Dunkirk Q95M-200 User manual

INSTALLATIONMANUAL
Q95M-200GAS-FIREDDIRECTVENT
MODULATINGHOTWATERBOILER
DUNKIRK BOILERS
85 Middle Rd.
Dunkirk, NY 14048
www.dunkirk.com
An ISO 9001-2000 Certified Company
P/N 240006103D, Rev. 1.1 [04/06]

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GAS-FIRED DIRECT VENT MODULATING HOT WATER BOILER
INSTALLATION MANUAL
P/N# 240006103D, Rev. 1.1 [04/06] • Printed in USA • Made In USA
TABLE OF CONTENTS
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.
I - INTRODUCTION
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.

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III. RULES FOR SAFE INSTALLATION AND OPERATION
WARNING
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.
IMPORTANT: Failure to follow these instruc-
tions could cause a malfunction of the boiler
and result in death, serious bodily injury, and/or
property damage. For assistance or additional
information, consult a qualified installer, service
agency, or the gas supplier.
WARNING
This boiler contains ceramic fiber materials.
Use care when handling these materials per
the instructions specified under “Modulating
Burner” in Section XI of this manual.
1. Check all applicable state and local building
codes and utility company requirements before
installation. This installation must conform with
these requirements in their entirety. In the absence
of these codes, use NFPA installation codes and
good industry practice.
2. Before servicing the boiler, allow it to cool. Al-
ways shut off any electricity and gas supply con-
nected to the boiler prior to servicing.
3. Inspect gas line for leaks.
4. Be certain gas input rate is correct. Overfiring
may result in early failure of the boiler components.
This may cause dangerous operation. Underfiring
may result in too much air for the pre-mix 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. Follow a regular service 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 do-it-yourself items. They must be in-
stalled and serviced by qualified professionals.Rat-
The following defined symbols are used throughout this manual to notify the reader of potential hazards
of varying risk levels.
II - SAFETY SYMBOLS AND WARNINGS
DANGER
Indicates an imminently hazardous situation
which, if not avoided, will result in death or
serious injury.
WARNING
Indicates a potentially hazardous situation
which, if not avoided, could result in death
or serious injury.
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CAUTION
Indicates a potentially hazardous situation
which, if not avoided, may result in minor or
moderate injury. It may also be used to alert
against unsafe practices.
IMPORTANT: Read the following instructions
completely before installing!!

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IV - BOILER RATINGS AND CAPACITIES
ings above are for sea level applications. The boiler
automatically derates input at a rate of 2% for every
1000 feet above an elevation of 2000 feet (see Table
2). The boiler will 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.
TABLE 1: SEA LEVEL RATINGS - NATURAL AND PROPANE GASES
Boiler Input Rate
(MBH)(1)
Heating Capacity
(MBH)(1)(2)
Net I=B=R Rating
(MBH)(1)
AFUE(2) Flue Diameter Shipping
Wt.
High Fire 200 190 165 95% 2” CPVC & 3” PVC 284 lbs.
Low Fire 80 76 66
(1) 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.
TABLE 2: 95M-200 HIGH ALTITUDE DERATE CHART
Boiler Input
Rate (MBH)
Altitude (In Feet)
3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000
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
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.
V - BEFORE INSTALLING THE BOILER
Review the following before installing the boiler.
CODES
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 for Automati-
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.

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Installers - Follow local regulations with respect
to installation of Carbon Monoxide Detectors.
Follow maintenance recommendations in this
manual.
BOILER SIZING
Check to be sure you have selected the
boiler with the proper capacity before con-
tinuing the installation. The I=B=R Rating of
the boiler selected should be greater than
or equal to the calculated peak heating load
(heat loss) for the building or area(s) served
by the boiler and associated hot water heat-
ing systems. See “Table 1: 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.
CONSIDERATIONS FOR BOILER LOCATION
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).
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.
Connected to a properly located thermostat or
operating control (not included with boiler).
Placed on level surface (must NOT be in-
stalled on carpeting).
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).
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LOCATING THE BOILER
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.
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.
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.
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
TABLE 3: BOILER CLEARANCES*
Dimension Combustible
Construction
Accessibility/
Cleaning Service
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
Water Piping 1” - -
* All distances measured from the cabinet of the boiler.

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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.
COMBUSTION AIR AND
VENT PIPE REQUIREMENTS
8" MINIMUM
VERTICAL SEPARATION
BETWEEN COMBUSTION
AIR INTAKE AND VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL
3'' MAXIMUM
SEPARATION
15'' MAXIMUM
COMBUSTION
AIR
12''
MIMIMUM
Figure 1 - Roof Vent/Intake Terminations
Figure 2 - Sidewall Vent/Intake Terminations
OVERHANG
12" MINIMUM
90°
VENT
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
3"
MAXIMUM
SEPARATION
18"
MAXIMUM
15"
MAXIMUM
LESS THAN 12" CLEARANCE
12"
MINIMUM
12"
MINIMUM
12" OR MORE CLEARANCE
90°
BRACKET
VENT
18"
MAXIMUM
MAINTAIN 12" MINIMUM
CLEARANCE ABOVE HIGHEST
ANTICIPATED SNOW LEVEL OR
GRADE
12" SEPARATION
BETWEEN BOTTOM OF
COMBUSTION AIR INTAKE
AND BOTTOM OF VENT
12" MINIMUM
OVERHANG
3"
MAXIMUM
SEPARATION
12"
MINIMUM
12"
MINIMUM
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.
CAUTION
Keep boiler area clean of debris and free of
flammable and combustible materials, va-
pors, and liquids.
WARNING
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 ½”Armaflex or
equivalent. In extremely cold climate ar-
eas, use ¾”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 include fluorides, chlorides, phos-
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ROOF
OVERHANG
12" MINIMUM
VENT MAINTAIN 12" IN. CLEARANCE
ABOVE HIGHEST ANTICIPATED
SNOW LEVEL OR GRADE
COMBUSTION AIR
1" MAXIMUM
12" MINIMUM
Figure 3 - Concentric Vent Terminations
(Continued on next page)

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Figure 4 - Concentric Vent w/Dimensions
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WARNING
(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
with skin or eyes.
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Figure 5 - Concentric Vent Roof Installation
CONDENSATE DRAIN REQUIREMENTS
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 ¼” 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 filling with water
until water is seen at the vent.
NOTES:
Condensate trap is integral to the boiler.
Wood frame or blocks may be used to raise the boiler to
maintain drain pitch or to be above external condensate
pump reservoir.
There is a 115 volt AC receptacle provided on the con-
trol panel to provide power for an external condensate
pump (if needed).
1.
2.
3.

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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.
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-latest 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-B149
for Canadian standards.
VI - PLACING THE BOILER
WARNING
The boiler must be located on a surface that
can support the weight of the installed boiler.
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.
NOTE: Refer to “Locating The Boiler” in Section V of this
manual for required clearances for servicing and mainte-
nance.
FOUNDATION REQUIREMENTS
Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
NOTES:
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.
Wood frame or blocks may be used to raise boiler to
maintain drain pitch or to be above external condensate
pump reservoir.
REMOVAL OF EXISTING BOILER
FROM COMMON VENT SYSTEM
When an existing boiler is removed from a 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
1.
2.

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VII - NEAR BOILER PIPING
CAUTION
Copper supply and return piping must NOT be
installed directly into aluminum boiler section
castings due to galvanic corrosion between
dissimilar metals. Iron or steel bushings or
pipe nipples should be used between copper
system piping and boiler to make final con-
nection to boiler. Also, the use of dielectric
unions is acceptable. The packaged boiler is
furnished with iron piping where necessary
for the supply and 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 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.
EXPANSION TANK AND MAKE-UP WATER
CAUTION
Non-potable water only piped directly to
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.
PRESSURE RELIEF VALVE /
TEMPERATURE PRESSURE GAUGE
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
IMPORTANT: For piping examples using the Gas-Fired Direct Vent Modulating Hot Water Boiler,
see the Piping Appendix in Section XIV of this manual.
Figure 6 - Diaphragm Type
Expansion Tank Piping
Figure 7 - Relief Valve Discharge Piping

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between such safety valve and the atmosphere.
Installation of the safety relief valve shall conform
to ANSI/ASME Boiler and Pressure Vessel Code,
Section IV. The manufacturer is not responsible for
any water damage.
SUPPLY AND RETURN LINES
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 boiler jacket at the top of the
unit.
NOTE: Circulator pump and isolation valves are furnished
within a carton inside the boiler cabinet and can be installed
at the installer preferred location.
CONDENSATE DRAIN PIPING
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.
FILLING CONDENSATE TRAP WITH WATER
IMPORTANT: On initial start up the condensate
trap must be manually filled 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 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.
CHILLED WATER PIPING
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.
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.
VIII - COMBUSTION AIR AND VENT PIPE
CONNECTIONS AND TERMINATION
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-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 Section 5.3, Air For Com-
bustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1-latest revision, CSA-B149.1
and B149.2, or applicable provisions of the local
building code.

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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 recirculated flue gases.
Termination should be positioned where it
will not be subjected to potential damage by
foreign objects, such as stones, balls, etc.
Termination should be positioned where vent
vapors are not objectionable.
Put vent on 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
•
•
•
•
•
•
•
•
3” Pipe Min. Venting 3” Pipe Max. Venting
15 ft. equivalent length 60 ft. equivalent length
2. Combustion air and vent pipe fittings must
conform to American National Standards Insti-
tute (ANSI) standards and American Society
for Testing and Materials (ASTM) standards
D1784 (schedule-40 CPVC), D1785 (schedule-
40 PVC), D2665 (PVC-DWV), D2241 (SDR-21
and SDR-26 PVC), D2661 (ABS-DWV), or F628
(schedule-40 ABS). Pipe cement and primer
must conform to ASTM standards D2564 (PVC)
or D2235 (ABS).
In Canada construct all combustion air and vent
pipes for this unit of CSA or ULC certified 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
be made in a vertical run. Transition pieces are not includ-
ed. (See Figure 8 for details.)
COMBUSTION AND VENT PIPING LENGTH
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

13
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.
INSTALLATION
IMPORTANT: When transitioning from CPVC to
PVC it is recommended to use Weld-On CPVC 724
or 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 all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth
on pipe.
NOTE: It is recommended that all pipes be cut, prepared, and
pre-assembled before permanently cementing any joint.
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.
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 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 seal open-
ings where vent and combustion air pipes pass
through roof or side wall.
IX - GAS SUPPLY PIPING
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 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.
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).
TABLE 4: GAS PIPING SIZES
Natural Gas
Pipe
Length
Pipe Capacity - BTU/Hr. Input Includes Fittings
½” ¾” 1” 1¼”
20’ 92,000 190,000 350,000 625,000
40’ 63,000 130,000 245,000 445,000
60’ 50,000 105,000 195,000 365,000
LP Gas
Pipe
Length
Pipe Capacity - BTU/Hr. Input Includes Fittings
Copper Tubing (O.D.) Iron Pipe
⅝” ¾” ½” ¾”
20’ 131,000 216,000 189,000 393,000
40’ 90,000 145,000 129,000 267,000
60’ 72,000 121,000 103,000 217,000
The length of pipe or tubing should be measured from the gas
meter or propane second stage regulator.

14
! !
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.
CONNECTING THE GAS PIPING
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.
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.
TABLE 5: GAS SUPPLY PRESSURE
Natural Gas 4” min. w.c. 10” max. w.c.
LP Gas 10” min. w.c. 14” max. w.c.
Please check line pressure while unit is running.
GAS CONNECTION
Figure 9 - Gas Piping
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.
CHECKING THE GAS PIPING
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
Never use a match or open flame to test for
leaks!!

15
! ! 2. Route all low voltage wires through grommet-
ed opening on the right jacket panel.
THERMOSTAT
1. Connect room thermostat or end switch (isolat-
ed contact only) between terminals T1 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.
OUTDOOR TEMPERATURE SENSOR
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 wall, 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.
DHW AQUASTAT
Connect storage indirect water heater (DHW) aqua-
stat between terminals DHW T1 and DHW T2.
X - ELECTRICAL WIRING
IMPORTANT: Wiring diagrams for the Gas-Fired Direct Vent Modulating Hot Water Boiler can be
found in Section XIII of this manual.
WARNING
For your safety, turn off electrical power sup-
ply at service panel before making any elec-
trical connections to avoid possible electric
shock hazard. Failure to do so can cause se-
vere personal injury or death.
IMPORTANT: Wiring must be N.E.C. Class 1.
If original boiler wiring must be replaced, use
only type 105°C wire or equivalent. Boiler must
be electrically grounded as required by National
Electrical Code ANSI/NFPA 70 - latest edition.
CODES
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.
LINE VOLTAGE CONNECTIONS
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.
LOW VOLTAGE CONNECTIONS
1. Connect low voltage wiring to low voltage
terminal strip as shown in the boiler wiring dia-
gram.

16
! !
XI - CONTROLS AND ACCESSORIES
This section provides a brief description of the key
controls and accessories found in this boiler. See the
Repair Parts Manual (P/N# 240006107) for illustra-
tions and the Control Manual and Operation Instruc-
tions (P/N# 240006104) for a detailed sequence of
operation and troubleshooting procedures.
ALUMINUM HEAT EXCHANGER
This appliance employs a cast aluminum heat ex-
changer that features a monoblock design. The
monoblock design eliminates the need for mating
sections and therefore eliminates leaks between
sections. Since the heat exchanger is cast of alu-
minum instead of iron, it has better heat transfer
properties which in turn lead to higher efficiency
and cooler exhaust temperatures. These cooler ex-
haust 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 il-
luminated 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 casting temperature safety switch has been
tripped or when the switch is in the OFF position.
MODULATING BOILER CONTROL
This appliance incorporates an integrated modulat-
ing control that senses the load necessary to heat
a structure and therefore uses less fuel than a con-
ventional fixed firing rate boiler when there is a low-
er than peak demand for heat. The control senses
the supply water, return water, and outside air tem-
peratures 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.
NTC SENSORS
The NTC sensors used with this appliance for mea-
suring supply water, return water, and outside air
temperature are specially configured to operate
with the modulating boiler control.
MODULATING BLOWER
The modulating blower provides a means of intro-
ducing the gas/air mixture through the burner and
into the combustion chamber where combustion can
begin and then out the exhaust vent where the com-
bustion products are discharged to the outdoors. The
blower is designed to communicate with the modu-
lating 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.
GAS CONTROL VALVE
The gas controls in this boiler have been developed
for domestic heating appliances with premix burn-
ers and automatic direct burner ignition and are
suitable for natural and LP gas. The gas controls
perform all the functions required to safely regulate
gas flow to the main burner of the boiler. The gas
valve is directly connected to the gas/air mixer.
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.
WARNING
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
a NIOSH (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.
DIRECT SPARK IGNITER
This appliance uses a direct spark igniter to ignite
the fuel/air mixture in the combustion chamber and

17
! !
sense flame during operation. The DSI is a durable,
reliable component that resists breakage due to
handling or inadvertent impact with other objects.
MANUAL RESET LOW WATER CUT OFF
This appliance employs a factory installed integral
low water cut off (LWCO) that has to be manually
reset if there is a low water condition. The LWCO
senses water through a probe at the top of the boiler
that sends a signal through the water to ground. If the
signal is not sensed through the ground, the LWCO
enters a lockout mode that disables the appliance.
If the LWCO is in normal mode a red indicator light
is illuminated on the LWCO panel in the boiler. Dur-
ing a low water condition, the red light goes out and
the LWCO and control reset buttons on the display
panel must be depressed to reset the LWCO.
NORMALLY CLOSED LWCO SWITCH
This switch is normally closed and spring loaded so
that, when depressed, it opens, and closes again
when pressure is removed. The switch is used as
the manual reset for the LWCO. When tripped the
LWCO will remain in lockout until the water level
reaches the probe and the switch is depressed to
an open state and then released to a closed state,
which sends a signal to the LWCO to resume nor-
mal operation. The boiler control reset button must
then be pressed to reset from a low water condi-
tion. The LWCO switch and control reset button are
located on the display panel of the boiler.
HIGH LIMIT AQUASTAT CONTROL
The high limit aquastat control is a redundant safety
limit control that determines the maximum boiler wa-
ter temperature and also provides a means for pro-
tecting the boiler and heating system from unsafe
operating conditions which could damage the boiler.
The aquastat is mounted in the ½” NPT control well
and ¾” x ½” bushing on the top of the front boiler
section at the hot water outlet. The aquastat is tied
in with the boiler control and is factory set at 200°F
water temperature. The high limit setpoint is field ad-
justable and may be set anywhere between 100°F
and 200°F, with the maximum high limit setpoint not
exceeding 200°F. The field high limit setpoint ad-
justment for each installation depends on heating
system requirements. The aquastat automatically
resets when the boiler water temperature decreases
ten degrees below the high limit setpoint value.
NOTE: Boiler operating temperature (temperature curve) is
calculated and set in 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 set-
point) installed on the top of the aluminum boil-
er 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 in-
terface panel. Verify that the boiler is properly filled
with water before resetting this switch.
WARNING
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 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.
AIR PROVING BLOCKED VENT
SAFETY ASSEMBLY
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

18
normally closed switch opens if there is a blockage
in the combustion air intake or exhaust vent pipes.
DRAIN VALVE
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.
ASME RATED PRESSURE RELIEF VALVE
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 will increase. The furnished relief valve
will 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.
EXTERNAL CONDENSATE PUMP (OPTIONAL)
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.
CONCENTRIC VENT/AIR INTAKE
TERMINATION (OPTIONAL)
The optional concentric vent/air intake termina-
tion utilizes a single opening per each appliance
through the wall or roof of a structure.
XII - MAINTENANCE AND CLEANING
NOTE: Maintenance as outlined below can be performed
by the owner unless otherwise noted.
The acidic nature of flue gases condensing on the
aluminum boiler sections will 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 a quali-
fied service agency must be performed at least
once every 12 months to assure safe, trouble
free operation and maximum efficiency.
BEGINNING OF EACH HEATING SEASON
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 reassembly
and resealing 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.
•
•
•
•
•

19
! !
Checking all gasketed joints for leakage
and tightening bolts or replacing gaskets as
needed.
Removing jacket front and top panels, check-
ing for piping leaks around relief valve and
other fittings, and repairing if found WITH-
OUT USING STOP LEAK COMPOUNDS.
2. Check that boiler area is free from combus-
tible materials, gasoline, and other flammable
vapors and liquids.
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.
DAILY DURING HEATING SEASON
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.
MONTHLY DURING HEATING SEASON
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.
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
reassembly 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,
•
•
including flushing of float type devices. Refer to
low water cut off manufacturer’s specific instruc-
tions.
ANNUAL SHUT DOWN PROCEDURE
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.
ANNUAL EXAMINATION AND CLEANING
OF BOILER COMPONENTS
WARNING
The following service procedures must be
performed by a qualified service agency us-
ing the Repair Parts Manual (P/N# 240006107)
for reference. The boiler owner should not
attempt these steps.
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.
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.
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Remove five nuts and remove blower adapt-
er assembly, burner, and gaskets.
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.
CAUTION
Debris rinsed away by this method will exit
through the condensate drain. Be wary of
drain lines getting clogged and causing wa-
ter to back up in the bottom of the casting.
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-
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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.
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