Dunkirk DKVLT-050 Instruction manual

WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company P/N# 240008888, Rev. F [01/2012]
Models
DKVLT-050
DKVLT-075
DKVLT-100
DKVLT-150
DKVLT-200
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com

2
(C)
DIMENSIONS
FIGURE 1-1 Dimensions
(D)
Wall Hanging
Bracket
(D)
(A)
(F)
Vent Connector
Combustion Air
Safety Relief
Valve
Connection
(¾ NPT)
(B)
Condensate Drain Connection (H)
Return Water (E)
Supply Water (E)
Gas Connection (G)
(I) (J)
Table 1 : Physical Data
Models 050/075/100 150/200
Width (A) 20"
(508mm)
23"
(584mm)
Height (B) 31"
(787mm)
42"
(1092mm)
Depth (C) 14"
(356mm)
16.0"
(406mm)
Bracket (D) 28"
(711mm)
40"
(1016mm)
Water
Connections
Location
(I) 2"
(51mm) 2" (51mm)
Size (E) 1-1/4" NPT
1-1/4" NPT
Gas
Connection
Location
(J) 4-1/2" (114mm) 4-1/2" (114mm)
Size (G) 1/2"
NPT
3/4"
NPT
Condensate Drain
Connection (H) 3/4" NPT
3/4" NPT
Weight Shipping 111 lb
(50 kg) ~182 lb (83 kg)
Unit 91 lb
(41 kg) ~157 lb (71 kg)
Vent Connector 2"
(51mm) 3" (76mm)

3
1 - Introduction............................................................................................................................... 4
2 - Important Safety Information....................................................................................................5
3 - Component Listing .....................................................................................................................6
4 - Locating Boiler...........................................................................................................................9
5 - Hydronic Piping........................................................................................................................11
5.2 Special Conditions................................................................................................................... 11
5.3 Safety Relief Valve and Air Vent .... ............................................................................................11
5.4 Trim Piping............................................................................................................................. 12
5.5 System Piping......................................................................................................................... 12
6 - Combustion Air And Vent Piping...............................................................................................17
6.2 Removal of Existing Boiler From Common Vent System..................................................................17
6.3 Materials ............................................................................................................................... 17
6.4 Pipe Installation...................................................................................................................... 18
6.5 Termination............................................................................................................................ 18
6.6 Condensate Piping................................................................................................................... 24
7 - Gas Supply Piping ....................................................................................................................25
8 - Electrical Connections..............................................................................................................27
8.3 Line Voltage Connections.......................................................................................................... 27
8.4 External Connections............................................................................................................... 27
9 - Start Up Procedure...................................................................................................................29
9.6 CSD-1 Compliance Test.............................................................................................................32
10 - Operating Instructions............................................................................................................34
11 - General Maintenance And Cleaning........................................................................................ 35
12 - Ratings And Capacities...........................................................................................................38
13 - Troubleshooting..................................................................................................................... 39
14 - Wiring Diagram......................................................................................................................53
15 - Glossary.................................................................................................................................55
Appendix A - Control Module .........................................................................................................57
1.1 Introduction ........................... ............................................................................................... 57
1.2 Operation............................... ............................................................................................... 57
1.3 Status Indication..................... ............................................................................................... 57
1.4 Sequence of Operation............. ............................................................................................... 58
1.5 Theory of Operation................. ............................................................................................... 60
TABLE OF CONTENTS
Check our website frequently for updates: www.ecrinternational.com
Information and specifications outlined in this manual in effect at the
time of printing of this manual. ECR International reserves the right to
discontinue, change specifications or system design at any time without
notice and without incurring any obligation, whatsoever.

4
1.1 Designated Use
Hot water heating boiler.•
Indoor installation.•
Closet or alcove installation.•
Direct vent boiler.•
For use with natural gas or liquefied petroleum gases• (LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
Exceed 50 psig (344 kPa) system pressure.•
Exceed 195°F (90.5°C) system design temperature.•
1.3 Operational Features
Modulating: 20-100%.•
Integral Dual Limit.•
Integral Low Water Cutoff (with test button).•
Outdoor Temperature Reset.•
Integral Multiple Boiler Control.•
1 - INTRODUCTION

5
2.3 Installation shall conform to requirements
of authority having jurisdiction or in absence of
such requirements:
National Fuel Gas Code, ANSI Z223.1/NFPA 54• .
National Electrical Code, NFPA 70.•
2.4 Where required by authority having
jurisdiction, installation shall conform to
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
Additional manual reset low water cutoff may be required.
2.5 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
limited to:
Installation by licensed plumber or gas fitter.•
NOTICE
Used to address practices not related to personal
injury.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you to
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
following this symbol to avoid possible injury or death.
2.2
2.2
Become familiar with symbols identifying
Become familiar with symbols identifying
potential hazards.
potential hazards.
2.1 General
Boiler installation shall be completed by qualified agency.
See glossary for additional information.
WARNING
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
!
2 - IMPORTANT SAFETY INFORMATION

6
3.1 Component Listing
User Interface 1. (see Appendix A) - Displays
information regarding boiler condition. Allows
adjustment of boiler operating parameters. NOTE: Does
not replace thermostat used to control central heating
space.
Combustion Air Inlet (2"/3" )
2. (see page 7 & 8)
Return Water From Heating System (In)
Return Water From Heating System (In) 3.
(see
(see
page 8)
page 8)
-
-
Connection supplied at bottom of boiler.
Connection supplied at bottom of boiler.
Low Voltage Terminal Strip
Low Voltage Terminal Strip 4.
(see page 8) -
(see page 8) -
Connection of all low voltage wiring, including
Connection of all low voltage wiring, including
thermostat. See section
thermostat. See section
8.
8.
Igniter 5. (see page 8)
Flame Sensor 6. (see page 8)
Sight Glass 7. (see page 8) - Permits observation of
burner flame.
Burner 8. (see page 35)
Heat Exchanger 9. (see page 8)
Condensate Collector 10. (see page 8)
Return Temperature Sensor 11. (not shown)
Drain Valve 12. (see page 12)
Heat Exchanger Ball Valve 13. (see page 8)
Supply Water Outlet to Heating System (Out) 14.
(see pages 8) - Connections supplied for connecting
from bottom of boiler. See section 5.
Vent Temperature Sensor 15. (see page 8)
Condensate Drain 16. (see page 8) - Boiler produces
a liquid (condensate) as a by-product of combustion.
Condensate must be piped to appropriate drain. See
section 6.
Heat Exchanger Pump
Heat Exchanger Pump 17. (see page 8)
Gas Shutoff Valve
Gas Shutoff Valve 18. (see page 8)
- Fuel supply isolation
- Fuel supply isolation
during servicing. See section 7
during servicing. See section 7
Combustion Air Blower
Combustion Air Blower 19. (see page 8)
- Delivers
- Delivers
proper quantity of combustion air, receives fuel from
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
gas valve, mixes air and fuel sending mixture to burner
for combustion.
for combustion.
Gas (Control) Valve
Gas (Control) Valve 20. (see page 8)
- Delivers
- Delivers
proper quantity of fuel to Combustion Air Blower.
proper quantity of fuel to Combustion Air Blower.
See section 7.
See section 7.
High Temperature Supply Switch
High Temperature Supply Switch 21. (see page 8)
Low Water Cutoff
Low Water Cutoff 22. (see page 8)
-
-
Senses inadequate
Senses inadequate
quantity of water. Turns off boiler before damage can
quantity of water. Turns off boiler before damage can
occur.
occur.
Safety Relief Valve 23. (see pages 7 & 8) - Factory
supplied, Field installed. See section 5.
High Voltage Junction Box 24. (see page 8) - For
connection of 120V components. See section
8
8.
Vent Connector 25. (see pages 7 & 8) - See section 6.
Gas Connection
Gas Connection 26. (see page 8)
- See section 7.
- See section 7.
Wall Hanging Support Bracket
27. (see page 7) -
Integral to boiler. Allows wall mounting when used
with supplied wall mounting bracket. See section 4.
Service Switch 28.
(see page 7)
(see page 7)
Air Vent 29. (see page 7 & 8)
Control Module
Control Module 30. (see page 8)
Lower Jacket Panel 31. (see page 7) - Gently pull upward
then forward to access.
Transformer 32. (see page 8) - Supplies 24V power to low
water cutoff.
Pressure Test Port 33. -(see page 8)
Combustion Analysis Test Port 34. - (see page 8)
Return Water Sensor 35. (see page 8)
User Interface - 36. (see page 7)
3 - COMPONENT LISTING

7
3 - COMPONENT LISTING
FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)
VENT CONNECTOR
NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions
COMBUSTION
AIR INLET
SAFETY RELIEF VALVE
SAFETY RELIEF VALVE
AIR VENT
AIR VENT
WALL HANGING
WALL HANGING
SUPPORT
SUPPORT
BRACKET
BRACKET
FIGURE 3-3 Upper and Lower Jacket Latch
(Viewed from front of boiler)
Upper and Lower
Jacket Latch Lift Jacket up,
engage jacket with chasis
push down.
FIGURE 3-2 Lower Jacket (Viewed from front of
boiler)
Disconnect connector
before removing Lower
Jacket
Lower Jacket
Connector to User
Interface
User Interface
Service Switch

8
3 - COMPONENT LISTING
FIGURE 3-4 Boiler Components (View from Front of Boiler)
GAS SHUTOFF
GAS SHUTOFF
VALVE
VALVE
(SHOWN IN OPEN
POSITION)
VENT CONNECTOR
COMBUSTION
COMBUSTION
AIR
AIR
BLOWER
BLOWER
GAS (CONTROL)
GAS (CONTROL)
VALVE
VALVE
LOW WATER
LOW WATER
CUTOFF
CUTOFF
HIGH TEMPERATURE
SUPPLY SWITCH
SAFETY RELIEF VALVE
SAFETY RELIEF VALVE
AIR VENT
AIR VENT
COMBUSTION
AIR INLET
NOTE:
See Section 5
For Piping
Instructions
HEAT EXCHANGER
HEAT EXCHANGER
PUMP
PUMP
HEAT
HEAT
EXCHANGER
EXCHANGER
CONDENSATE
COLLECTOR
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
SUPPLY WATER TO
SUPPLY WATER TO
HEATING SYSTEM
HEATING SYSTEM
(OUT)
(OUT)
LOW VOLTAGE
LOW VOLTAGE
TERMINAL STRIP
TERMINAL STRIP
CONTROL
MODULE
Fuse and
Holder
IGNITER
IGNITER
FLAME
SENSOR
SIGHT
SIGHT
GLASS
GLASS
GAS CONNECTION
GAS CONNECTION
CONDENSATE
CONDENSATE
DRAIN
DRAIN
COMBUSTION
COMBUSTION
ANALYSIS TEST
ANALYSIS TEST
PORT
PORT TRANSFORMER
HIGH VOLTAGE
HIGH VOLTAGE
JUNCTION BOX
JUNCTION BOX
HEAT EXCHANGER
HEAT EXCHANGER
BALL VALVE
BALL VALVE
RETURN WATER
SENSOR (Located
behind piping)
VENT TEMPERATURE
SENSOR (Located
behind gas line)
PRESSURE
TEST PORT

9
4 - LOCATING BOILER
FIGURE 4-1 Clearance to Combustible Materials
4.1 Boiler Location Considerations
Ambient room temperature always above 32°F (0°C) to• prevent freezing of liquid condensate.
Approved for installation in closets.•
Protect gas ignition system components from water• (dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap, control
replacement, etc.).
Wall mounting.•
Wall must be plumb and capable of supporting boiler• weight plus 60 lbs (28 kg). See Table 1.
Wall mounting. See section 4.2.•
Access to outdoors to meet minimum and maximum• pipe lengths for combustion air and vent piping. See
section 6.
Disposal of condensate. See section 6.•
Drainage of water (or water - antifreeze solution) during• boiler service or from safety relief valve discharge. See
section 5.
Access to system water piping, gas supply, and electrical• service. See sections 5, 7 and 8.
Clearances to combustible materials and service• clearances. See Table 2 and figure 4-1.
Multiple Boilers can be wall mounted, placed side by• side, or back to back.
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Model
Model 050/075/100/
150/200 050/075/100/ 150/200
Top (A)
Top (A) 0" (0 cm) 14" (36 cm)
Left Side (B)
Left Side (B) 0" (0 cm) 0" (0 cm)
Right Side (C)
Right Side (C) 0" (0 cm) 0" (0 cm)
Front (D)
Front (D) 0" (0 cm) 6" (16 cm)
Back (E)
Back (E) 0" (0 cm) 0" (0 cm)
Bottom (F)
Bottom (F) 0" (0 cm) 12" (32 cm)
Combustion Air/Vent
Combustion Air/Vent
piping
piping
0" (0 cm) 6" (16 cm)
Hot Water Piping
Hot Water Piping ½" (1.3 cm) 6" (16 cm)
(1) Required distances measured from boiler.
(2) Service, proper operation clearance recommendation.
A
E
ED
A
C
B
A
FLOOR
FLOOR
A
D
FF
F
F

10
4.2 Prepipe supply and return water connections with
factory fittings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included
with unit.
Structure must be capable of supporting boiler weight• plus 60 lbs (28 kg). See Table 1, page 2.
Wall mount bracket has 4 slots allowing mounting on• two (2) wall studs spaced at 11½" to 16½" on center.
See figure 4-2.
Boiler includes (4) 3/8" x 3" lag screws and (4) washers• for attaching wall mount bracket to wood studs. Field
source appropriate fasteners for other wall constructions
(masonry, concrete).
Attach wall mount bracket level on wall.•
Boiler must engage with wall mount bracket.•
Avoid overhang on sides of wall mount bracket. Verify• boiler bracket is centered on wall bracket. See figure
4-2.
4 - LOCATING BOILER
FIGURE 4-2 Wall Mount Bracket Engaged with
Bracket on Boiler
Center brackets. Avoid
overhang on sides of wall
mount bracket.
CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.
!
!
4 Slots for attaching Wall
Mount Bracket to Studs

11
5.1 General
Install piping in accordance with authority having jurisdiction.•
NOTICE
Use two (2) wrenches when tightening and fitting
to pipe boiler's threaded fittings. Boiler's internal
piping can be damaged if subjected to excessive
torque.
Support system piping and safety relief valve discharge• piping. Boiler's internal piping and wall mount bracket can
be damaged if subjected to excessive weight.
Size central heating pump (and domestic hot water pump,• if used) for system requirements only. Heat exchanger
pump compensates for pressure drop through boiler
internal piping and heat exchanger.
Thoroughly clean and flush system before connecting to• boiler.
5.2 Special Conditions
System piping exposed to freezing conditions: Use• inhibited proplyene glycol solutions certified by fluid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
Boiler installed above radiation level (or as required by• authority having jurisdiction). Integral low water cutoff
provided in boiler. See page 6.
Boiler used in connection with refrigeration system.• Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
System piping connected to heating coils located in air• handling unit exposed to refrigerated air circulation.
Install flow control valves or other automatic means to
prevent gravity circulation of boiler water during cooling
cycle.
5.3 Safety Relief Valve and Air Vent
NOTICE
Boiler rated at 50 psig (345 kPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. Field source
safety relief valve for system pressures greater than
30 psig (206 kPa). Temperature Pressure Gauge
and Air Vent satisfactory for 30-50 psig (206-345
kPa) operation.
Install safety relief valve and air vent using pipe fittings• provided with boiler. See figure 5-1
Install safety relief valve with spindle in vertical position.•
Do not install shutoff valve between boiler and safety• relief valve.
WARNING
Poison hazard. Ethylene glycol is toxic. Do not use• ethylene glycol.
Never use automotive or standard glycol antifreeze,• even ethylene glycol made for hydronic systems.
Ethylene glycol can attack gaskets and seals used in• hydronic systems.
Use only inhibited proplyene glycol solutions certified• by fluid manufacturer as acceptable for use with closed
water heating system.
Thoroughly clean and flush any system that used glycol• before installing new Boiler.
Provide user with Material Safety Data Sheet (MSDS)• on fluid used.
!
5 - HYDRONIC PIPING
NOTICE
Do not expose boiler and condensate piping to
freezing temperatures.
FIGURE 5-1 Safety Relief Valve & Air Vent (View
from front of boiler)
Air Vent
3/4" x 1/4" NPT
90° Elbow
Safety Relief
Valve
3/4"F x 3/4"M
NPT Tee
3/4" NPT
Close Nipple
3/4 NPT
Position Air Vent and Safety Relief Valve
to provide space for discharge piping.

12
Install discharge piping from safety relief valve. See• figure 5-2.
Use ¾" or larger pipe.•
Use pipe suitable for temperatures of 375°F (191°C)• or greater.
Individual boiler discharge piping shall be independent• of other discharge piping.
Size and arrange discharge piping to avoid reducing• safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
Run pipe as short and straight as possible to location• protecting user from scalding and properly drain
piping.
Install union, if used, close to safety relief valve outlet.•
Install elbow(s), if used, close to safety relief valve• outlet and downstream of union (if used).
Terminate pipe with plain end (not threaded).•
5.4 Trim Piping
Temperature - Pressure Gauge. Install temperature• pressure gauge using nipple, tee and bushing provided
with boiler. See figure 5-3.
Drain Valve. Install drain valve using nipple, tee and• bushing provided with boiler. See figure 5-3.
5.5 System Piping
Systems with automatic fill valves require back flow• prevention device.
Single boiler system. See figures 5-4, 5-5, 5-6, 5-7 for• general guidance. Additional considerations:
Control system designed for single central heating• pump. Installer responsible for integration of
multiple central heating pumps.
Control system allows domestic hot water• prioritization. Function could be lost if central
heating pump not directly connected to control
system.
Multiple boiler system. See figure 5-8 for general• guidance. Additional considerations:
Control system requires equivalent water• temperatures entering each boiler to properly
sequence and adjust system supply temperature.
Install multi boiler sensor kit. See "Parts, Kits &• Optional Accessories" manual for part number.
5 - HYDRONIC PIPING
FIGURE 5-3 Temperature Pressure Gauge and
Drain Valve Installations
Temperature Pressure
Gauge shown at
System Supply
Connection
Check Local Codes
For Maximum
Distance To Floor
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
FIGURE 5-2 Safety Relief Valve Discharge Piping
Drain Valve shown
at System Return
Connection to Boiler
Safety Relief Valve
Gas Supply

13
Piping Legend
FIGURE 5-4 System Piping
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping
concept only. Installer responsible for all equipment
and detailing required by authority having
jurisdiction.
Check Local Codes
For Maximum
Distance To Floor
System
Return
System
Supply
FLOOR
Safety Relief Valve

14
5 - HYDRONIC PIPING
5-5 TWO-PIPE ZONED SYSTEM WITH VALVES
5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS
Heat exchanger
ball valve open
(as shipped)
Heat exchanger
ball valve open
(as shipped)
DHW
Pump
CH/System
Pump
DHW
Pump
Zone
Pump
3/8"/10mm
Open End
Wrench
3/8"/10mm
Open End
Wrench

15
5 - HYDRONIC PIPING
5-7A SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
12"/305mm Max. apart
12"/305mm
Max. apart
Limit length
to
5'/1.6 m
CH/System
Pump
Heat exchanger
ball valve open
Heat exchanger
ball valves closed 3/8"/10mm Open
End Wrench
5-7B SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
CH/System
Pump
12"/305mm
Max. apart
12"/305mm Max. apart
Existing closely spaced tees
in primary system loop
Limit length
to
5'/1.6 m
3/8"/10mm Open
End Wrench
Existing closely spaced tees
in primary system loop

16
5 - HYDRONIC PIPING
5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)
CH/
System
Pump 12"/305mm Max. apart
System
Temperature
Sensor
Size common piping
according to
maximum heat
capacity of
entire system
Up to 16
boilers
All heat exchanger
ball valves closed
3/8"/10mm Open
End Wrench
DHW
Pump
(See Multiple Boiler Guide)

17
6.1 General
This boiler requires a dedicated direct vent system.
Install combustion air and vent piping in accordance
with these instructions, authority having jurisdiction,
and National Fuel Gas Code, ANSI 223.1/NFPA 54.
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common
Vent System
When existing boiler is removed from common venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall
be followed with each appliance remaining connected to
common venting system placed in operation, while other
appliances remaining connected to common venting system
are not in operation:
Seal any unused openings in common venting system.•
Visually inspect venting system for proper size and• horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
When practical, close all building doors, windows, and• all doors between space in which appliances remaining
connected to common venting system are located and
other spaces of building. Turn on clothes dryer and any
appliance not connected to common venting system.
Turn on exhaust fans, such as range hoods and bath-
room exhaust so they will operate at maximum speed.
Do not operate summer exhaust fan. Close fireplace
dampers.
Turn on appliance being inspected. Follow lighting• instructions. Adjust thermostat so appliances will operate
continuously.
Test for spillage at draft hood relief opening after 5• minutes of main burner operation. Use flame of match or
candle, smoke from cigarette, cigar or pipe.
Determine each appliance remaining connected to• common venting system properly vents when tested
as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition of use.
6 - COMBUSTION AIR AND VENT PIPING
Any improper operation of common venting system• should be corrected so installation conforms with National
Fuel Code, ANSI Z223.1/NFPA 54. When re-sizing any
portion of common venting system, common venting
system should be re-sized to approach minimum size as
determined using appropriate tables in Chapter 13 of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54.
6.3 Materials
See Table 3•
6.4 Pipe Installation
Table 3 - Combustion air and vent pipe fittings
must conform with the following:
Item Material Standards
Vent Pipe
and Fittings
PVC schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC schedule 40 ANSI/ASTM D1784/
F441
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40 ANSI/ASTM F628
Pipe
Cement/
Primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
IPEX is approved vent manufacturer in Canada listed• to ULC-S636.
IPEX System 636 Cements and Primers are approved• in Canada listed to ULC-S636.
DO NOT USE CELLULAR (FOAM) CORE PIPE
WARNING
Use of cellular core PVC for venting flue gas could
result in death, serious injury.
!

18
6 - COMBUSTION AIR AND VENT PIPING
WARNING
Vent extending through exterior wall shall not
terminate adjacent to wall or below building
extensions such as eaves, balconies, parapets or
decks. Failure to comply could result in death or
serious injury.
!
Minimum and maximum combustion air and vent pipe• lengths listed in Table (4). Pipe length counted from
combustion air connector to termination.
Install field-sourced 2" to 3" transition, if used, in vertical• section at combustion air inlet and vent connector.
90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows• equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length.
Slope vent pipes minimum 1/4" per foot (21 mm/m)• back toward boiler. Support horizontal sections to
prevent sags capable of accumulating condensate.
Support piping in accordance with pipe manufacturer's• instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2m) or less. Allow for
expansion/contraction of pipe.
Combustion air and vent piping must be air tight and• water tight.
Certified vent system components must NOT be• interchanged with other vent systems or unlisted pipe/
fittings.
6.5 Termination
Terminate combustion air and vent pipes with fittings or• concentric vent kit.
See "Parts, Kits and Optional Accessories" manual• for concentric vent kit part numbers.
Use horizontal pipe for vent and 90° elbow for• combustion air termination when using fittings.
Terminate combustion air and vent pipes in same• atmospheric pressure zone through exterior sidewall or
roof.
Locate combustion air termination as far as possible• from swimming pool, swimming pool pump house, and
other sources of airborne chlorine.
Locate combustion air and vent terminals as required by• authority having jurisdiction.
6.6 Condensate Piping
Combustion Air and Vent Pipe Equivalent Length
2” Pipe 3” Pipe
Model 050 075/100 075/100 150/200
Min. 6 ft.
(1.8 m) 6 ft. (1.8 m) 6 ft. (1.8 m) 6 ft. (1.8 m)
Max. 100 ft.
(30.5 m) 50ft. (15.2 m) 100 ft. (30.5 m) 100 ft. (30.5 m)
1 - 90° elbow = 5 ft (1.6 m)
1 - 45° elbow = 3.5 ft (1.1 m)
1- 2" x 3" adapter = 0 ft (0 m)
Note: Concentric Vent Kit=5 ft (1.6m) equivalent length
Table 4 - Combustion Air and Vent Piping Length
For Example: Boiler can be installed on outside wall and vented with
1-90° elbow and 1 ft (0.30 m) of vent pipe.

19
6 - COMBUSTION AIR AND VENT PIPING
Side Wall
Terminations
y3" (8 cm) Minimum horizontal
separation between combustion air
intake and vent terminations.
y8" (21 cm) Minimum vertical
separation between combustion air
intake and vent terminations.
y12" (30 cm) Separation between
bottom of combustion air intake and
bottom of vent.
yMultiple terminations as shown in
6-1, 6-2, and 6-3 must be a minimum
of 12” (30 cm) horizontally between
vent of one termination and air intake
of next appliance.
yMaximum allowable total outside
exposure vent length equals 10 ft.
(3.05m).
yMaintain a pitch of 1/2" per ft.
(42mm/m) outside exposure back to
boiler to ensure proper condensate
drainage for horizontal runs.
Roof
Terminations
y3" (8 cm) Maximum horizontal
separation between combustion air
intake and vent of same appliance.
y8" (21 cm) Minimum vertical
separation between combustion
air intake and vent of different
appliances.
y15" (38 cm) Maximum horizontal
length of vent.
yMaximum vent/intake between
different appliances 12" (30cm).
yMaximum allowable total vertical
vent length with outside exposure is
10 ft.(3.05m).
yAbandoned unused masonry
chimney may be used as chaseway
for combustion air and vent. Both
combustion air and vent pipe must
exit above top of chimney with
clearances as shown in Figure 6-1.
12" (30 cm)
Minimum
8" (21 cm)
Minimum
15" (38 cm)
Maximum
3" (8 cm)
Maximum
Vent Combustion
Air
12" (30 cm)
Minimum above
anticipated snow line
Vent
3" (8 cm)
Minimum
separation
12" (30 cm)
Minimum from
overhang
12" (30 cm) Separation
between bottom of
combustion air intake
and bottom of vent
See snow & ice
page 23 Combustion Air
Vent
12" (30cm)
Minimum
separation
See snow & ice
page 23
FIGURE 6-1
FIGURE 6-2
FIGURE 6-3
Combustion Air
Roof Line

20
1"(2.54cm)
Maximum
Combustion
Air
Vent
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-4
Maintain 12"
clearance above
highest anticipated
snow level or grade
* See Note
Below
Vent
Combustion
Air
1" (2.54cm)
Maximum Roof overhang
36"(0.9m) Minimum
Maintain 12"(30cm)
clearance above highest
anticipated snow level or
grade
12" (30cm) Minimum
FIGURE 6-5
*Must be less than 4" or greater than 24" Horizontal dis-
tance between end bells of each air intake to prevent flue
gas recirculation.
FIGURE 6-7
46-3/4" (1.2 m)
Vent
Combustion Air
1"(2.54cm)
Maximum
**See
Note
*2 or 3" (5.0 or 7.6cm) Diameter
PVC intake/combustion air
Elbow field
supplied
Combustion Air
Note: Securing strap must
be field installed to prevent
movement of termination
kit in side wall
*2" ( 5.0cm) Diameter = 41" Length (1.0m))
3" (7.6cm) Diameter = 47" Length (1.2m)
** Note Overall length may be modified by cutting or
extending both combustion air and vent pipes. 12" is
minimum allowable length and 60" is maximum allowable
length for this dimension. SDR-26 PVC (D2241) only may
be used for extending pipes. Do not use Schedule 40 PVC
or use couplings to extend pipes. Dimension will change if
intake/vent pipes are lengthened or shortened.
1" (2.54cm)
Maximum
OD 3½" ( 8.9cm) - *2" ( 5.0cm) kit
OD 4½" (11.4cm) - 3" (7.6cm) kit
* Note: 2" For use with models 050/075/100.
3" For use with models 075/100/150/200