Dunkirk Q95M-200 Owner's manual

Q95M-200
GAS-FIREDDIRECTVENT
MODULATINGHOTWATERBOILER
INSTALLATION, OPERATION &
MAINTANANCE MANUAL
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com P/N 240006103D, Rev.C [04/2009]

Installation Manual Printed in USA• Made In USA
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I-Introduction ............................................................ 2
III - Rules For Safe Installation and Operation ..........3
IV- Boiler Ratings and Capacities .............................. 4
V-Before Installing The Boiler .................................. 4
VI -Placing the Boiler .............................................. 10
VII- Near Boiler Piping ............................................ 10
VIII -Combustion Air And Vent Pipe....................... 12
IX -Gas Supply Piping .............................................. 14
X-Electrical Wiring .................................................. 15
XI -Controls and Accessories .................................. 17
XII - Water Treatment & Freeze Protection ........... 19
XIII -Putting the Boiler in Operation ...................... 22
XIV- Maintenance And Cleaning ............................. 23
XV -Boiler Wiring Diagram ..................................... 27
XVI -Piping and Wiring Appendix .......................... 28
IMPORTANT:Thisboileristo beinstalled by aqualified
installeronly.
Thisapplianceisa gas-fireddirect vent modulating cast aluminum
hot waterboiler.A revolutionary castaluminum monoblock heat
exchangermeans better heat transfer andthermal storagethan
similarlysizedcastiron boilers,which resultsin higher efficiency.
Theheating systemwaterabsorbslarge amounts ofheat from the
castaluminum heat exchanger,cooling the fluegasesand causing
condensation. Sealedcombustion, premix gasburner, and low flame
temperature means drasticallyreduced CO and NOxemissions,
whichcontribute to a cleanerand healthier environment.
Thisappliance,unlike normal residential atmospheric and induced
draft units, takes itscombustion airdirectlyfrom the outdoors
(sealedcombustion) and doesnot competewith building occupants
forfresh air.Sealedcombustion (alsoknown as "directvent") isthe
safestand best wayto obtain plenty of cleancombustion air.The
forceddraft fan draws in the outside combustion air to mix with gas,
whichflowsinto the pre-mix burner andburns. Thefan then forces
the resulting fluegasesfrom the boiler unit and providesapositive
removalofthe fluegasesfromthe building through inexpensiveand
readilyavailablePVCand CPVCpipes. ULC$636Materialmust be
usedin Canada.
Keepthis manual near boilerand retain for future
reference.

Thefollowingdefinedsymbolsareusedthroughoutthismanualtonotifythereaderofpotentialhazardsofvaryingrisklevels.
Indicatesanimminentlyhazardoussituationwhich,ifnot
avoided,willresultindeath,seriousinjuryorsubstantial
propertydamage.
Indicates an imminently hazardous situation which, if not
avoided, may result in injury or property damage.
Indicates an imminently hazardous situation which, if not
avoided,mayresult in death, seriousinjury or substantial
property damage.
Indicates informationwhich should be followedto ensure
proper installationand operation.
Thisappliance has been equipped for residential instal-
lations. If usedfor commercialapplications,anyand all
additional code requirements must be adhered to for in-
stallation.Thismayrequire additional controls,including
but not limitedto an externalwater cut off,amanual reset
high temperature limit, andwiring and/or pipingmodifi-
cations.Themanufacturer is not responsiblefor anyfield
installationchangesmade to aboiler installationwhich are
not described or acknowledgedin this manual.
IMPORTANT:Failure to followtheseinstructions could
causea malfunction ofthe boilerand result in death, seri-
ous bodily injury,and/or property damage.For assistance
or additional information, consult a qualifiedinstaller,
serviceagency,or the gassupplier.
1. Check allapplicable state and localbuilding codesand utility
company requirements before installation. Thisinstallation
must conform with theserequirements in their entirety. In the
absenceof thesecodes,useNFPA installation codesand good
industry practice.
2. Beforeservicingthe boiler, allowit to cool.Alwaysshut offany
electricityand gassupply connected to the boilerprior to servic-
ing.
3. Inspect gas line for leaks.
4. Be certaingas input rate is correct. Over firingmay result in
early failureof the boiler components. Thismay causedanger-
ous operation. Under firing mayresult in too much air for the
pre-mix burner causingpoor or lossof combustion.
5. Nevervent the products ofcombustion from this boilerto an
enclosed space.Alwaysvent to the outdoors. Nevervent to
another room or to inside abuilding.
6. Besure there is adequate outdoor air supplyto boiler for com-
plete combustion.
7. Followaregular service and maintenance schedulefor efficient
and safeoperation.
8. Keepboiler areaclean ofdebris and free ofcombustible and
flammablematerials.
go
10.
Proper through-the-wall or through-the-roof combustion
venting shallbe in accordance with the materials and methods
described in this manual. Installation must complywith local
codes.
Thisboilerand related hot water heating systemsare not do-it-
yourself items. Theymust be installed and serviced by qualified
professionals.Ratingsabove are for sealevelapplications.The
boiler automatically derates input ata rate of2% for every 1000
feet above an elevationof2000feet (see Table2). Theboilerwill
alsoderate relative to the calorificvalueofthe gas beingused.
Usethe formula specifiedin "Measure TheNatural GasInput
Rate"in the Control Manual and Troubleshooting Guide (PIN#
240006104) to determine the proper rate due to derated gas.To
ensure proper operation at 5,000feet of altitude and above, the
minimum RPM setting; parameter 17, must be raised to 3,200.
Instructions on how to change theparameters areincluded in
the Parameter Guide, part number 240006105.

High Fire _ 200 190 165 2" 3"
95% CPVC & PVC
Low Fire |80 76 66
_1 MBH =1,000 BTUH (British Thermal Units Per Hour)
_2_Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
284 Ibs.
High Fire 196 192 177 174.5 172 169 168 167
Low Fire 78.4 76.8 115 113.5 112 110 109 108
1) Boiler Input Rate is determined at minimum vent length. The rate will decrease as vent length increases.
2) Parameter 17 is set to 2,250 at elevations of 2,000 feet above and below.
3) Parameter 17 must be raised to 3,200 at altitudes or elevations of 2,000 feet and above.
Theselowpressure gas-firedhot water boilers are design certified
by CSAInternational, for usewith natural and propane gases.The
boilersareconstructed and hydrostaticallytestedfor amaximum
working pressureof 50PSIG(pounds per square inch gauge)in ac-
cordance with ASME(AmericanSocietyof MechanicalEngineers)
Boilerand Pressure VesselCode Section IVStandardsfor heating
boilers.
TheBoilersare certifiedin accordance with ANSI(AmericanNa-
tional Standards Institute) Z21.13standards asgas-fired,direct vent,
condensing, hot water boilers.
TheHeating Capacityindicates the amount ofheat availableafter
subtracting the lossesup the stack. Mostof this heat isavailableto
heatwater.A smallportion is heat lossfrom the jacket and surfaces
ofthe boiler,and it isassumed that this heat staysin the structure.
TheNetI=B=RRating representsthe portion of the remaining heat
that can be appliedto heatthe radiation orterminal units (i.e.,finned
tube baseboard, castiron radiators, radiant floor,etc.)Thedifference
between the HeatingCapacityand the Net I=B=RRating, called
the piping and pickup allowance,establishesa reservefor heating
the volume ofwaterin the system and offsettingheat lossesfrom
the piping. TheNet I=B=RRatingsshown are based on a piping
and pickup factorof 1.15in accordancewith the I=B=RStandard
aspublishedby the Hydronics Institute.TheNet I=B=RRatingof
the boiler selectedshould be greater than or equalto the calculated
peak heatingload (heat loss)for the building or area(s)servedby the
boiler and associatedhot waterheating systems.Themanufacturer
shouldbe consulted before selectingaboiler forinstallations having
unusual piping and pickuprequirements.
Reviewthe following before installing the boiler
Thisboilerproduct is agas-fired,direct vent, condensingboiler and
must beinstalled in accordancewith allapplicablefederal,state and
localbuilding codesincluding,but not limitedto the following:
United States - Installation shallconform with NationalFuelGas
Code (NFPA-54/ANSIZ223.1-latest edition)
Canada - Installation shall be in accordancewith CSA-B149.1and
.2installation codes.
Where requiredby the authority havingjurisdiction, the installa-
tion must conform to the ASMESafetyCode for Controls and Safety
Devicesfor AutomaticallyFired Boilers,No.CSD-1.
Theinstallationmust conform to the requirements ofthe authority
havingjurisdiction or,in the absenceofsuch requirements, to the
NationalFuel GasCode, ANSIZ223.1- latest revision.
Installers- Followlocalregulationswith respectto instal-
lation of Carbon Monoxide Detectors. Followmaintenance
recommendations in this manual.
In the State of Massachusetts, boiler installation must conform
to state code 248 CMRwhich includes but is not limited to:
•This product must be installed by a licensed Plumber or
Gas fitter.
•When flexibleconnectors are used, the maximum length
shallnot exceed36 inches.
•When levertypegas shutoffs are used,they shallbe T-
handle type.
For allside wall horizontallyvented gas fueled equipment installed
in every dwelling,buildingor structure used in wholeor in part
for residential purposes, including those owned or operated by the
commonwealthand where the side wall exhaustvent termination is

lessthanseven(7)feetabovefinishedgradeintheareaofthevent-
ingincludingbutnotlimitedto,decksandporches,thefollowing
requirementsshallbesatisfied:
1. Installation of carbonmonoxidedetectors:At the time
ofinstallation ofthe sidewallhorizontal vented gas fueled
equipment, the installingplumber or gas fitter shallobserve
that ahard wired carbon monoxide detector with an alarm
and battery back-up is installedon the floor levelwherethe gas
equipment is to beinstalled. In addition, theinstalling plumber
or gasfittershall observethat a battery operated or hard wired
carbon monoxide detector with an alarm isinstalled on each
additional levelofthe dwelling,building or structure servedby
the sidewall horizontal vented gasfueled equipment. It shallbe
the responsibilityofthe property owner to securethe servicesof
qualifiedlicensedprofessionalsfor the installation ofhard wired
carbon monoxide detectors.
A. In the eventthat the sidewall horizontallyvented gasfueled
equipment is installedin acrawl space or an attic, the hard
wired carbon monoxide detector with alarm and battery
back-upmay beinstalled on the next adjacent floor level.
B. In the eventthat the requirements ofthis subdivision can
not be met at the time of completion ofinstallation, the
owner shall have a period of thirty (30)days to complywith
the aboverequirements; provided, however,that during
said thirty (30)day period, a battery operated carbon mon-
oxidedetectorwith an alarm shallbe installed.
.
.
Approved carbonmonoxide detectors:Each carbon
monoxide detector as required in accordance with the above
provisions shallcomply with NFPA720 and beANSI/UL2034
listedand IAScertified.
Signage:Ametal or plasticidentification plate shallbeperma-
nently mounted to the exterior of the building at aminimum
height of eight (8)feet abovegrade directlyin line with the ex-
haust vent terminal for the horizontally vented gasfueled heat-
ing applianceor equipment. Thesignshall read, in print sizeno
lessthan one-half (1/2) inch in size,"GASVENTDIRECTLY
BELOW.KEEPCLEAROFALLOBSTRUCTIONS".
4. Inspection:Thestate or localgasinspector ofthe sidewall
horizontallyvented gasfueled equipment shallnot approve
the installation unless,upon inspection,the inspector observes
carbon monoxide detectors and signageinstalledin accordance
with theprovisions of 248CMR 5.08(2)(a)1through 4.
5. Product-approved vent/air intake: Aproduct-approved
ventterminal must beused and, if applicable,aproduct-
approved air intakemust be used. Installationshall be in strict
compliance with the manufacturer's instructions.
6. Installation instructions: A copyofall installation instruc-
tions for allProduct Approved sidewall horizontallyvented
gasfueledequipment, allventing instructions, allparts listsfor
venting instructions, and/or allventing design instructions shall
remain with the applianceor equipment atthe completion of
the installation.
BoilerSizing
•Checkto besure you have selectedthe boilerwith the prop-
er capacitybefore continuing the installation. TheI=B=R
Ratingofthe boiler selectedshould begreater than or equal
to the calculatedpeak heatingload (heat loss) for the build-
ingor area(s) servedby the boiler and associatedhot water
heating systems.See"Tableh SeaLevelRatings-Natural
and PropaneGases"in SectionIV ofthismanual.
•Heat loss calculationsshould bebased on approved indus-
try methods.
Considerations for Boiler Location
Beforeselectingalocationfor the boiler,the followingshould be
considered.Each boiler considered for installationmust be:
•Suppliedwith the correct typeof gas(natural gasor pro-
pane).
•Connected to a suitable combustion air intake piping
systemto supplythe correct amounts of fresh (outdoor)
airfor combustion (15'minimum equivalentlength/100'
maximum equivalent length).
•Connected to a suitableventing systemto remove the haz-
ardous products of gas combustion (15' minimum equiva-
lent length/100' maximum equivalentlength).
•Connected to a suitable hot water heating system.
•Suppliedwith a suitable electricalsupply for allboiler mo-
tors and controls.
•Connected to aproperly locatedthermostat or operating
control (not included with boiler).
•Placedon levelsurface (must NOT be installed on carpet-
ing).
•Condensate drain line must be pitched down to floordrain
or external condensate pump with reservoir at1A,,per foot
(woodframe or blocksmay beused to raise boiler).
Locatingthe Boiler
1. Select a location which is level, central to the piping systems
served and as close to the vent and air intake terminals as pos-
sible.
2. Accessibilityclearances,if more stringent (i.e.larger clearances)
than required fireprotection clearances,must beused for the
boiler installation. Accessibilityclearancesmay be achieved
with the useofremovable wallsor partitions.
3. Theboiler is approved for installation in closetsand on com-
bustible floors.Thisboiler shallNOT be installed on carpeting.

oTheclearancesshown in Table3 indicate required clearances
per CSAlisting.A minimum 1"clearancemust bemaintained
betweencombustible construction and eachofthe right, top
and back surfacesof the boiler.Allow at least24" at the front
and leftside and 8"atthe top for servicing.Nocombustible
clearancesare required to venting or combustion air intake
piping.
TABLE 3: BOILER CLEARANCES*
Top 1" 8" 8"
Left Side 1" 24" 24"
RightSi& 1"
Base 1"
Front 0 24" 24"
Back 6"
Intake/VentPiping 0
NearBoilerHot 1 "
WaterPiping
*All distances measured from the cabinet of the boiler.
5, Equipment shallbe installedin alocation which facilitatesthe
operation of venting and combustion air intake piping systems
asdescribed in thismanual.
6. Advise owner of boiler to keep venting and combustion air
intake passages free of obstructions. Both the venting and com-
bustion air intake piping systems connected to the outdoors
must permit flow through the piping systems without restric-
tions for the boiler to operate.
7. The boiler shall be installed such that the automatic gas ignition
system components are protected from water (dripping, spray-
ing, rain, etc.) during operation and service (circulator replace-
ment, control replacement, etc.).
8. The boiler must be located where ambient room temperatures
(minimum possible temperatures where boiler is installed as-
suming boiler is not in operation and therefore contributes no
heat to the space) are always at or above 32°F to prevent freez-
ing of liquid condensate.
Combustion Air and Vent Pipe Requirements
This boiler requires a dedicated direct vent system. In a direct vent
system, all air for combustion is taken directly from outside atmo-
sphere, and all flue products are discharged to outside atmosphere.
Combustion air and vent pipe connections must terminate together
in the same atmospheric pressure zone, either through the roof or
sidewall (roof termination preferred). See Figures 1and 2 for re-
quired clearances. If necessary, use of screening no smaller than 1/2"
hardware cloth is acceptable.
Figure 1- Roof Vent/Intake Terminations
3" MAX.]
8" MAX.
12" MIN ABOVE
HIGHEST ANTICIPATED
SNOW LEVEL
.COMBUSTION AIR
Figure 2 - Sidewall Vent/Intake Terminations
jJ
OVER_
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
D BOTTOM OF VENT
MAINTAIN 12" MINIMUM
ABOVE HIGHEST
_ANTICIPATED SNOW LEVEL OR
GRADE
LESS THAN 12" CLEARANCE ABOVE GRADE
!IMUM
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
BOTTOM OF VE_T
_J
"-"-- MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
12" OR MORE CLEARANCE ABOVE GRADE

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If the concentric vent termination is being used, refer to Figure 3
for proper setup.
Figure 3 - ConcentricVent Terminations
Figure 3A - Clearances To Other Residential Features
NOTE: IF THERE IS A POTENTIAL FOR EXCESSIVE WINDS, SPECIAL
CONSIDERATION SHOULD BE GIVEN TO LOCATE THE VENT TERMINATION
AWAY FROM THE WINDWARD SIDE OF THE BUILDING,
VENT TERMINATION MUST BE AT LEASI '_
36" (92 CM) HORIZONTALLY FROM /\
ANY ELECTRIC METERS, GAS METERS \\
OR RELIEF EQUIPMENT PER NEC. \\
LOCATEVENTTERMINATIONTOALLOW
12" (31 CM) MINIMUM ABOVE GRADE
/MOUNT VENT TERMINATION AT LEAST
36" (92 CM) FROM INSIDE CORNERS
VENT TERMINATION MUST BE AT LEAST
36" (92 CM) ABOVE ANY FORCED
AIR INLET LOCATED WITHIN 10 FT (305 CM)
VENT TERMINATION MUST BE INSTALLED WITH
A CLEARANCE OF AT LEAST 12 INCHES (31 CM)
FROM ANY AIR OPENING INTO A BUILDING.
Through the wall vents for Category II and IV appliances and non categorized condensing appliances shall not terminate over public walk-
ways or over an area where condensate or vapor could create a nuisance or hazard or could be detrimental to the operation of regulators,
relief vales, or other equipment. Where local experience indicates that condensate is a problem with Category I and Ill appliances, this provi-
sion shall also apply.

Whenutilizingtwoormoreboilers,eachterminationmusthaveatleast12inchesofclearancefromanyadjacenttermination.Seediagrams
below.
12'
MINIMUM
J
Jj
/BETWEEN BOTTOM OF
AND BOTTOM OF VENT
MAINTAIN 12' MINIMUM
ANTICIPATED SNOW LEVEL OR
GRADE
Keep boiler area clean of debris and free of flammable and
combustible materials, vapors, and liquids.
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]]]]]]]]]]]]]]]ii Failure to follow these warnings could result in fire, prop-
erty damage, personal injury, or death.
When vent pipe is exposed to temperatures below freez-
ing, such as when it passes through an unheated space or
when a chimney is used as a chaseway, vent pipe must be
insulated with _/2'Armaflexor equivalent. In extremely cold
climate areas, use _ Armaflex or equivalent.
Combustion air must be clean outdoor air. Combustion air
must not be taken from inside the structure because that
air is frequently contaminated by halogens, which indude
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.
Condensate trap is integral to the boiler.
Wood flame or concrete blocks may be used to raise the
boiler to maintain drain pitch or to be above external con-
densate pump reservoir.
There is a 115 volt AC receptacle provided on the control
panel to provide power for an external condensate pump
(if needed).
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Failure to follow these warnings could result in fire, prop-
erty damage, personal injury, or death.
Locate combustion air inlet as far away aspossible from
swimming pool and swimming pool pump house. All
combustion air and vent pipes must be airtight and water-
tight. Combustion air and vent piping must also terminate
exactly as shown in Figures 1 and 2. Ifa concentric vent
termination is being used, refer to Figures 3 through 5 for
proper setup.
Vent connections serving appliances vented by natural
draft shall not be connected into any portion of mechani-
cal draft systems operating under positive pressure.
Solvent cements are combustible. Keep away from heat,
sparks, or open fame. Use only in well ventilated areas.
Avoid breathing in vapor or allowing contact with skin or
eyes.
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Figure 4- Concentric Vent w/Dimensions
Concentric Vent w/Dimensions
CondensateDrainRequirements
At therear of the unit a 1/2>>PVC pipe nipple with NPT threads is
provided for the attachment of the condensate drain line. Attach
the 1/2"PVCtee in the parts bagto act asavent asshown.Attach
?2"PVCfrom this point to either adrain or an external condensate
pump (not furnished). Ifthe drain levelisabovethe condensatetrap,
acondensate pump must be used. Thecondensatepump must be
designed for afluegascondensate application.Thecondensate drain
line must bepitched down to the floor at a minimum of 1A,,per foot
and must berouted within the conditioned spaceto avoidfreezingof
condensateand blockageofthe drain line.Ifthe unit willbe started
immediatelyupon completion of installation, prime trap byfilling
with water until water isseen at the vent.
3" DiameterPVCVent/Exhaust
Figure 5- Concentric Vent Roof Installation
COMBUSTION AiR
ROOF BOOTIFLASHING
(FIELD SUPPLIED)
NOTEI
SUPPORT MUST BE
FIELD INSTALLED TO
SECURE TERMINATION
KITTO STRUCTURE,
VENT MAINTAIN 12 IN,
t(i 8 IN, FOR CANADA)
MINIMUM CLBARANCE
ABOVE HIGHEST
ANTICIPATED SNOW
LEVEL MAXIMUM OF
24 INoABOVE ROOF,
(FIELD SUPPLIED)
ELBOW
COMBUSTION AIR
Foundation Requirements
Boilermust be placed on levelsurface.Boileris NOT to be installed
on carpeting.
If boiler is not levelcondensate drain lines willnot
function properly. Adjustable feetare located on the
boiler to make up for minor surfaceirregularities or
tilt.
Wood flame or blocks may be used to raise boiler to
maintain drain pitch or to be above external conden-
sate 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 islikelyto betoo largefor proper vent-
ing ofthe appliancesremaining connected to it. At the time of re-
movalof an existingboiler,the followingsteps shallbe followedwith
eachappliance remaining connected to the common venting system
placed in operation, while the other appliancesremaining connected
to the common venting systemare not in operation.
1. Seal any unused openings in the common venting system.
o
3,
Visuallyinspect the venting systemfor proper sizeand hori-
zontalpitch and determine there isno blockageor restrictions,
leakage,corrosion and other deficiencieswhich could causean
unsafe condition.
When it ispractical, closeallbuilding doors andwindows and
alldoors between the space in which the appliancesremaining
connected to the common venting system arelocated and other
spacesofthe building. Turn on clothesdryer and anyappliance
not connected to the common ventingsystem.Turn on any
exhaustfans, such asrange hoods and bathroom exhaust, so
theywilloperate atmaximum speed. Do not operate a summer

o
So
exhaust fan.Closefireplacedampers.
Place in operation the appliance being inspected. Follow the
lighting instructions. Adjust thermostat so appliances will
operate continuously.
After it has been determined that each appliance remaining
connected to the common venting system properly vents when
tested as outlined above, return doors, windows, exhaust fans
and any other gas-burning appliance to their previous condition
of use.
6, Any improper operation of the common venting system should
be corrected so the installation conforms with the National Fuel
Code, NFPA-54/ANSI -Z223.1-1atest revision, or section 5 of
CSA-B149for Canadian standards. 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 the National Fuel Gas Code,
NFPA-54/ANSI- Z223. l-latest revision, or section 5of CSA-
B149 for Canadian standards.
Theboiler must belocated on asurface that can support
the weightof the installedboiler.
Theboiler shouldbe placed to provide the most direct connections
to the combustion air,vent and systempiping aspossible.
Placecrated boileras closeto selectedlocation aspossibleand
uncrate boiler.Theuncrated boiler may bemoved into position
with an appliancedollyor 2-wheelhand truck. Thedollyorhand
truck should be inserted under the right hand sideof the boiler. It is
possible to slidethe boiler for a short distanceon a smooth flooror
surface.
NOTE: Referto "LocatingTheBoiler"in SectionVof this
manual forrequired clearancesfor servicingand mainte-
nance.
Copper supplyand return pipingmust NOT be installed
directlyinto aluminum boiler sectioncastings dueto
galvaniccorrosion betweendissimilarmetals. Iron or steel
bushingsor pipe nipples shouldbe used between cop-
per systempipingand boiler to make finalconnection to
boiler.Also,the useof dielectricunions is acceptable.The
packagedboiler isfurnished with iron piping where neces-
sary forthe supplyand return connections.
When the installation of the boiler is for a new heating system, first
install all of the radiation units (panels, radiators, baseboard, or tub-
ing) and the supply and return mains. After all heating system piping
and components have been installed, make final connection of the
system piping to the boiler.
According to code, a hot water boiler installed above radiation level
must be equipped with a low water cut off device. A periodic inspec-
tion is necessary, as is flushing of float type devices, per low water
cut offmanufacturers specific instructions. This boiler is factory
equipped with a manual reset probe-type low water cut
Off.
Non-potable wateronly piped directlyto boiler.DO NOT
connect drinking water to heating system.
Determine required system fill pressure, system design
temperature, and system water content. Boiler contains
2.6 gallons (US). 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.

Figure6- Diaphragm Type Expansion Tank Piping
Figure 7 - Relief Valve Discharge Piping
Pressure Relief Device
Check local codes
for maximum dis-
tance from floor.
Pressure Relief Valve/Temperature Pressure Gauge
The boiler is furnished with a relief valve in the boiler parts bag. Pro-
vide %" piping from the supplied relief valve to a local floor drain,
but leave an air gap between piping and drain. No shutoff of any
description shall be placed between safety relief valve and the boiler,
or on the discharge pipes between such safety valve and the atmo-
sphere. Installation of the safety relief valve shall conform to ANSI/
ASME Boiler and Pressure Vessel Code, Section IV.The manufac-
turer is not responsible for any water damage. Check local codes for
maximum height from discharge piping to floor.
Supply & Return Lines
The packaged boiler unit is set up to receive 11_'' NPT return piping
from the rear of the unit with an option for left or right return con-
nections, llA'' NPT supply piping exits the boiler jacket at the top of
the unit.
NOTE:On some boilers the circulator pump and isolation
valvesare furnished in a carton insidethe boiler cabinet
and can be installedat the installerpreferred location.
Condensate Drain Piping
Thecondensatetrap is integralto the boiler.Usethe supplied 1/2"
PVCtee,then transition to _/2"pipe and fittingsfor PVCcondensate
drain line.Condensate drain line to be pitcheddown to floordrain
ata minimum of 1_,,per foot.
The_/2"diameter schedule 40 PVCcondensate drain piping and pipe
fittingsmust conform to ANSIstandards and ASTMD1785.Sched-
ule40 PVCcement and primer must conform to ASTMD2564.In
Canada, useCSAor ULCcertifiedschedule 40 PVCdrain pipe and
cement.
A condensate pump with a reservoir (not furnished) may be used
to remove condensate to a drain line (sanitary line) above boiler if a
floor drain is not available or is inaccessible.
Fillingthe Condensate Trap with Water
The following are the steps required to initially fill the condensate
trap for start up, these steps are only required at the initial start up or
if maintenance requires draining of the condensate trap:
1. Pour about 1cup of cold tap water into the vent drain line using
the 1/2" PVC vent tee provided with the boiler.

2. Excesswater should go through the overflowand out through
the condensate drain line. Verify proper operation of the drain
line (or external condensate pump if used).
3. Reinstallthe vent drain line.
Chilled Water Piping
The boiler, when used in connection with a refrigeration system,
must beinstalled so the chillermedium ispiped in parallel with the
boiler with appropriatevalvesto prevent the chilledmedium from
entering theboiler.
Theboiler piping systemof ahot water boiler connected to heating
coilslocatedin air handling units where they may be exposedto re-
frigerated aircirculation must be equippedwith flowcontrolvalves
or other automaticmeans to prevent gravitycirculation ofthe boiler
waterduring coolingcycle.
Connections & Terminations
For boilers connected to gas vents or chimneys, vent installations
shall be in accordance with Venting Requirements of the National
Fuel Gas Code, ANSI Z223. l-latest revision, CSA-B149.1 and
B149.2, and applicable provisions of the local building codes.
Provisions for combustion and ventilation air must be in accordance
with the National Fuel Gas Code, ANSI Z223. l-latest revision, CSA-
B149.1 and B149.2, or applicable provisions of the local building
code.
NOTE: The exhaust transition from 2" pipe to 3" pipe
must be made in a vertical run. Transition pieces are not
included. (See Figure 8 for details.)
Combustion and Vent Piping Length
Theseboilersrequire adedicated direct vent system.All airfor com-
bustion istaken directly from outdoors through the combustion air
intakepipe. Allflueproducts aredischarged to the outdoors through
thevent pipe. Insulatelengths ofcombustion pipe in unconditioned
areas.
.See Figures 1through 5 for combustion air and vent pipe
roof and sidewall termination (roof termination is preferred).
Combustion air and vent pipes must terminate together in
same atmospheric pressure zone as shown. Construc-
tion through which vent and air intake pipes may be installed is
a maximum 24" and a minimum 1_,,thickness.
PVC 158 70
CPVC 210 100
ASTM F 891 *
ASTM D2665 **
ASTM D1785 **
ASTM D2241 **
ASTM D2846 **
ASTM F441 **
ASTM F442 **
ASTM D2661 ***
ABS 180 82 - - ASTM F628 ***
2. Combustion air and vent pipe fittingsmust conform to
AmericanNational StandardsInstitute (ANSI)standards and
American Societyfor Testing and Materials (ASTM)standards
D1784(schedule-40CPVC),D1785(schedule-40PVC),D2665
(PVC-DWV), D2241(SDR-21and SDR-26PVC),D2661 (ABS-
DWV), or F628(schedule-40ABS).Pipe cement and primer
must conform to ASTMstandards D2564(PVC) or D2235
(ABS).
3. For Canadian installations all plasticventing material must be
listedto ULC$636.
Do not use cellular core PVC for venting flue gas.
Radel- UL-1738
414 212 - -
A200 ULC $636
*Allowable temperatures based on Classifications covered in
ASTM D4396 [Deflection Temperatures under Load (264psi)
(1819 KPa)].
**Allowable temperatures based on Classifications covered in
ASTM D1784 [Deflection Temperatures under Load (264psi)
(1819 KPa)].
***Allowable temperatures based on Classifications covered in
AsTM D3965 [Deflection Temperatures under Load(264psi)
(1819 KPa)].
.Combustion air and vent pipe connections on boiler are 2" but
must increase to 3".Due to potential for fluegastemperatures
above 155°F,the first 30"ofsupplied vent pipe isCPVC while
the remaining ventpipe can be PVC.Any replacement ofthe
first 30"of vent pipe must be made with CPVC.
Thelength of pipe is counted from the end ofthe supplied 2"CPVC
pipe exitingthe boiler.Thetermination is not counted in the "Total
Equipment Length:' Thecombustion air supplypipe must terminate
at the samelocation as the exhaustpipe.

Figure 8- Combustion Air&Vent Piping
FIELDINSTALL2" BY3"
TRANSITIONIN THE
VERTICALPOSITION
ONLY
(2 REQ'D,NOT FUR-
NISHED)
3" INTAKEAND EX-
HAUST
TERMINATIONS
2" (50.8MM)CPVC
VENT PIPING
(FURNISHED&
REQUIRED)
2" (50.8MM)COMBUSTION
AIRINTAKEPIPING
(FURNISHED)
Reducethe maximum vent length by 5' per each 90° elbow.
1. Exhaust air piping to be pitchedback to boiler at minimum 1A,,
per foot from vent terminals so that allmoisture in vent piping
drains to boiler. Pipesmust bepitched continuously with no
sagsor low spotswhere moisture can accumulate and block the
flowof fluegas. Combustion air and vent pipes must be airtight
and watertight.
2. Consideration for the following shouldbe usedwhen deter-
mining an appropriate locationfor termination ofcombustion
air and vent piping:
•Complywith allclearancesrequired.
•Termination should be positioned wherevent vapors will
not damage plants/shrubs or air conditioning equipment.
•Termination should be positioned so that it willnot be ef-
fectedbywind eddy, air born leaves,snow,or recirculated
fluegases.
•Termination should be positioned where itwillnot be
subjectedto potential damage by foreign objects,such as
stones,balls,etc.
•Termination should be positioned wherevent vapors are
not objectionable.
•Put vent on a wall away from the prevailing winter wind.
Locate or guard the vent to prevent accidental contact with
people or pets.
•Terminate the vent abovenormal snow line.Avoid
locations wheresnow may drift andblock the vent. Ice
or snowmaycause the boilerto shut down ifthe vent
becomesobstructed.
•Under certain conditions, fluegaswillcondense, form-
ing 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.
3. Theventing systemshall terminate at least3' aboveanyforced
air inlet (except boiler's combustion air inlet) within 10'. The
venting systemshall terminate atleast 12"from any airopen-
inginto anybuilding. Thebottom ofthe ventshall belocated at
least 12"above grade. Thevent terminal shallnot be installed
closerthan 3'from the inside corner ofan "L" shaped structure.
Termination ofthe vent should bekept at least3' awayfrom
vegetation. Theventing systemshallterminate at least 4' hori-
zontallyfrom, and in no case aboveor below,electricmeters,
gasmeters, regulators,and reliefequipment, or under adeck or
porch.
4. Throughthe wallvents for CategoryII and IV appliances and
non categorizedcondensing appliances shall not terminate over
public walkwaysor over an areawhere condensate orvapor
couldcreate anuisance or hazard or couldbe detrimental to the
operation of regulators,reliefvales,or other equipment. Where
local experienceindicates that condensate isa problem with
CategoryI and III appliances,this provision shall also apply.If
multiple terminations are used, there must be aminimum of
12"betweenthe exhaust ofone termination and the air intake
of the next termination. See Figures 1-3for illustrations.
Installation
IMPORTANT:When transitioning from CPVCto PVC
it isrecommended to use Weld-On CPVC724or other
cement approved for CPVCto PVC.In Canada ULC $636
approvedcement must be used.
1. Attach combustion air intake piping to supplied 2" PVC Intake
Connector. Attachvent piping to furnished 2" CPVC vent pipe.
Usea2" x 3"adapter in both airinlet and exhaust.
NOTE:Allpipe joints are to bewatertight.
2. Working from theboiler to the outside, cut pipe to required
length(s).
3. Deburr inside and outside ofpipe, and remove all shavings
from pipe.
4. Chamfer outside edge of pipe forbetter distribution of primer
and cement.
5. Cleanand dry all surfacesto be joined.
6. Checkdry fitof pipe and mark insertion depth on pipe.

iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_
NOTE: It is recommended that all pipes be cut, prepared,
and pre-assembled before permanently cementing any
joint.
oAfterpipes havebeen cutand pre-assembled, apply cement
primer to pipefitting socketand end ofpipe to insertion mark.
Quicklyapplyapproved cement to end ofpipe and fitting
socket(over primer). Applycement in light, uniform coat on
the insideof socketto prevent buildup of excesscement. Apply
second coat.
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_
NOTE: Primer and cement will discolor jacket. Take pre-
cautions to protect jacket while cementing vent pipe.
8. While cement is still wet, insert pipe into socket with a 1Aturn
twist. Be sure pipe is fully inserted into fitting socket.
9. Wipe excess cement from joint. A continuous bead of cement
will be visible around perimeter of a properly made joint.
10. Handle pipe joint carefully until cement sets.
11. Support combustion air and vent piping a minimum of every 5'
using pre-formed metal hanging straps. Support combustion
air and vent piping so no weight is resting on the boiler jacket.
Do not rigidly support pipes. Allow movement due to expan-
sion and contraction.
12.
13.
Slope combustion air and vent pipes toward boiler a mini-
mum of ¼" per linear foot with no sags between hangers.
Use appropriate methods to seal openings where vent and
combustion air pipes pass through roof or side wall.
Check Gas Supply
The gas pipe to your boiler must be the correct size for the length of
run and for the total BTU per hour input of all gas utilization equip-
ment connected to it. See Table 4 for proper size. Be sure your gas
line complies with local codes and gas company requirements.
The boiler and its individual shutoff valve must be disconnected
from the gas supply piping system during any pressure testing of that
system at test pressures in excess of 1/2psig (3.SkPa).
The boiler must be isolated from the gas supply piping system by
closing its individual manual shutoff valve during any pressure
TABLE 4: GAS PIPING SIZES
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
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
ThelengN ofp@eortubNgshouldbe measuredfrom Negas meteror
propaneseconds_gereguN_
testing of the gas supply piping system at test pressures equal to or
greater than 1/2psig (3.5kPa).
In order for proper operation of the boiler, it is recommended that
the line pressure be within the minimum and maximum values in
Table 5.
TABLE 5: GAS SUPPLY PRESSURE
4" min. w.c. 10" max. w.c.
10" min. w.c. 14" max. w.c.
Check line pressure while unit is running in high fire mode.
Connecting the GasPiping
Refer to Figure 9 for the general layout at the boiler, which
shows the basic fittings you will need. As shipped, the gas line
enters the boiler through the right side but, as an option, it can
be routed through either the rear or left side panel.

Figure9- GasPiping
1/2" GAS CONNECTION
*NOTE: 3/4" GAS SUPPLY
TO BOILER JACKET
REQUIRED TO FEED
THE BOILER.
The boiler is equipped with a V2"NPT connection on the gasvalve
for supply piping and V2"NPT ball valve for manual shut off. The
following rules apply for boiler piping:
.Useonly those piping materials and joining methods listed
asacceptableby the authority having jurisdiction, or in the
absenceof suchrequirements, bythe National Fuel GasCode,
ANSIZ223.1-latest revision.In Canada,followthe CAN/CGA
B149.1and .2Installation Codes for GasBurning Appliances
and Equipment.
2. Usepipe joint compound suitable for liquefiedpetroleum gas
on male threads only.
3. Useground joint unions.
4. Install asediment trap upstream ofgas controls.
5. Usetwo pipe wrenches when making the connection to the gas
valveto keep it from turning.
6. Install amanual shutoffvalvein the verticalpipe about 5' above
flooroutside the boilerjacket in addition to the shutoffvalve
suppliedwith theboiler.
7. Tighten alljoints securely.
8. Propane gas connections should onlybe made by alicensed
propane installer.
9. Twostageregulation should be used by the propane installer.
10. Propane gaspiping should be checkedout by the propane
installer.
Checking the GasPiping
After all connections have been made, check immediately for leaks.
Open the manual shutoff valve. Test for leaks by applying soap suds
(or a liquid detergent) to each joint. Bubbles forming indicate leak.
Correct even the smallest leak at once.
Neverusea matchor open flameto test forleaks!!
IMPORTANT: Wiring diagrams for the Gas-Fired Direct Vent Modulating Hot Water Boiler can be
found in Section XIV of this manual. Codes
For your safety, turn off electrical power supply at service
panel before making any electrical connections to avoid
possible electric shock hazard. Failure to do so can cause
severe personal injury or death.
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_
IMPORTANT:Wiringmust be N.E.C.Class1.Iforiginal
boiler wiring must be replaced,use onlytype105°cwire
or equivalent. Boilermust be electricallygrounded as re-
quired by National ElectricalCode ANSI/NFPA70-latest
edition, and operation.
Installations must comply with National Electrical Code, any other
national, state, provincial, or local codes or regulations, and, in
Canada, with CSA C22.1 Canadian Electrical Code (Part 1) and any
local codes. (L1, L2)
Line Voltage Connections
I. Connect 120VAC power wiring to line voltage terminal strip
on boiler control panel.
2. Provide and install a fused disconnect or service switch (15 amp
recommended) as required by code.
3. Boiler circulator is shipped loose. Wire boiler circulator as
shown in wire diagram label on boiler side panel. (CH L1, CH
L2) CH = Control Heat
4. When connecting a DHW circulator, connect wiring to line
voltage terminal strip on boiler control panel. (DHW L1, DHW
L2) DHW = Domestic Hot Water

5. Route allwires and conduits to the openings in the right jacket
panel.
Line Voltage Monitor
This boiler is factory equipped with a line voltage monitor that and
continuously monitors incoming voltage for errors. When incom-
ing line voltage is greater than 12% or less than 8% of the nominal
voltage monitor will flash indicating a fault. Ten minutes after the
line voltage is back within the acceptable range the green light will il-
luminate on the monitor and the boiler will restart. The line voltage
monitor is factory set at 115VAC. It is important that the monitor be
set to the voltage that is present at the installation site by following
these directions:
1. Using a multimeter, locate the wall outlet nearest to the boiler
and determine the line voltage present on site.
2. Disconnect power to the boiler.
3. Remove the boiler cover.
4. Locate the line voltage monitor mounted to the display panel.
S. Remove line monitor protective cover.
6. Using a small screwdriver turn the left dial until the arrow
points at the input voltage measured during step 1.
7. The right dial should be set at 0.1 minutes, this is the factory
setting.
8. Reinstall line monitor protective cover.
9. Replace boiler cover and re-connect power to the unit.
Figure 10- Line Voltage Monitor
Low Voltage Connections
1. Connect low voltage wiring to low voltage terminal strip as
shown in the boiler wiring diagram.
2. Route all low voltage wires through opening on the right
jacket panel. Use shielded cable.
Thermostat
1. Connect room thermostat or end switch (isolated contact
only) between terminals T1 and T2.
oInstall thermostat on inside wall away from influences of
drafts, hot or cold water pipes, lighting fixtures, televisions,
sun rays, or fireplaces.
3. Thermostat anticipator (if applicable):
A. If connected directly to boiler, set for 0.1 amps.
B. If connected to relays or other devices, set to match total
electrical power requirements of connected devices. See
device manufacturers' specifications and thermostat in-
structions for details.
Outdoor Temperature Sensor
1. Connect outdoor temperature sensor between terminals
A1 and A2 to enable outdoor reset operation of the boiler.
If fixed temperature operation is required, do not install
outdoor sensor.
o
3,
,
Mount sensor on exterior wall, shielded from direct sunlight
or flowof heat or cooling from other sources.
If desired, install a summer/winter switch across terminals
A1 and A2. When the switch is closed, the boiler (space
heating) circulator is disabled.
Route sensor wires through the holes provided on the right
jacket panel of the boiler.
DHWAquastat
Connect storage indirect water heater (DHW) aquastat between
terminals DHW T1 and DHW T2.

This section provides a brief description of the key controls and
accessories found in this boiler. See the Repair Parts Manual
(PIN# 240006107) for illustrations and the Control Manual and
Operation Instructions (PIN# 240006104) for a detailed sequence
of operation and troubleshooting procedures.
Aluminum HeatExchanger
This appliance employs a cast aluminum heat exchanger that
features a monoblock design. The monoblock design eliminates
the need for mating sections and therefore eliminates leaks be-
tween sections. Since the heat exchanger is cast of aluminum
instead of iron, it has better heat transfer properties which in
turn lead to higher efficiency and cooler exhaust temperatures.
These cooler exhaust temperatures create condensation of the
flue gas, which would cause corrosion in traditional cast iron
heat exchangers.
Main Power Switch
This appliance features a main power switch located on the display
panel. The main power switch is illuminated when it is receiving
power and in the ON position. The only time that the switch should
not be illuminated once the boiler is ready for use is when the switch
is in the OFF position.
Modulating BoilerControl
This appliance incorporates an integrated modulating control
that senses the load necessary to heat a structure and therefore
uses less fuel than a conventional fixed firing rate boiler when
there is a lower than peak demand for heat. The control senses
the supply water, return water, and outside air temperatures if
the outside air sensor is connected and calculates the load on
the system. It then adjusts the firing rate to deliver the amount
of heat that is needed at that particular time.
Modulating Blower
The modulating blower provides a means ofintroducing the gas/
air mixture through the burner and into the combustion chamber
where combustion can begin and then out the exhaust vent where
the combustion products are discharged to the outdoors. The
blower is designed to communicate with the modulating control
to run at variable speeds dependent on the heat load experienced
by the heating system. The variable speeds create pressures felt
by the gas valve and gas/air mixer that dictate how much fuel is
introduced to the combustion process.
GasControl Valve
The gascontrols in this boiler havebeen developed for domes-
ticheating applianceswithpremix burners and automaticdirect
burner ignition and are suitablefor natural and LPgas.The gas
controlsperform allthe functions required to safelyregulategas
flowto the main burner of the boiler.The gasvalve is directly
connected to the gas/airmixer.
Gas/Air Mixer
The venturi design of the gas/air ensures that there is always the
correct mixture of air and gas.
Modulating Burner
This burner is designed to operate over the full range of input for
this boiler. The burner can operate under normal (blue flame)
and infrared conditions.
Direct Spark Igniter (DSI)
This appliance uses a DSI to ignite the fuel/air mixture in the
combustion chamber and sense flame during operation. The
DSI is a durable, reliable component that resists breakage due to
handling or inadvertent impact with other objects.
NTCSensors
The NTC sensors used with this appliance for measuring sup-
ply water, return water, and outside air temperature are specially
configured to operate with the modulating boiler control.
Manual Reset LowWater Cut Off
This appliance employs afactory installed integral low water cut
off (LWCO) that has to be manually reset if there is a low water

condition.TheLWCOsenseswaterthroughaprobeatthetop
oftheboilerthatsendsasignalthroughthewatertoground.If
thesignalisnotsensedthroughtheground,theLWCOenters
alockoutmodethatdisablestheappliance.IftheLWCOisin
normalmodearedindicatorlightisilluminatedontheLWCO
panelin theboiler.Duringalowwatercondition,theredlight
goesoutandtheLWCOandcontrolresetbuttonsonthedisplay
panelmustbedepressedtoresettheLWCO.
NormallyClosedLWCOSwitch
Thisround button switch locatednext to the digitaldisplayis nor-
mallyclosedand springloaded sothat, when depressed, it opens,
and closes againwhen pressureis removed.Theswitch isused as the
manual reset forthe LWCO.When tripped the LWCOwillremain
in lockout until the water levelreaches the probe and the switchis
depressedto an open state and then releasedto aclosedstate,which
sendsa signalto the LWCOto resume normal operation. Theboiler
controlreset button must then be pressedto reset from alowwater
condition. TheLWCOswitchand controlreset button are located on
the displaypanelof the boiler.
before resetting this switch.
Taco Pump Curve [HTWM?H
2 3 4 S 6 ? S 9 H_
:3oI __ '%_ <............................:............................................_t _
/ 0 {
%S ie _ s
o .l.............
0 5 1{} 5 2,!) _5 30 5 a0 45
If_rGq_6 G [>_a_
GrundfosPump Curve
High LimitAquastat Control
Thehigh limit aquastat control isa redundant safetylimit control
that providesameans for protecting theboiler and heating system
from unsafe operating conditions which could damage the boiler.
Theaquastat ismounted in the 1/2"NPT control well and %"X _/2"
bushing on the top of thefront boiler sectionat the hot wateroutlet.
Theaquastat istied in with the boilercontrol and isfactory set at
200°Fwatertemperature. Thehigh limit setpoint is fieldadjustable
and maybe set anywherebetween 100°Fand 200°Ewith the maxi-
mum high limit setpoint not exceeding200°E Thefieldhigh limit
setpoint adjustment foreach installationdepends on heating system
requirements. Theaquastat automaticallyresetswhen the boilerwa-
ter temperature decreases ten degreesbelowthe high limit setpoint
value. (Adjustabledifferentialfrom 5°Fto 30°F)
:::::::::::::::::::::::::::::::::::::::::::3
NOTE:Boileroperating temperature (temperaturecurve)
is calculatedand setin the parameters of the boiler control.
Casting Temperature Safety Switch
In the event of lack of or loss of water in the boiler, the casting
temperature safety switch (230°F setpoint) installed on the top
of the aluminum boiler section behind the supply piping shuts off
the boiler by shutting off power to the boiler control and causes a
failure code to be displayed on the digital readout. This fault requires
manual reset of the casting temperature safety switch to restart the
boiler and the reset to be pressed on the user interface panel. Verify
that the boiler is properly filled with water and no air is trapped in
the top of the casting (check cap on Cam Vent at the heat exchanger)
No_ (tpm)
Bell & Gossett Pump Curve
!/ :
c ,J...... .........................,_...........................................
..............i 7 {
/
............>......;--=i
x,..... i L l
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i: N/

Never run cold water into a hot, empty boiler.
Circulator Pump
Every forced hot water system requires at least one circulating pump.
The circulating pump imparts the necessary energy to move water
through the closed loop supply and return piping systems, terminal
heating equipment (finned tube radiators, etc.) and back through the
boiler for reheating. To provide the required hot water flow rates, the
circulator pump must be properly sized to overcome frictional losses
(usually measured in feet of water, also referred to as "pump head
loss") of the supply and return piping systems and boiler. The cir-
culator pump is furnished in a carton within the boiler cabinet. The
circulator(s) should always be located on the downstream ("pumping
away") side of the expansion tank.
ASME Rated Pressure Relief Valve
Eachboiler must havea properly sizedand installed American
Societyof MechanicalEngineers (ASME)rated pressure reliefvalve.
Water expandsas itis heated by the burner/boiler sections. Ifthere
isno placefor the water to expand its volume, (i.e.,a properly sized
and properly functioningexpansion tank) pressure on the inside
of the boiler and heating systemwillincrease. Thefurnished relief
valvewillautomaticallyopen at 30psig pressureto relievethe strain
on the boiler andheating systemfrom the increasing pressure.The
pressure reliefvaNedischargemust be piped with the same sizepipe
asthe vane dischargeopening to anopen drain, tub or sink, or other
suitabledrainage point not subject to freezing,in accordancewith
ASMEspecifications.Failureto provide the pressurereliefvaNewith
piping as herein described may causewater damage and/or serious
bodily injury.Theboiler manufacturer isnot responsiblefor any
water damage or personal injury. Checklocal codesfor maximum
dischargeheight from floor.
Air Proving Blocked Vent Safety Assembly
The air proving blocked vent safety assembly incorporates two
pressure switches that are designed to discontinue operation of the
appliance if there is a problem with the blower or venting system.
The normally open switch closes upon the initiation of the blower
and functions as an air proving switch. The normally closed switch
opens if there is a blockage in the combustion air intake or exhaust
vent pipes.
Drain Valve
The manual drain vane provides a means of draining the water in
the heating system, including the boiler and hot water supply and
return piping systems installed above the drain vane. This drain
vane is installed in the return piping at the bottom front of the boiler
section. Any piping installed below the elevation of this drain vane
will require additional drain vanes to be installed at low points in
the piping systems in order to drain the entire system.
External Condensate Pump (optional)
For installations where there is no floor drain or other appropriate
drainage receptacle available to receive condensate from the boiler,
an external float activated condensate pump with integral sump
is required. The condensate pump can be piped to a remote tie in
point to a sanitary sewer system. For this application, the boiler must
be installed so that proper pitch of piping to the external condensate
reservoir (sump) can be accomplished. Use wood flame or concrete
blocks to raise boiler as required for proper installation.
Concentric VentlAir Intake Termination (Optional)
The optional concentric vent/air intake termination utilizes a single
opening per each appliance through the wall or roof of a structure.
When filling the boiler water is the preferred heating solution. Most
potable water supplies may be used to charge and re-fill provided the
chlorine and chloride ions levels are less than 100 ppm.
Antifreeze may be used in most applications provided all of the fol-
lowing conditions are met:
1. Unless a strict schedule of sampling, analysis and maintenance
of the antifreeze solution is followed, the boiler must be piped
as a primary loop connected to secondary loop as shown in the
Piping & Wiring Diagram Appendix. Failure to perform regular
maintenance to the antifreeze manufacturer's instructions will
result in damage to the heat exchanger and the voiding of boiler
warranty.
2. Only the antifreeze manufacturers listed below are selected.
3. At installation of a new or replacement boiler and at least on
an annual basis the system antifreeze must be analyzed by the
antifreeze supplier or their recommended laboratory.
4. Adjustments to the system antifreeze must be made according
to the antifreeze manufacturers recommendations using only
their recommended products.
5. All existing systems MUST be flushed of ALL old system fluid.
Failure to do so may void the boiler warranty if evidence of
improper flushing is revealed.
Consult with your heating professional for recommendations.
Piping Recommendations
•System leaks may not always be visible. An unseen system

leakwillbecome obviousif boiler pressure decreaseswhen
make up valveis closed.
•All systemleaksmust berepaired immediately.Constant
introduction of make up water willintroduce dissolved
oxygen,resulting in acceleratedboiler corrosion.
•It is recommended that Primary/Secondary piping be used
with any of the recommended antifreeze solutions found in
this manual. See the Piping & Wiring Diagram Appen-
dix.
WaterChemistry:
•Thisboiler isdesigned for aclosedloop hydronic heat
systemONLY!Thisboiler is not suitable for natural gravity
typeinstallations, or anyother open type system.
•System fluid pH must be maintained between 7.0 and 8.0.
•Maintain water hardness below7grainshardness.
•Filling with chlorinated flesh water should be acceptable
since drinking water chlorine levels are typically less than 5
ppm. Do not fill boiler with water containing chlorine and
chloride ions levels greater than 100 ppm.
•Do not useinhibitors or other additivesthat are not spe-
cificallyapproved by the antifreezemanufacturer for this
product.
•Consult the antifreeze manufacturer if any of the above are
outside the stated ranges.
Cleaning the Hydronic System:
iiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiiii_
IMPORTANT:Donot mix differentmanufacturers' prod-
ucts. Doing so will void the warranty of the boiler.
Consideration MUST be given to cleaning the heating system, par-
ticularly in retrofit situations where a new boiler with an aluminum
heat exchanger is being installed in an existing piping system.
All existing systems must be cleaned and flushed according to the
antifreeze manufacturer's recommendations.
Systems that have antifreeze that is not recommended by the boiler
manufacturer must be completely flushed to ensure no unapproved
antifreeze remains according to the recommended antifreeze manu-
factures recommendations. Evidence of an alternate antifreeze in the
system may void the boiler warranty.
In older systems obviously discolored, murky or dirty water; or a pH
reading outside the boiler manufacturer's stated acceptable range
(pH 7.0 to 8.0) are indications that the system should be cleaned or
treated.
1. Measuretotal capacityofthe systemincluding the piping, tanks,
boiler, collector plates,etc. The most accurate method of mea-
suring fluid capacity isto fillthe systemand then completely
drain it, volumetrically measuring the fluiddrained.
2. Thoroughlyflush the systemwith clean water to remove any
sediment or contaminants. Sludgeand iron oxide deposits can
causerapid breakdown of inhibitors.
3. Cleaningfluid - Flushingwith cleanwater ispreferred. Ifclean-
ingfluid is used,only use cleaner specificallyapproved for use
with aluminum boilers. Useonly cleaningfluids and the proce-
dure recommended by the antifreezemanufacturer.
Freeze Protection
Aluminum Safe Antifreeze, Treatments and Additive
Guidelines:
Antifreeze, if required, must be one of the antifreeze manufacturers
listed in this manual. See the "Recommended Aluminum Antifreeze
& Inhibitor Suppliers" section of this manual for a list of boiler
manufacturer approved products.
•Always clean system prior to using antifreeze, refer to the
Cleaning the Hydronic System section of this manual for
details.
•Only use the antifreeze manufacturers' products outlined in
this document.
•Use of antifreeze must be in accordance with local plumb-
ing codes.
•Dispose of old antifreeze and boiler system water in accor-
dance with local authorities.
•Antifreeze will raise the pH of the hydronic solu-
tion in a heating system above the recommended
level due to the corrosion inhibitors in the anti-
freeze. The solution must be treated to maintain a pH
within the boiler manufacturer's recommended level to
avoid damage to the heat exchanger. Follow antifreeze
manufacturer's instructions for details on how to adjust the
pH.
•Ifthe systemhasleaked for some reason, the water and
antifreezechemistrywillneed to beadjusted. To avoid
damage to the boiler, checkthe pH and chemistryof the
boiler solution and consult the antifreezemanufacturer for
recommendations.
•It is recommended that a pH reading istaken annually, and
adjustedas necessary.Followantifreeze/inhibitor manu-
facturer's instructions for details on how to adjust the pH.