replace pump cartridge by removing the four allen
screws.

48 No - Check if the zone valves are open.

Are the radiators hot ?. - Check if you have air in the radiators (purge from the radiators)
Yes - Check if you have air in the heater (loosen the cap of
automatic air vent)

Pump runs until thermostat is

satisfied or the temperature inside
the heater is less than
140°F (60°C)

Troubleshooting Sequence of Operation for Domestic Hot Water

Start
The temperature inside the heater
is set more than 122°F (50°C)
- Check if the external mixing valve is installed correctly and
that it is set more than 104°F (40°C)
No - Check if the domestic hot water coil is dirty (domestic side)
Is the domestic hot water side hot?.
- Check if the domestic hot water exchanger is dirty
(heating system side)
Yes
- Check if the domestic hot water flow restrictor is correctly set
(see TABLE 1 “DHW output rise”)
OK
 D TROUBLESHOOTING
PROBLEMS CAUSES CHECKS (IF NECESSARY) REMEDIES
(IF NECESSARY)
the pilot light of power switch is off there isn’t electrical supply check the electrical supply level restore the electrical supply
the fuse doesn’t 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 doesn’t work check the power switch operating replace the power switch
pilot light of power switch doesn’t check the pilot light of power switch replace the power switch
work operating
the transformer lamp control, 115V isn’t reaching the transformer check the transformer has 115V restore the electrical supply
(DL8), is off input input
the transformer doesn’t work check the transformer has 24V replace the transformer
output
the DL8 doesn’t work check DL8 operating replace the electrical control board
the heater temperature lamp the heater temperature control check that the heater has the increase the heater temperature
control, (DL1) is off contacts are open required temperature set
24V isn’t reaching “C” contact of check 24V presence on “C” heater restore the electrical connection
heater temperature control temperature control contact
the heater temperature control check heater temperature control replace the heater temperature
doesn’t work operating control
the DL1 doesn’t work check DL1 operating replace the electrical control board
the low water cutoff lamp control, there isn’t enough water in the check there’s enough water in the restore the water right level in the
(DL2), is off heater heater heater
low water cutoff doesn’t work check the low water cut-off replace the low water cut-off
operating
DL2 doesn’t work check DL2 operating replace the electrical control board
the NC pressure switch lamp control, 24V
(DL3),
isn’t reaching the “C” contact check there’s 24V on the “C” restore 24V on the “C” contact of
is off of pressure switch contact of pressure switch pressure switch
pressure switch contact is on “NO” check the flue gas discharge fan is replace pressure switch
49
off
DL3 doesn’t work check DL3 operating replace electrical control board
the NO pressure switch lamp flue gas discharge fan is off check the flue gas discharge fan is replace the flue gas discharge fan
control, (DL4), is off on
115V isn’t reaching the flue gas check 115V is reaching the flue restore the electrical supply
discharge fan gas discharge fan contacts
pressure switch contact is on “NC” check the pressure switch replace the pressure switch
operating
DL4 doesn’t work check DL4 operating replace the electrical control board
the ignition module lamp control, 24V isn’t reaching ignition module check 24V is reaching ignition restore 24V
(DL7), is off module contacts
DL7 doesn’t work check DL7 operating replace the electrical control board
the gas valve lamp control, (DL5), 24V isn’t reaching gas valve check 24V is reaching gas valve replace ignition module
is off contacts
DL5 doesn’t work check DL5 operating replace the electrical control board
the room thermostat lamp control, room thermostat contacts are check room thermostat operating replace the room thermostat
(DL6), is off open, (if any)
room thermostat doesn’t work, (if check room thermostat operating replace the room thermostat
any)
DL6 doesn’t work check DL6 operating replace the electrical control board
the circulator pump switch light is circulator pump switch is off check heater temperature is higher check heater temperature is higher
off than 140°F than 140°F
dhw priority thermostat contacts check heater temperature is higher increase the heater temperature, (if
are open than 140°F necessary)
room thermostat contacts are open check room thermostat operating replace the room thermostat
circulator pump switch light doesn’t check circulator pump switch light replace the circulator pump switch
work operating
6=> KI=
 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.

• A routine maintenance contract, with a licensed authorized technician, will

guarantee the heater works properly as well as ensuring a longer life.

Controlling Heater Operation

The customer must know how to fill and drain the circuit; he must also know
how to control and correct if necessary the pressure in the central heating
system.

50 What to do when:

the smell of gas is present-

Turn the gas cock off and ventilate the room. Call a licensed authorized
technician and, if necessary your local gas company.
Follow the gas supplier’s instructions - If you cannot reach your gas supplier;
call the fire department.

the heater is heating up but the system stays cold-

Open the radiator taps and make sure that the heater temperature control
knob is on the 150°F position. If the system still does not warm up and the
circulator pump is not working, turn the heater off and call a licensed authorized
technician.

water is leaking from the domestic water side-

Turn off the main cold water supply valve. Call a licensed authorized technician.

Cleaning the heater jacket

Use a damp cloth. Do not use any abrasive detergents.
 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.com