Archer Highlander HLR-3-070NT Service manual

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Highlander Installation, Operating & Service Manual
• Water Boiler
• Cast Iron
• Induced Draft
• Gas Fired
WARNING
Read these instructions carefully before
installing. This boiler must only be installed,
serviced, or repaired by a qualified installer,
service agency, or gas supplier. Improper
installation, adjustment, alteration, service or
maintenance can cause severe personal injury,
death, or substantial property damage. For
assistance or additional information, consult
a qualified installer, service agency, or gas
supplier.
!
Installation, Operating and Service Instructions for
9700609
Highlander
Models:
• HLR-3-070NT • HLR-3-063PT
• HLR-4-105NT • HLR-4-095PT
• HLR-5-140NT • HLR-5-126PT
• HLR-6-175NT • HLR-6-158PT
• HLR-7-210NT • HLR-7-189PT
WARNING
Attention Installer - Affix these instructions
adjacent to boiler. Provide model number and
serial number when seeking information and
support.
Attention Building Owner - Retain these
instructions for future reference. Contact a
qualified installer, service agency or gas
supplier for all issues and support.
!
Manual Contents Page
1. Qualified Installer, Service Agency or Gas Supplier
Read Before Proceeding .....................3
2. User/Homeowner Read Before Proceeding ......4
3. Specifications ..............................5
4. Locating the Boiler ..........................6
5. Preparing Boiler ............................8
6. Air for Combustion and Ventilation .............9
7. Venting ...................................11
8. Water Piping ..............................22
9. Gas Piping ...............................26
10. Electrical .................................27
11. Start-up and Checkout ......................30
12. Operation ................................34
13. Before Leaving Jobsite......................36
14. Service and Maintenance ....................37
15. How It Works ..............................42
16. Troubleshooting ...........................44
17. Service Parts ..............................46
Appendix A: Direct Vent Installations ..........54
Appendix B: Instructions for High Altitude ......
Installations (US Only) ......................59
Appendix C: Low Return Water .................
Temperatures .............................61
Appendix D: Special Requirements For Side- Wall
Vented Appliances In The Commonwealth of
Massachusetts ............................63

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Highlander Installation, Operating & Service Manual
The following terms are used throughout this manual to bring attention to the presence of hazards of various
risk levels, or to important information concerning product life.
The city of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved these boilers. See the Massachusetts Board
of Plumbers and Gas Fitters website https://licensing.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the
latest Approval Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a licensed Plumber or Gas fitter.
NOTICE: Indicates special instructions on
installation, operation, or maintenance which
are important but not related to personal injury
hazards.
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death, serious
injury or substantial property damage.
CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, may result in moderate or
minor injury or property damage.
DANGER
Explosion Hazard. DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of
this or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or
use any phone in the building. Immediately, call the gas supplier from a remotely located phone.
Follow the gas supplier’s instructions or if the supplier is unavailable, contact the fire department.
WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
• If any controls are replaced, they must be replaced with identical models.
• Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
• If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.
• Never jump out or bypass any safety or operating control or component of this boiler.
• Assure that all safety and operating controls and components are operating properly before placing
the boiler back in service.
• Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.
! !
!
!
!

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Highlander Installation, Operating & Service Manual
DANGER
Asphyxiation Hazard, Burn Hazard, Electrical
Shock Hazard.
• Carefully read all instructions in literature
packet and posted on boiler before attempting
installation, startup, or service of this boiler.
Perform steps in order given. Failure to follow
all instructions in proper order could result in
severe personal injury, death or substantial
property damage.
• Use proper personal protective equipment
when installing, servicing, or working near this
boiler. Materials of construction, flue products,
and fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, and/or
other toxic or harmful substances that can be
hazardous to health and life and that are known
to the State of California to cause cancer, birth
defects, and other reproductive harm.
• Do not disconnect pipe fittings on boiler or
in heating system without first verifying system
is cool and free of pressure and that your
clothing will protect you from a release of hot
water or steam. Do not rely solely on boiler
temperature and pressure gauge when making
this judgement.
• Install all guards, cover plates, and
enclosures before leaving boiler in operation.
• Disconnect electrical supply before installing
or performing maintenance.
!NOTICE:
1. Size boiler properly. A grossly oversized boiler
will cycle excessively leading to premature
failure of boiler and its components. Warranty
does not cover damage from excessive
cycling.
2. Systems employing baseboard and/or
radiators, use an industry accepted
sizing method such as the I=B=R "Residential
Hydronic Heating Installation and Design"
guide published by the Air Conditioning,
Heating and Refrigeration Institute (AHRI).
3. Inspect shipment carefully for signs of
damage. Any claim for damage or shortage
in shipment must be filed immediately against
carrier by consignee. No claims for variances
or shortages will be allowed by boiler
manufacturer, unless presented within 60
days after receipt of equipment.
1Qualified Installer, Service Agency or Gas Supplier Read Before Proceeding

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Highlander Installation, Operating & Service Manual
2User/Homeowner Read Before Proceeding
CAUTION
Burn Hazard.
Keep children and pets away from hot surfaces
of the boiler including boiler piping, vent piping,
and vent terminals.
!
NOTICE: Boiler may leak water or steam at the
end of its useful life. Be sure to protect walls,
carpets, and valuables from water or steam that
could leak from boiler.
WARNING
Asphyxiation Hazard. Fire Hazard.
• A qualified installer, service agency or gas
supplier should annually inspect boiler.
• If you are not qualified to install or service
boilers, do not install or service this one.
• Carbon monoxide is an odorless, deadly gas
that may be introduced into your home by any
malfunctioning fuel burning product or vent
system failure. Consider installing CO alarms
near bedrooms in all levels of building to
warn you and your family of potential CO
exposure.
• Do not block air flow into or around boiler
or opening for fresh air into boiler room.
Insufficient air may cause the boiler to produce
carbon monoxide or start a fire.
!
NOTICE: Protect your home in freezing weather.
A power outage, operating control, or component
failure will prevent your boiler from lighting. In
winter your pipes may freeze and cause extensive
property damage. Do not leave heating system
unattended during cold weather unless alarms
or other safeguards are in place to prevent such
property damage.
NOTICE: This boiler contains controls which
may cause the boiler to shut down and not restart
without service. If damage due to frozen pipes
is a possibility, heating system should not be
left unattended in cold weather; or appropriate
safeguards and alarms should be installed on
heating system to prevent damage if boiler is
inoperative.

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Highlander Installation, Operating & Service Manual
3Specifications
Electrical Requirements: 120 VAC, 60 Hz, less than 12A
Maximum Allowable Working Pressure - 50 psi. Boiler shipped from factory with a 30 psi safety relief valve.
Table 3-2: Dimensions and Connections
Boiler Model # of
Sections
Depth
(in.)
Width
(in.)
Height
(in.)
Gas
(NPT)
Vent
(in.)
Supply
NPT
Return
NPT
Relief
Valve
NPT
Drain
Valve
NPT
Maximum
Allowable
Working
Pressure
(PSI)
HLR-070-NT 3 26-1/2 12-3/4 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-105-NT 4 26-1/2 15-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-140-NT 5 26-1/2 18-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-175-NT 6 26-1/2 21-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-210-NT 7 26-1/2 24-3/4 37-3/4 3/4 3 1-1/4 1-1/4 3/4 3/4 50
HLR-063-PT 3 26-1/2 12-3/4 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-095-PT 4 26-1/2 15-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-126-PT 5 26-1/2 18-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-158-PT 6 26-1/2 21-1/2 37-3/4 1/2 3 1-1/4 1-1/4 3/4 3/4 50
HLR-189-PT 7 26-1/2 24-3/4 37-3/4 3/4 3 1-1/4 1-1/4 3/4 3/4 50
Boiler Model
Water
Content
(gal)
Approx.
Shipping
Weight (lbs)
Direct Vent Kit
(supplied with
boiler) (PN)
Shipping
Crate Depth
(in.)
Shipping
Crate Width
(in.)
Shipping
Crate Height
(in.)
Heat
Exchanger
Surface Area
(ft.2)
HLR-070-NT 2 260 110019-03 39 26 47 7.72
HLR-105-NT 3 310 110019-04 39 26 47 11.58
HLR-140-NT 4 360 110019-05 39 26 47 15.44
HLR-175-NT 5 415 110019-06 39 26 47 19.31
HLR-210-NT 6 470 110019-07 39 35 47 23.17
HLR-063-PT 2 260 110019-03 39 26 47 7.72
HLR-095-PT 3 310 110019-04 39 26 47 11.58
HLR-126-PT 4 360 110019-05 39 26 47 15.44
HLR-158-PT 5 415 110019-06 39 26 47 19.31
HLR-189-PT 6 470 110019-07 39 35 47 23.17
Table 3-3: Weights and Volume
Table 3-1: Ratings
Model Number Fuel AFUE% Input (MBH)(1) Heating Capacity (MBH) Net AHRI Rating, Water(2) (MBH)
HLR-070-NT Nat. Gas 85.0 70 60 52
HLR-105-NT Nat. Gas 85.0 105 90 78
HLR-140-NT Nat. Gas 85.0 140 120 105
HLR-175-NT Nat. Gas 85.0 175 150 130
HLR-210-NT Nat. Gas 85.0 210 179 156
HLR-063-PT Propane 85.0 63 54 47
HLR-095-PT Propane 85.0 94.5 81 70
HLR-126-PT Propane 85.0 126 108 94
HLR-158-PT Propane 85.0 157.5 135 117
HLR-189-PT Propane 85.0 189 161 140
(1) Input ratings can be used for elevations up to 2,000 ft. Refer to System Start-Up and Checkout Sections for elevations 2,000 ft. or higher.
(2) Net AHRI Ratings shown are based on a piping and pickup allowance of 1.15. The manufacturer should be consulted before selecting a boiler for
installations having unusual piping and pickup requirements, such as intermittent operation, extensive piping systems, etc.

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Highlander Installation, Operating & Service Manual
4Locating Boiler
Code Requirements
2. All wiring must comply with National Electrical
Code ANSI/NFPA 70.
3. Where required by authority having
jurisdiction, installation must conform to
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
Location Considerations
1. Provide combustion and ventilation air in
accordance with section "Air for Combustion and
Ventilation," of National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of local
building codes.
2. If replacing an existing boiler, check for and
correct common system problems including:
A. System leaks resulting in premature heat
exchanger failure from oxygen corrosion or
hardness deposits.
B. Inadequate freeze protection resulting in
system freezing and leaking.
C. Dirt or debris left in existing piping if it has not
been properly flushed or cleaned.
3. Appliance is listed for installation on combustible
flooring and must not be installed on carpeting.
4. Install on level floor. For basement installation
provide concrete base if floor is not level or if
water may be encountered on floor around boiler.
5. Protect gas ignition system components from
water (dripping, spraying, etc.) during appliance
operation and service.
6. Locate boiler to avoid water damage in case
there is a leak. If boiler must be located in an
area sensitive to water damage, install drain
pan underneath boiler and pipe to a suitable
drain location. Manufacturer will not be held
responsible for water damage resulting from
this appliance or any of its components.
7. Check for and remove any combustible
materials, gasoline, or other flammable liquids
from area around boiler.
8. Check for and remove any potential combustion
air contaminants from area around boiler. See
Table 4-1.
Clearances
1. Provide clearances between boiler jacket and
combustible material in accordance with
authority having jurisdiction. Minimum
clearances to combustible material shown in
Figure 4-2.
2. Recommend 24 in. service clearance from left
side, right side and front.
NOTICE: If recommended service clearances
are not provided, it may be necessary to remove
boiler for service.
3. Boiler must not be installed on carpeting.
1. Installations must conform to requirements of
authority having jurisdiction or, in the
absence of such requirements, to National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
Table 4-1: Corrosive Combustion Contaminants
and Sources
Contaminants to avoid:
Spray cans containing chloro/fluorocarbons (CFC’s)
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning
solvents found in household laundry rooms.
Adhesives used to fasten building products and
other similar products
Excessive dust and dirt
Areas likely to have contaminants:
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
NOTICE: Flue side corrosion caused by
contaminants is not covered by warranty.

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Highlander Installation, Operating & Service Manual
After Removing Existing Boiler
When an existing boiler is removed from a
common venting system, the common venting
system is likely to be too large for proper venting
of appliances remaining connected to it.
At time of removal of an existing boiler, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to the
common venting system are not in operation:
1. Seal any unused openings in the common venting
system.
2. Visually inspect venting system for proper size
and horizontal pitch and determine there is no
blockage or restriction, leakage, corrosion, and
other deficiencies which could cause an unsafe
condition.
Before Removing Existing Boiler
Take pictures and measure and/or mark existing
steam and condensate return piping to ensure
proper re-piping of new boiler. Support existing
piping before disconnecting to prevent change in
pitch.
3. Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected
to the common venting system are located and
other spaces of building. Turn on clothes dryers
and any appliance not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhausts, so they
will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
4. Place in operation appliance being inspected.
Follow Operating Instructions. See Figure 11-
2. Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use flame of a
match or candle, or smoke from a cigarette, cigar
or pipe.
6. After it has been determined that each appliance
remaining connected to the common venting
system properly vents when tested as outlined
above, return doors, windows, exhaust fans,
fireplace dampers and any other gas-burning
appliance to their previous condition of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54. When resizing any portion of the
common venting system, the common venting
system should be resized to approach minimum
size as determined using appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
4Locating Boiler (continued)
WARNING
Adequate combustion an ventilation air must be
provided to assure proper combustion.
!
Figure 4-2: Minimum Clearances to Combustible
Construction

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Highlander Installation, Operating & Service Manual
5Preparing Boiler
Unpack boiler
1. Move boiler to approximate installed position.
2. Remove all crate fasteners.
3. Lift outside container and remove with all other
inside protective spacers and bracing. Save two
of the wooden slats from the container sleeve for
use in Steps 5 and 6.
4. Remove all boiler hold-down fasteners.
5. Tilt the boiler to one side and slide a wooden slat
under the two raised feet.
6. Tilt the boiler to the other side and slide another
wooden slat under the two raised feet.
7. Slide the boiler forward or backward off the skid
using the two wooden slats as runners.
8. Move boiler to its permanent location.
DANGER
Use precautions and appropriate rigging
apparatus when moving heavy objects.
!
CAUTION
Do not drop boiler. Do not bump boiler jacket
against floor.
!

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Highlander Installation, Operating & Service Manual
Provide provisions for combustion and ventilation air
in accordance with the section “Air for Combustion
and Ventilation,” of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or Clause 8.2, 8.3 or 8.4 of Natural
Gas and Propane Installation Code, CAN/CSA B149.1,
or applicable provisions of the local building codes.
In almost all cases, one of the following two
techniques will be best for supplying this boiler with
adequate fresh air:
Indoor Combustion Air – Combustion air is drawn
into the boiler room from other parts of the building
and from outdoors through natural infiltration (cracks
under doors, etc). This method cannot be used in
all cases – see discussion below.
Direct Venting – Combustion air is pulled directly from
outside using the appropriate Direct Vent Conversion
Kit shown in Table 3-3 with installer supplied PVC
or galvanized air intake piping. See Appendix A
for details on installing this boiler with a direct vent
system.
WARNING
PROVIDE ENOUGH AIR to ventilate the boiler
room and sustain combustion. Ignition failure,
overheating, fire, carbon monoxide, and
spillage of flue gases may result from poor air
supply.
!
WARNING
INSUFFICIENT COMBUSTION AIR SUPPLY may
result in the production and release of deadly
carbon monoxide (CO) into the home.
!
WARNING
Do not install this boiler in areas where it
will draw combustion air from areas where
chemicals, such as bleaches, fabric softeners,
paints, cleaners, refrigerants, and cat boxes
are used or stored. Do not draw combustion
air containing large amounts of dust such as
that generated by dry wall construction or
woodworking. Failure to observe this warning
could result in objectionable odors, severe
boiler damage, personal injury or loss of life.
!
NOTICE: Although this boiler is supplied with
a direct vent conversion kit shown in Table 3-3,
this kit does not need to be installed if adequate
combustion air can be obtained from indoors.
If combustion air is being brought to this boiler
using one of the Direct Vent Conversion Kits
shown in Table 3-3, requirements in Section 6 do
not apply: See Appendix A for combustion and
ventilation air requirements.
6Air for Combustion and Ventilation
The National Fuel Gas Code does describe some
other acceptable techniques for bringing outdoor
combustion air to the boiler room, but these should
rarely be needed and are not discussed here.
1. Using the Indoor Combustion Air Method
A. Total the input of all appliances in the boiler
room in thousands of BTU/hr.
B. Find the volume of the boiler room in cubic
feet:
Volume (ft.3) = Length (ft.) x Width (ft.) x
Height (ft.)
If the boiler room adjoins another room and
there is no door present between these
two rooms, add the volumes of the rooms
together. Repeat for any other connected
rooms which do not have doors. Do not add
the volume of two rooms separated by a
door even if that door is “always left open”.
C. Divide the volume obtained in Step 2 by the
input calculated in Step 1.
D. If the result is at least 50 ft.3per 1,000 BTU/
hr, and none of the conditions described in (6)
below are met, normal infiltration should
provide adequate fresh air into the boiler
room.
E. If the result is less than 50 ft.3per 1,000 BTU/
hr, provide two openings into the boiler room,
one near the floor and one near the ceiling.
The top edge of the upper opening must be
within 6 in. of the ceiling and the bottom edge
of the lower opening must be within 6 in. of
the floor (Figure 6-1):
• For rooms that are both on the same floor,
each opening must have a free area of
1 square inch per 1,000 BTU/hr input of
all gas burning appliances in the boiler
room.
• For rooms that are not all on the same
floor (such as a boiler room and adjoining
hall with stairway), each opening must
have a free area of 2 square inches per
1,000 BTU/hr input of all gas burning
appliances in the boiler.
• The minimum opening dimension is 3
inches. Minimum opening free area is 100
square inches per opening.

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Highlander Installation, Operating & Service Manual
• If the total volume of both the boiler room
and the room to which the openings
connect is less than 50 cubic feet per
1,000 BTU/hr of total appliance input,
install a pair of identical openings into
a third room. Connect additional rooms
with openings until the total volume of all
rooms is at least 50 cubic feet per 1,000
BTU/hr of input. Note that if any of the
connected rooms, is on a different floor,
each of the two openings between all
connected rooms must have a free area
of 2 square inches per 1,000 BTU/hr of
input.
• The “free area” of an opening takes into
account the blocking effect of mesh,
grills, and louvers. Where screens are
used, they must be no finer than ¼ in. (4 x
4) mesh.
• If providing openings into adjacent
rooms is undesirable, use the Direct Vent
Conversion Kit.
F. Do not use the Indoor Combustion Air Method
described above if any of the following are
true:
i. The indoor space is so tightly
constructed that the number of air
changes per hour is known to be 0.4
or less.
ii. The boiler room is depressurized
relative to the outdoors. This
depressurization is possible if the
structure is tightly constructed and/or
is equipped with exhaust fans.
iii. The building is known to be of
unusually tight construction, which
is defined here as construction having
all of the following characteristics:
• Walls exposed to the outdoor
atmosphere having a continuous
water vapor retarder with a rating of
1 perm or less with openings
gasketed or sealed.
• Openable windows and doors are
weather stripped.
• Caulking or sealants are applied
to areas, such as joints around
window and door frames, between
sole plates and floors, between
wall-ceiling joints, between wall
panels, at penetrations for
plumbing, electrical and gas lines
and at other openings.
6Air for Combustion and Ventilation (continued)
Example:
A 105,000 BTU/hr input boiler and a
water heater are to be installed in a room
measuring 6 ft. - 3 in. x 7 ft. with an 8 ft.
ceiling. The water heater has an input of
30,000 BTU/hr:
Total input in thousands of BTU/hr = (105,000
BTU/hr + 30,000 BTU/hr) ÷ 1,000 = 135
Volume of room = 6.25 ft. x 7 ft. x 8 ft. = 350
ft3
350 ÷ 135 = 2.59. Since 2.59 is less than 50,
there will be an inadequate fresh air supply
in the boiler room unless openings are in-
stalled between the boiler room and at least
one adjacent room. It turns out that the boiler
room in this example is adjacent to a full
basement which is 20 ft. x 45 ft. x 8 ft. high.
If two openings are installed into this base-
ment that each have a free area of 135 in.2,
the combined volume of the boiler room and
basement will be:
350 ft.3+ 6,400 ft.3 = 6,750 ft.3 and:
6,750 ÷135 = 50 ft.3per 1,000 BTU/hr.
In the absence of one of the conditions
described in (6) above, this arrangement
should provide an adequate fresh air supply
to all the appliances in the boiler room.
2. Using Outdoor Combustion Air (“Direct Venting”)
This method requires the Direct Vent Conversion Kit
shown in Table 3-3. Appendix A describes how to size
and run the intake pipe.
Although combustion air is supplied through the air
intake piping, ventilation air is still required around the
boiler to prevent overheating of boiler components.
If the boiler is installed in a closet, provide two
openings in the closet, each having a net free area of
100 square inches as shown in Figure 6-1. Note that
these openings are independent of the boiler size.
Additional area may be required if other fuel burning
appliances are installed in this closet.
6” MAX
6” MAX
Figure 6-1: Indoor Combustion Air Method

11
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Highlander Installation, Operating & Service Manual
Figure 6-1: Indoor Combustion Air Method
DANGER
Asphyxiation Hazard.
• Failure to vent this boiler in accordance with
these instructions could cause products of
combustion and/or carbon monoxide to enter
living space, resulting in severe personal injury,
death or substantial proper damage.
• Vent installation shall be in accordance with local
codes, authority having jurisdiction or National
Fuel Code, ANSI Z223.1/NFPA 54 or applicable
requirements of the local building codes.
Do not vent this boiler with vent systems not
specifically specified in this manual. Prohibited
vent system components include, but are
not limited to:
○CPVC, PVC, Radel® (polyphenolsulfone)
and other Non-metallic pipe.
○Metallic pipe that is not AL29-4C stainless
steel.
•Do not attempt to vent this boiler into a masonry
or “B” vent chimney.
•Do not use a barometric damper, draft hood or
vent damper with this boiler.
•Do not attempt to mix components from different
approved vent systems.
•Do not common vent this boiler with any other
appliances.
•Do not penetrate vent pipe with holes or
fasteners.
• Do not locate vent termination under a deck.
7Venting
!
1. Vent System Design
There are two basic ways to vent this boiler:
• Horizontal (“side wall”) venting using an
approved AL29-4C stainless steel vent system.
• Vertical venting using an approved AL29-4C
stainless steel vent system.
Table 7-1 summarizes these venting options. One
of the columns in Table 7-1 must describe the
planned vent system exactly. In addition, observe
the following guidelines:
A. Approved Vent Systems - Use only one of
the approved vent systems shown in Table
7-7. These systems are made of a special
stainless steel alloy (AL29-4C) for protection
against corrosive flue gas condensate. They
are also designed to provide a gas tight
seal at all joints and seams so that flue gas
does not enter the building. Each approved
vent system has unique method for installation
- do not attempt to mix components from
different vent systems.
B. Maximum Vent Lengths
The maximum length of the vent piping
depends upon the vent option selected,
the vent pipe size, and the boiler size.
See Table 7-1 for the maximum vent length.
The maximum allowable vent length must
be reduced by the amount shown in Table
7-8 for each elbow used. Note: Termination
fittings are not counted when counting
additional elbows.
Example:
A 3 in. vent system is planned for a horizontal
direct vented 105,000 BTU/hr boiler which
has the following components:
2 ft. vertical pipe
1 90 elbow
5 ft. horizontal pipe
1 90 elbow
3 ft. horizontal pipe
1 45 elbow
4 ft. horizontal pipe
1 termination tee
The Vent Option #1 column in Table 6.1
describes a horizontal direct exhaust system
using 3 in. vent pipe. From this column,
we see that this boiler may have a vent
length of up to 50 ft. The termination tee
is not considered. From Table 6.8, the
equivalent length of the 3 in. 45 elbow, is 4 ft.
and the equivalent length of the 3 in. 90
degree elbow, is 5.5 ft. The maximum
allowable run of straight pipe on this system is
therefore:
50 ft. – 5.5 ft. – 5.5 ft. - 4.0 ft. = 35 ft.
Since the planned installation has only
14 ft. of straight pipe, the planned vent length
is acceptable.
NOTICE: When this boiler is direct vented,
refer to this section for proper installation of the
venting system. Refer to Appendix A for the
proper design and assembly of the air intake
system.

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Highlander Installation, Operating & Service Manual
NOTICE: Do not exceed maximum vent system length. Refer to Table 7-1 in this section for maximum vent
system length. Use only vent terminals and terminal locations shown in Tables 7-1, and 7-6 and related Figures
in this section.
C. Permitted Terminals for Horizontal Venting
(Vent Option 1, 2) - Table 7-1 shows
permitted types of terminals.
D. Horizontal Vent Terminal Location - Observe
the following limitations on the vent terminal
location (also see Figure 7-9):
• Terminal must be at least 4 feet below
or 4 feet horizontally from any operable
window, door, or gravity air inlet into the
building.
• The bottom of the terminal must be at least
12 in. above the normal snow line. In no
case should it be less than 12 in. above
grade level.
• Do not locate the vent terminal over a
public walkway.
• The bottom of the terminal must be at
least 3 feet above any forced air inlet
located within 10 feet.
• Minimum clearance from electric meters,
gas meters, regulators, and relief
equipment:
United States - Minimum 4 ft. (1.22 m)
horizontally from and in no case above or
below, unless a 4 ft. (1.22 m) horizontal
distance is maintained.
Canada - Minimum 6 ft. (1.83 m)
horizontally from and in no case above or
below, unless a 6 ft. (1.83 m) horizontal
distance is maintained.
• Do not locate the terminal under decks or
similar structures.
• In general, the top of the vent terminal
must be at least 4 ft. below eves, soffits,
and other overhangs. If the overhang is
unventilated and if the terminal can extend
beyond the overhang while meeting the
stick-out requirements shown in Figure
7-3 or 7-4, this vertical clearance can be
reduced to as little as 12 in. See Figure
7-9c. Note that flue gas condensate
will form under such overhangs and
construction in this area must be
appropriately protected.
• Terminal must be at least 12 in. from an
inside corner. Exception: if window and/or
air inlet is within four (4) feet of an inside
corner, then vent terminal must be at least
six (6) feet from adjoining wall of inside
corner.
• Under certain conditions, water in the
flue gas may condense on the structure
in areas around the terminal. If these areas
are made of materials subject to damage
from flue gas condensate or ice, they
should be protected.
7A Vent System Design (continued)
Table 7-1: Summary Of Venting Options Using Indoor Combustion Air
(See Appendix A for Options Using Outdoor Air)
Classification Used in this Manual Horizontal Direct Exhaust Vertical Direct Exhaust
Vent Option # 1 2 3 4
Illustrated in Figure 7-2 7-6
Structure Penetration Wall Roof
Material Listed AL29-4C Stainless Special Gas Vent System (See Table 7-7)
Nominal Diameter (inches) 3 433 43
Maximum
Vent Length
HLR-3-070NT thru HLR-6-175NT
HLR-3-063PT thru HLR-6-158PT 50 ft. Not Permitted 50 ft. Not Permitted
HLR-7-210NT and HLR-7-189PT 15 ft. 50 ft. 15 ft. 50 ft.
Terminal Option A 3 in. Tee14 in. Tee13 in. Cap14 in. Tee1
Terminal Option B Miter + 45 Elbow2Not Permitted
1. Tee or Cap terminal is supplied by the installer and is compatible with special gas vent system. See Table 7-7 for details.
2. Miter terminal is part #8110701 and is purchased separately. 45° Elbow is by special gas vent manufacturer.
3. The HLR-7-210NT and HLR-7-189PT is factory supplied with a 3 in. adaptor. A 3 x 4 increaser compatible with the special gas vent
system is required when this model is vented using 4 in. pipe. When used, this increaser must be the first fitting installed on the boiler
adaptor.

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Highlander Installation, Operating & Service Manual
Figure 7-2: Horizontal Direct Exhaust Vent System (Vent Option 1, 2)
Figure 7-3: Tee Terminal Figure 7-4: Optional Miter Terminal
7A Vent System Design (continued)
7-7)

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Highlander Installation, Operating & Service Manual
• If possible, install the terminal on a wall
away from the prevailing wind. Reliable
operation of this boiler cannot be
guaranteed if the terminal is subjected to
winds in excess of 40 mph.
• The noise level in the vicinity of the
terminal is approximately 65 dB (roughly
the level of a normal conversation). Avoid
positioning the terminal in areas where this
might be objectionable.
E. Terminal Offsets - Tee terminals may be offset
by as much as 7 ft. as shown in Figure 7-5.
This sometimes helps maintain the 12 in.
minimum clearance required above the
snow line. The extra two elbows and
the section of vertical pipe on the outside
of the building must be counted when
checking that the maximum vent
pipe length is not exceeded. When
this offset is used, the horizontal section of
vent pipe must be pitched away from the
outside so that condensate cannot collect in
the lower offset elbow.
F. Permitted Terminals for Vertical Venting (Vent
Option 3, 4) - Terminals used on these
systems are caps provided by the vent
system manufacturer. Vent manufacturer part
numbers for these caps are shown in Table
7-7.
G. Vertical Vent Terminal Locations (Vent Option
3, 4) - The lowest discharge opening on
the cap must be at least 2 feet above any
object located within 10 feet. (Figure 7-6)
H. Wall Thimbles – Wall thimbles are required
where the vent pipe passes through
combustible walls with less than the required
clearance shown in Figure 4-2 or as required
by local codes. Vent manufacturer’s wall
thimble part numbers are shown in Table 7-7.
I. Condensate Traps and Pitch of Horizontal
Piping – All installations require a condensate
trap. Pitch all horizontal piping ¼ in. per
foot so that any condensate or rain water in
the vent system will run towards this trap. Vent
manufacturer’s part numbers for suitable traps
are shown in Table 7-7.
J. Fire Stops and Wall Thimbles – Use
fire stops where required by code or by
the vent system manufacturer. Consult vent
system manufacturer’s literature for
information on suitable fire stops.
K. Supports - Vertical and horizontal sections of
vent pipe must be properly supported. See
the Vent System assembly section of this
manual for more information.
L. Access for Inspection - Refer to the vent
manufacturer's instructions for access
requirements to vent components.
Figure 7-5: Optional Terminal Offset for Horizontal Vent Systems
7A Vent System Design (continued)

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Highlander Installation, Operating & Service Manual
Figure 7-6: Vertical Direct Exhaust System (Vent Option 3, 4)
7A Vent System Design (continued)
7-7
7-7

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Highlander Installation, Operating & Service Manual
Table 7-8: Vent Fitting Equivalent Length
VENT FITTING EQUIVALENT LENGTH (ft.)*
3 in. 90 ELBOW 5.5
3 in. 45 ELBOW 4.0
4 in. 90 ELBOW 8.0
4 in. 45 ELBOW 4.5
* Where different equivalent lengths are published by the
vent system manufacturer, these may be used in lieu of the
values shown in Table 7-8
7A Vent System Design (continued)
Table 7-7: Permissible Vent Systems And Principle Vent Components
MANUFACTURER VENT SYSTEM SIZE CONDENSATE
TRAP
WALL
THIMBLES
HORIZONTAL
TERMINATION
VERTICAL
TERMINATION
HEAT FAB
SAF-T VENT
EZ SEAL
39321
(NOTE 2)
7393GC
7393GCS
5391CI
TEE: 7390TEE 5300CI
49421
(NOTE 2)
7493GC
7493GCS
5491CI
TEE: 7490TEE 5400CI
PROTECH
SYSTEMS
INC.
FASNSEAL
3 FSHDT3 FSWT3 TEE: FSTT3 FSRC3
4
FSHDT4
OR FSCD4
(NOTE 3)
FSWT4 TEE: FSTT4 FSRC4
Z-FLEX
SVE
SERIES III
(“Z-VENT III”)
3 SVEDWCF03 2SVSWTEF03 TEE: 2SVSTTF03 2SVSRCF03
4 SVEDWCF04 2SVSWTEF04 TEE: 2SVSTTF04 2SVSRCF04
METAL-FAB CORR/GUARD
3 CGSWDS(3”) CGSWWPK(3”) TEE: CGSWTTM(3”) CGSWC(3”)
4 CGSWDS(4”) CGSWWPK(4”) TEE: CGSWTTM(4”) CGSWC(4”)
NOTES:
1. See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops and vent supports.
2. All Heat Fab condensate traps shown may be installed in vertical or horizontal run.
3. Protech FSCD4 condensate trap may be installed in a vertical or horizontal run. All other Protech traps must be installed in a horizontal run
only.
4. Metal-Fab CGSWDS condensate traps may only be installed in a horizontal run.
5. 8110701 Miter terminal may be used as shown in Figure 7-4. 45° elbow is supplied by vent system manufacturer.

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Highlander Installation, Operating & Service Manual
Figure 7-9a: Location of Vent Terminal Relative to Windows, Doors and Grades
7A Vent System Design (continued)
Figure 7-9b: Location of Vent Terminal Relative to Meters and Forced Air Inlets

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Highlander Installation, Operating & Service Manual
Figure 7-9c: Location of Vent Terminal Under Overhangs
'Y' 'X' Max. Overhang
0 - 12 in. NOT PERMITTED
12 - 48 in. 17 - 29 in. X minus 7 in.
Greater than 48 in. 17 - 29 in. 36 in.
Note: Overhang may not be ventilated if 'Y' is less than 48 in.
7A Vent System Design (continued)

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Highlander Installation, Operating & Service Manual
Au moment du retrait d’une chaudière existante,
les mesures suivantes doivent être prises pour
chaque appareil toujours raccordé au système
d’évacuation commun et qui fonctionne alors que
d’autres appareils toujours raccordés au système
d’évacuation ne fonctionnent pas:
A. Sceller toutes les ouvertures non utilisées du
système d’évacuation.
B. Inspecter de façon visuelle le système
d’évcuation pour déterminer la grosseur
et l’inclinaison horizontale qui conviennent
et s’assurer que le système est exempt
d’obstruction, d’étranglement, de fuite,de
corrosion et autres défaillancesqui pourraient
présenter des risques.
C. Dans la mesure du possible, fermer toutes les
portes et les fenêtres du bâtiment et toutes les
portes entre l’espace où les appareils toujours
raccordés au système d’évacuation sont
installés et les autres espaces du bâtiment.
Mettre en marche les sécheuses, tous
les appareils non raccordés au système
d’évacuation commun et tous les ventilateurs
d’extraction comme les hottes de cuisinière et
les ventilateurs des salles de bain. S’assurer
que ces ventilateurs fonctionnent à la
vitesse maximale. Ne pas faire fonctionner
les ventilateurs d’été. Fermer les registres des
cheminées.
D. Mettre l’appareil inspecté en marche Suivre les
instructions d’allumage. Régler le thermostat
de façon que l’appareil fonctionne de façon
continue.
E. Faire fonctionner le brùleur principal pendant
5 min ensuite, déterminer si le coupe-tirage
déborde à l’ouverture de décharge. Utiliser
la flamme d’une allumette ou d’une chandelle
ou la fumée d’une cigarette, d’un cigare ou
d’une pipe.
2. Removing Boiler From Common Chimney
When an existing boiler is removed from a
common venting system, the common venting
system is likely to be too large for proper venting
of the appliances remaining connected to it.
At the time of removal of an existing boiler, the
following steps shall be followed with each
appliance remaining connected to the common
venting system placed in operation, while the
other appliances remaining connected to the
common venting system are not in operation:
A. Seal any unused openings in the common
venting system.
B. Visually inspect the venting system for proper
size and horizontal pitch and determine
there is no blockage or restriction, leakage,
corrosion, and other deficiencies which could
cause an unsafe condition.
C. Insofar as is practical, close all building doors
and windows and all doors between the space
in which the appliances remaining connected
to the common venting system are located and
other spaces of the building. Turn on clothes
dryers and any appliance not connected to the
common venting system. Turn on any exhaust
fans, such as range hoods and bathroom
exhausts, so they will operate at maximum
speed. Do not operate a summer exhaust fan.
Close fireplace dampers.
D. Place in operation the appliance being
inspected. Follow the Lighting (or Operating)
Instructions. Adjust thermostat so appliance
will operate continuously.
E. Test for spillage at the draft hood relief opening
after 5 minutes of main burner operation. Use
the flame of a match or candle, or smoke from
a cigarette, cigar or pipe.
F. After it has been determined that each
appliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans, fireplace dampers and any other gas-
burning appliance to their previous condition of
use.
G. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code,
ANSI Z223.1/NFPA 54. When resizing any
portion of the common venting system, the
common venting system should be resized
to approach the minimum size as determined
using the appropriate tables in Chapter 13
WARNING
Never common vent this boiler with other
appliances.
!
of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or the Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
7B Removing Boiler From Common Chimney

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Highlander Installation, Operating & Service Manual
F. Une fois qu’il a été déterminé, selon la
méthode indiquée ci-dessus, que chaque
appareil raccordé au système d’évacuation est
mis à l’air libre de façon adéquate. Remettre
es portes et les fenêtres, les ventilateurs, les
registres de cheminées et les appareils au
gaz à leur position originale.
G. Tout mauvais fonctionnement du système
d’évacuation commun devrat être corrigé
de façon que l’installation soit conforme
au National Fuel Gas Code, ANSI Z223.1/
NFPA 54 et (ou) aux codes d’installation
CAN/CSA-B149.1. Si la grosseur d’une
section du système d’évacuation doit
être modifiée, le système devrait être
modifié pour respecter les valeurs
minimales des tableaux pertinents de
l’appendice F du National Fuel Gas Code,
ANSI Z223.1/NFPA 54 et (ou) des codes
d’installation CAN/CSA-B149.1.
CAUTION
Approved vent systems rely on gaskets for proper
sealing. Take the following precautions:
• Make sure that gasket is in position and
undamaged in the female end of the pipe.
• Make sure that both the male and female pipes
are free of damage prior to assembly.
• After making the vent adapter connection,
only cut vent pipe as permitted by the vent
manufacturer in accordance with their
instructions. When pipe is cut, cut end must be
square and carefully deburred prior to
assembly.
!
Figure 7-10: Installation of Vent Adapter
3. Vent System Assembly
A. General Assembly Notes:
i. Where the use of “silicone” is called for in the
following instructions, use GE RTV 106 for the
vent adapter.
ii. Longitudinal welded seams should not be
placed at the bottom of horizontal sections of
exhaust pipe.
iii. Do not drill holes in vent pipe.
iv.Do not attempt to mix vent components of
different vent system manufacturers.
v. In some cases, there are differences
between the vent system installation
instructions in this manual and those in
the vent system manufacturer’s manual.
Where such differences exist, this manual
takes precedence over the vent system
manufacturer’s manual.
B. Vent Adapter Installation – The vent adapter is
shipped loose. Mount the vent adapter to the
fan outlet on the boiler as shown in Figure 7-10
using the two stainless steel screws provided.
C. Connection of Vent Pipe to Vent Adapter
i. If using Heat Fab Saf-T- Vent, cut the
spigot off of the first piece of pipe using
a sharp pair of aviation snips, an
abrasive cut-off, or a plasma cutter. The male
end of the pipe made by other vent system
manufacturers should slip into the vent
adapter without modification.
ii. Remove the hose clamp shipped on the
vent adapter. Bend the three hose clamp
tabs on this adapter outward slightly.
iii. Clean the exterior of the male end of the
first piece of pipe and the inside of the vent
adapter on the boiler with an alcohol pad.
7B Removing Boiler From Common Chimney (continued)