Dunkirk Q90-125 Instruction manual

Q90 125-200 SERIES II
GAS-FIRED DIRECT VENT
CONDENSING HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
P/N 240009431, Rev. B [12/2012]
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
Models
Q90-125
Q90-150
Q90-175
Q90-200

2
1 - Boiler Ratings & Capacities....................3
2 - Safe Installation And Operation .............5
3 - Locating The Boiler ..............................6
5 - Combustion Air/ Vent Requirements..... 11
6 - Combustion Air And Vent Pipe ............. 13
7 - Gas Supply Piping.............................. 15
8 - Electrical Wiring ................................ 16
9 - Controls And Accessories.................... 20
10 - Startup........................................... 22
11 - Detailed Sequence Of Operation......... 27
12 - Sequence Of Operation Diagnostics.... 28
13 - Checkout Procedure & Adjustments.... 29
14 - High Limit Control And LWCO..............31
15 - Troubleshooting............................... 33
16 - Maintenance And Cleaning ................ 42
Appendix A -
Dielectric Isolation &Antifreeze Protection ...44
Parts, Kits and Accessories........................49
Warranty. ................................................61
Check Out Certificate...............................63
TABLE OF CONTENTS
Safety Symbols & Warnings
The following defined symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
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
!
IMPORTANT: Read following instructions
COMPLETELY before installing!!
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
WARNING
Keep boiler area clear and free from combustible
materials, gasoline and other flammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualified installer.
TO THE INSTALLER - Leave all instructions with
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
!
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.
!

3
1 -BOILER RATINGS & CAPACITIES
Table 1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)
Model Input
(MBH)(1) Heating Capacity (MBH)(1)(2) Net AHRI Rating (MBH)(1) Shipping Weight (lbs.) AFUE
(2) Flue Diameter
125 125 113 98 284 90.0 2” CPVC & 3” PVC
150 150 134 117 284 90.0 2” CPVC & 3” PVC
175 175 158 137 284 90.0 2” CPVC & 3” PVC
200 200 180 157 284 90.0 2” CPVC & 3” PVC
(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)
(2) AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on Department of Energy test procedure.
Figure 1 - Boiler Jackets
These low pressure gas-fired hot water boilers are design certified by CSA International, for use with natural and propane
gases. Boilers are constructed and hydrostatically tested for 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 heating boilers.
Boilers are certified in accordance with ANSI (American National Standards Institute) Z21.13 standards as gas-fired, direct
vent, condensing, hot water boilers.
Heating Capacity indicates amount of heat available after subtracting losses up the stack. Most of this heat is available
to heat water. Small portion is heat loss from jacket and surfaces of boiler, it is assumed this heat stays in the structure.
Net AHRI Rating represents portion of remaining heat applied to heat radiation or terminal units (i.e. Finned tube
baseboard, cast iron radiators, radiant floor, etc.). Difference between Heating Capacity and Net AHRI Rating, called piping
and pickup allowance, establishes reserve for heating volume of water in the system and offsetting heat losses from
piping. Net AHRI Ratings shown are based on piping and pickup factor of 1.15. Net AHRI Rating of boiler selected should
be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated
hot water heating systems. Manufacturer should be consulted before selecting boiler for installations having unusual
piping and pickup requirements.

4
1 - BOILER RATINGS & CAPACITIES
This is gas-fired direct vent cast aluminum hot water boiler. Cast aluminum heat exchanger means better heat transfer
and thermal storage than similarly sized cast iron boilers, which results in higher efficiency. Heating system water
absorbs large amounts of heat from cast aluminum heat exchanger, cooling flue gases and causing condensation. Sealed
combustion, premix gas burner, and low flame temperature means drastically reduced CO and NOx emissions, which
contribute to cleaner and healthier environment.
Appliance, unlike normal residential atmospheric and induced draft units, takes its combustion air directly from outdoors
(sealed combustion) and does not compete with building occupants for fresh air. Sealed combustion (also known as “direct
vent”) is safest and best way to obtain plenty of clean combustion air. Forced draft fan draws in outside combustion air to
mix with gas, which flows into pre-mix burner and combusts. Fan forces resulting flue gases from boiler unit and provides
positive removal of flue gases from building through PVC and CPVC vent pipes.
Table 3 - LP GAS
Nominal
Input 200,000 175,000 150,000 125,000
Vent Lengths Vent Lengths Vent Lengths Vent Lengths
Altitude Min. Max Min. Max Min. Max Min. Max
0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000
1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250
2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500
3,000 187,700 187,250 165,700 163,600 140,700 140,100 119,150 116,750
4,000 183,600 183,000 162,600 159,800 137,600 136,800 117,200 114,000
5,000 179,500 178,750 159,500 156,000 134,500 133,500 115,250 111,250
6,000 175,400 174,500 156,400 152,200 131,400 130,200 113,300 108,500
7,000 171,300 170,250 153,300 148,400 128,300 126,900 111,350 105,750
8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000
9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250
10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500
Table 2 - NATURAL GAS
Nominal
Input 200,000 175,000 150,000 125,000
Vent Lengths Vent Lengths Vent Lengths Vent Lengths
Altitude Min Max Min. Max Min. Max Min. Max
0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000
1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000
2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000
3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000
4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000
5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000
6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000
7,000 179,000 175,500 156,800 155,400 134,600 131,800 114,500 111,000
8,000 176,000 172,000 154,200 152,600 132,400 129,200 113,000 109,000
9,000 173,000 168,500 151,600 149,800 130,200 126,600 111,500 107,000
10,000 170,000 165,000 149,000 147,000 128,000 124,000 110,000 105,000
Ratings shown are for sea level applications. Boiler automatically derates input as altitude
increases. No alterations to boiler are required for altitudes above sea level.

5
Boiler is equipped for residential installations. If used for
commercial applications; additional code requirements
must be adhered to. This may require additional controls,
including but not limited to manual reset low water cut off,
manual reset high temperature limit, and wiring and/or
piping modifications.
1. 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/NFPA 54.
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
3. Be certain gas input rate is correct. Over-firing may
result in early failure of boiler components; this may
cause dangerous operation. Under-firing may result in
too much air for pre-mix burner causing poor or loss of
combustion.
4. Never vent products of combustion from this boiler to
enclosed space. Always vent to outdoors. Never vent to
another room or to inside building.
5. Verify adequate outdoor air supply to boiler for
complete combustion.
6. Follow regular service and maintenance schedule for
efficient and safe operation.
7. Keep boiler area clean of debris and free from
combustible materials, gasoline and other flammable
vapors and liquids.
8. Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with
materials and methods described in this manual.
Installation must comply with local codes.
9. Boiler and related hot water heating systems are
not do-it-yourself items. Installation and service by
qualified professionals are required.
2 - SAFE INSTALLATION AND OPERATION
Installers -Follow local regulations with respect to
installation of CO (Carbon Monoxide) Detectors. Follow
maintenance recommendations in this manual. See
“Maintenance And Cleaning” on page 42.
Boiler Sizing
• Verify you have selected the boiler with proper capacity
before continuing installation. AHRI Rating of boiler
selected should be greater than or equal to calculated
peak heating load (heat loss) for building or area(s) served
by boiler and associated hot water heating systems. See
“Boiler Ratings & Capacities” on page 3.
• Heat loss calculations should be based on approved
industry methods.
Considerations For Boiler Location
Before selecting boiler location, consider following.
• Supplied with correct type of gas (natural gas or
propane).
• Connected to suitable combustion air intake piping
system to supply correct amount of fresh (outdoor) air
for combustion. See “Combustion Air And Vent Pipe” on
page 13.
• Connected to suitable venting system to remove
hazardous products of gas combustion. See “Combustion
Air And Vent Pipe” on page 13.
• Connected to suitable hot water heating system.
• Supplied with suitable electrical supply for all boiler
motors and controls.
• Connected to properly located thermostat or operating
control. (Not included with boiler)
WARNING
Fire hazard. Do not install boiler on carpeting.
Failure to follow these instructions could result in
death or serious injury.
!
• Placed on level surface (DO NOT install on carpeting)
• Condensate drain line must be pitched down to floor
drain or external condensate pump with reservoir at ¼”
per foot (21 mm/m) (wood frame or blocks may be used
to raise boiler).
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
!

6
Locating The Boiler
1. Select level location, central to piping systems served
and close to vent and air intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e. larger
clearances) than required fire protection clearances,
must be used for boiler installation. Accessibility
clearances may be achieved with use of removable
walls or partitions.
3. Clearances shown in Table 4 indicate required
clearances per CSA listing. Minimum 1” (25 mm)
clearance must be maintained between combustible
construction and each of the right, top and back
surfaces of boiler. Minimum 8” (203 mm) clearance is
required on left side, to allow room for inlet air pipe.
18” (457 mm) clearance must be maintained at front
where passage is required for cleaning or servicing,
inspection or replacement of any parts that normally
require such attention. Allow 24” (610 mm) at front
and left side and 8” (203 mm) at top for servicing.
No combustible clearances are required to venting or
combustion air intake piping.
Table 4 - BOILER CLEARANCES
Unit Combustible
Clearance Accessibility, Cleaning, and Servicing
Top 1” (25 mm) 8” (203 mm)
Left Side 8” (203 mm) 24” (610 mm)
Right Side 1” (25 mm) -
Base 1” (25 mm) -
Front 0” (0 mm) 24” (610 mm)
Back 1” (25 mm) -
Intake/Vent
Piping 0” (0 mm) -
Near Boiler Hot
Water Piping 1” (25 mm) -
All distances measured from boiler cabinet.
4. Keep boiler area clean of debris and free of flammable
and combustible materials, liquids and vapors.
5. Install equipment in location which facilitates operation
of venting and combustion air intake piping systems as
described in this manual.
6. Advise owner to keep venting and combustion air
intake passages free of obstructions. Both venting
and combustion air intake piping systems connected
to outdoors must permit flow through piping systems
without restrictions for boiler to operate.
7. Boiler shall be installed such that automatic gas
ignition system components are protected from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap,
control replacement, etc.).
8. Boiler must be located where ambient temperatures
(minimum possible room temperatures where boiler
is installed assuming boiler is not in operation and
therefore contributes no heat to space) are always
at or above 32°F (0°C) to prevent freezing of liquid
condensate.
9. If boiler is not level condensate drain lines will not
function properly. Adjustable feet are located on boiler
to make up for minor surface irregularities or tilt.
10. Wood frame or blocks may be used to raise boiler
to maintain drain pitch or to be above external
condensate pump reservoir.
3 - LOCATING THE BOILER
Removal Of Existing Boiler From Common Vent
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 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 the venting system for proper size and
horizontal pitch and determine there is no blockage
or restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.
3. In so far 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 dryer and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhaust, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fire dampers.
4. Place in operation appliance being inspected. Follow
lighting instructions. Adjust thermostat so appliances
operate continuously.
5. Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use flame of match
or candle, or smoke from cigarette, cigar or pipe.

7
6. After it has been determined each appliance remaining
connected to common venting system properly vents
when tested as outlined above, return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition.
7. Any improper operation of common venting system
should be corrected so installation conforms with the
National Fuel Code, ANSI Z223.1/NFPA 54. When
resizing any portion of common venting system,
common venting system should be resized to approach
minimum size as determined using appropriate tables
in chapter 13 of the National Fuel Code, ANSI Z223.1/
NFPA 54.
Placing The Boiler
• Place boiler to provide most direct connections to
combustion air, vent, and system piping as possible.
• Place crated boiler as close to selected location as
possible and uncrate boiler.
• Move uncrated boiler into position with appliance dolly
or 2-wheel hand truck.
• Insert dolly or hand truck under right hand side of
boiler. It is possible to slide boiler for short distance on
smooth floor or surface.
3 - LOCATING THE BOILER

8
1. Do not install copper supply and return piping directly
into aluminum boiler section castings due to galvanic
corrosion between dissimilar metals.
2. Use iron, steel bushings or pipe connectors between
copper system piping and boiler to make final
connection to boiler.
3. Use of dielectric unions is acceptable, installer supplied.
4. Packaged boiler is furnished with iron piping in front
boiler section for supply and return connections.
5. Install all of radiation units (panels, radiators,
baseboard, or tubing) and supply and return mains
first, when installation of boiler is for new heating
system.
6. After installation of all heating system piping and
components; make final connection of system piping to
boiler.
7. Hot water boiler installed above radiation level or
as required by authority having jurisdiction must be
equipped with low water cut off device (included with
boiler).
8. Periodic inspection is necessary, as is flushing of float
type devices, per low water cut off manufacturers
specific instructions.
Expansion Tank And Make-Up Water
• Determine required system fill pressure, design
temperature, and water content.
• Boiler contains 2.6 gallons (U.S.). Size expansion tank
accordingly. Consult expansion tank manufacturer for
proper sizing information.
• Connect properly sized expansion tank (not furnished)
See Figure 2, for diaphragm type expansion tank.
For diaphragm type expansion tanks, adjust tank air
pressure to match system fill pressure.
• Install air vent (furnished) as shown for diaphragm type
expansion tank system only.
• Install make-up water connections as shown and per
local codes.
• If pressure reducing valve is used, adjust to match
system fill pressure. Verify clean water supply is
available when connecting cold make-up water supply
to boiler. When water supply is from well or pump,
install sand strainer at pump.
4 - NEAR BOILER PIPING
Figure 2 - Diaphragm Type Expansion Tank
Piping
Figure 3 - Relief Valve Discharge Piping
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
Check local codes
for maximum
distance from
floor or other
allowable safe
point of discharge
RELIEF VALVE
DISCHARGE
PIPING

9
Safety Relief Valve / Temperature Pressure Gauge
Boiler is furnished with safety relief valve and temperature
pressure gauge.
• Install safety relief valve using pipe fittings provided
with boiler. Figure 3, Page 8.
• Install safety relief valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety
relief valve.
• Install discharge piping from safety relief valve.
A. Use ¾” or larger pipe.
B. Use pipe suitable for temperatures of 375°F
(191°C) or greater.
C. Individual boiler discharge piping shall be
independent of other discharge piping.
D. Size and arrange discharge piping to avoid
reducing safety relief valve relieving capacity below
minimum relief valve capacity stated on rating
plate.
E. Run pipe as short and straight as possible to
location protecting user from scalding and properly
drain piping.
F. Install union, if used, close to safety relief valve
outlet.
G. Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
H. Terminate pipe with plain end (not threaded).
NOTE: When zoning with
circulators, use furnished
circulator pump as one of
zone pumps. Tape or wire
nut each stripped end of
electrical wire for circulator
pump inside junction box
to prevent short circuits.
Unplug circulator pump
wiring at integrated boiler
control.
Supply And Return Lines
Packaged boiler receives 1¼” NPT supply and return piping
from top access.
4 - NEAR BOILER PIPING
Figure 4 - Single Zone Boiler Piping
Figure 5 - Multi Zone Boiler Piping With Zone
Valves
Figure 6 - Multi-zone Boiler Piping with
Circulators

10
Condensate Drain Requirements
Pitch condensate drain line down to floor drain
at minimum of ¼” per foot (21mm/m). External
condensate pump (not furnished) may be used if
floor drain is not available. Condensate pump must be
designed for flue gas condensate application.
Condensate trap is proved with boiler.
1. Build condensate trap in the field. See Figure 7.
2. Wood frame or blocks may be used to raise boiler
to maintain drain pitch or to be above external
condensate pump reservoir.
3. 115 volt AC receptacle provided on service switch
junction box which is located at boiler right side,
to provide power for external condensate pump (if
needed).
Condensate Drain Piping
• Condensate trap is to be field installed as shown in
Figure 7.
• Provided are ½” PVC fittings for condensate drain
trap (assembled in field).
• The ½” diameter schedule 40 PVC condensate
drain piping and pipe fittings must conform to ANSI
standards and ASTM D1785 or D2846.
• Schedule 40 PVC cement and primer must conform
to ASTM D2564 or F493. In Canada, use CSA or ULC
certified schedule 40 PVC drain pipe and cement.
• Condensate pump with reservoir (not furnished) may
be used to remove condensate to drain line (sanitary
line) above boiler if floor drain is not available or is
inaccessible
Filling Condensate Trap With Water
Manually fill condensate trap at initial start up with water.
Following steps are required to fill condensate trap for
start up. Steps are only required at initial start up or if
maintenance requires draining of condensate trap:
1. Pour about 1 cup of cold tap water into condensate trap
vent.
2. Excess water will go through condensate drain line.
Verify proper operation of drain line (and external
condensate pump if used).
Chilled Water Piping
Install boiler used in connection with refrigeration system,
so chiller medium is piped in parallel with boiler with
appropriate valves to prevent chilled medium from entering
boiler.
Boiler piping system of hot water boiler connected to
heating coils located in air handling units where they may
be exposed to refrigerated air circulation must be equipped
with flow control valves or other automatic means to
prevent gravity circulation of boiler water during cooling
cycle.
4 - NEAR BOILER PIPING
Figure 7 - Condensate Trap and Vent
To Exhaust Vent
(2” CPVC)
½” Adapter
Male NPT x Socket
Weld PVC Piping
1 3/8” Long
To Boiler Flue Outlet (2” CPVC)
2” Unthreaded Male x 2” NPT Male PVC Bushing
1/2” Unthreaded PVC Elbow
1/2” Unthreaded PVC Piping 3 3/4” Long
1/2” Unthreaded PVC Elbow
1/2” Unthreaded PVC Piping 2” Long
1/2” Unthreaded PVC Piping 3 3/4” Long
1/2” Unthreaded PVC Tee
To Condensate Drain (Field Supplied)
2” NPT Male PVC Bushing
1/2” Unthreaded PVC Piping 12” Long

11
If concentric vent termination is being used, refer to
Figure 10 for proper setup.
5 - COMBUSTION AIR/ VENT REQUIREMENTS
Figure 8 - Roof Vent / Intake Terminations
Figure 9 - Sidewall Vent/Intake Terminations
Combustion Air/Vent Pipe Requirements
Boiler requires dedicated direct vent system. Direct vent
system, all air for combustion is taken directly from outside
atmosphere, and all flue products are discharged to outside
atmosphere.
Combustion air and vent pipe connections must terminate
together in same atmospheric pressure zone, either
through roof or sidewall (roof termination preferred). See
Figures 8 and 9 for required clearances.
12" (305mm)
Minimum
8" (203mm)
Minimum
15" (381mm)
Maximum
3" (76mm)
Maximum
Vent Combustion
Air
12" (305mm)
Minimum Above
Anticipated Snow Line
Vent
3" (76mm)
Minimum
Separation
12" (305mm)
Minimum From
Overhang
12" (305mm) Separation
Between Bottom Of
Combustion Air Intake
And Bottom Of Vent
See Snow &
Ice Page 23 Combustion Air
Vent
12" (305mm)
Minimum
Separation
Combustion Air
Figure 10 - Concentric Vent Terminations
Combustion Air
Vent
1" (26mm)
Maximum
Maintain 12"
clearance above
highest anticipated
snow level or grade
* See Note
Below 36"(0.9m) Minimum
Maintain 12"(305mm)
Clearance Above Highest
Anticipated Snow Level
Or Grade
12" (305mm) Minimum
*Must be less than 4" or greater than 24" Horizontal distance
between end bells of each air intake to prevent flue gas recirculation.
1" (26mm)
Maximum
Overhang
•Avoid locations where
snow may drift and block
vent and combustion air.
•Ice or snow may cause
boiler to shut down if
vent or combustion air
becomes obstructed.
Vent
Combustion Air

12
5 - COMBUSTION AIR/ VENT REQUIREMENTS
Figure 11 - Concentric Vent
3” Diameter PVC
Vent/Exhaust
1½”
4½” Dia.
31⅞”
A
A
B
B
C
C
D
E
F
G
G
3” Diameter PVC
Intake/Combustion Air
46¾”
Dimension
1³⁄ΟΤ”
D
E
F
Dimension
VENT
VENT
A
A
B
B
C
C
D
D
COMBUSTION
AIR
COMBUSTION AIR
ROOF BOOT/FLASHING
(FIELD SUPPLIED)
ELBOW
(FIELD SUPPLIED)
SUPPORT
(FIELD SUPPLIED)
MAINTANIN 12 IN.
(18IN. FOR CANADA)
MINIMUM CLEARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL. MAXIMUM OF
24 IN. ABOVE ROOF
NOTE:
SUPPORT MUST BE
FIELD INSTALLED TO
SECURE TERMINATION
KIT TO STRUCTURE.
Figure 12 - Concentric Vent Roof Installation
• Covering non-metallic vent pipe and fittings with
thermal insulation shall be prohibited.
• Combustion air must be clean outdoor air. Do not take
combustion air from inside structure because that air
is frequently contaminated by halogens, which includes
fluorides, chlorides, phosphates, bromides and iodides.
These elements are found in aerosols, detergents,
bleaches, cleaning solvents, salts, air fresheners, paints,
adhesives, and other household products.
• Locate combustion air inlet as far away as possible from
swimming pool and swimming pool pump house.
• All combustion air and vent pipes must be airtight and
watertight.
• Combustion air and vent piping must also terminate
exactly as shown in Figures 8 and 9.
• Use of concentric vent termination refer to Figures 10,
11 and 12 for proper setup.
• Vent connections serving appliances vented by
natural draft shall not be connected into any portion
of mechanical draft systems operating under positive
pressure.
WARNING
Fire, explosion, asphyxiation hazard. Solvent
cements are combustible. Keep away from heat,
sparks, or open flame. Use only in well ventilated
areas. Avoid breathing in vapor or allowing contact
with skin or eyes. Improper installation could result
in death or serious injury. Read this manual and
understand all requirements before beginning
installation.
!
ARoof Boot/Flashing
(Field Supplied)
B
Elbow (Field Supplied)
C Support (Field Supplied)
D
Maintain 12” (305mm),
18” (457mm)
Minimum Clearance
Above Highest
Anticipated Snow
Level.
Maximum of (610mm)
Above Roof.

13
Connections And Termination
To prevent damage to gas burner and ensure proper
operation of unit, installer must clean and remove all
shavings from interior of all PVC pipe used on air intake.
Boilers require dedicated direct vent system. All air for
combustion is taken directly from outdoors through
combustion air intake pipe. All flue products are discharged
to outdoors through vent pipe. Install vent system in
accordance with these instructions.
1. Figures 8 and 9 “Combustion Air and Vent Pipe
Requirements, for standard two-pipe roof and sidewall
terminations and Figures 10, 11, and 12 for concentric
vent terminations (roof termination is preferred).
Combustion air and vent pipes must terminate
together in same atmospheric pressure zone as shown.
Construction through which vent and air intake pipes
may be installed is minimum ¼” and maximum 24”
thickness.
2. Combustion air and vent pipe fittings must conform
to one of the following American National Standards
Institute (ANSI) and American Society for Testing and
Materials (ASTM) standards:
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.
Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel
®
(Polyphenolsulfone) in venting systems shall be prohibited.
WARNING
Use of cellular core PVC for venting flue gas could result
in death, serious injury.
!
3. Combustion air and vent piping connections on boiler
are 2”, but must increase to 3”. Due to potential for
flue gas temperatures over 155°F, first 5 feet of vent
pipe must be CPVC (furnished), remaining vent pipe
can be PVC. If any elbows are employed within first
2 ½’ of vent, they must be CPVC. Two 30” pieces of 2”
CPVC pipe and one 2” CPVC coupling are furnished with
boiler. See
Figure 13.
Length of pipe is counted from boiler jacket (air intake
pipe) or from vent tee (vent pipe). First five feet of “Total
Equivalent Length” of vent pipe must be CPVC.
Reduce maximum vent length 5 feet per each additional
elbow.
4. Combustion air and vent piping to be pitched back to
boiler at minimum ¼” per foot (21mm/m) from intake
and vent terminals so that all moisture in combustion
air and vent piping drains to boiler. Pipes must be
pitched continuously with no sags or low spots where
moisture can accumulate and block the flow of air
or flue gas. Combustion air and vent pipes must be
airtight and watertight.
Figure 13 - Combustion Air & Vent Piping
Combustion Air and Vent Pipe Equivalent Length
3 in. Pipe
Minimum Venting
3 in. Pipe
Maximum Venting
6 ft. (1.8 m) in length 60 ft. (18.3 m) in length and
up to four (4) 90° elbows
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)
6 - COMBUSTION AIR AND VENT PIPE

14
Installation
1. Recommend all pipes be cut, prepared, and pre-
assembled before permanently cementing any joint.
2. Rigid supports cause excess noise in vent piping.
3. Attach combustion air intake piping to supplied 2”
coupling on CVI gas valve. Attach vent piping to
furnished 2” CPVC vent tee on draft inducer outlet.
4. All pipe joints are to be water tight.
5. Working from boiler to outside, cut pipe to required
length(s).
6. Deburr inside and outside of pipe. Remove all chips and
shavings.
7. Chamfer outside edge of pipe for better distribution of
primer and cement.
8. Clean and dry all surfaces to be joined.
9. Check dry fit of pipe and mark insertion depth on pipe.
10. After pipes have been cut and pre-assembled, apply
cement primer to pipe fitting socket and end of pipe to
insertion mark. Quickly apply approved cement to end
of pipe and fitting socket (over primer). Apply cement
in light, uniform coat on inside of socket to prevent
buildup of excess cement. Apply second coat.
11. While cement is still wet, insert pipe into socket with
¼ turn twist. Be sure pipe is fully inserted into fitting
socket.
12. Wipe excess cement from joint. Continuous bead of
cement will be visible around perimeter of properly
made joint.
13. Handle pipe joint carefully until cement sets.
14. Support combustion air and vent piping minimum of
every 5 feet using pre-formed metal hanging straps. Do
not rigidly support pipes. Allow for movement due to
expansion and contraction.
15. Slope combustion air and vent pipes toward boiler
minimum of ¼” per linear foot with no sags between
hangers.
16. Use appropriate methods to seal openings where vent
and combustion air pipes pass through roof or side
wall.
6 - COMBUSTION AIR AND VENT PIPE
NOTICE
Exhaust transition from 2” pipe to 3” pipe must be made
in vertical run. (Transition pieces not included.)
5. Consider following when determining appropriate
location for termination of combustion air and vent
piping:
A. Position termination where vent vapors will not
damage plants/shrubs, air conditioning equipment,
or siding on the house.
B. Position termination so it will not be effected by
wind eddy, air born leaves, snow, or recirculated
flue gases.
C. Position termination where it will not be subjected
to potential damage by foreign objects, such as
stones, balls, etc.
D. Position termination where vent vapors are not
objectionable.
E. Put vent on wall away from prevailing winter wind.
Locate or guard vent to prevent accidental contact
with people or pets.
F. Terminate vent above normal snow-line. Avoid
locations where snow may drift and block vent.
Ice or snow may cause boiler to shut down if vent
becomes obstructed.
G. Under certain conditions, flue gas will condense,
forming moisture, and may be corrosive. In such
cases, take steps to prevent building materials at
vent from being damaged by exhaust of flue gas.
оTerminate venting system at least 3 feet (0.3m)
above any forced air inlet (except boiler’s
combustion air inlet) within 10 feet (3m).
оTerminate venting system at least 12 inches
(300mm) from any air opening into any building.
оLocate bottom of vent at least 12 inches
(300mm) above grade.
оTerminate vent not less than 7 feet (2.1m) above
adjacent public walkway.
оVent terminal shall not be installed closer than
3 feet (0.9m) from inside corner of L shaped
structure.
оTermination of vent should be kept at least 3 feet
(0.9m) away from vegetation.
оIf multiple terminations are used, minimum of
12 inches (300 mm) between exhaust of one
termination and air intake of next termination.
See Figure 8, 9, and 10.
оAll field installed vent pipe must be 3”.
Terminate vent system at least 4 feet (1.22 m) horizontally
from, and in no case above or below, unless a 4 feet (1.22
m) horizontal distance is maintained, from electric meters,
gas meters, regulators and relief equipment.

15
Check Gas Supply
• Gas pipe to boiler must be correct size for length of
run and total Btuh input of all gas utilization equipment
connected to it.
• See Tables 6 and 7 for proper size.
• Verify your gas line complies with local codes and gas
company requirements.
Connecting Gas Piping
Table 5 - Gas Supply Pressure
Pressure Natural Gas Propane Gas
Minimum 4” w.c. 10” w.c.
Maximum 10” w.c. 14” w.c.
Please check line pressure while unit is running.
Table 6 - Natural Gas Piping Sizes
Pipe Length Pipe Capacity - BTU/Hr. Input (1)
½” ¾” 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
Table 7 - Propane Gas Piping Sizes
Pipe
Length
Pipe Capacity - BTU/Hr. Input (1)
Copper Tubing (2) Iron Pipe
⅝”¾”½”¾”
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
(1)Includes Fittings (2)Outside Diameter
Refer to Figure 14 for general layout at boiler. Gas line
enters boiler through left side panel.
Boiler is equipped with ½” NPT connection on gas valve for
supply piping and ½” NPT ball valve for manual shut off.
Following rules apply:
1. Use only those piping materials and joining methods
listed as acceptable by the authority having jurisdiction,
or in the absence of such requirements, National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
2. Use pipe joint compound suitable for liquefied
petroleum gas on male threads only.
3. Use ground joint unions.
4. Install sediment trap upstream of gas controls.
5. Use two pipe wrenches when making connection to
gas valve to keep it from turning.
6. Install manual main shutoff valve in vertical pipe
about 5 feet (1.5m) above floor outside boiler
jacket.
7. Tighten all joints securely.
8. Propane gas connections made by licensed propane
installer.
9. Two stage regulation used by licensed propane
installer.
10. Propane installer to verify Propane gas piping.
11. Recommend use ½” union suitable for natural and
propane gas after ball valve to facilitate service on
unit.
Leak Check Gas Piping
Pressure test boiler and gas connection before placing
boiler in operation.
• Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler
and its individual gas shutoff valve from gas supply
system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler
from gas supply system by closing manual gas shutoff
valve.
• Locate leakage using gas detector, noncorrosive
detection fluid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open flames, or other methods
providing ignition source.
• Correct leaks immediately and retest.
7 - GAS SUPPLY PIPING
Figure 14 - Gas Piping
Length of pipe or tubing should be measured from gas
meter or propane second stage regulator.

16
WARNING
Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
!
NOTICE
Use copper conductors only.
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.
Electric Power Supply
Turn OFF electrical power supply at service panel and boiler
before making electrical connections.
• Run 120 volt circuit from separate over current protection
device in electrical service entrance panel, 15 ampere
circuit.
• Service switch is pre-wired and located on exterior boiler
jacket. See Figure 15 for location of service switch,
junction box, and power supply connection points.
• Connect black (hot) lead from power supply to either of
unused brass screws on service switch.
• Connect white (neutral) lead from power supply to white
screw on service switch.
• Connect green (ground) lead from power supply to
ground (green) screw on service switch.
• Receptacle on service switch is powered regardless of
whether switch is on or off, and could be used as power
supply for external condensate pump if one is used.
• Run 14 gauge or heavier copper wire from boiler to
grounded connection in service panel or properly driven
and electrically grounded ground rod.
8 - ELECTRICAL WIRING
Figure 15 - Field Wiring Connection
Service Switch
Junction Box

17
AVOID THE FOLLOWING
Dead Spots
Corners
Alcoves
Behind doors
Cold Spots
Concealed pipes or ducts
Stairwells - drafts
Unheated rooms on the other side
of the wall
Hot Spots
Concealed pipes
Fireplaces
TVs or radios
Lamps
Direct sunlight
Kitchens
Thermostat Installation
• Follow instructions included with your thermostat.
• Locate thermostat five feet above floor on inside wall.
• Mount directly on wall or vertically mount on outlet box.
Thermostat should sense average room temperature.
• Set heat anticipator at 0.7 amps.
• Connect 24 volt thermostat leads to the two (2) yellow
wires located in service switch junction box, located
on outer jacket of boiler. See
Figure 15, Page 16 for
service switch junction box and thermostat field wiring
connections.
Connect Circulator Pump Wiring
NOTICE
Label all wires prior to disconnection when servicing
controls. Wiring errors can cause improper and
dangerous operation. Verify proper operation after
servicing.
See Figure 16, Page 18 and Figure 17, Page 19 for service
switch junction box and circulator pump field wiring
connections. If the two 120 volt circulator wire terminals
inside junction box are not used, leave two wire nuts to
prevent short circuit.
8 - ELECTRICAL WIRING

18
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C
Thermoplastic wire or its equivalent.
8 - ELECTRICAL WIRING
Figure 16 - Schematic Wiring Connections

19
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C
Thermoplastic wire or its equivalent.
8 - ELECTRICAL WIRING
Figure 17 - Ladder Wiring Diagram

20
See “Troubleshooting” on page 34 for detailed sequences of
operation and troubleshooting procedures. See separately
provided “Repair Parts Manual” for locations of control
components and accessories described.
Integrated Boiler Control (IBC)
• Integrated Boiler Control (IBC) is a microprocessor
based controller for high efficiency gas boilers.
• Controller monitors all safety controls which control
operation of combustion air blower, circulator pump,
burner, and combination hot surface igniter/flame
sensor.
• Controller is not intended for use with vent damper.
Controller is mounted on control panel inside boiler.
Contains five diagnostic indicator lights.
Gas Control Valve
Electronic 24 volt gas control valve contains 1:1 gas/air
pressure regulator, controls gas flow to main burner of
appliance. Suited for both natural and LP gas, and rated in
accordance with ANSI Z21.21 - latest revision and CGA-
6.5-M95.
Hot Surface Igniter
• 120 volt hot surface igniter heats up 1800°F initiates
combustion of gas in burner.
• Igniter is mounted next to burner through gas/air mixer.
• Igniter also serves as means for proving main burner
flame by flame rectification.
A. In event of lack of flame signal on three consecutive
trials for ignition, IBC will lock out.
B. “Valve” and “Flame” diagnostic indicator lamps blink
indicating failure mode as lack of flame signal.
C. Manually reset IBC from lockout by removing and
re-establishing thermostat’s call for heat, or turn
service switch off, then back on. See Figure 19.
High Limit Control
NOTICE
Maximum set-point of limit control must not exceed
190°F.
• High limit control determines maximum boiler water
temperature and provides means for protecting boiler
and heating system from unsafe operating conditions
which could damage boiler.
• Control is mounted in ½” NPT control well and ¾” x ½”
bushing on top of front boiler section at hot water outlet.
• Control is tied in with IBC and factory set at 190°F water
temperature.
• High limit set-point is field adjustable and may be set
between 100°F and 190°F.
• Field set-point adjustment for each installation depends
on heating system requirements.
• Differentials are automatic, vary based on control
settings and boiler temperature.
• Refer to limit manufacturer instructions provided with
limit control.
Casting Temperature Safety Switch
NOTICE
Never run cold water into hot, empty boiler.
Casting temperature safety switch (230°F set-point) shuts
off boiler by shutting off power to IBC, result of lack or loss
of boiler water. Power indicator light goes out.
Switch is installed on top of aluminum boiler section behind
supply piping.
Fault requires manual reset of casting temperature safety
switch, restarting boiler. Verify boiler is filled with water
before resetting switch.
9 - CONTROLS AND ACCESSORIES
Figure 18 - Gas Valve
Figure 19 - Indicator Lights