Dunkirk PVWB User manual

1
DUNKIRK BOILERS
DUNKIRK, NEW YORK 14084 • AREA CODE 716 366-5500
MEMBER: The Hydronics Institute
INSTALLATION INSTRUCTIONS
These instructions must be affixed on or adjacent to the boiler
Warning: Improper installation, adjustment, alteration, service or maintenance can cause injury or
property damage. Refer to this manual. For assistance or additional information consult a qualified
installer, service agency or the gas supplier
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These Gas-Fired Water Boilers are low pressure, sectional
cast iron boilers Designed Certified by C.S.A. (Canadian
Standards Association) for use with Natural and Propane
Gases. Theyareconstructedandhydrostaticallytestedfora
maximum working pressure of 50 psi (pounds per square
inch) in accordance with A.S.M.E. (American Society of
Mechanical Engineers) Boiler and Pressure Vessel Code
Section IV Standards for cast iron heating boilers.
MODEL PVWB
Continuous Pilot
MODEL PWB
Electronic
Intermittent Ignition
PLPL
PLPL
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SERIES 2

2
New York City MEA Number 39-86-E Vol. IV.
TheRatingsmarked“Net1=B=RRatings” indicate the amount
of remaining heat input that can be used to heat the radiation
orterminalunits. The Net 1=B=R Ratings shownarebasedon
an allowance of 1.15 in accordance with the factors shown on
the 1=B=R Standard as published by The Hydronics Institute.
Selection of boiler size should be based upon “Net 1=B=R
Rating” being equal to or greater than the calculated heat loss
of the building.
Themanufacturershouldbeconsulted before selectingaboiler
forinstallationshavingunusualpipingand pickuprequirements.
These boilers must stand on a non-combustible floor. If in
Boiler Ratings and Capacities
Electronic Ignition Continuous Pilot NO. OF AGA/CG
A
HEATING NET I=B=R
With With SECTIONS INPUT CAPACITY RATING FLUE "A"
V
ent Dampe
r
V
ent Dampe
r
*MBH *MBH *MBH DIAMETER WIDTH
PWB-2D PVWB-2D 2 37.5 30 26 4‡ 8
PWB-3D PVWB-3D 3 70 57 50 5 11¼
PWB-4D PVWB-4D 4 105 85 74 6 14½
PWB-5D PVWB-5D 5 140 113 98 6 17¾
PWB-6D PVWB-6D 6 175 142 123 7 21
PWB-7D PVWB-7D 7 210 170 148 7 24¼
PWB-8D PVWB-8D 8 245 198 172 7 27½
PWB-9D PVWB-9D 9 280 226 197 7 30¾
BASIC BOILER UNIT NO. DIMENSIONS
(Inches)
NATURAL AND PROPANE GAS
GAS-FIRED HOT WATER BOILERS
* MBH = 1,000 Btuh = British Thermal Unit Per Hour
Boilers are equipped for altitudes up to 2,000 feet only
U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each 1,000 feet above sea level.
Canada Only - Boilers may be used at high altitude by using a certified field conversion kit, resulting in a 10% derate.
+ Heating Capacity based on D.O.E. (Department of Energy) test procedure. Add 5½” to height when vent damper is used.
‡ 2 section boilers are equipped with a 3” diameter flue collar on the draft diverter, and use a furnished 3” x 4” increaser fitting to install
the furnished 4” vent damper.
stalled on a combustible floor, use Combustible Floor Base
Number 42135-1 or 146-14-031 (2-6 section boilers) or
42135-2 or 146-14-032 (7-9 section boilers).
BOILERS FOR USE AT HIGH ALTITUDE
This boiler is factory equipped for use at altitudes of 0-2,000
feet above sea level. For use at altitudes above 2,000 feet
above sea level, the input ratings are reduced by a change in
main burner orifice size.
U.S.A. Only - For altitudes above 2,000 feet above sea
level, input ratings should be reduced at the rate of 4% for
each 1,000 feet above sea level. Consult the National Fuel
FIG. 1

3
Before You Start
Installers - Follow local regulations with respect to
installation of CO detectors. Follow maintenance
recommendations in this instruction manual.
Techniciens - Veuillez vous conformer a la
réglementation en vigueur concernant I’ installation des
détecteurs d’oxyde de carbone. Suivre les consignes
d’entretien figurant dans le manuel dínstruction ci-joint.
KEEP BOILER AREA CLEAN AND FREE FROM COMBUSTIBLE MATERIALS,
GASOLINE AND OTHER FLAMMABLE VAPORS AND LIQUIDS
Gas Code (NFPA54/ANSI Z223.1-latest edition), or the
manufacturer for correct orifice sizing information. High
altitude orifices are available from the boiler manufacturer.
Canada Only - For altitudes in the range of 2,000-4,500
feet above sea level, boilers may be field equipped for use
at high altitude by using a certified field conversion kit. The
change in main burner orifice size results in the boiler’s
input rating being reduced by 10%. The conversion shall
be carried out by a manufacturer’s authorized
representative, in accordance with the requirements of the
manufacturer, provincial or territorial authorities having
jurisdiction and in accordance with the requirements of the
CSA-B149.1 and CSA-B149.2 Installation Codes. The
certified field conversion kit includes a conversion data
plate, which must be attached to the boiler adjacent to the
rating plate, indicating that the boiler has been converted
for high altitude use. The conversion data plate must be
filled in with the correct conversion information.
Check to be sure you have the right size boiler before starting
the installation. _ See rating and capacity table on previous
page. Also be sure the new boiler is or the type of gas you are
using. Check the rating plate on the right side of the boiler.
You must see that the boiler is supplied with the correct type
ofgas,fresh air forcombustion,andasuitable electrical supply.
Also,theboilermustbe connected to a suitable venting system
andanadequatepipingsystem.Finally,athermostat,properly
located, is needed for control of the heating system. If you
have any doubts as to the various requirements, check with
local authorities and obtain professional help where needed.
Take the time to complete all of the steps for SAFE and
PROPER operation of the heating system.
If this boiler is installed in a building under construction,
special care must be taken to insure a clean combustion
air supply during the construction process. Airborne
particulates such as from drywall dust and from fiberglass
insulation can clog the burner ports and cause incomplete
combustion and sooting.
Where required by the authority having jurisdiction, the
installation must conform to American Society of Mechanical
Engineers Safety Code for Controls and Safety Devices for
Automatically Fired Boilers, No. CSD-1.
The installation must conform to the requirements of the
authority having jurisdiction or, in the absence of such
requirements, to the National Fuel Gas Code, ANSI Z223.1-
latest revision.
In Canada, the boiler shall be installed according to CSA-
13149.1 and .2, Installation Code for Gas Burning
Appliances and Equipment.

4
Locating the Boiler
1. Select level location as centralized with piping system, and
as near chimney, as possible.
2. Place crated boiler at selected location, remove crate
by pulling crate sides from top and bottom boards.
Combustible floors: When boiler is to be installed on a
combustible floor, a Special Base Plate must be used -
146-14-031 (2-6 Section) or 146-14-032 (7-9 Section).
This boiler must not be installed on carpeting.
3. Boiler is to be level. Metal shims may be used under
base legs for final leveling.
4. Additional clearances for service may exceed clearances
for fire protection. Always comply with the minimum fire
protection clearances shown on the boiler. An 18 inch
clearance should be maintained on any side where
passage is required to access another side for cleaning,
servicing, inspection or replacement of any part that may
need attention. An 18-inch clearance is recommended
on the control side for servicing.
Figure 2 shows minimum clearances to combustible
construction. Rooms that are large in comparison with
the size of the boiler are defined as rooms having a
volume equal to or greater than 16 times the volume of
the boiler. Where the actual ceiling height of a room is
greater that 8', the volume of a room shall be figured on
the basis of a ceiling height of 8'. Determination of room
size should be based do the total volume of all gas fired
equipment installed in the room. Consult section 6.3.1
of the National Fuel Gas Code for further information,
including approved methods for reducing clearances in
large rooms.
5. Equipment shall be installed in a location in which the
facilities for ventilation permit satisfactory combustion
of gas, proper venting, and maintenance of ambient
temperature at safe limits under normal conditions of use.
Equipment shall be located so as not to interfere with
proper circulation of air. When normal infiltration does
not provide the necessary air, outside air shall be
introduced (See Page 4 - “Fresh Air for Combustion”).
6. Advise owner to keep air passages free of obstructions.
Ventilating and combustion air must enter boiler room
without restrictions.
7. The boiler shall be installed such that the automatic gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during appliance operation
and service (condensate trap, control replacement, etc.).
2-5 SECT. 6-9 SECT. 2-9 SECT.
Top 6" 6" 6"
Rear 6" 6" 6"
Control Side 8" 24" 6"
Opposite Side 6" 24" 6"
Front 18" 18" 18"
Flue/Vent Connector 6" 6" 6"
Near Boiler Piping 1" 1" 1"
Alcove, or Room Not
Large in Comparison
With Boiler
Room Large In
Comparison
With Boiler
FIG. 2 - MINIMUM CLEARANCE DIMENSIONS
Minimum Room
Boile
r
Boile
r
V
olume Required
Size
V
olume To Be Large
(Cu. Ft.) Room (Cu. Ft)*
2 sect. 3.8 61.6
3 sect. 5.4 86.6
4 sect. 7.0 111.6
5 sect. 8.5 136.6
6 sect. 10.1 161.7
7 sect. 11.7 186.7
8 sect. 13.2 211.7
9 sect. 14.8 236.7
* FOR ROOM WITH SINGLE BOILER ONLY THIS UNIT MUST
BE SET ON A CONCRETE OR OTHER NON-COMBUSTIBLE
MATERIAL BASE OR FLOOR.

5
WARNING
Besuretoprovide enough fresh air for combustion. Enough
airinsuresproper combustion and assures that no hazard
will develop due to the lack of oxygen.
You must provide for enough fresh air to assure proper combustion. The
fireintheboilerusesoxygen.Itmusthave acontinuoussupply.Theairin
a house contains only enough oxygen to supply the burner for a short
time.Outsideairmustenterthehousetoreplacethatusedbytheburner.
Studyfollowingexamples1and2todetermineyourfreshairrequirements.
EXAMPLE1:BoilerLocatedin UnconfinedSpace
An unconfined space is defined as a space whose volume is not less
than 50 cubic feet per 1,000 Btu per hour of the total input rating of all
appliances installed in that space.
If your boiler is in an open area (unpartitioned basement) in a
conventionalhouse,the air that leaksthroughthecracksaround doors
and windows will usually be adequate to provide air for combustion.
The doors should not fit tightly. Do not caulk the cracks around the
windows.
Equipmentlocatedinbuildingsofunusuallytightconstruction shall be
providedwithairforcombustion,ventilation,and dilution of flue gases
using the methods described in example 2B or shall be specially
engineered. The authority having jurisdiction must approve specially
engineeredinstallations.
EXAMPLE 2: Boiler Located in Confined Space
A. All Air from Inside the Building: The confined space shall be
providedwith two permanentopeningscommunicatingdirectly with
an additional room(s) of sufficient volume so that the combined
volume of all spaces meets the criteria for an unconfined space.
The total input of all gas utilization equipment installed in the
combinedspaceshall beconsidered in making this determination.
Each opening shall have a minimum free area of one square inch
per 1,000 Btu per hour of the total input rating of all gas utilization
equipment in the confined space, but not less that 100 square
inches. One opening shall be within 12 inches of the top and one
within 12 inches of the bottom of the enclosure. The minimum
dimension of air openings shall not be less than 3 inches.
B. All Air from Outdoors: The confined space shall communicate
withtheoutdoors in accordance withmethods1or2.Theminimum
dimension of air openings shall not be less than 3 in. Where ducts
are used, they shall be of the same cross-sectional area as the
free area of the openings to which they connect.
1.Twopermanent openings,onecommencing within 12 inchesof
the top. and one commencing within 12 inches of the bottom,
of the enclosure shall be provided. The openings shall
communicate directly, or by the ducts, with the outdoors or
spaces(crawlorattic)thatfreelycommunicatewiththeoutdoors.
a) Where directly communicating with the outdoors or where
communicating to the outdoors through vertical ducts. each
opening shall have a minimum free area of 1 sq. in. per 4000
Btuperhourof totalinputratingofallequipmentintheenclosure.
(See Figure 3B)
b)Where communicatingwiththe outdoorsthrough horizontalducts.
each opening shall have a minimum free area of 1 sq. in. per
2000 Btu per hour of total input rating of all equipment in the
enclosure. (See Figure 38.)
Fresh Air for Combustion
NOTE
Ifyouusea fireplace or a kitchen or bathroomexhaust fan,
you should install an outside air intake. These devices will
rob the boiler and water heater of combustion air.
2. One permanent opening commencing with 12 inches of
the top of the enclosure, shall be permitted where the
equipment has clearance of at least 1 inch from the sides
andbackand 6 inches from the frontof theappliance. The
opening shall directly communicate with the outdoors or
shall communicate through a vertical or horizontal duct to
the outdoors or spaces (crawl or attic) that freely
communicate with the outdoor, and shall have a minimun
free area of:
a) 1 sq. inch per 3000 Btu per hour of the tatal input of all
equipment located in the enclosure ( See Figure 4), and
b)Notless than the sum of the areas ofall ventconnectors
in theconfined space.
Provision for combustion and ventilation air must be in accordance with Section 5.3, Air for Combustion and Ventilation,
of the National Fuel Gas Code, ANSI Z223.1-latest revision, or applicable provisions of the local building codes.
100% Free 75% Free 25% Free
Area Area Area
Fresh Air ¼" Wire Metal Wood
Duct Size Mesh Louvers Louvers
3" x 12" 144,000 108,000 36,000
8" x 8" 256,000 192,000 64,000
8" 12" 384,000 288,000 96,000
8½" x 16" 512,000 384,000 128,000
1 Square Inch per 4,000 Btuh
100% Free 75% Free 25% Free
Area Area Area
Fresh Air ¼" Wire Metal Wood
Duct Size Mesh Louvers Louvers
3" x 12" 72,000 54,000 18,000
8" x 8" 128,000 96,000 32,000
8" 12" 192,000 144,000 48,000
8½" x 16" 256,000 192,000 64,000
1 Square Inch per 2,000 Btuh
100% Free 75% Free 25% Free
Area Area Area
Fresh Air ¼" Wire Metal Wood
Duct Size Mesh Louvers Louvers
3" x 12" 108,000 81,000 27,000
8" x 8" 192,000 144,000 48,000
8" 12" 288,000 216,000 72,000
8½" x 16" 384,000 288,000 96,000
1 Square Inch per 3,000 Btuh
Figure 3A - FRESH AIR DUCT CAPACITIES (Btuh)
Figure 3B - FRESH AIR DUCT CAPACITIES (Btuh)
Figure 4 - FRESH AIR DUCT CAPACITIES (Btuh)

6
Installation - System Piping
1. Place boiler in the selected location (as near chimney as
possible.) Your boiler is shipped assembled. You need only
to install the Relief Valve and a drain line to carry any water
or steam to a drain.
2. Install Relief Valve into the 3/4" pipe on the top of the boiler.
See Figure 5. Use 3/4” Pipe and an elbow (not furnished) to
carry the water or steam to a nearby drain. Do not connect
directly to a drain but leave an air gap. No shutoff of any
description shall be placed between the safety relief valve
and the boiler, or on discharge pipes between such safety
valves and the atmosphere. Installation of the safety relief
valve shall conform to the requirements of the ANSI/ASME
Boiler and Pressure Vessel Code, Section IV. The
manufactureris notresponsibleforany waterdamage.Install
Drain Valve in lower left side of boiler as marked.
3.ConnectSupplyandReturnLinestoboiler.Theconnections
may require certain additional fittings and parts, as shown
on diagram (Figs. 5 and 6).
4. This boiler is equipped with 1 1/4" supply and return
connections on both the left and right sides of the boiler.
In connecting the cold water supply to the water inlet valve,
make sure that a clean water supply is available. When the
water supply is from a well or pump, a sand strainer should be
installed at the pump.
A hot water boiler installed above radiation level must be
equipped with a low water cutoff device. A periodic inspection
is necessary, as is flushing of float type devices, per
manufacturers specific instruction.
FOR USE WITH COOLING UNITS
A. This boiler, when used in connection with chilled water
systems,mustbe installed so that the chilledwater ispiped
in parallel with the heating boiler. Appropriate valves must
beused topreventthechilledwaterfromenteringtheheating
boiler (Fig. 6).
B. When this boiler is connected to heating coils located in air
handling units where they may be exposed to refrigerated
aircirculation,thepipingsystemshallbeequippedwithflow
control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
LOW DESIGN WATER TEMPERATURE
SYSTEMS (BELOW 140°)
If the boiler is to be used in a heating system where design
watertemperaturesbelow140°Fare desired (e.g. radiant floor
heating), a 3-way or 4-way mixing valve or suitable alternative
is required to prevent low temperature return water from
entering the boiler. Follow the mixing valve manufacturer’s
installation instructions.
The minimum design return water temperature to the boiler to
prevent condensation in the boiler and venting is 120° F. The
minimum high limit setting is 140° F.
CAUTION
THE ISOLATION BALL VALVES CONTAIN TEFLON
SEATSAND SEALS. OVERHEATING THISVALVE MAY
CAUSE PREMATURE FAILURE.
FIG. 5 - TYPICAL HOT WATER PIPING
FIG. 6 - CHILLED WATER PIPING

7
CHECK YOUR CHIMNEY
Thisis a very importantpart of your heatingsystem.It must be
clean, the right size, properly constructed and in GOOD
CONDITION. No boiler can function properly with a bad
chimney. Fig. 7 gives typical chimney sizes. Fig. 8 gives you
an idea how a boiler might be vented to a chimney. Note that
the height (HT) is measured from the vent pipe to the top.
CHIMNEY SIZING
Chimney sizing, and all other aspects of the vent installation
must be in accordance with Part 7 of the National Fuel Gas
Code, ANSI Z223.1 latest revision, and applicable provisions
of the local building codes.
In Canada, follow CAN/CGA B149.1 and B149.2, Installation
Codes for Gas Burning Appliances and Equipment.
CONNECTING THE VENT DAMPER AND VENT
CONNECTOR
RefertoFig.1 flue diagram for the size and location of thevent
(flue opening). Use a 28 gauge (minimum) galvanized pipe to
connect to the chimney.
IMPORTANT - Thedamperbladeonthefurnishedventdamper
has a 1/2 square inch hole (approximately3/4 diameter). On
boilersequippedwithstandingpilot,theholemust be left open.
On boilers equipped with intermittent ignition, the hole should
be plugged by using the plug supplied with the vent damper.
1.Position furnished vent damperontopof flue outlet collar.
Fasten damper securely to flue outlet collar with sheet
metal screws. Make sure damper blade has clearance to
operate inside of diverter.
On 2 section boilers equipped with vent damper, the
supplied 4-inch vent damper is equipped with a 3- to 4-
inch adapter so that the 4-inch vent damper may be
installed on the boiler’s 3-inch flue outlet collar. Fasten all
fittings securely.
As An Option (U.S.A. Only)
The damper may be installed in any horizontal or vertical
position, closer to the flue outlet collar preferred. Follow
the diagrams - Figures 9, 10 and 11.
2. Install the vent damper to service only the single boiler for
which it is intended. The damper position indicator shall
be in a visible location following installation. Locate the
damper so that it is accessible for servicing.
3. The damper must be in the open position when appliance
main burners are operating.
4. The boiler is equipped with a factory wired harness that
plugs into the vent damper.
5.Vent pipemustbe samesizeas theflueoutlet collar,except
2 section boilers with vent damper as noted above.
6. Slopepipeupfromboilertochimneynotlessthan1/4”perfoot.
Chimney and Vent Pipe Connection
For boilers for connection to gas vents or chimneys, vent installations shall be in
accordance with Part 7, Venting of Equipment, of the National Fuel Gas Code, ANSI
Z223.1-latest revision and applicable provisions of the local building codes.
7. Run pipe as directly as possible with as few elbows as
possible.
8. Do not connect to fireplace flue.
9. End of vent pipe must be flush with inside face of chimney
flue. Use a sealed-in thimble for the chimney connection.
10. Horizontal run should not be longer than 3/4 the
chimney height (HT) (Fig, 8).
The sections of vent pipe should be fastened with sheet metal
screwstomake the piping rigid. Horizontal portionsofthevent
system must be supported to prevent sagging. Use stovepipe
wires every 5' to support the pipe from above If the vent pipe
must go through a crawl space, double wall vent pipe should
be used Where vent pipe passes through a combustible wall
orpartition,use a ventilated metal thimble. Thethimble should
be 4 inches larger in diameter than the vent pipe.
Boiler Input *HT. *HT. *HT.
Btuh 10-15 Ft. 10-25 Ft. 25 Ft. UP
Up to 100,000 6 x 6 6 x 5 5 x 5
Up to 155,000 6 x 7 6 x 6 6 x 5
Up to 230,000 7 x 8 7 x 7 6 x 7
Up to 350,000 9 x 9 8 x 9 8 x 8
FLUE AREA IN INCHES
* HT = top of thimble to top of flue. See Fig. 8
For boiler input refer to table, page 2.
For information only - not meant to imply minimum sizes.
MINIMUM VENT PIPE CLEARANCE
Woodandothercombustiblematerialsmustnotbecloserthan
6" from any surface of single wall metal vent pipe. Listed Type
B vent pipe or other listed venting systems shall be installed in
accordance with their listing.
REMOVING EXISTING BOILER FROM
COMMON VENTING SYSTEM
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
thecommon ventingsystemplacedin operation, whiletheother
appliancesremaining connectedtothe commonventingsystem
are not in operation.
1. Seal any unused openings in the common venting system.
2. 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.
FIG. 7 - TYPICAL CHIMNEY SIZES

8
3.Insofaras is practical,closeallbuildingdoorsand 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.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5. Test for spillage at the draft hood relief opening after 5
minutesofmain burneroperation.Usetheflame of amatch
or candle, or smoke from a cigarette, cigar or pipe.
6. After it has been determined that each appliance remain-
ing connected to the common venting system properly
ventswhen testedasoutlinedabove, returndoorswindows,
exhaustfans,fireplace dampersandanyothergas-burning
appliance to their previous conditions 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-latest revision.
Whenresizingany portion of the common venting system,
thecommonventing system shouldberesizedtoapproach
the minimum size as determined using the appropriate
tables in Part 11 in the National Fuel Gas Code, ANSI
Z223.1-latest revision.
Vent Damper Operation
Ventconnectors serving appliancesvented by naturaldraft
shallnotbe connected into anyportionof mechanical draft
systems operating under positive pressure.
FIG. 9 FIG. 10
FIG. 8 TYPICAL MASONRY CHIMNEY REQUIREMENTS

9
FIG. 11
VENT DAMPER POSITION INDICATOR
NOTES FOR CANADA ONLY
1. Canadian Standard CAN1-2.28-M81 prohibits the use of
vent dampers on propane fired appliances equipped with
intermittent ignition.
2. In Canada, the vent damper must be attached directly to
the flue outlet collar, with the exception of the 2 section
boiler, where the 3- to 4-inch adapter is supplied with the
vent damper.
No other interconnectng pieces are allowed between the
boiler and the vent damper.
3. In Canada, vent dampers are not an option. Boilers are
either factory built for use with a vent damper and the vent
damper is supplied with the boiler, or they are factory built
for use without a vent damper. In the second case a vent
damper cannot be installed later.
TYPICAL INSTALLATION FOR VENT DAMPER
NOT CAUTION AND FOOTNOTES
1. Install the vent damper to service only the single
appliance for which it is intended. If improperly
installed, a hazardous condition, such as an explosion
or carbon monoxide poisoning, could result.
2. Do not install the vent damper on pipe curve.
3. Do not run wires near high temperature surfaces. Use
stand-off brackets if necessary.
Forsafe, efficientoperation,theventdamperandallflue product
carrying areas of the appliance must be checked annually by
you, with particular attention given to deterioration from
corrosion or other sources. If you see corrosion or other
deterioration,contact yourheatingcontractorfor repairs. Check
vent damper operation as follows:
1. Whenthe boilerisoff,check thattheventdamper positions
indicator points to the closed position, Fig. 11.
2. Turn the thermostat or controller up to call for heat and
check the vent damper indicator points to the open
position, Fig. 11.
3. Turn the thermostat or controller down again and check
that the damper position indicator returns to the closed
position.
MANUAL OPERATION OF THE VENT DAMPER
The vent damper may be placed in the open position to permit
burneroperationbyusingthe“HOLD DAMPER OPEN” switch,
located on the damper controller. The thermostat will control
the burner firing as before, while the damper will remain open.
DO NOT turn damper open manually or motor damage will
result. Setswitchto“AUTOMATICOPERATION” to close vent
damper during burner off cycle.
For further information, and for a vent damper troubleshooting
guide, refer to the manual that was packaged with the vent
damper.
The vent damper must be inspected at least once a year
by a trained, experienced service technician. The name of
the person who originally installed your vent damper is
shown on the installation label.

10
CHECK GAS SUPPLY
The gas pipe to your boiler must be the correct size for the
length of the run and for the total Btu per hour input of all gas
utilizationequipmentconnectedtoit.SeeFig.12fortheproper
size. Be sure your gas line complies with local codes and gas
company requirements.
Theboilerand its individual shutoffvalvemustbedisconnected
fromthe gas supply pipingsystemduringany pressure testing
ofthatsystemattest pressures in excess of 1/2 psig (3.5 kPa).
The boiler must be isolated from the gas supply piping system
by closing its individual manual shutoff valve during any pres-
sure testing of the gas supply piping system at test pressures
equal to or less than 1/2 psig (3.5 kPa).
CONNECTING THE GAS PIPING
Refer to Fig. 13 for the general layout at the boiler. It shows
the basic fittings you will need. The gas line enters the boiler
from the right side.
The following rules apply:
1.Useonlythosepipingmaterialsandjoiningmethodslisted
as acceptable by the authority having jurisdiction, or in
the absence of such requirements, by the National Fuel
Gas Code, ANSI 223.1-latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes for Gas
Burning Appliances and Equipment.
2. Use pipe joint compound suitable for LP gas on male
threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas controls.
5. Use two pipe wrenches when making the connection to
the gas valve to keep it from turning.
6. Install a manual shut-off valve in vertical pipe about 5
feet above floor.
7. Tighten all joints securely.
8. Propane gas connections should only be made by a
licensed propane installer.
9. Two-stage regulation should be used by the propane
installer.
10. Propane gas piping should be checked out by the
propane installer.
CHECKING THE GAS PIPING
Upon completion of piping, check immediately for gas leaks.
Openthe manual shut-offvalve.Testfor leaksbyapplyingsoap
suds(oraliquiddetergent)toeachjoint.Bubblesformingindicate
a leak. CORRECT EVEN THE SMALLEST LEAK AT ONCE.
WARNING
Never use a match or open flame to test for leaks.
Gas Supply Piping
FIG. 12 - GAS PIPE SIZES
Length of
Pipe - Ft. 1/2" 3/4" 1" 1¼"
20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
Length of
Pipe - Ft. 5/8" 3/4" 1/2" 3/4"
20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000
Copper Tubing* Iron Pipe
Pipe Capacity - Btu Per Hour Input
Includes Fittings
NATURAL GAS
PROPANE GAS
Pipe Capacity - Btu Per Hour Input
Includes Fittings
* Outside diameter
The lenght of pipe or tubing should be measured from the gas
meter or propane second stage regulator.
FIG. 13 - GAS PIPE SIZES

11
All electrical work must conform to local codes as well as the
National Electrical Code, ANSI/NFPA-70, latest revision. In
Canada,electricalwiringshall comply with the Canadian Elec-
trical Codes, CSA-C22.1 and.2.
ELECTRIC POWER SUPPLY
Run a separate 120 Voltcircuit from a separate overcurrent
protective device in the electrical service entrance panel.
This should be a 15 ampere circuit. Locate a shut-off switch
at the boiler. It must be turned off during any maintenance.
Connect 120 Volt power supply to aquastat terminals L1
(HOT) and L2.
The boiler, when installed, must be electrically grounded in
accordance with the requirements of the authority having ju-
risdiction or, in the absence of such requirements, with the
National Electrical Code, ANSI/NFPA No. 70-latest revision.
Run a 14 gauge or heavier copper wire from the boiler to a
grounded connection in the service panel or a properly driven
and electrically grounded ground rod.
WARNING
Turn off electric power at fuse box before making any line
voltage connections. Follow local electrical codes.
INSTALL YOUR THERMOSTAT
Thethermostat locationhasan importanteffectontheoperation
of your boiler system. BE SURE TO FOLLOW THE
INSTRUCTIONS INCLUDED WITH YOUR THERMOSTAT.
Locate the thermostat about five feet above the floor on an
inside wall. It may be mounted directly on the wall or on
a vertically mounted outlet box. It should be sensing average
room temperature, so avoid the following:
DEAD SPOTS:
Behind doors
Corners and alcoves
HOT SPOTS:
Concealed pipes
Fireplace
TV sets
Radios
Lamps
Direct sunlight
Kitchens
COLD SPOTS:
Concealed pipes or ducts
Stairwells - drafts
Doors – drafts
Unheated rooms on other side of wall
Set heat anticipator at .2 amps. 24 Volt thermostat connects
to aquastat terminals T and TV.
VENT DAMPER WIRING
The boiler is equipped with a factory wired harness with 4 pin
molex plug, that plugs into a 4 pin molex receptacle inside the
vent damper operator.
The vent damper must be connected for the boiler to
operate.
Wiring diagrams follow for the various different models.
CAUTION
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and dangerous
operation. Verify proper operation after servicing.
Electrical Wiring
The pump does not come pre-installed on the boiler. It must
beconnected to the circulatorharnessin the field accordingto
the pump manufacturer’s instructions and the wiring diagrams
in this manual.

12
WIRING DIAGRAMS FOR HOT WATER BOILERS
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.
NOTE: THE CIRCULATOR HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS
NEEDS TO BE CONNECTED TO THE CIRCULATOR IN THE FIELD.
INTERMITTENT IGNITION

13
WIRING DIAGRAMS FOR HOT WATER BOILERS
STANDING PILOT
IF ANY OF THE ORIGINAL WIRE AS SUPPLIED WITH THIS APPLIANCE MUST BE REPLACED,
IT MUST BE REPLACED WITH TYPE 105°C THERMOPLASTIC WIRE OR ITS EQUIVALENT.
NOTE: THE CIRCULATOR HARNESS IS FACTORY WIRED TO THE AQUASTAT. THIS HARNESS
NEEDS TO BE CONNECTED TO THE CIRCULATOR IN THE FIELD.

14
Equipment and Optional Accessories - What They Do
RELIEF VALVE
You must have a relief valve on your boiler. Water expands as
it is heated. If there is no place for the water to expand into,
waterpressure willbuildupinside theboilerandsystem.Should
this happen, the relief valve will automatically open at a
predeterminedpressure.This will relievethestrainonthe boiler
and system. Run a pipe from the relief valve outlet (pipe must
besamesizeasoutlet and the open end must not bethreaded)
to an open drain, tub or sink, or other suitable drainage point
not subject to freezing. Failure to do so may cause water
damage or injury should relief valve release.
EXPANSION TANK
In a properly assembled system, the expanding water flows
into a expansion tank. This tank should be of the correct size.
The tank is filled with air. As the water expands it compresses
theairinthetank to form an air pressure cushion. This “spring-
like” cushion serves to maintain correct operating water
pressure regardless of water temperature. This assures a “full
measure” of a water, even in the highest radiation unit of the
system. It also prevents blowing off of the relief valve.
Theair in the tank inthebeginning(with system filled withcold
water) is sufficient for proper operation. The tank also serves
as a trap for excess air in the system. The air would cause
gurgling in the pipes and inefficient circulation in the radiators
if left in the system . It is possible for a tank to become
“waterlogged” (filled with water). It can also become overfilled
withair.This can happenafterfillingthesystem with new water.
Fittings provided on the tank and in the line to the tank are for
bleeding off excess water or air.
When installing this tank, it is important:
1) That the tank be higher than the boiler top.
2) That the pipe to the tank continuously rises up to the tank
(so that air can “bubble” up to it).
DIAPHRAGM TYPE EXPANSION TANK
Thediaphragm typeexpansiontank(EX-TROL) takestheplace
of the conventional expansion tank. Carefully read the
instructions packed with your EX-TROL tank assembly.
TheEX-TROLtankcomestoyouwitha10-12poundspersquare
inch air charge. This is the same as the pressure produced in
the system by the automatic fill valve. When the system is first
filled, the EX TROL tank will contain little or no water.
As the water is heated its pressure increases. It expands into
the EX-TROL tank, compressing the air in the tank. This
compressed air cushion permits the water in the system to
expand as the temperature changes.
The diaphragm type tank can be mounted on the air purger
fitting or at any convenient place in the supply or return line.
AIR ELIMINATING FITTING (AIR PURGER)
An air purger is used to remove excess air from the system. It
is installed in the supply line. It will eliminate air from the water
before it reaches the radiators and bleed off this air.
MAIN AIR VENT FOR DOWN FLOW SYSTEMS
OR DIAPHRAGM TYPE EXPANSION TANK
Before a system is filled with water, there is air in the pipes and
radiation units. Some of it will be trapped as the system is filled .
It is possible to eliminate most of this air through the air vents
on the radiation units. A main air vent will speed and simplify
this. It should be installed on the highest point in the supply
main when all radiation is below top of boiler.
AUTOMATIC FILL VALVE
For safe, efficient operation, a hot water system must be
completely filled withwater. Adding new water, when needed
can be done manually (by use of a hand valve in the water
supply line). This requires regular attention to the system’s
needs. An automatic fill valve accomplishes this without
attention. It is installed in the supply line on hot water boilers
only. The valve operates through water pressure differentials.
It does not require an electrical connection.
DRAIN VALVE
Thismanualvalve Provides a means of drainingallwaterfrom
the boiler and system. It is often installed in the 3/4” tapping at
the bottom of the end boiler section. Or it can be installed in a
tee where the return line enters the boiler.
WATER TEMPERATURE CONTROL
The water temperature limit control in the relay is adjustable
and may be set as necessary. It may be set as low as 140°F,
or as high as 240°F. This depends on the type and amount of
radiation involved and weather conditions.
CIRCULATING PUMP
Every forced hot-water system requires a circulating pump. A
separate pump or zone valve is required for each zone, if you
have a two or more zone system. This pump must have the
capacity to provide the circulation required by your system.
VENT DAMPER
Thisproductis an automatic, motorized stack damper that has
been developed to increase the efficiency of heating system
by reducing standby losses from the heating apparatus and
the conditioned air space. The damper closes the chimney
ventwhen the burner is off andfully opensit whencombustion
is required.

15
ROLLOUT SWITCH
(FLAME ROLLOUT SAFETY SHUTOFF)
The rollout switch is a temperature-sensitive fuse link device.
It is located on the boiler base just outside the fire box. In the
event of heat exchanger flueway blockage causing flame to
rolloutofthe fire box, the fuse will blow, shutting downthe flow
of gas to the main burners. The fuse does not change in
appearance when blown.
If the rollout switch blows, it must be replaced with an exact
replacement. Check heat exchanger flueways for blockage
whenrestoringsystem to operatingcondition.DONOToperate
system without a rollout switch.
SPILL SWITCH
(BLOCKED VENT SAFETY SHUTOFF)
Thespillswitchisamanualresetdiscthermostatwithafixedsetpoint
(340° F), and normally closed contacts. It is located at the relief
opening of the integral draft diverter. In the event of chimney or
venting system blockage causing products of combustion to spill
out of the relief opening, the spill switch disc heats up and the spill
switch contacts open, shutting down the flow of gas to the main
burners by removing power to the gas valve.
In the event that the spill switch contacts open, the reset button
on the back of the switch will pop up. The spill switch must be
reset manually, after the switch has cooled off, by pushing the
reset button down. Check the venting system and chimney for
blockage when restoring the system to operating condition. DO
NOT operate the boiler without a spill switch.
Starting Your Boiler
HOW A HOT-WATER SYSTEM OPERATES
Your entire heating system (boiler, piping and radiation units) is
filledwith water.Asthewaterintheboiler isheated,it ispumped
from the top of the boiler through the supply main to the radia-
tion units. The cooler water in them flows back through the re-
turnmaintothe boiler.Thisprovidespositiveandrapidresponse
to the thermostat.
FILLING SYSTEM WITH WATER
Close the air vents on all radiation units. Open the valves to
these units. Make sure the boiler and expansion tank drain
cocks are closed. The air bleed screw on the tank drain fitting
should be closed. Open the valve in the line from the boiler to
the expansion tank. Open the water inlet to your boiler and
leave it open. Start with the lowest radiationunit. Open the air
ventonthisunit.Whenallthe air has escaped and water starts
toflowfrom the vent, close it.Go tothe nextradiation unit,and
repeat this process. Repeat until you have covered every
WARNING
Never run water into a hot empty boiler.
radiationunitinthe system (ending up at the highest unit in the
system).Ifyour unitshaveautomaticvents,this manualventing
is unnecessary but it will speed up the proper filling of your
system.
If your system is a closed expansion tank system, you may
leaveit opentorefill thesystemautomatically asneeded.Check
the temperature pressure gauge. Not the position of the hand
indicating pressure. This should be between 10 and 15 lbs.
Any lowering of this movable hand below 10 lbs. Will indicate
loss of water due to leakage. The automatic fill valve should
compensate for this. Instructions are packages with the valve.

16
For Your Safety Read Before Operating
A. Some boilers are equipped with an intermittent ignition
device which automatically lights the pilot. Do not try to
light the pilot by hand.
Someboilersareequippedwithacontinuous pilot and must
be manually lighted. (See operating instructions on page
16-18.) A match holder is included in the parts bag.
B. BEFORE OPERATING smell all around the appliance
area for gas. Be sure to smell next to the floor because
some gas is heavier than air and will settle on the floor.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone
in your building.
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result causing property damage, personal injury or loss of life.
•Immediately callyourgas supplierfroma neighbor’sphone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire
department.
C. Use only your hand to push in or turn the gas control knob.
Never use tools. If the knob will not push in or turn by hand,
don’ttrytorepairit,callaqualifiedservicetechnician.Force
or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water.
Immediately call a qualified service technician to inspect
the appliance and to replace any part of the control system
and any gas control which has been under water.
Intermittent Ignition Boiler - VR8204A/VR8304M Gas Valve Operating Instructions
1. STOP! Read the safety information above.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4.Thisappliance is equipped with anignitiondevice
which automatically lights the pilot. Do not try to
light the pilot by hand.
5. Remove lower front panel.
6. Rotate the gas control knob clockwise
to“OFF”
7. Wait five (5) minutes to clear out any gas. Then smell for
gas,includingnear the floor. Ifyousmellgas,STOP! Follow
“B” in the safety information on page 19 If you don’t smell
gas, go to next step.
8. Rotate the gas control knob counterclockwise
to “ON.”
9. Replace lower front panel.
10. Turn on all electric power to the appliance.
11. Set thermostat to desired setting.
12. If the appliance will not operate, follow the instructions “To
TurnOffGas To Appliance” andcallyourservicetechnician
or gas supplier.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
3. Push in gas control knob slightly and turn clockwise
to “OFF” Do not force.

17
Continuous Pilot Boiler - VR8200A/VR8300A Gas Valve Operating Instructions
1. STOP! Read the safety information on page 16.
2. Set the thermostat to lowest setting.
3. Turn off all electric power to the appliance.
4. Remove lower front panel.
5. Rotate gas control knob slightly and turn clockwise
to “OFF”
6. Wait five (5) minutes to clear out any gas. Then smell for
gas,includingnearthefloor. If you smell gas, STOP! Follow
“B” in the safety information on page 19 If you don’t smell
gas, go to next step.
7. Find pilot - follow metal tube from gas control. The pilot is
between two burner tubes as shown in Fig. 14 on page 18.
8. Turn knob on gas control counterclockwise to
“PILOT”
9. Rotate the gas control knob counterclockwise
to “PILOT” Push down and hold the red reset button while
you light pilot burner with a match.
After about one minute, release reset button. Pilot should
remain lit. If it goes out, turn gas control knob clockwise
to OFF To relight, repeat steps 5-9.
• If button does not pop up when released, stop and
immediately call your service technician or gas supplier.
• If the pilot will not stay lit after several tries, turn the gas
control knob to “OFF” and call your service technician or
gas supplier.
10. After pilot remains lit when red reset button is released,
turn gas control knob counterclockwise to “ON.”
11. Replace lower front panel.
12. Turn on all electric power to the appliance.
13. Set thermostat to desired setting.
TO TURN OFF GAS TO APPLIANCE
1. Set the thermostat to lowest setting.
2. Turn off all electric power to the appliance if service is to
be performed.
3. Push in gas control knob slightly and turn clockwise
to “OFF” Do not force.
Operating Your Boiler
AUTOMATIC GAS VALVE
The Automatic Gas Valve opens or closes according to the
heat requirements of the thermostat and temperature limit
control. It closes if the pilot goes out. Each individual control
must be operating correctly before any gas can pass to the
burners. Any one control can hold the gas supply from burner
regardless of the demand of any other control.
SAFETY PILOT
Safety Pilot prevents the flow of gas to burner if the pilot goes
out, or will not ignite.
GAS VALVE SAFETY SHUTDOWN TEST
1.Forboilersequipped with continuous pilot, withmainburners
firing, disconnect the thermocouple from the gas valve. The
gasvalve should immediately shut offthemainburners and
the pilot.
2. For boilers equipped with intermittent ignition, with main
burners firing, disconnect the ignition cable from the
intermittent pilot control box. The gas valve should shut off
the main burners.
TURN OFF ELECTRIC POWER to boiler before
reconnecting ignition cable, to prevent electric shock.
RELIGHT
Theelectricandgasshallbeofffor5minutesbeforerelighting.
THERMOSTAT
Keep it set at a desired room temperature. If windows are to
beopenedor heat is not needed, move thermostatpointer toa
lower setting.
NOTE
Intheeventof failure of any component, the system willnot
operate or will go into safety lockout. The system is
completely self-checking. On every call for heat, each
componentmust befunctioningproperlyto permitoperation.
On safety lockout the system has to be reset by turning the
thermostat to the lowest setting for one minute, then back
to the normal setting.
Safe lighting and other performance criteria were met with
thegasmanifoldandcontrolassemblyprovidedonthe boiler
when the boiler underwent tests specified in ANSI Z21.13 -
latest revision.

18
Checking and Adjusting
FIG. 14 - LIGHTING PILOT FIG. 15 -VR8200A/VR8300A AUTOMATIC
GAS VALVE
FIG. 17
FIG. 16 -VR8204A/VR8304M AUTOMATIC
GAS VALVE
ADJUST PILOT BURNER
Pilot flame should surround 3/8" to 1/2" of the pilot sensor.
Refer to Fig. 18. If flame needs adjusting, do it as follows:
1. Remove screw cover over pilot adjusting screw.
2. Insertsmallscrewdriverandadjustflameasneeded.Turnscrew
counterclockwise to increase flame, clock-wise to decrease.
3. Replace screw cover over pilot adjusting screw.
MAIN BURNER(S)
The main burners do not require primary air adjustment and
arenotequipped with primary air shutters. Mainburner flames
shouldform sharpblueinner conesina softerblueouter mantel,
with no yellow. Puffs of air from blowing on the flame or
stamping on the floor will cause the flames to turn orange
momentarily. This is not unusual. Remain still when observing
themainburner flames. If the flame appearanceisnotcorrect,
check main burner orifices and the burner throat and flame
ports for dust and lint obstruction. It may be necessary to
remove the rollout shield to observe the main burner flames.
Replace rollout shield after observation. Refer to Figure 17.
ADJUST LIMIT CONTROLS
Instructions for each control are included with the controls.
These settings can be changed after you have had some
idea how the system works. Example: If your system does not
give quite enough heat in very cold weather, you can raise the
limit setting to 220° F Use the boiler gauge to check your
settings.Make theadjustmentsaccordingtoitsreadings.Check
thermostat operation. When set above temperature indicated
on the thermometer, boiler should ignite. Make certain the
thermostatturnsofftheboilerwhenroomtemperaturereaches
the selected setting and starts the boiler operating when room
temperature falls a few degrees.
After setting limit control to limit setting, check to see if it shuts
offthegas supplytotheburners.Turn yourthermostatupto call
forheatandletyour boiler run until the temperature of thewater
reaches the limit setting. The gas valve should shut off and the
circulator keep running until the thermostat is satisfied, or the
watercoolsenoughtorestarttheburnersthroughthelimitcontrol.
Finally,setthethermostatforthedesiredtemperature.Special
conditions in your home and the location of the thermostat will
govern this setting.
RECOMMENDED BOILER WATER TEMPERATURES
Type of Heating Unit Limit Control Setting
StandingRadiators...................................180ºF.
Baseboard and Convector Radiators........200º F.
FIG. 18

19
Maintaining Your Boiler
BURNERS
A visual check of the pilot end main burner flames should be
made at least once each year, preferably at the beginning of
the heating season. See page 21
RELIEF VALVE
This valve should open automatically if the system pressure
exceeds the pressure rating (usually 30 psi) of the relief valve.
Should it ever fail to open under this condition, shut down your
system. Drain the system until system pressure is reduced
below the relief valve pressure rating. If valve discharge oc-
curs, or if valve fails to open as described above, contact an
authorizedcontractororqualified service technician to replace
the relief valve and inspect the heating system to determine
the cause, as this may indicate an equipment malfunction.
Thisvalve shouldbetestedevery monthduringperiodsof boiler
operation, and at the beginning and end of any extended non-
service period. Prior to testing, make certain discharge pipe is
properly connected to valve outlet and arranged so as to con-
tainandsafelydispose of boiler discharge. Test at normal sys-
tem operating pressure. Hold the trip lever fully open for at
least five seconds in order to flush free any sediment that may
lodge on the valve seat. Then permit the valve to snap shut.
EXPANSION TANK
As previously noted, this tank may become waterlogged, or
may receive an excess of air. Frequent automatic opening of
the relief valve indicates water logging. A high boiler tempera-
ture accompanied by unusually low radiation unit temperature
(and “knocking”) indicates excess air in tank.
To correct either condition, close the valve between the boiler
and the tank. Drain the tank until it is empty. Check all the tank
plugs and fittings. Tighten as necessary. Open the valve be-
tween the boiler and tank. Water will rise to the normal height
inthetankifyouhaveanautomaticfillvalve (otherwise, manu-
ally refill the system).
BOILER FLUE PASSAGES
Under normal operating conditions, with the burners properly
adjusted, it should not be necessary to clean the boiler flue
gas passages. However, to assure trouble-free operation, we
recommend that you have the flue passages, burner
adjustment, and operation of the controls checked once each
year by a competent Service Technician.
Before the start of each season (or whenever system has
been shut down for some time) recheck the whole system for
leaks...andrecheck the boiler andventpipeforleaks.Replace
or patch any boiler seals that are faulty.
VENT PIPE
The venting of this unit is very important and the piping
shouldbe checked atleastonce a season.If the ventpiping
shows any sign of leaking, replace it immediately.
WATER SYSTEM
If system is to remain out of service during freezing weather,
alwaysdrain it completely (water left in to freezewillcrackthe
pipes and/or boiler).
CLEANING YOUR BOILER AND BURNERS
Flue passages between sections should be examined yearly
andcleanedifnecessary.To clean, remove burners, pilot, and
vent pipe, Remove top and front jacket panels. Remove the
two screws attaching the intermediate front panel to the left
and right side jacket panels. Remove the draft diverter and
intermediatefrontpanelasa unit. Carefully remove the cerafelt
gasket strips. Clean passageways between sections with a
flexible handle wire brush. Remove dirt from bottom of boiler
andfrombetweensectionsby vacuuming. Make sure all flame
ports in burners are open and clear. Shake out or blow out all
loosedirtinburners.Resealseamsbetweenadjacent sections
as necessary with 400°F RTV silicone sealant. Reassemble
all parts. Be sure to check tightness of pilot connections and
condition of burner flames after reassembly (see Figures 17
and 18). Be sure vent pipe connections to chimney are secure
and no obstructions are present.
CIRCULATOR PUMP ISOLATION VALVES
The isolation valves in the circulator pump flanges should be
operatedmanuallyonceortwiceperyeartopreventthevalves
from becoming stuck in the open position Rotate the valves
from the open position to the closed position and back to the
open position.

20
Service Hints
You may avoid inconvenience and service calls by checking these points before you call for service.
FOR YOUR SAFETY
WHAT TO DO IF YOU SMELL GAS
1. Do Not try to light any appliance.
2. Do not touch any electric switch, do not use the phone.
3. Leave the building immediately, then call your gas supplier.
4. If you cannot reach the gas supplier, call the fire department.
HAVE YOUR SERVICE TECHNICIAN CHECK ANY PROBLEM YOU ARE UNABLE TO CORRECT.
Possible Cause What to do
Thermostat is not set correctly Reset thermostat above room temperature
Burner is not operating properly Check flame. If it is yellow, the burner is not getting enough air.
Or, if flame is blue and noisy and seems to lift off the burner, the
burner is getting too mush air. Contact your service technician.
No electric power to boiler Check overcurrent protection. Check to be sure electric power
supply circuit is “ON”.
Controls out of adjustment Reset according to instructions.
Radiators not heating Open radiator vents to excess air. Check flow control valve (if
used). It may be in closed position.
Circulating pump not running Check overcurrent protection. Check relay operation.
Poor electrical contact Check all control terminals and wire joints.
Rollout switch blown Have your service technician check heat exchanged for blockage.
Replace rollout switch with exact replacement.
Spill switch blown Have your service technician check venting system and chimney
for blockage, or down draft condition. Reset spill switch.
Vent damper not operating Consult troubleshooting guide in Effikal manual, packaged with
vent damper.
Possible Cause What to do
Gas input amount is incorrect Contact your service technician.
Possible Cause What to do
Dirt on seat Open valve manually. Allow water to run and clear valve seat.
Water logged expansion tank Drain tank, see instructions.
IF YOUR SYSTEM IS NOT HEATING OR NOT GIVING ENOUGH HEAT . . .
IF BURNER IS NOISY . . .
RELIEF VAVLE LEAKING . . .