ECR International CCB-150 Instruction manual

COMBI
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
P/N# 240010632, Rev. B [07/17/2014]
Model
CCB-150
Manufacturedfor:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
cod. 3541F060

Figure 1 - Overall Dimensions
Rear View
Bottom View
1 = 1“ MPT Supply Water to Heating
System (Out)
2 = 3/4” MPT Tap Water Outlet
3 = 3/4” FPT Gas Inlet
4 = 3/4” MPT Tap Water Inlet
5 = 1” MPT Return Water From
Heating System (IN)
2
DIMENSIONS
Top View
Side View Front View

TABLE OF CONTENTS
3
1 - Introduction................................................................................................................... 4
2 - Important Safety Information........................................................................................... 5
3 - General view and main components .................................................................................. 6
4 - Locating Boiler ............................................................................................................... 9
5 - Hydronic Piping ............................................................................................................11
6 - Combustion Air And Vent Piping - Category I (Chimney Vent) ............................................ 15
6 - Combustion Air And Vent Piping of direct vent and Category III .......................................... 17
6 - Combustion Air And Ventilation....................................................................................... 19
7 - Gas Supply Piping......................................................................................................... 22
8 - Electrical Connections ................................................................................................... 23
9 - Start Up Procedure ....................................................................................................... 24
10 - Operating Instructions................................................................................................. 26
11 - General Maintenance And Cleaning................................................................................ 33
12 - Ratings And Capacities ................................................................................................ 34
13 - Trouble Shooting......................................................................................................... 37
Wiring diagram ............................................................................................................... 38
Repair Parts List.............................................................................................................. 40

1 - INTRODUCTION
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Catagory I or III Venting.
• Direct vent boiler.
• For use with natural gas or liquefied petroleum gases
(LP/propane).
• Directly heat potable water. Indirect heating is
acceptable.
1.2 The unit MUST NOT:
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 185°F (85°C) system design temperature.
• Exceed MWAP 43.5 PSIG
1.3 Operational Features
• Modulating: 3-1 turn down.
• Integral Dual Limit.
Information and specifications outlined in this manual in effect at the
time of printing of this manual. ECR International, Inc. reserves the right to
discontinue, change specifications or system design at any time without
notice and without incurring any obligation, whatsoever.
4

2 - IMPORTANT SAFETY INFORMATION
NOTICE
Used to address practices not related to
personal injury.
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
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
2.2 Become familiar with symbols identifying
potential hazards.
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.
!
2.3 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 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.
2.5
Where required by the authority having jurisdiction, the
installation must conform to the
Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD1.
2.1 General
Boiler installation shall be completed by qualified agency.
See glossary for additional information.
5

Figure 2 Component Listing
6
3 - GENERAL VIEW AND MAIN COMPONENTS

Item
Number
Description
5Sealed Chamber
7Gas Inlet
8Domestic Hot Water (DHW) Outlet
9Domestic Cold Water (DHW) Inlet
10 Supply System
11 System Return
16 Modulating Fan
19 Combustion Chamber
20 Burner Assembly
22 Burner
26 Combustion Chamber Insulation
27 Copper Heat Exchanger
28 Exhaust Manifold
29 Exhaust Outlet Manifold
32 Heating circulating pump
36 Automatic Air Vent
39 DHW Flow Regulator
42 DHW Temperature Sensor
44 Gas Valve
81 Ignition and Detection Electrode
95 3 Way Diverter Valve
114 Water Pressure Switch
136 Flow Meter
194 DHW Flate Plate Heat Exchanger
278 Double Sensor - High Limit NTC
297 Air Pressure Switch
364 Condensate Union
Unit Weight - 74 LBS (33.5 kg)
Shipping Weight - ~ 78 LBS (35.5 kg)
7
3 - GENERAL VIEW AND MAIN COMPONENTS

Remove Boiler Jacket
1. Unscrew screws (A).
2. Pivot jacket upwards. See figure 3.
3. Raise Jacket up and off boiler. See figure 4.
1
3
2
A
A
Figure 3 - Jacket Removal - Screw
Locations
Figure 4 - Pivot Jacket and Raise to Remove
WARNING
Fire, explosion, asphyxiation and electrical
shock hazard. Disconnect electrical power
supply and turn off gas at shutoff valve before
attemting to remove boiler jacket. Failure to
follow these instructions could result in death
or serious injury.
!
8
3 - GENERAL VIEW AND MAIN COMPONENTS

Figure 5 - Boiler Clearances
9
4 - LOCATING BOILER
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent freezing.
• Approved for installation in closets.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, control replacement,
etc.).
• Wall mount only.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air and vent piping. 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 5.
• The boiler must not be installed on carpeting.
A
D
FLOOR
F
TABLE 1: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Top (A) 16” (41cm) 16" (41cm)
Left Side (B
)
) 0" (0 cm) 1” (3 cm)
Right Side (C) 0" (0 cm) 1” (3 cm)
Front (D) 0" (0 cm) 1" 3 cm)
Back (E) 0" (0 cm) 0” (0 cm)
Bottom (F) 0" (0 cm) 12" (30 cm)
Combustion Air/piping 0" (0 cm) 3/8" (1 cm)
Vent piping 6" (15 cm) 6" (15 cm)
(1) Required distances measured from boiler jacket.
(2) Service, proper operation clearance recommendation.
F
Boiler
(Side View)
Boiler
(Front View)
F
BC
Front

Figure 6 - Wall Mounting Bracket
10
4 - LOCATING BOILER
4.2 Pre-pipe supply and return water connections
with factory fittings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included
with unit.
• Structure must be capable of supporting boiler weight
plus 60 lbs (28 kg). See page 7.
• Wall mount bracket has 2 slots, spaced at
9¼”
(23.5cm) on center .
• Attach wall mount bracket level on wall.
• Boiler must engage with wall mount bracket. See figure 6.
CAUTION
Boiler weight exceeds 75 pounds (34 kg). Do not
lift boiler onto wall without assistance.
!
!
NOTICE
Lift boiler using chassis. Using front jacket, vent
piping, water or gas fittings to lift boiler may cause
damage to the boiler.
9¼” (23.5cm)
2⅜”
(2.4cm)
2⅜”
(2.4cm)

11
5 - HYDRONIC PIPING
5.1 General
• Install piping in accordance with authority having jurisdiction.
NOTICE
Use two (2) wrenches when tightening and fitting
pipe to 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. Internal
heat exchanger pump compensates for pressure drop
through boiler internal piping and heat exchanger.
• Thoroughly clean and flush system before connecting to boiler.
• If oil is present in system water, use approved detergent to
wash system.
• Flush system to remove any solid objects such as metal chips,
fibers, or Teflon tape, etc.
5.2 Water System Characteristics
• Water in the heating system must have protection of
metallic materials against corrosion.
• Filling water and subsequent replenishing, must be
clear, with hardness under 150 ppm CaCO3,
A. treated with approved conditioning chemicals
to ensure prevention of corrosion and attack on
metals and plastics, that gases do not form,
B. and bacterial or microbial masses do not proliferate
in low temperature systems.
• Hardness exceeding 150 ppm CaCO3, appropriate water
softening treatment and/or use of suitable anti-fouling
agents must be provided.
Water contained in the system must be checked at least
yearly and have:
A. pH above 7 and under 8.5 (under 8 with presence
of components in aluminum or light alloys),
B. iron content (Fe) less than 0.5 mg/l,
C. copper content (Cu) less than 0.1 mg/l,
D. total content of chlorides, nitrates and sulfates less
than 50mg/l,
E. must contain conditioning chemicals in
concentration sufficient to protect system for a
year.
There must be no microbial or bacterial loads in low
temperature systems.
Conditioners, additives, inhibitors and anti-freeze fluids can
be used only if manufacturer guarantees they are suitable
for use in heating systems and they do not cause damage
to heat exchanger or other components and/or materials of
boiler and system.
Use of generic chemicals not specifically suitable for use in
heating systems and/or incompatible with boiler materials
and system is forbidden.
Conditioning chemicals must ensure complete deoxygenation
of water and contain specific protective agents for yellow
metals (copper and its alloys), anti-fouling agents for
limescale at least up to 150 ppm CaCO3, pH neutral
stabilizers and, in low temperature systems, specific biocides
for use in heating systems.
In systems with continuous intake of oxygen (e.g. floor
systems without anti-diffusion pipes, open expansion
vessels), or intermittent (e.g. in case of frequent
replenishing), a separator must be provided. Regarding
domestic hot water (DHW), no type of treatment which
could prevent its possible food use can be provided for.
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 propylene 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.
NOTICE
Do not expose boiler to freezing temperatures.
5.3 Special Conditions
• System piping exposed to freezing conditions: Use
inhibited propylene 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) shall have low water cutoff
protection.
• 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
.
!

12
WARNING
Burn and Scald Hazard. Safety relief vlave
could discharge steam or hot water during
operation. Install discharge piping per these
instructions. Failure to do so could result in
death or serious injury.
!
5.4 Safety Relief Valve
NOTICE
Boiler rated at 43.5 psig (.30MPa) maximum allowable
working pressure. Boiler provided with 30 psig
(.21MPa) safety relief valve.
• Install safety relief valve using pipe fittings provided with
boiler. See figure 7.
• Install safety relief valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety
relief valve.
• Install discharge piping from safety relief valve. See
figure 8.
• 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 - HYDRONIC PIPING
Figure 7 - Safety Relief Valve & Air Vent
(Viewed from front of boiler)
1” MPT
Coupling 1” NPT
Nipple 1”x 5”
Tee 1”x 1”x ¾”
Safety Relief
Valve
Street Elbow ¾”

13
5 - HYDRONIC PIPING
Check Local Codes
for Maximum
Distance to Floor
Safety Relief
Valve
Gas Shutoff
Valve
in Open
position
Figure 8 - Safety Relief Valve Discharge
Piping

14
5 - HYDRONIC PIPING
Figure 9 - Hydronic Piping
27
32
136
1110 8 9
278
95
241
42
114
36
- Plumbing circuit
8 Domestic Hot Water Outlet
9 Domestic Cold Water Inlet
10 Heating System Supply
11 Heating System Return
27 Copper Exchanger For Heating And Hot Water
32 Heating Circulating Pump
36 Automatic Air Vent
42 DHW Temperature Sensor
95 Diverter Valve
114 Water Pressure Switch
136 Flow Meter
241 Automatic Bypass
278 Double Sensor (Safety + Heating)

15
6 - COMBUSTION AIR AND VENT PIPING - CATEGORY I (CHIMNEY VENT)
6.1 Check Your Chimney
Chimney must be clean, right size, properly constructed
and in GOOD CONDITION.
1. Installation must conform to requirements of the
authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or Natural Gas and Propane
Installation Code, CAN/CSA B149.1.
2. Increaser fitting is required on this boiler for Category I
venting, and 4” is minimum permissible vent diameter.
This does not imply vent connector is intended to be 4”
diameter pipe. Vent connector shall be sized according
to appropriate venting tables in the National Fuel
Gas Code and may be required to be larger than 4”
diameter.
NOTICE
Boiler installation for chimney venting is not
complete unless increaser fitting is located and
secured.
3. Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe
B. Listed flexible vent liner
C. Poured ceramic liner.
4. Outside chimneys should not be used unless they are
(choose one of the following):
A. Enclosed in a chase
B. Lined with Type B vent pipe
C. Use listed flexible vent liner
D. Use certified chimney lining system
5. Vent connector from boiler to chimney should run as
directly as possible with as few elbows as possible.
6. Common venting shall not be allowed. Boiler and
other certified appliances. appliances can share same
chimney vent. Consult appropriate Vent Sizing Tables
in National Fuel Gas Code for specific requirements of
multiple appliance venting.
7. Boiler is only appliance connected to vent, Type B vent
pipe is recommended for vent connector.
8. Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
9. End of vent pipe must be flush with inside face of
chimney flue. Use sealed-in thimble for chimney
connection.
10. Fasten sections of vent pipe with sheet metal screws to
make piping rigid. Use stovepipe wires to support pipe
from above.
11. Do not connect to fireplace flue.
12. Do not install damper on this boiler.
Figure 10 - Combustion Air Fitting
3 3
Horizontal Venting requires field supplied appliance adapter
for the boiler flue outlet.
Boiler is provided with a 3” vent connection, 3” x 4”
increaser must be field sourced for chimney application.
This does not mean that the connection to the chimney will
always be 4”.
WARNING
Boiler and venting installations shall be performed
by a qualified expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to fire or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!

16
6 - COMBUSTION AIR AND VENT PIPING- CATEGORY I (CHIMNEY VENT)
6.2 Minimum Vent Pipe Clearance
• Use Type B vent pipe through crawl space. Where vent
pipe passes through combustible wall or partition, use
ventilated metal thimble. Thimble should be 4 inches
larger in diameter than vent pipe.
• Boiler installed with single wall vent, must have 6”
clearance between its surface and any combustible
material. New Type B gas vent or flexible liner must be
installed in accordance with instructions furnished with
vent. Maintain clearances as specified for vent pipe.
• Verify vent pipe is fire-stopped where it goes through
floor or ceiling. It should have approved vent cap with
clearances from roof. If clearances are less than shown,
have vent checked by local authorities. Figure 12, Page
20.
• Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.
6.3 Removing Existing Boiler From Common
Venting System
When an existing boiler is removed from a common
venting system, common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it.
1. 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 appliance
remaining connected to the common venting system
are not in operation.
2. Seal any unused openings in the common venting
system.
3. Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
restriction, leakage, corrosion and other deficiencies
which could cause an unsafe condition.
4. Insofar as is practical, close all building doors and
windows and all doors between the space in which the
appliances remaining connected to the common venting
system are located and other spaces of the building.
Turn on clothes dryers and any appliance not connected
to the common venting system. Turn on any exhaust
fans, such as range hoods and bathroom exhausts, so
they will operate at maximum speed. Do not operate a
summer exhaust fan. Close fireplace dampers.
5. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
6. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use flame of a
match or candle, or smoke from a cigarette, cigar, or
pipe.
7. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas-burning appliance to their previous
conditions of use.
8. Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1. When re-sizing any portion of the
common venting system, the common venting system
should be re-sized to approach the minimum size
determined using the appropriate tables in Chapter 13
of the National Fuel Gas Code, ANSI Z223.1/NFPA 54,
and/or the Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
9. It is recommended that existing gas vents be checked
to be sure they meet local codes.
6.4 Modulating Fan
• Unit is equipped with an advanced combustion air, vent
flow control system, with modulating fan and pressure
sensor.
• Unit automatically adapts its operation to flue type
and length, without requiring adjustments during
installation or use of baffles in combustion circuit.
• Unit consistantly and automatically regulates
combustion air and vent flow according to change in
thermal load. Combustion and heat exchange occur in
optimum conditions. Unit’s thermal efficiency remains
high throughout its power range.
6.5 Venting Materials
• See Table 2
Table 2 - Combustion Air and Vent Pipe Fittings
Category I (Chimney Vent)
Item Material Standards
Vent Pipe & Fittings
Type B Vent UL 441, ULC S605
Masonry Chimney
- must conform to
proper sizing and
materials
National Fuel Gas
Code, ANSI Z223.1/
NFPA 54
Combustion Air
Stainelss Steel,
PVC, CPVC, PP,
Aluminum
ANSI/ASTM D2564,
ANSI/ASTM F493,
UL 1738/ULC636-08

17
6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III
Induced Draft Boilers
Horizontal (Category III) venting systems installation
shall conform to the requirements of the authority having
jurisdiction or, in the absence of such requirements, to
the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/
or Natural Gas and Propane Installation Code, CAN/CSA
B149.1
1. Boilers may be vented horizontally. Vent pipe is pitched
down from boiler to vent termination. Do not connect
other appliances to this vent.
2. Vent Pipe Material UL Listed - AL294C Stainless Steel
vent pipe and fittings.
3. Clearance to Combustible Materials: For stainless steel
vent pipe maintain 6” minimum air space clearance to
combustible materials.
4. Vent Pipe Size: 3” vent pipe connected directly to the
outlet of the induced draft blower.
5. Vent Pipe Length:
A. For stainless steel vent pipe, the maximum
horizontal vent length is 65 equivalent feet.
B. Minimum horizontal vent length is 5 equivalent
feet.
C. For 3” 90° elbows = 5 equivalent feet of vent
length.
6. Vent Termination Fitting: For all vent pipe materials,
you may use either:
A. 90° elbow pointing down, fitted with a minimum
1/4” mesh screen to keep out rodents and birds.
The elbow shall be of the same material and size
as vent pipe. The elbow exit should be at least 6”
away from exterior wall.
-or-
B. Concentric side wall vent hood.
7. Vent Pipe Termination Location :
A. When venting through combustible walls,
combustible clearances must be considered. ECR
vent termination, 5612601, is a certified direct vent
termination (for Catagory III venting) providing
both the outside vent termination and a double
wall pipe for passing through a combustible
wall up to 10” thick. Vent terminations by other
manufacturers may also be used as long as they
are certified for catagory III venting.
B. If the 90° elbow is the termination fitting of choice,
then the single wall pipe will be passing through the
side wall. For combustible walls, a UL listed thimble
shall be used where the single wall pipe passes
through the wall.
C. For single wall pipe through non-combustible
walls, the hole through the wall need only be large
enough to maintain the pitch of the vent pipe, and
provide proper sealing. A thimble is not required for
single wall pipe passing through non-combustible
walls.
D. The venting system shall terminate at least 3 feet
0.9m) above any forced air inlet located within
10 feet (3m). The venting system shall terminate
at least 4 feet (1.2m) below, 4 feet (1.2m)
horizontally from, or 1 foot (300 mm) above any
door, window, or gravity air inlet into any building.
The bottom of the vent shall be located at least 12
inches (300mm) above grade. Termination of the
vent shall be not less than 7 feet (2.13m) above
adjacent public walkway. The vent terminal shall
not be installed closer than 3 feet (0.9m) from the
inside corner of an L shaped structure. Termination
of the vent should be kept at least 3 feet (0.9m)
away from vegetation. The venting system shall
terminate at least 4 feet horizontally from, and in
no case above or below, unless a 4 foot horizontal
distance is maintained, from electric meters, gas
meters, regulators, and relief equipment.
• The venting system shall terminate at least 4 feet
below any eave, soffit, or roof overhang.
• The venting system shall not terminate
underneath any deck, patio, or similar structure.
• Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent
accidental contact with people or pets.
• Terminate the vent above normal snow-line. Avoid
locations where snow may drift and block the
vent. Ice or snow may cause the boiler to shut
down if the vent becomes obstructed.
• Under certain conditions, flue gas will condense,
forming moisture. In such cases, steps should be
taken to prevent building materials at the vent
terminal from being damaged by exhaust of flue
gas.
United States - Terminate vent system at least
4 feet (1.22m) horizontally from, and in no case
above or below, unless a 4 feet (1.22m) horizontal
distance is maintained, from electric meters, gas
meters, regulators and relief equipment.
Canada - Terminate vent system at least 6 feet
(1.83 m) horizontally from, and in no case above
or below, unless a 6 feet (1.83m) horizontal
distance is maintained, from electric meters, gas
meters, regulators and relief equipment.
8. Joining and Sealing the Vent Pipe: The vent pipe needs
to be both watertight and gas tight. Seal all joints and
seams following vent pipe manufacture’s installation
instructions.
9. Support Spacing: Do not restrict thermal expansion
movement of the vent. The vent pipe must expand
and contract freely with temperature change. Each run
of vent piping shall be supported following vent pipe
manufacture’s instructions.

18
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.
!
Table 3 - Combustion Air and Vent Pipe Fittings
6 - COMBUSTION AIR AND VENT PIPING OF DIRECT VENT AND CATEGORY III
10. If the horizontal vent must go through a crawl space or
other unheated space, the cool temperatures will likely
cause the flue gases to continuously condense inside
the vent pipe. Do not insulate the vent pipe. It must be
visible for monthly inspection. Insure that the vent pipe
is properly pitched away from the boiler, with no low
spots, so that condensate in the vent will drain away
from the boiler. An insulated enclosure or chase, with
access for inspection and servicing of the vent, may
be required to prevent freezing of liquid condensate.
Consult the vent pipe manufacturer’s instructions for
specific guidelines.
11. At beginning of each heating season and monthly
during the heating season, check all vent pipes and
vent terminal to make sure there are no obstructions.
Periodically clean the screen in the vent terminal.
Equivalent Length of Venting Components:
5 ft. equivalent for a 3” 90° elbow.
2 1/2 ft. equivalent for a 3” 45° elbow.
Type Item Diameter Min Lenght Max Lenght Material Standards
Direct vent
Vent 3” 5 ft 65 ft AL294C Stainless
Steel, Aluminum
UL1738,
ULC S636
Air intake 3” 5 ft 65 ft
Stainelss Steel,
PVC, CPVC, PP,
Aluminum
ANSI/ASTM
D2564, ANSI/
ASTM F493, UL
1738/ULC636-08
Category III Vent 3” 5 ft 65 ft AL294C Stainless
Steel, Aluminum
UL1738,
ULC S636

19
6 - COMBUSTION AIR AND VENTILATION
Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54, or Sections
8.2, 8.3 or 8.4 of Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable provisions of local
building codes.
Provide make-up air where exhaust fans, clothes dryers,
and kitchen ventilation equipment interfere with proper
operation.
National Fuel Gas Code recognizes several methods
of obtaining adequate ventilation and combustion air.
Requirements of the authority having jurisdiction may
override these methods.
• Engineered Installations. Must be approved by
authority having jurisdictions.
• Mechanical Air Supply. Provide minimum of 0.35
cfm per Mbh for all appliances located within space.
Additional requirements where exhaust fans installed.
Interlock each appliance to mechanical air supply
system to prevent main burner operation when
mechanical air supply system not operating.
• All Indoor Air. Calculate minimum volume for all
appliances in space. Use a different method if minimum
volume not available.
◊Standard Method. Cannot be used if known air
infiltration rate is less than 0.40 air changes per
hour. See Table 4 for space with boiler only. Use
equation for multiple appliances.
Volume ≥50 ft3 x Total Input [Mbh]
◊Known Air Infiltration Rate. See Table 3 for space
with boiler only. Use equation for multiple appliances.
Do not use an air infiltration rate (ACH) greater than
0.60.
Volume ≥15 ft3/ACH x Total Input [Mbh]
◊Refer to National Fuel Gas Code for opening
requirements between connection indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
◊Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in 2 per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts. Provide
minimum free area of 1 in2 per 2 Mbh of total input
rating of all appliances in enclosure.
◊One Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides
and back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).
◊Combination Indoor and Outdoor Air. Refer to
National Fuel Gas Code for additional requirements
for louvers, grilles, screens and air ducts.
• Combination Indoor and Outdoor Air. Refer toNational
Fuel Gas Code for application information. National Gas
and Propane Installation Code Requires providing air
supply in accordance with:
• Section 8.2 and 8.3 when combination of applianceshas
a total input of up to and including 400 Mbh (120kW).
Does not have draft control device.
• Section 8.4 when combination of appliances has total
input exceeding 400 Mbh (120 kW).
• Refer to Natural Gas and Propane Installation Code
for specific air supply requirements for enclosure or
structure where boiler is installed, including air supply
openings and ducts.
Table 4 - Air Infiltration
Input Mbh Standard
Method
Known Air Infiltration Rate Method (Air Changes Per Hour)
0.1 0.2 0.3 0.4 .05 0.6
150 7500 22,500 11,250 7,500 5,625 4,500 3,750

20
6 - COMBUSTION AIR AND VENT PIPING
( = Combustion Air / = Venting)
Figure 11 - Horizontal Venting Clearances
Figure 12 - Two Pipe Venting
NOTICE
Maintain 12” (30cm) US, 18” (46cm) Canada
clearance above highest anticipated snow level
or grade.