Dunkirk Q90-200 Instruction manual

Q90 125-200
GAS-FIRED DIRECT VENT
CONDENSING HOT WATER BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
An ISO 9001-2008 Certified Company
DUNKIRK BOILERS
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
P/N 240004826D, Rev. B [08/11]

2
H
90 125200 CAST ALUMINUM BOILER
SAFETY SYMBOLS
!
DANGER
Indicates a hazardous situation which, if not
avoided, will result in death, serious injury.
!
WARNING
Indicates a hazardous situation which, if not
avoided, may result in death, serious injury.
!
CAUTION
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
The following defined symbols are used throughout this manual to notify the reader of potential hazards of varying risk
levels.
KEEP THIS MANUAL NEAR BOILER AND RETAIN FOR FUTURE REFERENCE.
NOTICE
Indicates information which should be
followed to ensure proper installation and
operation.
Safety Symbols........................................................................................................................... 2
Rules For Safe Installation And Operation ....................................................................................... 3
Boiler Ratings & Capacities ........................................................................................................... 4
Before Installing The Boiler........................................................................................................... 5
Placing The Boiler........................................................................................................................ 9
Near Boiler Piping.......................................................................................................................10
Combustion Air And Vent Pipe ......................................................................................................13
Gas Supply Piping.......................................................................................................................15
Electrical Wiring .........................................................................................................................16
Controls And Accessories.............................................................................................................20
Startup .....................................................................................................................................22
Checkout Procedure & Adjustments...............................................................................................25
Maintenance And Cleaning...........................................................................................................28
Detailed Sequence Of Operation ...................................................................................................30
Troubleshooting..........................................................................................................................33
Installation And Check-Out Certificate ...........................................................................................43

3
NOTICE
Read and understand the following
instructions completely before installing.
Introduction
This appliance is a gas-fired direct vent cast aluminum
hot water boiler. A revolutionary cast aluminum heat
exchanger means better heat transfer and thermal storage
than similarly sized cast iron boilers, which results in
higher efficiency. The heating system water absorbs large
amounts of heat from the cast aluminum heat exchanger,
cooling the flue gases and causing condensation. Sealed
combustion, premix gas burner, and low flame temperature
means drastically reduced CO and NOx emissions, which
contribute to a cleaner and healthier environment.
This appliance has been equipped for residential
installations. If used for commercial applications, any and
all additional code requirements must be adhered to for
installation. This may require additional controls, including
but not limited to a manual reset low water cut off, a
manual reset high temperature limit, and wiring and/or
piping modifications.
The manufacturer is not responsible for any field
installation changes made to a boiler installation which are
not described or acknowledged in this manual.
Check all applicable state and local building codes and
1.
utility company requirements before installation. This
installation must conform with these requirements in
their entirety. In the absence of these codes, use NFPA
installation codes and good industry practice.
Before servicing the boiler, allow it to cool. Always 2.
shut off any electricity and gas supply connected to the
boiler prior to servicing.
Inspect gas line for leaks. 3.
Be certain gas input rate is correct. Over-firing may 4.
result in early failure of the boiler components. This
may cause dangerous operation. Under-firing may
result in too much air for the pre-mix burner causing
poor or loss of combustion.
Never vent the products of combustion from this boiler 5.
to an enclosed space. Always vent to the outdoors.
Never vent to another room or to inside a building.
Be sure there is adequate outdoor air supply to boiler 6.
for complete combustion.
Follow a regular service and maintenance schedule for 7.
efficient and safe operation.
Keep boiler area clean of debris and free from 8.
combustible materials, gasoline and other flammable
vapors and liquids.
Proper through-the-wall or through-the-roof 9.
combustion venting shall be in accordance with the
materials and methods described in this manual.
Installation must comply with local codes.
This boiler and related hot water heating systems are 10.
not do-it-yourself items. They must be installed and
serviced by qualified professionals.
RULES FOR SAFE INSTALLATION AND OPERATION
!
WARNING
Failure to follow these instructions could cause
a malfunction of the boiler and result in death,
serious bodily injury, and/or property damage.
For assistance or additional information,
consult a qualified installer, service agency, or
the gas supplier.
This appliance, unlike normal residential atmospheric and
induced draft units, takes its combustion air directly from
the outdoors (sealed combustion) and does not compete
with building occupants for fresh air. Sealed combustion
(also known as “direct vent”) is the safest and best way
to obtain plenty of clean combustion air. The forced draft
fan draws in the outside combustion air to mix with gas,
which flows into the pre-mix burner and combusts. The
fan then forces the resulting flue gases from the boiler unit
and provides a positive removal of the flue gases from the
building through inexpensive and readily available PVC and
CPVC vent pipes.
90 125200 CAST ALUMINUM BOILER

4
TABLE #1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)
Model Input
(MBH)(1) Heating Capacity
(MBH)(1)(2) Net I=B=R 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 ermal Units Per Hour)
(2) AFUE (Annual Fuel Utilization Eciency) and Heating Capacity is based on Department of Energy test procedure.
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. The boiler automatically de-rates input as
altitude increases. No alterations to boiler are required for altitudes above sea level.
BOILER RATINGS & CAPACITIES
Figure 1 -Boiler Jackets

5
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
These low pressure gas-fired hot water boilers are design
certified by CSA International, for use with natural
and propane gases. The boilers are constructed and
hydrostatically tested for a maximum working pressure of
50 psig (pounds per square inch gauge) 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 I=B=R 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 I=B=R Rating, called piping and pickup allowance,
establishes reserve for heating volume of water in the
system and offsetting heat losses from piping. Net I=B=R
Ratings shown are based on piping and pickup factor of
1.15. Net I=B=R 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.
Complete the following prior to installing boiler.
Codes
This boiler product is a gas-fired, direct vent, condensing
boiler. Installation must conform to the requirements of
authority having jurisdiction or, in the absence of such
requirements:
United States • - National Fuel Gas Code, NFPA 54/
ANSI Z223.1
Canada • -Natural Gas Propane Installation Code,
CAN/CSA B149.1
Where required by the authority having jurisdiction,
installation must conform to the Standard for Controls and
Safety Devices for Automatically Fired Boilers, ANSI/ASME
CSD-1.
BOILER RATINGS & CAPACITIES
BEFORE INSTALLING THE BOILER

6
In the State of Massachusetts:
This product must be installed by a licensed plumber• or gas fitter.
When flexible connectors are used, the maximum• length shall not exceed 36 inches.
When lever type gas shut-offs are used, they shall• be T-handle type.
Installers -Follow local regulations with respect to
installation of CO (Carbon Monoxide) Detectors. Follow
maintenance recommendations in this manual.
Boiler Sizing
Check to be sure you have selected the boiler with• the proper capacity before continuing the installation.
The I=B=R Rating of the boiler selected should be
greater than or equal to the calculated peak heating
load (heat loss) for the building or area(s) served by
the boiler and associated hot water heating systems.
See “Boiler Ratings and Capacities,” (page 4) for more
information.
Heat loss calculations should be based on approved• industry methods.
Considerations For Boiler Location
Before selecting a location for the boiler, the following
should be considered. Each boiler considered for
installation must be:
Supplied with the correct type of gas (natural gas or• propane).
Connected to a suitable combustion air intake piping• system to supply the correct amounts of fresh
(outdoor) air for combustion (max. length 60’).
Connected to a suitable venting system to remove• the hazardous products of gas combustion (max.
length 60’).
Connected to a suitable hot water heating system.•
Supplied with a suitable electrical supply for all• boiler motors and controls.
Connected to a properly located thermostat or• operating control. (Not included with boiler)
Placed on level surface (must NOT be installed 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).
Locating The Boiler
Select location which is level, central to piping systems
1.
served and as close to vent and air intake terminals as
possible.
Accessibility clearances, if more stringent (i.e. larger
2.
clearances) than required fire protection clearances,
must be used for boiler installation. Accessibility
clearances may be achieved with use of removable
walls or partitions.
Boiler is approved for installation in closets and on 3.
combustible floors. Boiler shall NOT be installed on
carpeting.
Clearances shown in Table 4 indicate required 4.
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
may require such attention. Allow at least 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 the cabinet of the boiler.
!
CAUTION
Keep boiler area clean of debris and free of
flammable and combustible materials, liquids
and vapors.
Equipment shall be installed in location which facilitates 5.
operation of venting and combustion air intake piping
systems as described in this manual.
BEFORE INSTALLING THE BOILER

7
OVERHANG
12" MINIMUM
90°
VENT
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
3"
MAXIMUM
SEPARATION
18"
MAXIMUM
15"
MAXIMUM
LESS THAN 12" CLEARANCE
12"
MINIMUM
12"
MINIMUM
12" OR MORE CLEARANCE
90°
BRACKET
VENT
18"
MAXIMUM
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
12" MINIMUM
OVERHANG
3"
MAXIMUM
SEPARATION
12"
MINIMUM
12"
MINIMUM
Advise owner of boiler to keep venting and combustion 6.
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.
Boiler shall be installed such that automatic gas
7.
ignition system components are protected from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap,
control replacement, etc.).
Boiler must be located where ambient temperatures 8.
(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.
Combustion Air/Vent Pipe Requirements
Boiler requires dedicated direct vent system. In 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 #1 and #2 for required clearances.
If concentric vent termination is being used, refer to
Figure #3 for proper setup.
Less Than 12” Clearance
12” or More Clearance
BEFORE INSTALLING THE BOILER
Figure 1 - Roof Vent / Intake Terminations
Figure 2 - Sidewall Vent/Intake Terminations
Figure 3 - Concentric Vent Terminations

8
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 1³⁄16”
D
E
F
Dimension
Combustion Air/Vent Pipe Requirements Continued
VENT
COMBUSTION AIR
COMBUSTION
AIR
1” MAXIMUM
NOTE:
SECURING STRAP MUST BE FIELD INSTALLED TO
PREVENT MOVEMENT OF TERMINATION KIT IN SIDE
WALL.
ELBOW
(FIELD SUPPLIED)
A
A
B
B
C
C
STRAP
(FIELD SUPPLIED)
VENT
VENT
VENT
A
AB
B
C
C
D
D
COM
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.
BEFORE INSTALLING THE BOILER
!
WARNING
Failure to follow these warnings could result
in fire, property damage, personal injury, or
death.
When vent pipe is exposed to temperatures
below freezing, such as when it passes through
unheated space or when chimney is used as
chaseway, vent pipe must be insulated with
1/2”armaflex or equivalent. In extremely cold
climate areas, use 3/4”armaflex or equivalent.
Combustion air must be clean outdoor air.
Combustion air must not be taken from
inside structure because that air is frequently
contaminated by halogens, which include
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 #1 – #2.
If a concentric vent termination is being used,
refer to figures #3 – #5 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.
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.
Figure 4 - Concentric Vent
Figure 5 - Concentric Vent Roof Installation

9
Foundation Requirements
Boiler must be placed on level surface. Boiler is NOT to be
installed on carpeting.
NOTICE
If boiler is not level condensate drain lines
will not function properly. Adjustable feet are
located on the boiler to make up for minor
surface irregularities or tilt.
Wood frame or blocks may be used to raise
boiler to maintain drain pitch or to be above
external condensate pump reservoir.
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.
Seal any unused openings in the common venting 1.
system.
Visually inspect the venting system for proper size and 2.
horizontal pitch and determine there is no blockage
or restriction, leakage, corrosion or other deficiencies
which could cause an unsafe condition.
In so far as is practical, close all building doors and
3.
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.
Place in operation the appliance being inspected.
4.
Follow the lighting instructions. Adjust thermostat so
appliances will operate continuously.
Test for spillage at the draft hood relief opening after 5 5.
minutes of main burner operation. Use the flame of a
match or candle, or the smoke from a cigarette, cigar
or pipe.
After it has been determined that each appliance 6.
remaining connected to the 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 of use.
Any improper operation of the common venting system 7.
should be corrected so the installation conforms with
the National Fuel Code, ANSI Z223.1/NFPA 54, or
Natural Gas and Propane Installation Code, CAN/CSA
B149.1. When resizing any portion of the common
venting system, the common venting system should be
resized to approach the minimum size as determined
using the appropriate tables in chapter 13 of the
National Fuel Code, ANSI Z223.1/NFPA 54, or Natural
Gas and Propane Installation Code, CAN/CSA B149.1.
The boiler should be placed to provide the most direct
connections to the combustion air, vent and system piping
as possible.
Place crated boiler as close to selected location as possible
and uncrate boiler. The uncrated boiler may be moved into
position with an appliance dolly or 2-wheel hand truck.
The dolly or hand truck should be inserted under the right
hand side of the boiler. It is possible to slide the boiler for
a short distance on a smooth floor or surface.
BEFORE INSTALLING THE BOILER
PLACING THE BOILER
NOTICE
Refer to “locating the boiler” for required
clearances for servicing and maintenance.

10
!
CAUTION
Copper supply and return piping must not be
installed directly into aluminum boiler section
castings due to galvanic corrosion between
dissimilar metals. Iron or steel bushings or
pipe nipples should be used between copper
system piping and boiler to make final
connection to boiler. Use of dielectric unions is
acceptable. Packaged boiler is furnished with
iron piping in front boiler section for supply
and return connections.
When installation of boiler is for new heating system, first
install all of radiation units (panels, radiators, baseboard,
or tubing) and supply and return mains. After all heating
system piping and components have been installed, make
final connection of system piping to boiler.
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). A
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, system design
temperature, and system 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) as
shown in Figure #6 for diaphragm type expansion tank.
For diaphragm type expansion tanks, adjust the tank air
pressure to match the 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 a pressure reducing valve is used,
adjust to match the system fill pressure. In connecting the
cold make-up water supply to the boiler, make sure that
clean water supply is available. When the water supply is
from a well or pump, a sand strainer should be installed at
the pump.
Pressure Relief Valve / Temperature Pressure Gauge
The boiler is furnished with a relief valve and temperature
pressure gauge in the boiler parts bag.
Install safety relief valve and air vent using pipe• fittings provided with boiler. See figure 7.
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. See• figure 5-2.
Use ¾” or larger pipe.• Use pipe suitable for temperatures of 375°F• (191°C) or greater.
NEAR BOILER PIPING
Figure 6 - Diaphragm Type Expansion Tank Piping Figure 7 - Relief Valve Discharge Piping

11
NOTE: When zoning with
circulators, the furnished
circulator pump should be
used as one of the zone
pumps. Each stripped end
of the electrical wires for
the circulator pump inside
the junction box should
be taped or wire nutted
to prevent short circuits.
Unplug the circulator pump
wiring at the integrated
boiler control.
Supply And Return Lines
The packaged boiler unit is set up to receive 1¼” NPT
supply and return piping from top access.
NEAR BOILER PIPING
Figure 8 - Single Zone Boiler Piping
Figure 9B - Multi Zone Boiler Piping With Zone Valves
Figure 9A - Multi-zone Boiler Piping with Circulators
Individual boiler discharge piping shall be• independent of other discharge piping.
Size and arrange discharge piping to avoid• reducing safety relief valve relieving capacity below
minimum relief valve capacity stated on rating
plate.
Run pipe as short and straight as possible to• location protecting user from scalding and properly
drain piping.
Install union, if used, close to safety relief valve• outlet.
Install elbow(s), if used, close to safety relief valve• outlet and downstream of union (if used).
Terminate pipe with plain end (not threaded).•

12
Condensate Drain Requirements
Condensate drain line to be pitched 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.
NOTES:
Condensate trap is to be built in the field per Figure
1.
#10
Wood frame or blocks may be used to raise boiler 2.
to maintain drain pitch or to be above external
condensate pump reservoir.
There is 115 volt AC receptacle provided on service 3.
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 previously
shown in
Figure #10 . Provided are ½” PVC fittings for
condensate drain trap (assembled in field). Condensate
drain is to be pitched down to floor drain at minimum of ¼”
per foot (21mm/m).
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
NOTICE
On initial start up the condensate trap must
be manually filled with water.
Following are steps required to initially fill condensate trap
for start up, these steps are only required at initial start up
or if maintenance requires draining of condensate trap:
Pour about 1 cup of cold tap water into condensate trap 1.
vent.
Excess water should go through condensate drain line. 2.
Verify proper operation of drain line (and external
condensate pump if used).
Chilled Water Piping
Boiler, when used in connection with refrigeration system,
must be installed 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.
NEAR BOILER PIPING
Figure 10 - Condensate Drain Piping

13
Connections And Termination
NOTICE
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.
See Figures 1 – 21. “Combustion Air and Vent Pipe
Requirements, for standard two-pipe roof and sidewall
terminations and Figures 3 – 5 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.
Combustion air and vent pipe fittings must conform 2.
to one of the following American National Standards
Institute (ANSI) and American Society for Testing and
Materials (ASTM) standards:
D1784 (schedule-40 CPVC)•
D1785 (schedule-40 PVC)•
D2665 (PVC-DWV)•
D2241 (SDR-21 and SDR-26 PVC)•
D2661 (ABS-DWV)•
F628 (schedule-40 ABS).•
Pipe cement and primer must conform to ASTM standards
D2564 (PVC) or D2235 (ABS).
In Canada construct all combustion air and vent pipes
for this unit of CSA or ULC certified schedule-40 CPVC,
schedule-40 PVC, PVC-DWV or ABS-DWV pipe and pipe
cement. SDR pipe is NOT approved in Canada.
For Canadian installations all plastic venting material must
be listed to ULC S636.
Combustion air and vent piping connections on boiler
3.
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. (Figure #11)
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.
Combustion air and vent piping to be pitched back to
4.
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.
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
COMBUSTION AIR AND VENT PIPE
Figure 11 - Combustion Air & Vent Piping
NOTICE
Exhaust transition from 2” pipe to 3” pipe
must be made in vertical run. (Transition
pieces not included.)

14
Installation
Attach combustio 1. n air intake piping to supplied Fernco
2” coupling on CVI gas valve. Attach vent piping to
furnished 2” CPVC vent tee on draft inducer outlet.
NOTICE
All pipe joints are to be water tight.
Working from boiler to outside, cut pipe to required 2.
length(s).
Deburr inside and outside of pipe. Remove all chips and 3.
shavings.
Chamfer outside edge of pipe for better distribution of 4.
primer and cement.
Clean and dry all surfaces to be joined. 5.
Check dry fit of pipe and mark insertion depth on pipe. 6.
NOTICE
It is recommended all pipes be cut, prepared,
and pre-assembled before permanently
cementing any joint.
After pipes have been cut and pre-assembled, apply 7.
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.
While cement is still wet, insert pipe into socket with 8.
¼ turn twist. Be sure pipe is fully inserted into fitting
socket.
Wipe excess cement from joint. Continuous bead of 9.
cement will be visible around perimeter of properly
made joint.
Handle pipe joint carefully until cement sets. 10.
Support combustion air and vent piping minimum of 11.
every 5 feet using pre-formed metal hanging straps. Do
not rigidly support pipes. Allow for movement due to
expansion and contraction.
Slope combustion air and vent pipes toward boiler 12.
minimum of ¼” per linear foot with no sags between
hangers.
Use appropriate methods to seal openings where vent 13.
and combustion air pipes pass through roof or side
wall.
NOTICE
Rigid supports will cause excess noise in vent
piping.
COMBUSTION AIR AND VENT PIPE
Consideration for following should be used when 5.
determining appropriate location for termination of
combustion air and vent piping:
Comply with all clearances required as stated in• paragraph 6 (below).
Termination should be positioned where vent• vapors will not damage plants/shrubs, air
conditioning equipment, or siding on the house.
Termination should be positioned so that it will not• be effected by wind eddy, air born leaves, snow, or
recirculated flue gases.
Termination should be positioned where it will• not be subjected to potential damage by foreign
objects, such as stones, balls, etc.
Termination should be positioned where vent• vapors are not objectionable.
Put vent on wall away from prevailing winter wind.• Locate or guard vent to prevent accidental contact
with people or pets.
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.
Under certain conditions, flue gas will condense,• forming moisture, and may be corrosive. In such
cases, steps should be taken to prevent building
materials at the vent from being damaged by
exhaust of flue gas.
Venting system shall terminate at least 3 feet
6.
(0.3m) above any forced air inlet (except the boiler’s
combustion air inlet) within 10 feet (3m). The venting
system shall terminate at least 12 inches (300mm)
from any air opening into any building. Bottom of vent
shall be located at least 12 inches (300mm) above
grade. Termination of vent shall be not less than 7 feet
(2.1m) above adjacent public walkway. Vent terminal
shall not be installed closer than 3 feet (0.9m) from
inside corner of L shaped structure. Termination of
vent should be kept at least 3 feet (0.9m) away from
vegetation.
If multiple terminations are used, there must be minimum
of 12 inches (300 mm) between exhaust of one termination
and air intake of next termination. See Figures 1–3 for
illustrations.
United States - 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.
Canada - Terminate vent system at least 6 feet (1.83m)
horizontally from, and in no case above or below,
unless 6 feet (1.83m) horizontal distance is maintained,
from electric meters, gas meters, regulators and relief
equipment.
NOTICE
All field installed vent pipe must be 3”.

15
Check Gas Supply
Gas pipe to your boiler must be correct size for length of
run and for total BTU per hour input of all gas utilization
equipment connected to it. See Tables #6A & #6B for
proper size. Be sure your gas line complies with local codes
and gas company requirements.
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 #6A - 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 #6B - 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
NOTICE
Length of pipe or tubing should be measured
from gas meter or propane second stage
regulator.
Connecting Gas Piping
Refer to Figure #12 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:
Use only those piping materials and joining methods 1.
listed as acceptable by the authority having jurisdiction,
or in the absence of such requirements,
United States - National Fuel Gas Code, ANSI• Z223.1/NFPA 54.
Canada - Natural Gas and Propane Installation Code,• CAN/CSA B149.1.
Use pipe joint compound suitable for liquefied 2.
petroleum gas on male threads only.
Use ground joint unions.
3.
Install sediment trap upstream of gas controls. 4.
Use two pipe wrenches when making connection to 5.
gas valve to keep it from turning.
Install manual main shutoff valve in vertical pipe 6.
about 5 feet (1.5m) above floor outside boiler
jacket.
Tighten all joints securely. 7.
Propane gas connections should only be made by 8.
licensed propane installer.
Two stage regulation should be used by propane 9.
installer.
Propane gas piping should be checked out by 10.
propane installer.
Recommend use ½” union suitable for natural and 11.
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.•
GAS SUPPLY PIPING
Figure 12 - Gas Piping

16
!
WARNING
Turn off electrical power at fuse box before
making any line voltage connections. Follow
local electrical codes.
All electrical work must conform to local codes as well as
National Electrical Code, ANSI/NFPA-70, latest revision.
In Canada, electrical wiring shall comply with Canadian
Electrical Codes, CSA-C22.1 and .2.
Electric Power Supply
Prior to making any line voltage connections, service switch
at boiler should be in the off position and the power turned
off at the fuse box.
Run a 120 volt circuit from a separate over current
protection device in electrical service entrance panel.
NOTICE
Use copper conductors only.
This should be 15 ampere circuit. A service switch has
been pre-wired and located on exterior boiler jacket. See
Figure #13 for diagram showing 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 always powered regardless of whether switch is
on or off, and could be used as power supply for external
condensate pump if one is used.
Boiler, when installed, must be electrically grounded in
accordance with the requirements of the authority having
jurisdiction or, in the absence of such requirements, with:
United States - National Electrical Code, ANSI/NFPA 70• Canada - Canadian Electrical Code Part I, CSA C22.1,• Electrical Code.
ELECTRICAL WIRING
Figure 13 - Field Wiring Connection

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
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
#13 for service switch junction box and thermostat field
wiring connections.
Connect Circulator Pump Wiring
See
Figures #14A & #14B for service switch junction
box and circulator pump field wiring connections. If the
two 120 volt circulator wire terminals inside the junction
box are not used, please leave the two wire nuts to prevent
the short circuit.
!
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
Run 14 gauge or heavier copper wire from boiler to
grounded connection in service panel or properly driven
and electrically grounded ground rod.
Installing The Thermostat
Thermostat location has important effect on
operation of your boiler system. BE SURE TO
FOLLOW INSTRUCTIONS INCLUDED WITH YOUR
THERMOSTAT.
Locate thermostat about five feet above floor on inside
wall. It may be mounted directly on wall or on vertical
mounted outlet box. It should be sensing average room
temperature.
ELECTRICAL WIRING

18
2
3
G
W
3
2
Y
1
BK
1
BK
G
W
(PS-122)
LWCO
YW
G
Y
BK
ON/OFF SWITCH
NEUTRAL (L2)
HOT (L1)
GROUND
W
24V THERMOSTAT
60 HZ, 1 Ø
120 VAC
R
PUMP
CIRCULATOR
COMMON
W
VAC
120
24 VAC
Y
EAEF03801
TRANSFORMER
CONTROL
BK
GAS VALVE
RECTIFIER PLUG
Y
2
DIAGNOSTIC INDICATOR LIGHTS
FLAME
VALVE
IGNITOR
PURGE
POWER
R
R
R
G
R
120VAC
321P7
IGNITER
TO
CASTING
2
1
BLOWER
BLOWER
P10
G
3
W
2
BK
1
TRANSFORMER
PRIMARY
R
R
32P1
1
1
P6
BLOWER
G
2
431P5
WBK
CASTING TEMPERATURE SAFETY SWITCH (MANUAL RESET)
BR
BL
W
V
BR
SET AT
+ 3.5" WC
SWITCH (N.C.)
AIR PRESSURE
DIFFERENTIAL
CONTROL
HI LIMIT
AQUASTAT
SET AT
+ 0.5" WC BL
BR
AIR PRESSURE
DIFFERENTIAL
SWITCH (N.O.) V
CIRCULATOR
2
431P4
9
3 6 Y
24 VAC
SECONDARY
TRANSFORMER
147
85
2
BR CONTROL
P3
12
V1
3
P2
Y
2Y
1
1013-10 INTEGRATED BOILER CONTROL
W
BK
(NOTE: USE COPPER CONDUCTORS ONLY)
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.
ELECTRICAL WIRING
Figure 14A - Schematic Wiring Connections

19
LWCO
(PS-122)
HIGH LIMIT
FLAME
P3-4
THERMOSTAT
P3-7
RW
P3-9
1013-10 CONTROL
P1-2
CONTROL
AQUASTAT
P3-3
P3-6
P3-1
(MANUAL RESET)
SAFETY SWITCH
CASTING TEMPERATURE
+ 0.5" WC 1
3
AIR PRESSURE
SWITCH (N.O.)
SET AT
2
DIFFERENTIAL
1
P2-1
INDICATOR LIGHTS
IGNITER
VALVE
POWER
PURGE
LOGIC & TIMERS
ELECTRONIC
MICROPROCESSOR
4K
2K
1K
3K
5K
GAS VALVE
4K1 3K1 P3-5
24 VAC
45
P2-2
P3-2
BLOWER
P5-1
1K1 P10-1
2K1
P7-1 P4-1
TRANSFORMER
P1-1
120 VAC
3
P1-3
1
HOT SURFACE IGNITER
P12-1P6-1
5K1 P12-2 5K2
P6-2 P10-3
CIRCULATOR FIELD WIRED P5-3P10-2
P7-3
P4-3
P7-2
(NOTE: USE COPPER CONDUCTORS ONLY)
ON/OFF BLK
HOT
L1
WHT
L2
SWITCH
120 VOLT POWER SUPPLY
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.
ELECTRICAL WIRING
Figure 14B -Ladder Wiring Diagram

20
This section provides a brief description of the key controls
and accessories found in this boiler.
See, “Troubleshooting,” page 33 in this installation manual
for detailed sequences of operation and troubleshooting
procedures. See the separately provided “Repair Parts
Manual” for locations of all control components and
accessories described.
Integrated Boiler Control (IBC)
The Integrated Boiler Control (IBC) is a microprocessor
based controller for high efficiency gas boilers that
monitors all safety controls and which controls the
operation of the combustion air blower, circulator pump,
burner, and a combination hot surface igniter/flame sensor.
This controller is not intended for use with a vent damper.
This controller is mounted on the control panel inside the
boiler and contains five diagnostic indicator lights.
Gas Control Valve
The electronic 24 volt gas control valve contains a 1:1
gas/air pressure regulator to control gas flow to the main
burner of the appliance, is suited for both natural and LP
gas, and is rated in accordance with ANSI Z21.21 - latest
revision and CGA-6.5-M95.
Hot Surface Igniter
The 120 volt hot surface igniter heats up to 1800°F to
initiate combustion of the gas in the burner. The igniter is
mounted next to the burner through the gas/air mixer. The
igniter also serves as a means for proving the main burner
flame by flame rectification. In the event of a lack of flame
signal on three consecutive trials for ignition, the IBC will
lock out. The “Valve” and “Flame” diagnostic indicator lamps
(see Figure #16) will blink indicating the failure mode as a
lack of flame signal. The IBC is manually reset from lockout
by either removing and reestablishing the thermostat’s call
for heat, or by turning the service switch off, then back on.
High Limit Aquastat Control
The high limit aquastat control determines the maximum
boiler water temperature and also provides a means for
protecting the boiler and heating system from unsafe
operating conditions which could damage the boiler. The
aquastat is mounted in the ½” NPT control well and ¾” x ½”
bushing on the top of the front boiler section at the hot water
outlet. The aquastat is tied in with the IBC and is factory set
at 180°F water temperature. The high limit setpoint is field
adjustable and may be set anywhere between 100°F and
200°F. The field setpoint adjustment for each installation
depends on heating system requirements. The aquastat
automatically resets when the boiler water temperature drops
20°F below the set-point value. This reset value can be field
adjusted within a range of 5-30°F.
NOTICE
Maximum set-point of the aquastat must not
exceed 200° F.
Casting Temperature Safety Switch
In the event of lack of or loss of water in the boiler, the
casting temperature safety switch (230°F set-point)
installed on the top of the aluminum boiler section behind
the supply piping shuts off the boiler by shutting off power
to the IBC and causes the power indicator light to go out.
This fault requires manual reset of the casting temperature
safety switch to restart the boiler. Verify that the boiler is
properly filled with water before resetting this switch.
NOTICE
Never run cold water into a hot, empty boiler.
CONTROLS AND ACCESSORIES
Figure 15 -Gas Valve
Figure 16 - Indicator Lights