Dunkirk Q95M-200 User manual

Q95M-200 GAS-FIRED DIRECT VENT
MODULATING HOT WATER BOILER
_i!i!i
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk. NY 14048
www. dunkirk, com
An ECR Ir
An ISO 9001
P/N 240006103D. Rev. 1 1 [04/06.t

INSTALLATION MANUAL
P/N# 240006103D, Rev. 1.1 [04/06] • Printed in USA • Made In USA
O
LEFTSiDE
TOP
................s' ......
FRONT RIGHT SIDE BACK
AR VENi r;AKE
OPENING
"f ?_'PVC
OP IONAq
'CONDENSATE
DA[N
OP NING
1/2' PVC
I Introduction .......................................... 3
II Safety Symbols .................................... 4
III Rules for Safe Installation and Operation 4
IV Boiler Ratings and Capacities ............. 5
V Before Installing The Boiler .................. 6
VI Placing The Boiler ................................ 9
VII Near Boiler Piping ................................ 10
VIII Combustion Air and Vent Pipe ............. 11
IX Gas Supply Piping ............................... 13
X Electrical Wiring ................................... 15
XI Controls and Accessories .................... 16
XII Maintenance and Cleaning .................. 18
XIII Boiler Wire Diagram ............................ 21
XIV Piping and Wiring Appendix ................. 22
Keep this manual near boiler
and retain for future reference.
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This appliance is a gas-fired direct vent modulat-
ing cast aluminum hot water boiler. A revolutionary
cast aluminum monoblock heat exchanger means
better heat transfer and thermal storage than simi-
larly sized cast iron boilers, which results in higher
efficiency. The heating system water absorbs large
amounts of heat from the cast aluminum heat ex-
changer, cooling the flue gases and causing con-
densation. Sealed combustion, premix gas burner,
and low flame temperature means drastically re-
duced CO and NOx emissions, which contribute to
a cleaner and healthier environment.
This appliance, unlike normal residential atmo-
spheric and induced draft units, takes its combus-
tion air directly from the outdoors (sealed combus-
tion) 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 inexpen-
sive and readily available PVC and CPVC pipes.

The following defined symbols are used throughout this manual to notify the reader of potential hazards
of varying risk levels
dicates a potentially hazardous situation I
hich, if not avoided, could result in death I
serious injury: j/
Iw IAc u,,o.A
ndicates a potentially hazardous situation I
hich, if not avoided, may result in minor or I
oderate injury. It may also be used to alert I
gainst unsafe practices, j)
'-cMoPORTANT: Read the following instructlon_
mpletely before mstalhngll
wAR.I.GA i
This appliance has been equipped for resi-
dential installations. If used for commercial
applications, any and all additional code re-
quirements must be adhered to for installa-
tion. This may require additional controls,
including but not limited to an external wa-
ter 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 ac-
knowledged in this manual. J
PORTANT: Failure to follow these mstruc-'-_
ns could cause a malfunction of the boiler I
d result in death, serious bodily injury, and/or I
operty damage For assistance or additional I
ormatlon, consult a quahfled installer, service I
ency, or the gas supplier ,j/
his boiler contains ceramic fiber materials. I
se care when handling these materials per I
Ithe instructions specified under "Modulating I
k...Burner' in Section xI of this manual, j)
1 Check all applicable state and local building
codes and utility company requirements before
installation This installation must conform with
these requirements m their enhrety In the absence
of these codes, use NFPA installation codes and
good industry practice
2 Before serwcmg the boiler, allow it to cool Al-
ways shut off any electricity and gas supply con-
nected to the boiler prior to serwcmg
3 Inspect gas line for leaks
4 Be certain gas input rate is correct Overflrmg
may result in early failure of the boiler components
This may cause dangerous operation Underflrlng
may result in too much air for the pre-mlx burner
causing poor or loss of combustion
5 Never vent the products of combustion from this
boiler to an enclosed space Always vent to the out-
doors Never vent to another room or to inside a
building
6 Be sure there is adequate outdoor air supply to
boiler for complete combustion
7 Followa regularserwce and maintenance sched-
ule for efficient and safe operation
8 Keep boiler area clean of debris and free of com-
bustible and flammable materials
9 Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with the
materials and methods described in this manual
Installation must comply with local codes
10 This boiler and related hot water heating sys-
tems are not do4t-yourself items They must be m-
stalled and serwced by quahfled professionals Rat-

TABLE1:SEALEVELRATINGS- NATURALANDPROPANEGASES
HighFire
Low Fire 200 190 165 80 76 66 95% 2" CPVC & 3" PVC 284 Ibs.
I_)1 MBH =1,000 Btuh (British Thermal Units Per Hour)
12_Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.
TABLE 2:95M-200 HiGH ALTITUDE DERATE CHART
High Fire 196 192 188 184 181 177 174 170
Low Fire 78.4 76.8 75.3 73.8 72.3 70.9 69.5 68.1
ings above are for sea level applications. The boiler
automatically derates input at a rate d2% for every
1000 feet above an elevation of 2000 feet (see Table
2). The boiler wilt also derate relative to the calorific
value of the gas being used. Use the formula speci-
fied in "Measure The Natural Gas Input Rate" in Sec-
tion VII of the Control Manual and Operating Instruc-
tions (P/N# 240006104) to determine the proper rate
due to derated gas. No alterations to the boiler are
required for altitudes above sea level.
These low pressure gas-fired hot water boilers are
design certified by CSA International, for use with
natural and propane gases. The boilers are con-
structed and hydrostatically tested for a maximum
working pressure of 50 PSIG (pounds per square
inch gauge) in accordance with ASME (American
Society of Mechanical Engineers) Boiler and Pres-
sure Vessel Code Section IV Standards for heating
boilers.
The Boilers are certified in accordance with ANSI
(American National Standards Institute) Z21.13
standards as gas-fired, direct vent, condensing,
hot water boilers.
Review the following before installing the boiler.
The Heating Capacity indicates the amount of heat
available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small
portion is heat loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in
the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied
to heat the radiation or terminal units (i.e., finned
tube baseboard, cast iron radiators, radiant floor,
etc.) The difference between the Heating Capacity
and the Net I=B=R Rating, called the piping and
pickup allowance, establishes a reserve for heating
the volume of water in the system and offsetting
heat losses from the piping. The Net I=B=R Rat-
ings shown are based on a piping and pickup factor
of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net 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. The
manufacturer should be consulted before selecting
a boiler for installations having unusual piping and
pickup requirements.
This boiler product is a gas-fired, direct vent, con-
densing boiler and must be installed in accordance
with all applicable federal, state and local building
codes including, but not limited to the following:
United States - Installation shall conform with
National Fuel Gas Code (NFPA-54/ANSI Z223.1-
latest edition)
Canada - Installation shall be in accordance with
CSA-B149.1 and .2 installation codes.
Where required by the authority having jurisdiction,
the installation must conform to the ASME Safety
Code for Controls and Safety Devices forAutomati-
cally Fired Boilers, No.CSD-1.
The installation must conform to the requirements
of the authority having jurisdiction or, in the ab-
sence of such requirements, to the National Fuel
Gas Code, ANSI Z223.1 -latest revision.

Installers - Followlocalregulationswith respect
to installationof Carbon MonoxideDetectors.
Follow maintenancerecommendationsin this
manual.
Check to be sure you have selectedthe
boilerwith thepropercapacitybeforecon-
tinuingtheinstallation.TheI=B=RRatingof
the boiler selectedshould be greaterthan
orequaltothecalculatedpeakheatingload
(heatloss)forthebuildingorarea(s)served
bytheboilerandassociatedhotwaterheat-
ingsystems.See "Table1: Sea Level Rat-
ings -Natural and Propane Gases" in Sec-
tion IV of this manual.
• Heat loss calculations should be based on
approved industry methods.
e | "_ 0 O" ;0 " 0 _0
1. Select a location which is level, central to the pip-
ing systems served and as close to the vent and air
intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e.
larger clearances) than required fire protection
clearances, must be used for the boiler installation.
Accessibility clearances may be achieved with the
use of removable walls or partitions.
3. The boiler is approved for installation in closets
and on combustible floors. This boiler shall NOT be
installed on carpeting.
4. The clearances shown in Table 3 below indicate
required clearances per CSA listing.
TABLE 3: BOILER CLEARANCES*
Before selecting a location for the boiler, the follow-
ing 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 in-
take piping system to supply the correct
amounts of fresh (outdoor) air for combustion
(15' minimum length/60' maximum length).
Top 1" 8" 8"
Left Side 1" 24" 24"
Right Side 1"
Base 1"
Front 0 24" 24"
Back 6"
Intake/Vent Piping 0
Near Boiler Hot 1"
Water Piping
*All distances measured from the cabinet of the boiler.
Connected to a suitable venting system to
remove the hazardous products of gas com-
bustion (15' minimum length/60' maximum
length).
Connected to a suitable hot water heating
system,
Supplied with a suitable electrical supply for
all boiler motors and controls.
A minimum 1" clearance must be maintained be-
tween combustible construction and each of the
right, top and back surfaces of the boiler. Allow at
least 24" at the front and left side and 8"at the top
for servicing. No combustible clearances are re-
quired to venting or combustion air intake piping.
5. Equipment shall be installed in a location which fa-
cilitates the operation of venting and combustion air
intake piping systems as described in this manual.
Connected to a properly located thermostat or
operating control (not included with boiler).
Placed on level surface (must NOT be in-
stalled on carpeting).
6. Advise owner of boiler to keep venting and com-
bustion air intake passages free of obstructions.
Both the venting and combustion air intake piping
systems connected to the outdoors must permit
flow through the piping systems without restrictions
for the boiler to operate.
Condensate drain line must be pitched down
to floor drain or external condensate pump
with reservoir at ¼" per foot (wood frame or
blocks may be used to raise boiler).
7. The boiler shall be installed such that the auto-
matic gas ignition system components are protect-
ed from water (dripping, spraying, rain, etc.) during

operation and service (circulator replacement, con-
trol replacement, etc )
8 The boiler must be located where ambient room
temperatures (minimum possible temperatures
where boiler is installed assuming boiler is not in
operation and therefore contributes no heat to the
space) are always at or above 32°F to prevent
freezing of liquid condensate
Figure 1 - Roof Vent/Intake Terminations
Figure 2 - Sidewall Vent/Intake Terminations
L LESSTH_I] 12 CLEAR_I]CE
This boiler requires a dedicated direct vent system
In a 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 the same atmospheric pres-
sure zone, either through the roof or sidewall (roof
termination preferred) See Figures 1 and 2 for re-
quired clearances
If the concentric vent termination is being used, re-
fer to Figure 3 for proper setup
Figure 3 - Concentric Vent Terminations
I rl. _lllijii
/_. 12 I IlNfI, IUM
cor 'BUSTION _,IR
i ~
EHT
pO.D=
D EP PI - r 1,3
ot°
I
12 FllNlr IUr,
rI_INT_EN l-" IN CLE-P-NCE
_BO E HIGHEST .NTICIP.TED
SrdC LE EL D = SPADE
t c 0,,o.
Keep boiler area clean of debris and free of I
lammable and combustible materials, va- I
ors, and liquids. .i)
Failure to follow these warnings could result
in fire, property damage, personal injury, or
death.
• When vent pipe is exposed to tempera-
tures below freezing, such as when it pass-
es through an unheated space or when a
chimney is used as a chaseway, vent pipe
must be insulated with W'Armaflex or
equivalent. In extremely cold climate ar-
eas, 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,
H-'H H which include fluorides, chlorides, phos-
12"ORMORECLEARANCE LIr (Continued on next page)j

wAR"'"Ga,l -
(Continued from previous page)
phates, bromides and iodides. These ele-
ments 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 swim-
ming pool pump house. All combustion
air and vent pipes must be airtight and
watertight. Combustion air and vent pip-
ing must also terminate exactly as shown
in Figures 1 and 2. if a concentric vent
termination is being used, refer to Fig=
ures 3 through 5 for proper setup.
Vent connections serving appliances
vented by natural draft shall not be con-
nected 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
k,. with skin or eyes. ,J
Figure 4 - Concentric Vent w/Dimensions
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_r
-i
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I
,-, F} 41H:-fH S',,,'(} IrJ:!b_,Cc_riLbu_t,ur_ Al_
Figure 5 - Concentric Vent Roof Installation
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At the rear of the unit a ½" PVC pipe nipple with
NPT threads is provided for the attachment of the
condensate drain line Attach the ½" PVC tee in
the parts bag to act as a vent as shown Attach ½"
PVC from this point to either a drain or an exter-
nal condensate pump (not furnished) If the drain
level is above the condensate trap, a condensate
pump must be used The condensate pump must
be designed for a flue gas condensate application
The condensate drain line must be pitched down to
the floor at a minimum of 1/4"per foot and must be
routed within the conditioned space to avoid freez-
ing of condensate and blockage of the drain line If
the unit will be started immediately upon comple-
tion of installation, prime trap by fllhng with water
until water is seen at the vent
f NOTES: _'_
1
2
3
pump tlf needed)
Condensate trap is integral to the boiler
Wood frarne or blocks may be used to raise the boiler to
maintain dram pitch or to be above external condensate
pump reservoir
There _s a 115 volt AC receptacle provided on the con-
trol panel to provide power for an external condensate
J

Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
f NOTES: _'
1. If boiler is not level condensate drain lines will not func-
tion properly. Adjustable feet are located on the boiler to
make up for minor surface irregularities or tilt,
2. Wood frame or blocks may be used to raise boiler to
maintain drain pitch or to be above external condensate
pump reservoir, j
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 ex-
haust, so they will operate at maximum speed.
Do not operate a summer exhaust fan. Close
fire dampers.
4. Place in operation the appliance being inspect-
ed. Follow the lighting instructions. Adjust ther-
mostat so appliances will operate continuously.
When an existing boiler is removed from a com-
mon venting system, the common venting system
is likely to be too large for proper venting of the
appliances remaining connected to it. At the time
of removal of an existing boiler, the following steps
shall be followed with each appliance remaining
connected to the common venting system placed
in operation, while the other appliances remaining
connected to the common venting system are not
in operation.
1. Seal any unused openings in the common
venting system.
2. Visually inspect the venting system for proper
size and horizontal pitch and determine there is
no blockage or restrictions, leakage, corrosion
and other deficiencies which could cause an un-
safe condition.
3. When it is practical, close all building doors
and windows and all doors between the space
5. Test for spillage at the draft hood relief open-
ing after 5 minutes of main burner operation. Use
the flame of a match or candle, or the smoke
from a cigarette, cigar or pipe.
6. After it has been determined that each ap-
pliance 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.
7. Any improper operation of the common vent-
ing system should be corrected so the instal-
lation conforms with the National Fuel Code,
NFPA-54/ANSI -Z223.1-tatest revision, or sec-
tion 5 of CSA-B149 for Canadian standards.
When resizing any portion of the common vent-
ing system, the common venting system should
be resized to approach the minimum size as de-
termined using the appropriate tables in part 11
in the National Fuel Gas Code, NFPA-54/ANSI-
Z223.1 -latest revision, or section 5 of CSA-B 149
for Canadian standards.
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 dol-
ly 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.
NmaOTE: Refer to "Locating The Boiler" in Section V of this'_
nual for required clearances for servicing and mainte- J
ce. J

--'JsMPORTANT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler,
ee the Piping Appendix in Section XIV of this manual.
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 con-
nection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is
furnished with iron piping where necessary
k.for the supply and return connections. J
When the installation of the boiler is for a new
heating system, first install all of the radiation units
(panels, radiators, baseboard, or tubing) 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.
A hot water boiler installed above radiation level
must be equipped with a low water cut off device.
A periodic inspection is necessary, as is flushing
of float type devices, per low water cut off manu-
facturers specific instructions. This boiler is factory
equipped with a manual reset probe-type low water
cut off.
0
I Non-potable water only piped directly t
_,boiler.
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 manufac-
turer for proper sizing information. Connect prop-
erly 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. In-
stall 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 wa-
ter supply is from a well or pump, a sand strainer
should be installed at the pump.
Figure 6 - Diaphragm Type
Expansion Tank Piping ..... o.........
/vEN]
i SU :'i>LY iIi1{
EX'AN I)r, TANK Db/IE \'AL_'E
{ATE VALVE O_ FJLL
8ALL YAL_E ',
COL}
REDUCEC PRESSURE
BACKFLO,k PREVE TER
FX ANSI)N TANK
ST OPTION F(;R FEED _yATE{,
2NO OPTION FOR FEE} W#TE:_
Figure 7 - Relief Valve Discharge Piping
,PRESSURE RELIEF DEVCE
/
/
/
/
/
/
/
The boiler is furnished with a relief valve in the
boiler parts bag. Provide ¾" piping from the sup-
plied 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 re-
lief valve and the boiler, or on the discharge pipes

betweensuch safety valve and the atmosphere.
Installationof the safetyreliefvalveshallconform
toANSI/ASMEBoilerand PressureVesselCode,
SectionIV.Themanufacturerisnotresponsiblefor
anywaterdamage.
The packaged boiler unit is set up to receive 1¼"
NPT return piping from the rear of the unit with an
option for left or right return connections. 1¼" NPT
supply piping exits the boiter jacket at the top of the
unit.
/_OTE: Circulator pump and isolation valves are furnished_
[within a carton inside the boiler cabinet and can be installed I
_,a! the installer preferred location. ,,,j/
The condensate trap is integral to the boiler.
Provide ½" pipe and fittings for PVC condensate
drain line. Condensate drain line to be pitched
down to floor drain at a minimum of ¼" per foot.
The ½" diameter schedule 40 PVC condensate
drain piping and pipe fittings must conform to ANSI
standards and ASTM D1785. Schedule 40 PVC ce-
ment and primer must conform to ASTM D2564.
In Canada, use CSA or ULC certified schedule 40
PVC drain 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.
lrMaPORTANT: On initial start up the condensate_
p must be manually filled with water. 1/'
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 1 cup of cold tap water into the
vent drain line.
2. Excess water should go through the overflow
and out through the condensate drain line. Ver-
ify proper operation of the drain line (or external
condensate pump if used).
3. Reinstall the vent drain line.
The boiler, when used in connection with a refrig-
eration system, must be installed so the chiller me-
dium is piped in parallel with the boiler with appro-
priate valves to prevent the chilled medium from
entering the boiler.
The boiler piping system of a hot water boiler con-
nected to heating coils located in air handling units
where they may be exposed to refrigerated air cir-
culation must be equipped with flow control valves
or other automatic means to prevent gravity circu-
lation of the boiler water during cooling cycle.
For boilers connected to gas vents or chimneys,
vent installations shall be in accordance with Part
7, Venting of Equipment, of the National Fuel Gas
Code, ANSI Z223.1-1atest 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 Section 5.3, Air For Com-
bustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1-tatest revision, CSA-B149.1
and B149.2, or applicable provisions of the local
building code.
These boilers require a dedicated direct vent sys-
tem. All air for combustion is taken directly from
outdoors through the combustion air intake pipe.
All flue products are discharged to the outdoors
through the vent pipe. Insulate lengths of combus-
tion pipe in unconditioned areas.
1. See Figures 1 through 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 at-
mospheric pressure zone as shown. Construc-
tion through which vent and air intake pipes may
be installed is a maximum 24" and a minimum
¼" thickness.

2. Combustionair and vent pipe fittingsmust
conformto AmericanNationalStandardsInsti-
tute (ANSI) standardsand American Society
for Testing and Materials (ASTM) standards
D1784(schedule-40CPVC),D1785(schedule-
40 PVC),D2665(PVC-DWV),D2241(SDR-21
andSDR-26PVC),D2661(ABS-DWV),orF628
(schedule-40ABS). Pipe cement and primer
mustconformtoASTMstandardsD2564(PVC)
orD2235(ABS).
In Canada construct all combustion air and vent
pipes for this unit of CSA or U LC certified sched-
ule-40 CPVC, schedule-40 PVC, PVC-DWV or
ABS-DWV pipe and pipe cement• SDR pipe is
NOT approved in Canada.
3. Combustion air and vent pipe connections on
boiler are 2" but must increase to 3". Due to po-
tential for flue gas temperatures above 155°F,
the first 30" of supplied vent pipe is CPVC while
the remaining vent pipe can be PVC. Any re-
placement of the first 30" of vent pipe must be
made with CPVC.
NOTE: The exhaust transition from 2" pipe to 3" pipe must_
made in a vertical run. Transition pieces are not includ- J
•(See Figure 8 for details.) j
15 ft. equivalent length J60 ft. equivalent length J
The length of pipe is counted from the end of the
supplied 2" CPVC pipe exiting the boiler• The com-
bustion air supply pipe must terminate at the same
location as the exhaust pipe.
Reduce the maximum vent length by 5' per each
90 ° elbow•
Figure 8 - Combustion Air and Vent Piping
INSTALL FIELD SUPPLIED
2' BY 3' TRANSITION IN
THF VERTICA_ POS_T_ON ONLY
2' {50 8_ 'M)
NTAKE PIPING (FURNISHED)
1. Combustion air piping to be pitched back to
boiler at minimum ¼" per foot from vent terminals
so that all moisture in 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 flue gas. Combustion air and
vent pipes must be airtight and watertight.
2. Consideration for the following should be used
when determining an appropriate location for ter-
mination of combustion air and vent piping:
•Comply with all clearances required•
*Termination should be positioned where vent
vapors will not damage plants/shrubs or air
conditioning equipment•
*Termination should be positioned so that it
will not be effected by wind eddy, air born
leaves, snow, or recircutated flue gases•
*Termination should be positioned where it
wilt 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 a wall away from the prevailing
winter wind. Locate or guard the vent to pre-
vent accidental contact with people or pets.
Terminate the vent above normal snowline.
Avoid locations where snow may drift and
block the vent. Ice or snow may cause the
boiler to shut down if the vent becomes ob-
structed.
Under certain conditions, flue gas will con-
dense, forming moisture, and may be cor-
rosive• In such cases, steps should be taken
to prevent building materials at the vent from
being damaged by exhaust of flue gas.
3. The venting system shall terminate at least 3'
above any forced air inlet (except boiler's com-
bustion air inlet) within 10'. The venting system
shall terminate at least 12" from any air opening
into any building• The bottom of the vent shall be
located at least 12" above grade• Termination of
the vent shall be not less than 7' above an adja-
cent public walkway• The vent terminal shall not
be installed closer than 3' from the inside corner
of an "L" shaped structure• Termination of the
vent should be kept at least 3' away from veg-
etation. The venting system shall terminate at
least 4' horizontally from, and in no case above

or below, electric meters, gas meters, regula-
tors, and relief equipment.
If multiple terminations are used, there must be
a minimum of 12" between the exhaust of one
termination and the air intake of the next termi-
nation. See Figures 1-3 for illustrations.
MrVPORTANT: When transitioning from CPVC to_
C it is recommended to use Weld-On CPVC 724 I
other cement approved for CPVC and PVC. ,_
1. Attach combustion air intake piping to sup-
plied 2" PVC Intake Connector. Attach vent pip-
ing to furnished 2" CPVC vent pipe.
_NOTE: All pipe joints are to be water tight.
2. Working from the boiler to the outside, cut
pipe to required length(s).
3. Deburr inside and outside of pipe.
4. Chamfer outside edge of pipe for better distri-
bution of primer and cement.
5. Clean and dry att surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth
on pipe.
NrOTE: It is recommended that all pipes be cut, prepared, and_
e-assembled before permanently cementing any joint. J
7. After pipes have been cut and pre-assem-
bled, apply cement primer to pipe fitting socket
and end of pipe to insertion mark. Quickly apply
approved cement to end of pipe and fitting sock-
et (over primer). Apply cement in light, uniform
coat on the inside of socket to prevent buildup of
excess cement. Apply second coat.
NaOTE: Primer and cement will discolor jacket. Take pre-_
u!ions !o pro!ec!!acke! whi!e cemen!ing ven! p!pe: J
8. While cement is still wet, insert pipe into sock-
et with a ¼ turn twist. Be sure pipe is fully in-
serted 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 move-
ment due to expansion and contraction.
12. Slope combustion air and vent pipes toward
boiler a minimum of ¼" per linear foot with no
sags between hangers.
13. Use appropriate methods to seat open-
ings where vent and combustion air pipes pass
through roof or side wall.
TABLE 4: GAS PIPING SIZES
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 equipment connected to
it. See Table 4 at right for proper size. Be sure your
gas line complies with local codes and gas com-
pany requirements.
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
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 ½ psig (3.5kPa).
The boiler must be isolated from the gas supply pip-
ing system by closing its individual manual shutoff
valve during any pressure testing of the gas supply
piping system at test pressures equal to or greater
than ½ psig (3.5kPa).
20' 131,000 216,000 393,000
40' 90,000 145,000 267,000
60' 72,000 121,000 103,000 217,000
The _ng_ ofp_eortub_g should be measu_dfrom me gas
meterorpropaneseconds_geregu#_

In order for proper operation of the boiler, it is rec-
ommended that the line pressure be within the min-
imum and maximum values in Table 5.
TABLE 5: GAS SUPPLY PRESSURE
-- J4-m,o.w.c. lO-m x.w.o.
10- o.w.o. 14" w.o.I
Please check line pressure while unit is running.
Refer to Figure 9 for the general layout at the boil-
er, which shows the basic fittings you will need. As
shipped, the gas line enters the boiler through the
rear but, as an option, it can be routed through ei-
ther the right or left side panel.
Figure 9 - Gas Piping I
3AS CONNECTION,
The boiler is equipped with a ½" NPT connection
on the gas valve for supply piping and ½" NPT ball
valve for manual shut off. The following rules apply
for boiler piping:
1. Use only those piping materials and joining
methods listed as acceptable by the authority
having jurisdiction, or in the absence of such
requirements, by the National Fuel Gas Code,
ANSI Z223.1- latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes
for Gas Burning Appliances and Equipment.
2. Use pipe joint compound suitable for liquefied
petroleum gas on male threads only.
3. Use ground joint unions.
4. Install a sediment trap upstream of gas con-
trols.
5. Use two pipe wrenches when making the con-
nection to the gas valve to keep it from turning.
6. Install a manual shutoff valve in the vertical
pipe about 5' above floor outside the boiler jack-
et in addition to the shutoff valve supplied with
the boiler.
7. Tighten all joints securely.
8. Propane gas connections should only be
made by a licensed propane installer.
9. Two stage regulation should be used by the
propane installer.
10. Propane gas piping should be checked out
by the propane installer.
11. In addition to the components supplied with
the boiler, it is recommended to use a ½" union
and ball valve suitable for natural and propane
gas upstream of the furnished ½" NPT ball valve
to facilitate service on the unit.
After all connections have been made, check im-
mediately 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.
_ WARNING _i_

IflMPORTANT: Wiring diagrams for the Gas-Fired Direct Vent Modulating Hot Water Boiler can be
ound in Section XIII of this manual.
,_ WARNING ,_ 2. Route all low voltage wires through grommet-
_iPORTANT: Wiring must be N.E.C. Class 1._
original boiler wiring must be replaced, use I
ly type 105°C wire or equivalent. Boiler must I
electrically grounded as required by National I
ectrical Code ANSI/NFPA 70 - latest edition..1/
Installations must comply with National Electrical
Code, any other national, state, provincial, or lo-
cal codes or regulations, and, in Canada, with CSA
C22.1 Canadian Electrical Code (Part 1) and any
local codes.
ed opening on the right jacket panel.
1. Connect room thermostat or end switch (isolat-
ed contact only) between terminals TI and T2.
2. Install thermostat on inside wall away from in-
fluences of drafts, hot or cold water pipes, light-
ing fixtures, televisions, sunrays, 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 manufac-
turers' specifications and thermostat instruc-
tions for details.
1. Connect 120 VAC power wiring to line voltage
terminal strip on boiler control panel.
2. Provide and install a fused disconnect or ser-
vice 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.
4. When connecting a DHW circulator, connect
wiring to line voltage terminal strip on boiler con-
trol panel.
5. Route all wires and conduits to the openings
in the right jacket panel.
1. Connect outdoor temperature sensor between
terminals A1 and A2 to enable outdoor reset opera-
tion of the boiler. If fixed temperature operation is
required, do not install outdoor sensor.
2. Mount sensor on exterior watt, shielded from di-
rect sunlight or flow of heat or cooling from other
sources.
3. If desired, install a summer/winter switch across
terminals A1 and A2. When the switch is closed,
the boiler (space heating) circulator is disabled.
4. Route sensor wires through the holes provided
on the right jacket panel of the boiler.
1. Connect low voltage wiring to low voltage
terminal strip as shown in the boiler wiring dia-
gram.
Connect storage indirect water heater (DHW) aqua-
stat between terminals DHW T1 and DHW T2.

Thissectionprovidesa briefdescriptionof thekey
controlsandaccessoriesfoundinthisboilerSeethe
RepairPartsManual(P/N#240006107)for illustra-
tionsandtheControlManualandOperationInstruc-
tions(P/N#240006104)fora detailedsequenceof
operationandtroubleshootingprocedures
Thisapplianceemploysa castaluminumheatex-
changerthat features a monoblockdesign The
monoblockdesigneliminatesthe needfor mating
sectionsand thereforeeliminatesleaks between
sections Sincetheheatexchangeris castof alu-
minuminsteadof iron, it has better heattransfer
propertieswhich in turn lead to higherefficiency
andcoolerexhausttemperaturesThesecoolerex-
hausttemperaturescreatecondensationoftheflue
gas,whichwouldcausecorrosionintraditionalcast
ironheatexchangers
Thisappliancefeaturesamainpowerswitchlocated
on the displaypanel The mainpowerswitchis il-
luminatedwhenitisreceivingpowerandintheON
positionTheonlytimethattheswitchshouldnotbe
illuminatedoncetheboileris readyforuseis when
the castingtemperaturesafety switch has been
trippedorwhentheswitchisintheOFFposition
intothecombustionchamberwherecombustioncan
beginandthenouttheexhaustventwherethecom-
bustionproductsaredischargedtotheoutdoorsThe
blowerisdesignedto communicatewiththe modu-
latingcontrolto runat variablespeedsdependent
ontheheatloadexperiencedbytheheatingsystem
Thevariablespeedscreatepressuresfeltbythegas
valveandgas/airmixerthatdictatehowmuchfuelis
introducedtothecombustionprocess
Thegascontrolsinthisboilerhavebeendeveloped
for domesticheatingapplianceswith premixburn-
ers and automaticdirect burner ignitionand are
suitablefor naturaland LPgas Thegas controls
performallthefunctionsrequiredto safelyregulate
gasflow to the mainburnerofthe boiler Thegas
valveisdirectlyconnectedtothegas/airmixer
Theventundesignofthegas/airensuresthatthere
isalwaysthecorrectmixtureofairandgas
Thisburnerisdesignedtooperateoverthefullrange
ofinputforthisboilerTheburnercanoperateunder
normal(blueflame)andinfraredconditions
Thisapplianceincorporatesanintegratedmodulat-
ingcontrolthatsensestheloadnecessaryto heat
astructureandthereforeuseslessfuelthanacon-
ventionalfixedfiringratebollerwhenthereisalow-
erthanpeakdemandfor heat Thecontrolsenses
thesupplywater,returnwater,andoutsideairtem-
peraturesandcalculatestheloadonthesystem It
thenadjuststhefiringrateto delivertheamountof
heatthatisneededatthat particulartime
o_t
TheNTCsensorsusedwiththisapplianceformea-
suringsupplywater,returnwater,and outsideair
temperatureare specially configuredto operate
withthemodulatingboilercontrol
The burner in this unit contains ceramic fi=
bers which can be converted to a cancer-
causing substance called cristobalite in very
high temperature applications. When remov-
ing the burner, avoid breathing dust by using
aNIOSH (National Institute for Occupational
Safety and Health) certified dust respirator
and wear long-sleeved, loose fitting clothing,
gloves, and eye protection to avoid contact
with skin and eyes. In case of contact with
skin or eyes, wash or irrigate affected area
immediately, then wash potentially contami-
nated clothing separately and rinse clothes
washer thoroughly before reusing. For addi=
tional information, see the NIOSH homep-
age at www.cdc.gov/niosh/homepage.html, j
The modulating blower provides a means of intro- This appliance uses a direct spark igniter to ignite
duclng the gas/air mixture through the burner and the fuel/air mixture in the combustion chamber and

senseflameduringoperation.TheDSIisadurable,
reliablecomponentthat resistsbreakagedue to
handlingor inadvertentimpactwithotherobjects.
Thisapplianceemploysa factoryinstalledintegral
lowwatercut off (LWCO)that hasto be manually
resetif thereis a low watercondition.TheLWCO
senseswaterthroughaprobeatthetopoftheboiler
thatsendsasignalthroughthewatertoground.Ifthe
signalisnotsensedthroughtheground,theLWCO
entersa lockoutmodethatdisablestheappliance.
IftheLWCOisinnormalmodea redindicatorlight
isilluminatedon theLWCOpanelin theboiler.Dur-
ingalowwatercondition,theredlightgoesoutand
theLWCOandcontrolresetbuttonsonthedisplay
panelmustbedepressedtoresettheLWCO.
Intheeventoflackofor lossofwaterintheboiler,
the castingtemperaturesafetyswitch(230°Fset-
point) installedon the top of the aluminumboil-
er sectionbehindthe supplypipingshutsoff the
boiler by shuttingoff powerto the boiler control
and causesafailurecodeto be displayedon the
digitalreadout.Thisfault requiresmanualresetof
thecastingtemperaturesafetyswitchto restartthe
boilerandthe resetto be pressedon theuser in-
terfacepanel.Verifythattheboilerisproperlyfilled
withwaterbeforeresettingthisswitch.
Thisswitchisnormallyclosedandspringloadedso
that,whendepressed,it opens,and closesagain
whenpressureis removed.Theswitchis usedas
themanualresetfor the LWCO.Whentrippedthe
LWCOwilt remainin lockoutuntil the water level
reachestheprobeandthe switchis depressedto
anopenstateandthenreleasedto aclosedstate,
whichsendsa signalto theLWCOto resumenor-
maloperation.Theboilercontrolresetbuttonmust
then be pressedto resetfrom a low watercondi-
tion.TheLWCOswitchandcontrolresetbuttonare
locatedonthedisplaypaneloftheboiler.
Thehighlimitaquastatcontrolisaredundantsafety
limitcontrolthatdeterminesthemaximumboilerwa-
tertemperatureandalsoprovidesa meansfor pro-
tectingthe boilerand heatingsystemfrom unsafe
operatingconditionswhichcoulddamagetheboiler.
Theaquastatismountedinthe½"NPTcontrolwell
and¾" x ½"bushingon the topof the front boiler
sectionatthe hotwateroutlet.Theaquastatistied
inwiththeboilercontrolandisfactorysetat200°F
watertemperature.Thehighlimitsetpointisfieldad-
justableandmaybe setanywherebetween100°F
and200°F,withthemaximumhighlimitsetpointnot
exceeding200°F.The field high limitsetpointad-
justmentfor each installationdependson heating
systemrequirements.The aquastatautomatically
resetswhentheboilerwatertemperaturedecreases
tendegreesbelowthehighlimitsetpointvalue.
NatTE: Boiler operating temperature (temperature curve) is_
culated and set in the parameters of the boiler control. J
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 circulator 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.
I i:,
- +/
The air proving blocked vent safety assembly incor-
porates two pressure switches that are wired in se-
ries 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.
The manual drain valve provides a means of drain-
ing the water in the heating system, including the
boiler and hot water supply and return piping sys-
tems installed above the drain valve. This drain
valve is installed in the return piping at the bottom
front of the boiler section. Any piping installed below
the elevation of this drain valve will require additional
drain valves to be installed at low points in the piping
systems in order to drain the entire system.
Each boiler must have a properly sized and in-
stalled American Society of Mechanical Engineers
rated pressure relief valve. Water expands as it is
heated by the burner/boiler sections. If there is no
place for the water to expand its volume, (i.e., a
properly sized and properly functioning expansion
tank) pressure on the inside of the boiler and heat-
ing system wilt increase. The furnished relief valve
wilt automatically open at 30 psig pressure to re-
lieve the strain on the boiler and heating system
from the increasing pressure. The pressure relief
valve discharge must be piped with the same size
pipe as the valve discharge opening to an open
drain, tub or sink, or other suitable drainage point
not subject to freezing, in accordance with ASME
specifications. Failure to provide the pressure relief
valve with piping as herein described may cause
water damage and/or serious bodily injury. The
boiler manufacturer is not responsible for any water
damage or personal injury.
For installations where there is no floor drain or oth-
er appropriate drainage receptacle available to re-
ceive 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 conden-
sate reservoir (sump) can be accomplished. Use
wood frame or blocks to raise boiler as required for
proper installation.
The optional concentric vent/air intake termina-
tion utilizes a single opening per each appliance
through the walt or roof of a structure.
'_bNyOTE:Maintenance as outlined below can be 3erformed'_
the owner unless otherwise noted. J
The acidic nature of flue gases condensing on the
aluminum boiler sections wilt cause the formation
of aluminum oxide. This oxide formation is normal,
is generally uniform throughout the boiler sections,
and represents a negligible mass of aluminum
that is consumed by oxidation during the life of the
boiler. If left unchecked, this buildup may eventu-
ally cause blockage of the flue gas passages in the
boiler sections, reducing efficiency, and ultimately
shutting down the boiler due to lack of combustion
air flow.
Regular service and maintenance by aquali-
fied service agency must be performed at least
once every 12 months to assure safe, trouble
free operation and maximum efficiency.
1. Schedule an annual service call by a qualified
service agency which includes:
Examining flue passages between boiler
sections, burner, and condensate lines, and
cleaning (if necessary) by following the in-
structions in "Annual Examination and Clean-
ing of Boiler Components" in this section.
Visually inspecting the venting and air intake
system for proper operation, immediately re-
pairing or replacing any sign of deterioration
or leakage, and insuring proper reassembty
and reseating of the system.
Checking for and removing any obstruction
to the flow of combustion air or venting of
flue gases,
Following the instructions in Sections V and
VII of the Control Manual and Operating In-
structions (P/N# 240006104), "Putting The
Boiler In Operation" and "Checkout Proce-
dures And Adjustments. "
Visually inspecting the condensate drain line
for proper operation and checking for dete-
riorated or plugged condensate drain line.

• Checking all gasketedjoints for leakage
andtighteningboltsor replacinggasketsas
needed.
Removingjacketfrontandtoppanels,check-
ingfor pipingleaksaroundreliefvalve and
other fittings,and repairingif found WITH-
OUTUSINGSTOPLEAKCOMPOUNDS.
2. Checkthat boilerarea isfreefrom combus-
tible materials,gasoline,and other flammable
vaporsandliquids.
3. Circulator pump and blower motor furnished
with boiler are permanently lubricated from the
factory and require no further lubrication. Addi-
tional or non-factory supplied pumps and/or mo-
tors should be lubricated according to the pump
and/or motor manufacturer's instruction.
1. Check for and remove any obstruction to the
flow of combustion air or venting of flue gases.
2. Check that boiler area is free from combus-
tible materials, gasoline, and other flammable
vapors and liquids.
including flushing of float type devices. Refer to
low water cut off manufacturer's specific instruc-
tions.
1. Turn off gas to boiler as described "To Turn
Off Gas To Appliance" in Section V of the Con-
trol Manual and Operating Instructions (P/N#
240006104).
2. If heating system is to remain out of service
during freezing weather and does not contain
antifreeze, drain system completely. If boiler will
be exposed to freezing temperatures, drain con-
densate lines. Otherwise, do not drain system
or boiler.
1. Remove jacket front and top panels and check
for piping leaks around relief valve and other fit-
tings. If found, contact a qualified service agen-
cy. DO NOT USE STOP LEAK COMPOUNDS.
2. Test relief valve. Refer to valve manufacturers
instructions packaged with relief valve.
1. Before servicing, turn off electrical power to
boiler at service switch. Close manual gas valve
to turn off gas supply to boiler.
2. Examine flue passages by removing blower
assembly from casting. The procedure for ex-
amining and cleaning the burner is described
below.
3. Visually inspect the venting and air intake
system for proper operation. If the vent or air in-
take show any signs of deterioration or leakage,
contact a qualified service agency to repair or
replace them immediately and to insure proper
reassembty and resealing of the system.
4. Visually inspect the PVC condensate drain
pipe for proper operation. If the drain pipe shows
any signs of blockage, leakage, or deterioration
contact a qualified service agency to clean, re-
pair, or replace it immediately.
5. Check air vent(s) for leakage.
6. Where low water cut offs are used, a periodic
inspection of the low water cut off is necessary,
Any buildup of sediment or aluminum oxide
(white powdery or flaky substance) in the flue
passages must be cleaned as follows:
• Remove jacket front and top panels.
Confirm that manual gas valve is closed and
disconnect gas line to gas valve at union.
Then disconnect pressure switch hoses to
gas valve and air inlet.
•Disconnect wires to gas valve and igniter.
•Loosen but do not remove five nuts attach-
ing blower adapter assembly to boiler.
•Remove two igniter screws and very care-
fully remove the igniter.

• Removefivenutsandremovebloweradapt-
erassembly,burner,andgaskets.
Aluminum oxide deposits are water soluble
and may be rinsed away by inserting a hose
into the burner opening of the casting and
slowly running water through the flue side of
the boiler and out the condensate drain.
I c o,,o.I
ebris rinsed away by this method will e×it I
hrough the condensate drain. Be wary of I
rain lines getting clogged and causing wa= I
er to back up in the bottom of the casting. ,J
Use a flexible handle nylon brush to loosen
sediment and aluminum oxide on all acces-
sible heating surfaces of the boiler. Be sure
not to get brush stuck in heat exhanger!
• After brushing and rinsing, remove any re-
maining loosened sediment using a shop
vacuum with a snorkel attachment.
Inspect burner for any foreign matter in the
flame ports or inside the burner. Any foreign
matter should be removed by blowing with
compressed air or vacuuming.
• Reinstall burner and gaskets and position
blower adapter assembly over studs. In-
stall five nuts but do not tighten. Reinstall
igniter and igniter gasket and fasten with
two screws. Tighten five nuts holding blower
adapter assembly.
Connect gas line to gas valve, pressure
switch hose to gas valve and air inlet assem-
bly, igniter wires, and gas valve wires.
3. Visually inspect the condensate trap. Any
foreign material visible in the condensate lines
needs to be cleaned out as described below:
• Inspect for sediment or blockage.
• Flush out with water or vacuum.
• Follow the instructions in Section VII, "Filling
The Condensate Trap With Water."
4. Inspect the flue connector as follows:
Loosen the clamp on the vent tee side of the
2" flexible coupling that connects the vent
tee to the exhaust port.
Inspect interior of vent tee. Any buildup of
sediment on the inside surface must be
cleaned.
• Reconnect 2" flexible coupling to vent tee.

ELECTRICAL WIRING DIAGRAM (DIAGRAHHE DE CABLAGE _-LECTRIQUE)
/"X
RESET(7
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22:::::2
24 VOLT ----_vf--
-- ..--_R OUT
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DISPLAY
ODD o
DD DDD
HIGH LINIT
THER_DSTAT
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BLI]_ER
TIDN
41R P_OVING
_ CAST
S_,F_Ty
SVlTCH
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I _w_#m I 120 VOLT POWER SUPPLY
TE USE COPPEiONDUCTORS ONLY)
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TH-I THERMOSTAT (N]I.LIVOLT)
TIP2 THERMOSTAT (24 VOLT)
IN-3 THERMOSTAT (LINE VOLTAGE)
(VOLTAGE DE LIGNE)
TR-I TRANSFBRNER (120V/R4V 4OVA)
TRANSFBRNATEUR (I_OV/ _AV 4OVA)
TR-2 TRANSFORMER (120V/_4V 5OVA)
TRANSF[i_NATEUR (120V/ 2'$V 5OVA)
NOV _LLIVOLT GAS VALVE
SOU_APE _ OAZ MILL_VOLT
LOV 04 VOLT GAS VALVE
SOUPAPE _ GAZ 24 VOLT
LGV-I 24 VOLT GAS VALVE
snuPAPE _ GAZ 24 VOLT
PS PRESSURE SWITCH
INTERRUPTEUR DE PRESSIBN
NOT[:
CDHPDNENT CODING
MR-PS MANUAL RESET PRESSURE SW,
ROMISE EN NARCHE MANU_L DE
L'INTERRUPTEUR DE PRESSION
SD ST_CK DAMPER
REGISTRE DE LA CHENIN_E
--0-- CONTROL]IER_INAL
BORNE DU CONTR_LE
I K RELA_ CElL
BOBINE DU RELAYS
1 K1 RELAY CONTACTS
CONTACTS DU k_LAIS
1K£ RELAY CONTACTS
CONTACTS _U RELAIS
LS LIMIT SWITCH
INTERRUP'_UR _E LINITE
r FLAME SENSING
FLAMNE SENSING
(CODE DES COMPIqSANTES)
MS N_NUAL SWITCH
INTERRUPTEUR MANUEL
C_R CINCULATDR
CIRCULATEUR
ECO ENERGY CUT-OFF
COUPE-CIRCUIT
LVCO LOW VOTER CUT-OFF
POUR FERNER L'EAU
EWF ELECTRIC WATER FEEDER
ALIHENTEUR _LECTRIOUE D'EAU
PG POWER GENERA]I]R
G _N¢::RATEUR
PSC pllnT SAFETY CB@L
_DBINE DE Si_R_T IOE LA
VEILLEUSE
V_E CONNECT_N
RACCORD DES FILS
NOT ALL COMPONENTSLISTED ARE USED IN ALL CONTROl
SYSTEMS,
(LEg COMPOSANTES_zNUN_RtES NE SONT PAS TBUTES
UTILIS{ES DANg TOUS LOS SYST_:NES DE CONTROLES.)
WIRING (CADLAGE)
mLINE VOLTAGE _Y FACTORY
LIGNE DE VOLTAGE POR L'USINE
-- LOW VOLTAGE BY FACTORY
BAg VOLTAGE PAR L'USINE
m_mmmmm LINE VOLTAGE _'( INSTALLER
LIGNE DE VOLTAGE PAR L'INSTAGLATEUR
....... LOW VOLTAGE BY INSTALLER
BAS VOLTAGE pAR L'INSTALLATEUR
l, SWITCHES ARE SHOWN IN POSITION TAKEN DURING HEATING CYCLE,
(LEg ]NTERRUPTEURS SONT NONTR_'SEN POSITION DE CYCLE DE CHAUFFANT,)
2. IF ANY BF THE ORIGINAL WIRING SUPPLIED Vlll4 THE I_OILER IS REPLACED, _ MUST :BE REPLACED WITH L_E WIRE SIZE AND TYPE BF ]NSULAT_N OR EQUIVALENT.
(SI AUCUN _ES FILS ORIQINAUX FDURNIS AVOC LA CM&UD_RE EST REMPLAC{, IL DOIT _TRE RENPLAC£ OAR UN AUTRE FIL DE N_NE GROSSEURET DU R_NE TYPE D'ISOLATION
OU L'_'OU]VALENT.)
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