ECR International 75 Instruction manual

H
INSTALLATION,
OPERATION &
MAINTENANCE
MANUAL
P/N # 240008282, REV D [10/2010]
CONDENSING
GAS BOILER
Models 075 & 100

2
DIMENSIONS
FIGURE 1-1 Dimensions
Wall Hanging
Bracket
(D)
Gas
Connection
(G)
Supply Water
(E) Return Water
(E)
User Interface
(B)
(A)
Alternate
Return Water
(E)
Alternate
Supply Water
(E)
Alternate Gas
Connection
(F) (C)
(B)
(F)
Table 1 : Physical Data
Size Width
(A) Height (B) Depth (C) Bracket (D)
Water Connections Gas
Connection
(G)
Condensate Drain Weight
Shipping Unit
Size
(E) Height (F) (H) (I)
075
/100 22-1/16"
(560mm) 35-5/8" (905mm) 16-3/16" (411mm) 27-1/2" (969mm) 1-1/4" NPT 31-1/16" (789mm) 1/2" NPT 7-1/2" 5" 140 lb (63.5 kg) 115 lb (51.2 kg)
Vent Connection Combustion Air
Floor
(D)
(H)
(I)
Condensate
Drain

3
1 - Introduction............................................................................................................................... 4
2 - Important Safety Information....................................................................................................5
3 - Component Listing .....................................................................................................................6
4 - Locating Boiler.........................................................................................................................10
5 - Hydronic Piping........................................................................................................................12
5.2 Special Conditions................................................................................................................... 12
5.3 Safety Relief Valve and Air Vent .................................................................................................12
5.4 Trim Piping............................................................................................................................. 13
5.5 System Piping......................................................................................................................... 13
6 - Combustion Air And Vent Piping .............................................................................................. 18
6.2 Removal of Existing Boiler..........................................................................................................18
6.3 Materials ............................................................................................................................... 18
6.4 Pipe Installation...................................................................................................................... 19
6.5 Termination............................................................................................................................ 19
6.6 Condensate Piping...................................................................................................................25
7 - Gas Supply Piping ....................................................................................................................26
8 - Electrical Connections..............................................................................................................28
8.2 Line Voltage Connections.......................................................................................................... 28
8.3 Low Voltage Connections.......................................................................................................... 28
9 - Start Up Procedure...................................................................................................................30
10 - Operating Instructions...........................................................................................................34
11 - General Maintenance And Cleaning ........................................................................................35
12 - Ratings And Capacities........................................................................................................... 38
13 - Trouble Shooting....................................................................................................................39
14 - Wiring Diagram......................................................................................................................56
15 - Glossary.................................................................................................................................58
Appendix A - Control Module .........................................................................................................60
1.1 Introduction ........................................................................................................................... 60
1.2 Operation............................................................................................................................... 60
1.3 Status Indication..................................................................................................................... 60
1.4 Sequence of Operation............................................................................................................. 61
1.5 Theory of Operation................................................................................................................. 63
TABLE OF CONTENTS

4
1.1 Designated Use
Hot water heating boiler.•
Indoor installation.•
Closet or alcove installation.•
Direct vent boiler.•
For use with natural gas or liquefied petroleum gases• (LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
Exceed 50 psig (344 kPa) system pressure.•
Exceed 195°F (90.5°C) system design temperature.•
1.3 Operational Features
Modulating: 20-100%.•
Integral Dual Limit.•
Integral Low Water Cutoff (with test button).•
Outdoor Temperature Reset.•
Integral Multiple Boiler Control.•
1 - INTRODUCTION

5
NOTICE
Used to address practices not related to personal
injury.
2.3 Installation shall conform to requirements
of authority having jurisdiction or in absence of
such requirements:
United States •
National Fuel Gas Code, ANSI Z223.1/NFPA 54• .
National Electrical Code, NFPA 70.•
Canada•
Natural Gas and Propane Installation Code,• CAN/CSA B149.1.
Canadian Electrical Code, Part I, Safety Standard• for Electrical Installations, CSA C22.1
2.4 Where required by authority having
jurisdiction, installation shall conform to
Standard for Controls and Safety Devices for
Automatically Fired Boilers, ANSI/ASME CSD-1.
Additional manual reset low water cutoff may be required.
2.5 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
limited to:
Installation by licensed plumber or gas fitter.•
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you to
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
following this symbol to avoid possible injury or death.
2.2
2.2
Become familiar with symbols identifying
Become familiar with symbols identifying
potential hazards.
potential hazards.
2.1 General
Boiler installation shall be completed by qualified agency.
See glossary for additional information.
WARNING
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
!
2 - IMPORTANT SAFETY INFORMATION

6
3.1 Component Listing
User Interface 1. (see Page 8) - Displays information
regarding boiler condition. Allows adjustment of
boiler operating parameters. NOTE: Does not replace
thermostat used to control central heating space.
Combustion Air Inlet (2" PVC)
2. (see page 7 & 8)
Return Water From Heating System (In) 1-1/4"
Return Water From Heating System (In) 1-1/4" 3.
NPT
NPT
(see pages 7 & 8)
(see pages 7 & 8)
-
-
Connections supplied to con-
Connections supplied to con-
nection top and/or bottom of boiler.
nection top and/or bottom of boiler.
Low Voltage Terminal Strip
Low Voltage Terminal Strip 4.
(see pages 7 & 8)
(see pages 7 & 8)
- Connection of all low voltage wiring, including
- Connection of all low voltage wiring, including
thermostat. See section
thermostat. See section
8.
8.
Igniter 5. (see page 8)
Flame Sensor 6. (see page 8)
Sight Glass 7. (see page 8) - Permits observation of
burner flame.
Burner 8. (see page 8)
Combustion Chamber 9. (see page 8)
Condensate Collector 10. (see page 8)
Return Temperature Sensor 11. (see page 8)
Drain Valve 12. (see page 8)
Heat Exchanger Ball Valve 13. (see page 8)
Supply Water Outlet to Heating System (Out)
14.
1-1/4"NPT (see pages 7 & 8) - Connections supplied
for connecting from either top or bottom of boiler. See
section 5.
Vent Temperature Sensor 15. (see page 8)
Condensate Drain 16. (see page 8) - Boiler produces
a liquid (condensate) as a by-product of combustion.
Condensate must be piped to appropriate drain. See
section 6.
Heat Exchanger Pump
Heat Exchanger Pump 17. (see page 8)
Gas Shutoff Valve
Gas Shutoff Valve 18. (see page 8)
- Fuel supply isolation
- Fuel supply isolation
during servicing. See section 7
during servicing. See section 7
Combustion Air Blower
Combustion Air Blower 19. (see page 8)
- Delivers
- Delivers
proper quantity of combustion air, receives fuel from
proper quantity of combustion air, receives fuel from
gas valve, mixes air and fuel sending mixture to burner
gas valve, mixes air and fuel sending mixture to burner
for combustion.
for combustion.
Gas (Control) Valve
Gas (Control) Valve 20. (see page 8)
- Delivers
- Delivers
proper quantity of fuel to Combustion Air Blower.
proper quantity of fuel to Combustion Air Blower.
See section 7.
See section 7.
High Temperature Supply Switch
High Temperature Supply Switch 21. (see page 8)
Low Water Cutoff
Low Water Cutoff 22. (see page 8)
-
-
Senses inadequate
Senses inadequate
quantity of water. Turns off boiler before damage can
quantity of water. Turns off boiler before damage can
occur (with test button).
occur (with test button).
Safety Relief Valve 23. (see page 8) - Factory supplied,
Field installed. See section 5.
High Voltage Junction Box 24. (see page 8) - For
connection of 120V components. See section
8
8.
Vent Connector (2" PVC) 25. (see pages 7 & 8) - See
section 6.
Gas Connection
Gas Connection 26. (see page 7)
- Gas supply may be
- Gas supply may be
piped either through top or bottom of boiler. See
piped either through top or bottom of boiler. See
section 7.
section 7.
Bracket for Optional Wall Mount 27. (see page 7) -
Integral to boiler. Allows optional wall mounting when
used with supplied wall mounting bracket. See section 4.
Auxiliary Power Outlet 28. (see page 7) - Convenience
outlet for condensate pump or service. Controlled by
Service Switch (29)
Service Switch 29. (see page 7)
Air Vent 30. (see page 7)
Central Heating Pump Circuit Breaker 31. (see page 7)
5 amp circuit breaker protects control module.
Control Module
Control Module 32. (see page 9)
Internal Access Panel 33. (see page 9) - Gently pull
upward then forward to access control module.
Removable for access to internal components of boiler.
Central Heating Pump Relay 34. (see page 9)
Transformer 35. (see page 9) - Supplies 24V power to low
water cutoff.
Pressure Switch 36. (not shown)
Test Port 37. -(see page 8)
Combustion Analysis Test Port 38. - (see page 8)
3 - COMPONENT LISTING

7
3 - COMPONENT LISTING
FIGURE 3-1 Boiler Components
LOW VOLTAGE
LOW VOLTAGE
TERMINAL
TERMINAL
STRIP
STRIP COMBUSTION
AIR INLET- 2" PVC VENT
CONNECTOR - 2" PVC
SAFETY
SAFETY
RELIEF
RELIEF
VALVE
VALVE
AIR VENT
AIR VENT
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
HIGH VOLTAGE
HIGH VOLTAGE
JUNCTION BOX
JUNCTION BOX
SUPPLY WATER TO
SUPPLY WATER TO
HEATING SYSTEM
HEATING SYSTEM
(OUT)
(OUT)
GAS CONNECTION
GAS CONNECTION
SERVICE SWITCH
SERVICE SWITCH
AUXILIARY POWER
AUXILIARY POWER
OUTLET
OUTLET
CENTRAL HEATING
CENTRAL HEATING
PUMP CIRCUIT BREAKER
PUMP CIRCUIT BREAKER
BRACKET FOR
BRACKET FOR
OPTIONAL WALL
OPTIONAL WALL
MOUNT
MOUNT
NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions

8
3 - COMPONENT LISTING
FIGURE 3-2 Boiler Components
LOW
LOW
VOLTAGE
VOLTAGE
TERMINAL
TERMINAL
STRIP
STRIP
HIGH VOLTAGE
HIGH VOLTAGE
JUNCTION BOX
JUNCTION BOX
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
1-1/4" NPT
1-1/4" NPT
IGNITER
IGNITER
SIGHT
SIGHT
GLASS
GLASS
HEAT EXCHANGER
HEAT EXCHANGER
BALL VALVE
BALL VALVE
CONDENSATE
CONDENSATE
DRAIN 1/2" PVC
DRAIN 1/2" PVC
GAS SHUTOFF
GAS SHUTOFF
VALVE
VALVE
LOW WATER
LOW WATER
CUTOFF
CUTOFF
COMBUSTION
COMBUSTION
AIR
AIR
BLOWER
BLOWER
COMBUSTION
COMBUSTION
CHAMBER
CHAMBER
GAS (CONTROL)
GAS (CONTROL)
VALVE
VALVE
USER INTERFACE
USER INTERFACE
RETURN WATER
RETURN WATER
FROM HEATING
FROM HEATING
SYSTEM (IN)
SYSTEM (IN)
1-1/4" NPT
1-1/4" NPT
SUPPLY WATER TO
SUPPLY WATER TO
HEATING SYSTEM
HEATING SYSTEM
(OUT) 1-1/4" NPT
(OUT) 1-1/4" NPT
HEAT EXCHANGER
HEAT EXCHANGER
PUMP
PUMP
CONDENSATE
COLLECTOR
DRAIN
VALVE
FLAME
SENSOR
(SHOWN IN OPEN
POSITION)
VENT
TEMPERATURE
SENSOR
SAFETY RELIEF VALVE
SAFETY RELIEF VALVE
VENT CONNECTOR
(2" PVC)
COMBUSTION
AIR INLET
2" PVC
HIGH TEMPERATURE
SUPPLY SWITCH
RETURN TEMPERATURE
SENSOR
COMBUSTION
COMBUSTION
ANALYSIS TEST
ANALYSIS TEST
PORT
PORT
TEST PORT
NOTE:
See Section 5
For Piping
Instructions
IN-LINE
IN-LINE
PRESSURE
PRESSURE
SWITCH
SWITCH
VAPOR
VAPOR
COLLECTOR
COLLECTOR

9
3 - COMPONENT LISTING
INTERNAL ACCESS
PANEL - CLOSED
INTERNAL ACCESS
PANEL -OPEN
CONTROL
MODULE
CENTRAL HEATING
PUMP RELAY TRANSFORMER
Control Module
Fuse and holder
Note: To open
Lift panel up
then pull forward
LOW
VOLTAGE
TERMINAL
STRIP
HIGH VOLTAGE
JUNCTION BOX
RETURN WATER
FROM HEATING
SYSTEM (IN)
1-1/4" NPT
IGNITER
SIGHT
GLASS
HEAT EXCHANGER
BALL VALVE
CONDENSATE
DRAIN 1/2" PVC
GAS SHUTOFF
VALVE
LOW WATER
CUTOFF
COMBUSTION
AIR
BLOWER
COMBUSTION
CHAMBER
GAS (CONTROL)
VALVE
USER INTERFACE
RETURN WATER
FROM HEATING
SYSTEM (IN)
1-1/4" NPT
SUPPLY WATER TO
HEATING SYSTEM
(OUT) 1-1/4" NPT
HEAT EXCHANGER
PUMP
SAFETY RELIEF VALVE
COMBUSTION
ANALYSIS TEST
PORT
IN-LINE
PRESSURE
SWITCH
VAPOR
COLLECTOR

10
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Top (A) 0" (0 cm) 14" (36 cm)
Left Side (B) 6" (16 cm) 6" (16 cm)
Right Side (C) 0" (0 cm) 1½" (4 cm)
Front (D) 0" (0 cm) 6" (16 cm)
Back (E) 0" (0 cm) 0" (0 cm)
Bottom (F) 0" (0 cm) 0" (0 cm) Floor
12" (32 cm) for
Bottom Piped
Combustion
Air/Vent piping
0" (0 cm) 6" (16 cm)
Hot Water Pip-
ing
½" (1.3 cm) 6" (16 cm)
(1) Required distances measured from boiler.
(2) Service, proper operation clearance recommendation.
4 - LOCATING BOILER
FIGURE 4-1 Clearance to Combustible Materials
4.1 Boiler Location Considerations
Ambient room temperature always above 32°F (0°C) to• prevent freezing of liquid condensate.
Approved for installation in closets and on combustible• floors. Do not install boiler on carpeting.
Protection of gas ignition system components from• water (dripping, spraying, rain, etc.) during operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
Floor or wall mounting.•
Wall must be plumb and capable of supporting boiler• weight plus 60 lbs (28 kg). See Table 1.
Floor must be level. Leveling feet allow adjustment• up to 1/4" (6 mm).
Wall mounting. See section 4.2.•
Access to outdoors to meet minimum and maximum• pipe lengths for combustion air and vent piping. See
section 6.
Disposal of condensate. See section 6.•
Drainage of water (or water - antifreeze solution) during• boiler service or from safety relief valve discharge. See
section 5.
Access to system water piping, gas supply, and electrical• service. See sections 5, 7 and 8.
Clearances to combustible materials and service• clearances. See Table 2 and figure 4-1.
Multiple Boilers can be placed side by side, back to back• or wall mounted.
FLOOR FLOOR
A
E
ED
B
B
AA
C
C

11
4.2 Wall Mounting Option
Boiler can be wall mounted using wall mounting bracket
included with unit.
Structure must be capable of supporting boiler weight• plus 60 lbs (28 kg). See Table 1, page 2.
Wall mount bracket has 4 slots allowing mounting on• two (2) wall studs spaced at 11½" to 16½" on center.
See figure 4-2.
Boiler includes (4) 3/8" x 3" lag screws and (4) washers• for attaching wall mount bracket to wood studs. Field
source appropriate fasteners for other wall constructions
(masonry, concrete).
Attach wall mount bracket level on wall.•
Boiler must engage with wall mount bracket.•
Avoid overhang on sides of wall mount bracket. Verify• boiler bracket is centered on wall bracket. See figure
4-2.
4 - LOCATING BOILER
FIGURE 4-2 Wall Mount Bracket Engaged with
Bracket on Boiler
4 Slots for attaching Wall
Mount Bracket to Studs
Center brackets. Avoid
overhang on sides of wall
mount bracket.
CAUTION
Boiler weight exceeds 115 pounds (51.2 kg). Do
not lift boiler onto wall without assistance.
!
!

12
5.1 General
Install piping in accordance with authority having jurisdiction.•
NOTICE
Use two (2) wrenches when tightening and fitting
to pipe boiler's threaded fittings. Boiler's internal
piping can be damaged if subjected to excessive
torque.
Support system piping and safety relief valve discharge• piping. Boiler's internal piping and wall mount bracket can
be damaged if subjected to excessive weight.
Size central heating pump (and domestic hot water pump,• if used) for system requirements only. Heat exchanger
pump compensates for pressure drop through boiler
internal piping and heat exchanger.
Thoroughly clean and flush system before connecting to• boiler.
5.2 Special Conditions
System piping exposed to freezing conditions: Use• inhibited proplyene glycol solutions certified by fluid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
Boiler installed above radiation level (or as required by• authority having jurisdiction). Integral low water cutoff
provided in boiler. See page 6.
Boiler used in connection with refrigeration system.• Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
System piping connected to heating coils located in air• handling unit exposed to refrigerated air circulation.
Install flow control valves or other automatic means to
prevent gravity circulation of boiler water during cooling
cycle.
5.3 Safety Relief Valve and Air Vent
NOTICE
Boiler rated at 50 psig (345 kPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. Field source
safety relief valve for system pressures greater than
30 psig (206 kPa). Temperature Pressure Gauge
and Air Vent satisfactory for 30-50 psig (206-345
kPa) operation.
Install safety relief valve and air vent using pipe fittings• provided with boiler. See figure 5-1.
Install safety relief valve with spindle in vertical position.•
Do not install shutoff valve between boiler and safety• relief valve.
WARNING
Poison hazard. Ethylene glycol is toxic. Do not• use ethylene glycol.
Never use automotive or standard glycol antifreeze,• even ethylene glycol made for hydronic systems.
Ethylene glycol can attack gaskets and seals used• in hydronic systems.
Use only inhibited proplyene glycol solutions• certified by fluid manufacturer as acceptable for
use with closed water heating system.
Thoroughly clean and flush any system that used• glycol before installing new Boiler.
Provide user with Material Safety Data Sheet• (MSDS) on fluid used.
!
5 - HYDRONIC PIPING
NOTICE
Do not expose boiler and condensate piping to
freezing temperatures.
FIGURE 5-1 Safety Relief Valve & Air Vent
3/4" NPT
Close Nipple
3/4"F x 3/4"M
NPT Tee
3/4" x 1/4" NPT
90° Elbow
Air Vent
3/4 NPT
Safety Relief
Valve
3/4" NPT
90° Elbow

13
Systems with automatic fill valves require back flow• prevention device.
Install discharge piping from safety relief valve. See• figure 5-2.
Use ¾" or larger pipe.•
Use pipe suitable for temperatures of 375°F (191°C)• or greater.
Individual boiler discharge piping shall be independent• of other discharge piping.
Size and arrange discharge piping to avoid reducing• safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
Run pipe as short and straight as possible to location• protecting user from scalding and properly drain
piping.
Install union, if used, close to safety relief valve outlet.•
Install elbow(s), if used, close to safety relief valve• outlet and downstream of union (if used).
Terminate pipe with plain end (not threaded).•
5.4 Trim Piping
Supply and Return Piping•
Supply - Select either top, bottom or both.•
Return - Select either top, bottom, or both.•
Use second temperature pressure gauge when piping• top and bottom.
Install brass plug(s) provided with boiler in unused• tapping(s). Use provided sealant.
Temperature - Pressure Gauge. Install temperature• pressure gauge using nipple, bushing and tee provided
with boiler. See figure 5-3.
5.5 System Piping
Single boiler system. See figures 5-4, 5-5, 5-6, 5-7 for• general guidance. Additional considerations:
Control system designed for single central heating• pump. Installer responsible for integration of
multiple central heating pumps.
Control system allows domestic hot water• prioritization. Function could be lost if central
heating pump not directly connected to control
system.
Multiple boiler system. See figure 5-8 for general• guidance. Additional considerations:
Control system requires equivalent water• temperatures entering each boiler to properly
sequence and adjust system supply temperature.
Install multi boiler sensor kit. See "Parts, Kits &• Optional Accessories" manual for part number.
5 - HYDRONIC PIPING
FIGURE 5-3 Temperature Pressure Gauge
Installation
Temperature Pressure Gauge
shown at Optional Bottom
Supply Connection to Boiler
FIGURE 5-2 Safety Relief Valve Discharge Piping
Check Local Codes
For Maximum
Distance To Floor
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!

14
Piping Legend
FIGURE 5-4 System Piping
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping
concept only. Installer responsible for all equipment
and detailing required by authority having
jurisdiction.
Check Local Codes
For Maximum
Distance To Floor
System
Return
System
Supply
FLOOR

15
5 - HYDRONIC PIPING
5-5 TWO-PIPE ZONED SYSTEM WITH VALVES
5-6 TWO-PIPE ZONED SYSTEM WITH PUMPS
Heat exchanger
ball valve open
(as shipped)
Heat exchanger
ball valve open
(as shipped)
DHW
Pump
CH/System
Pump
DHW
Pump
Zone
Pump
3/8"/10mm
Open End
Wrench
3/8"/10mm
Open End
Wrench

16
5 - HYDRONIC PIPING
5-7 SINGLE BOILER USING PRIMARY/SECONDAY PUMPING
12"/305mm Max. apart
12"/305mm
Max. apart
Limit length
to
5'/1.6 m
Existing closely
spaced tees
in primary
system loop
CH/System
Pump
Heat exchanger ball
valve open Heat exchanger ball valves closed
3/8"/10mm Open
End Wrench
3/8"/10mm Open
End Wrench

17
5 - HYDRONIC PIPING
5-8 TYPICAL MULTIPLE BOILER PIPING - (See Multiple Boiler Guide)
CH/
System
Pump 12"/305mm Max. apart
System
Temperature
Sensor Size common piping
according to
maximum heat
capacity of
entire system
Up to 16
boilers
All heat exchanger
ball valves closed
3/8"/10mm Open
End Wrench
DHW
Pump
(See Multiple Boiler Guide)

18
Table 3 - Combustion Air and Vent Piping Length
For Example: Boiler can be installed on outside wall and
vented with 1-90° elbow and 1 ft (0.30 m) of vent pipe.
6.1 General
This boiler requires a dedicated direct vent system.
Install combustion air and vent piping in accordance
with these instructions, authority having jurisdiction,
and:
USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.•
Canada - Natural Gas and Propane Installation Code,• CAN/CSA B149.1
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common
Vent System
When existing boiler is removed from common venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall
be followed with each appliance remaining connected to
common venting system placed in operation, while other
appliances remaining connected to common venting system
are not in operation:
Seal any unused openings in common venting system.•
Visually inspect venting system for proper size and• horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
When practical, close all building doors, windows, and• all doors between space in which appliances remaining
connected to common venting system are located and
other spaces of building. Turn on clothes dryer and any
appliance not connected to common venting system.
Turn on exhaust fans, such as range hoods and bath-
room exhaust so they will operate at maximum speed.
Do not operate summer exhaust fan. Close fireplace
dampers.
Turn on appliance being inspected. Follow lighting• instructions. Adjust thermostat so appliances will operate
continuously.
Test for spillage at draft hood relief opening after 5• minutes of main burner operation. Use flame of match or
candle, smoke from cigarette, cigar or pipe.
Determine each appliance remaining connected to• common venting system properly vents when tested
as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
6 - COMBUSTION AIR AND VENT PIPING
their previous condition of use.
Any improper operation of common venting system• should be corrected so installation conforms with National
Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas
and Propane Installation Code, CAN/CSA B149.1. When
re-sizing any portion of common venting system, com-
mon venting system should be re-sized to approach
minimum size as determined using appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or Natural Gas and Propane Installation
Code, CAN/CSA B149.1.
6.3 Materials
See Table 4•
Combustion Air and Vent Pipe Equivalent
Length
2” Pipe 3” Pipe
Minimum 6 ft (1.8 m) 6 ft (1.8 m)
Maximum 60 ft (18.3 m) 100 ft (30.4 m)
1 - 90° elbow = 5 ft (1.6 m)
1 - 45° elbow = 3.5 ft (1.1 m)
1- 2" x 3" adapter = 0 ft (0 m)
Note: Concentric Vent Kit=5 ft (1.6m) equivalent
length

19
WARNING
Use of cellular core PVC for venting flue gas could
result in death, serious injury.
!
Table 4 - Combustion air and vent pipe fittings
must conform with the following:
Item Material Standards
Vent Pipe
and Fittings
PVC schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC schedule 40 ANSI/ASTM D1784/
F441
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40 ANSI/ASTM F628
Pipe
Cement/
Primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
IPEX is approved vent manufacturer in Canada listed• to ULC-S636.
IPEX System 636 Cements and Primers are approved• in Canada listed to ULC-S636.
DO NOT USE CELLULAR (FOAM) CORE PIPE
6 - COMBUSTION AIR AND VENT PIPING
WARNING
Vent extending through exterior wall shall not
terminate adjacent to wall or below building
extensions such as eaves, balconies, parapets or
decks. Failure to comply could result in death or
serious injury.
!
6.4 Pipe Installation
Minimum and maximum combustion air and vent pipe• lengths listed in Table (3). Pipe length counted from
combustion air connector to termination.
Install field-sourced 2" to 3" transition, if used, in vertical• section at combustion air inlet and vent connector.
90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows• equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length.
Slope vent pipes minimum 1/4" per foot (21 mm/m)• back toward boiler. Support horizontal sections to
prevent sags capable of accumulating condensate.
Support piping in accordance with pipe manufacturer's• instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2m) or less. Allow for
expansion/contraction of pipe.
Combustion air and vent piping must be air tight and• water tight.
Certified vent system components must NOT be inter-• changed with other vent systems or unlisted pipe/fittings.
Canadian installations only. All venting material, primer• and glue must be listed to ULC S636.
Canadian installations only. First 3 ft (0.9 m) of• plastic vent pipe from vent connector must be readily
accessible for visual inspection.
6.5 Termination
Terminate combustion air and vent pipes with fittings or• concentric vent kit.
See "Parts, Kits and Optional Accessory" manual for• concentric vent kit part numbers.
Use horizontal pipe for vent and 90° elbow for• combustion air termination when using fittings.
Terminate combustion air and vent pipes in same• atmospheric pressure zone through exterior sidewall or
roof.
Locate combustion air termination as far as possible• from swimming pool, swimming pool pump house, and
other sources of airborne chlorine.
Locate combustion air and vent as required by authority• having jurisdiction.

20
6 - COMBUSTION AIR AND VENT PIPING
Side Wall
Terminations
y3" (8 cm) Minimum horizontal
separation between combustion air
intake and vent terminations.
y8" (21 cm) Minimum vertical
separation between combustion air
intake and vent terminations.
y12" (30 cm) Separation between
bottom of combustion air intake and
bottom of vent.
yMultiple terminations as shown in
6-1, 6-2, and 6-3 must be minimum
of 12” (30 cm) horizontally between
vent of one termination and air intake
of next appliance.
yMaximum allowable total outside
exposure vent length equals 10 ft.
(3.05m).
yMaintain a pitch of 1/2" per ft
(0.15m/m) back to boiler to ensure
proper condensate drainage for
horizontal runs.
Roof
Terminations
y3" (8 cm) Maximum horizontal
separation between combustion air
intake and vent of same appliance.
y8" (21 cm) Minimum vertical
separation between combustion
air intake and vent of different
appliances.
y15" (38 cm) Maximum horizontal
length of vent.
yMaximum vent/intake between
different appliances 12" (30cm).
yMaximum allowable total vertical
vent length with outside exposure
equals 10 ft.(3.05m).
yAbandoned unused masonry
chimney may be used as chase-
way for combustion air and vent.
Both combustion air and vent pipe
must exit above top of chimney with
clearances as shown in figure 6-1.
12" (30 cm)
Minimum
8" (21 cm)
Minimum
15" (38 cm)
Maximum
3" (8 cm)
Maximum
Vent Combustion
Air
12" (30 cm) US, 18" (46 cm)
Canada Minimum above
anticipated snow line
Vent
3" (8 cm)
Maximum
separation
12" (30 cm)
Minimum from
overhang
12" (30 cm) Separation
between bottom of
combustion air intake
and bottom of vent
See snow & ice
page 23 Combustion Air
Vent
12" (30cm)
Minimum
separation
See snow & ice
page 23
FIGURE 6-1
FIGURE 6-2
FIGURE 6-3
Combustion Air
Roof Line