ECR International Dunkirk DMG-240 Instruction manual

CONDENSING GAS FIRED
BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Model
DMG-240
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel. [phone]
www.ecrinternational.com
PN 240011656 REV. K [11/01/2020]

2
Fully Assembled Boiler Metal Wall Bracket Safety Relief Valve
(Maximum 50 PSI)
Temperature
Includes essential documents.
Drain Valve Gas Shuto Valve TP Gauge and Safety Relief
Valve Connections Document Package
Used for measuring outside
temperature Used for connecting condensate piping to boiler
Outdoor Sensor Condensate Drain
Connections
VERIFY CONTENTS RECEIVED
PN 240011656 REV. K [11/01/2020]
For Parts lists see manual 240011657 included with your boiler literature package.

3
TABLE OF CONTENTS
1 - Important Information....................................5
2 - Introduction....................................................6
3 - Component Listing ..........................................7
4 - Locating Boiler................................................8
5 - Hydronic Piping.............................................11
5.1 General .....................................................11
5.2 Special Conditions.......................................11
5.3 Safety Relief Valve And Air Vent....................12
 .......................................12
5.5 Trim Piping.................................................13
5.6 System Piping ............................................13
5.7 Heating System And Refrigeration.................13
5.8 Manifold Installation (Supplied) ....................13
6 - Combustion Air And Vent Piping....................17
6.1 General .....................................................17
6.2 Removal Of Existing Boiler From Common Vent
System...........................................................17
 .................................................18
6.4 Approved Venting Materials..........................19
6.5 Coaxial .....................................................20
6.6 Mechanical Fastener Instructions...................21
6.7 Twin Pipe Polypropylene And CPVC Systems 21
.................................23
6.9 Side Venting Terminal Requirements........... 27
6.10 Multiple Boiler Venting - General ............ 30
6.11 Multiple Boiler Venting - Mounting.......... 30
6.12 Multiple Boiler Venting - Layout................ 32
6.13 Multiple Boiler Venting - Parameter Settings..34
6.14 Condensate Piping.....................................35
7 - Gas Supply Piping..........................................36
7.1 General .....................................................36
7.2 LP Conversion ............................................36
7.3 Leak Check Gas Piping.................................37
8 - Electrical Connections.....................................38
8.1 General......................................................38
8.2 Electric Knockouts ......................................38
8.3 Electrical Connections..................................38
8.4 Access To Connection Block..........................39
8.5 Main Supply Connection...............................39
8.6 Shutdown Input..........................................40
8.7 Release Input.............................................40
8.8 Optional Electrical Connections ....................40
8.9 Outdoor Temperature Sensor........................41
8.10 Central Heating Thermostat........................41
8.11 DHW Indirect Water Heater........................44
8.12 Frost Protection ........................................44
8.13 Pump Anti-Seize Protection ........................44
9 - Start Up Procedure........................................47
9.1 Fill Condensate Trap With Water....................47
9.2 Commission Setup (Water)...........................47
9.3 Commission Setup (Gas) .............................48
9.4 Commission Setup (Electric).........................48
9.5 Control Panel..............................................49
9.6 Deaeration Function....................................50
9.7 Commissioning...........................................51
9.8 Before Gas Conversion ................................51
9.9 Gas Conversion (Propane)............................51
9.10 Combustion Setup (High-Fire).....................52
9.11 Combustion Setup (Low-Fire) .....................52
9.12 Operational Check.....................................52
9.13 User Level Parameters...............................53
9.14 Installer Level Parameters..........................53
9.15 Parameters Settings ..................................54
9.16 Reading Measured Values..........................57
9.17 Status And Sub-Status...............................58
9.18 Return To The Factory Settings: ............... 59
10 - Operating Instructions................................60
10.1 Sequence Of Operation..............................60
10.2 Operating Instructions...............................60
 ......................60
11 - General Maintenance And Cleaning .............61
12 - Ratings And Capacities................................65
13 - Trouble Shooting.........................................66
13.1 Troubleshooting ........................................66
13.2 Shutdowns and Lock-Outs..............................68
13.3 Error History ............................................71
13.4 Error History Readout ................................71
13.5 Optional Sensors.......................................72
Troubleshooting Chart 1 ....................................73
Troubleshooting Chart 2 ....................................74
Troubleshooting Chart 3 ....................................75
Troubleshooting Chart 4 ....................................76
Troubleshooting Chart 5 ....................................77
Troubleshooting Chart 6 ....................................78
Troubleshooting Chart 7 ....................................79
Troubleshooting Chart 8 ....................................79
Troubleshooting Chart 9 ....................................80
Troubleshooting Chart 10 ..................................81
Troubleshooting Chart 11 ..................................82
Temperature-ResistanceChart.............................83
14 - Glossary......................................................84
PN 240011656 REV. K [11/01/2020]

4
PHYSICAL DATA
Table 1: Physical Data
Model 240
Width (A) 17-¾" (450mm)
Height (B) 31-¹/₁₆" (763mm)
Depth (C) 23" (585mm)
Bracket (D) Location of Bracket on
back of unit 
Water
Connections
Size 1" (25.4mm)
Location (G) 3-¾" (95.3mm)
Location (H)
Return 9" (228.6mm)
Location (I)
Supply 5" (127mm)
Gas
Connection Location (J) 3-¾" (95.3mm)
Size 3/4" NPT
Condensate Drain
Connection
Location (J) 2-¼" (57.2mm)
Size 3/4" NPT
Weight Shipping 145 LBS (65.8)
Unit 120 LBS (54.5kg)
Vent Connector 80/125 mm
Electrical Cord Length 5 ft. (1.5m)
Dimensions
Vent Connector
Combustion Air
A
D
B
Front View
Top View
Bottom View
Dimensions
IH
G
C
J
Condensate Drain
Connection
Return Water
Gas Connection
Bottom View
Connection
Identication
Supply Water
50 psi safety relief valve (3.44 bar)
Pressure relief valve connection 3/4"
(22.2m)
Wire Knockouts
PN 240011656 REV. K [11/01/2020]

5
1 - IMPORTANT INFORMATION
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.
Become familiar with symbols identifying potential hazards.

glossary for additional information.
1. Safety Information
WARNING
Do not tamper with or use this boiler for any purpose
other than its intended use. Failure to follow these
instructions could result in death or serious injury.
Use only manufacturer recommended parts and
accessories.
!
CAUTION
Laceration, burn hazard. Metal edges and parts
may have sharp edges and/or may be hot. Use
appropriate personal protection equipment to include
safety glasses and gloves when installing or servicing
this boiler. Failure to follow these instructions could
result in minor or moderate injury.
!!
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.
!
FOR YOUR SAFETY READ BEFORE OPERATING
Hot Water Can Scald!
Water heated to temperature for clothes washing,
dish washing and other sanitizing needs can scald
and cause permanent injury.

persons are more likely to be permanently injured by
hot water. Never leave them unattended in bathtub or
shower. Never allow small children to use a hot water
tap or draw their own bath.

above description, or if state laws or local codes
require certain water temperatures at hot water
taps, you must take special precautions:
• Use lowest possible temperature setting.
• Install some type of tempering device, such
as an automatic mixing valve, at hot water
tap or water heater. Automatic mixing valve
must be selected and installed according
to manufacturer's recommendations and
instructions.
• Water passing out of drain valves may be
extremely hot. To avoid injury:
• Make sure all connections are tight.
• 
DANGER
!
Water
Temperature
Seng
1st Degree Burn
Exposure Time For
An Adult
2nd and 3rd Degree Burn
Exposure Time For An
Adult
120° F 1 minute 5 minutes
130° F 5 seconds 30 seconds
140° F 2 seconds 5 seconds
150° F 1 second 1.5 seconds
160° F Instantaneous 0.5 seconds
Note: Warning for Infants, Children, and Elderly: Great
care must be taken when exposing the aforementioned
groups to warm or hot water as they can be badly burned
in exposure times less than half of the time for an adult.
Note Used to address practices not related to
personal injury.
WARNING
Fire, Explosion, Asphyxiation, Electrical shock hazard!
Flooding will result in damages such as electrical
problems, corrosion, inoperative parts, mold and
other unforeseen issues which can occur over time.
Any equipment determined by a professional as

other liquid, shall be replaced. Failure to follow these
directions will result in a Hazardous Situation.
!
PN 240011656 REV. K [11/01/2020]

6
Check our website frequently for updates: www.ecrinternational.com
Information and specications outlined in this manual in eect at the
time of printing of this manual. ECR International ECR reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
2 - INTRODUCTION
2.5 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Direct vent boiler or single vent pipe.
• 
(LP/propane).
2.6 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 (3.44 bar) maximum system pressure,
or drop below minimum system pressure 7.25 psig (.50
bar)
• Exceed 176°F (80°C) system design temperature.
2.7 Operational Features
• Modulating: 6.7:1 ratio.
• Integral Dual Limit.
• 
• Outdoor Temperature Reset.
• Heat exchanger over heat protection.
• Recommended system pressure (cold) 21.7 psig (1.5
bar)
2 - Introduction
2.1 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.
2.2 Where required by authority having jurisdiction,
installation shall conform to Standard for Controls and Safety
Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

2.3 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not limited
to:

2.4 Manufacturer recommends use of Carbon
Monoxide monitor may be requirement of local
jurisdiction.
PN 240011656 REV. K [11/01/2020]

7
3 - COMPONENT LISTING
1Condensate trap
2Gas Valve
3Fan
4Air/gas Mixer
5Heat exchanger
6Burner sight glass
7Manual air vent
8Flue sensor
9
10 Exhaust test port
11 Intake test port
12 Thermal fuse (#6 on wire diagram)
13 
wire diagram)
14 Ignition/Flame detection electrode
15 Spark generator
16 Automatic air vent
17 Auxiliary control board box
18 Air/gas venturi
19 Pump
20 Boiler drain
21 Low water pressure switch
ACondensate trap drain
BGas inlet connection
CHeating supply connection
DHeating return connection
PN 240011656 REV. K [11/01/2020]
DMG-240

8
4 - LOCATING BOILER
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 or alcove provided it
is correctly designed for that purpose.
• Not approved for outdoor installation.
• Protect gas ignition system components from water
(dripping, spraying, rain, etc.) during operation and
service (circulator replacement, condensate trap, control
replacement, etc.).
• 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

• 
capable of supporting the weight of the boiler.
• Boiler may be installed in any room or internal space,
special attention shall be given to the requirements
of the current electrical provisions with respect to the
installation of the boiler in a room or internal space
containing a bath or shower. Where a room- sealed
boiler is installed in a room containing a bath or shower,
it must not be possible for a person using the bath or
shower to touch any electrical switch or boiler control
utilizing line voltage electricity.
• Multiple Boilers can be wall mounted, placed side by
side, or back to back.
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Model
Top (A) 0" (0 mm) 11-13/16"
(300 mm)
Left Side (B))
1-3/4"
(45 mm) 1-3/4" (45 mm)
Right Side (C)
1-3/4"
(45 mm) 1-3/4" (45 mm)
Front (D)
1-3/4"
(45 mm) 17 3/4" (450 mm)
Back (E)
0" (0 mm) 0" (0 mm)
Bottom (F)
0" (0 mm) *9-7/8"
(250 mm)
Combustion Air/Vent
piping
0" (0 mm) 6" (160 mm)
(1) Required distances measured from boiler jacket.
(2) Service, proper operation clearance recommendation.
* Allowance for piping at the bottom of boiler not included.
WARNING
Fire Hazard! Do not install on carpeting. Failure to
follow these instructions could result in death or
serious injury.
!
PN 240011656 REV. K [11/01/2020]
DMG-240

9
A
E
ED
A
C
B
FLOOR
FLOOR
FF
FF
Boiler Front
View
Boiler Left Side View
FIGURE 4-1a Clearance to Combustible Materials
4 - LOCATING BOILER
FIGURE 4-2a Service Clearances - Boiler Front
FIGURE 4-1b Clearance to Combustible Materials
FIGURE 4-2b Service Clearances - Boiler Left side
Boiler
Front View
FIGURE 4-2c Service Clearances - Closet Installation
17 3/4 "
(  mm)
Minimum Service
clearance to front
of boiler
Boiler Left
Side View
17 3/4 "
(  mm)
CLOSET INSTALLATION
TOP VIEW
1 3/4 "
(  mm) 1 3/4 " (  mm)
1 3/4 "
(
 mm)
BACK
CLEARANCES REQUIRED FOR CLOSET
INSTALLATION
0 in. /0 mm between the Back of the Unit and the wall
0" (0mm)
A
0" (0mm)
1-3/4"
(45mm) 1-3/4" (45mm)
(See Table 2, page 8) (See Table 2, page 8)
0" (0mm) 0" (0mm)
0" (0mm)
0" (0mm)
0" (0mm)
1-3/4"
(45mm)
0" (0mm) 0" (0mm)
PN 240011656 REV. K [11/01/2020]

10
4 - LOCATING BOILER
CAUTION
Boiler weight exceeds 140 pounds (63.5 kg). Do not
lift boiler onto wall without assistance.
!!
4.2 Wall Mounting
Pre-pipe supply and return water connections with factory

Mount boiler on wall using wall mounting bracket included with
unit.
• Verify boiler is level and upright. Mark position of holes
for plumbing connections.
• 
• For horizontally terminating units continue to mark

side wall, then along side wall ensuring the lines have
a downward pitch back to the boiler. This will give the

• Cut 5-5/16” (135.00 mm) diameter hole in the wall for

• Lift boiler and hang it on wall.
• Adjust the position of the boiler verify it is level.
For Direct Vent installations, air vents are not required in
the room boiler is installed in, or when installed in closet or
compartment.
Note Lift boiler using chassis. Using front jacket, vent

damage to the boiler.
Note
FIGURE 4-3 Wall Mount Bracket (Included)
Center brackets. Avoid
overhang on sides of
wall mount bracket.
Use four (4) predrilled
holes for mounting
bracket to wall


piping can be damaged if subjected to excessive
torque.
PN 240011656 REV. K [11/01/2020]

11
• 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.
• 
boiler.
• If oil is present in system water, use approved detergent
to wash system.
• It is necessary to semi-annually check the water quality of
central heating systems.
• Flush system to remove any solid objects such as metal

• 
separately. If purge valves and isolation valves are not
installed, install them to properly clean the system.
• When purging installations that include standing iron
radiators and systems with manual vents at high points,
start with nearest manual air vent. Open the vent until

working toward furthest air vent.
• Install a basket strainer if large amounts of sediment is
present. Keep basket clear of sediment build up.
• Install a magnetic dirt separator in the hydronic system
where there are cast iron or steel components, or where
the previous boiler was a cast iron heat exchanger. The

and can deposit onto heat exchange surfaces and

and premature wear.
• Flush system until water runs clean and piping is free of
sediment.
• Manufacturer recommends a water treatment product be
used for sediment removal.
5.2 Special Conditions
Note
• System piping exposed to freezing conditions: Use

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
pressure switch is provided in boiler.
• 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.

prevent gravity circulation of boiler water during cooling
cycle.
5 - HYDRONIC PIPING
5.1 General
• Primary/Secondary piping required.
• Install piping in accordance with authority having
jurisdiction.
FIGURE 5-1 Safety Relief Valve
Note Boiler rated at 50 psig (345 kPa) maximum
allowable working pressure. Boiler provided with
50 psig (345 kPa) 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.
• Do not use petroleum based cleaning or sealing
compounds boiler system.
• 
water.
• Use only inhibited propylene glycol solutions

use with closed water heating system.
• 
glycol before installing new Boiler.
• Provide user with Material Safety Data Sheet

!
Do not expose boiler and condensate piping to
freezing temperatures.
Safety ReliefSafety Relief
ValveValve
Note When installing safety relief valve it must be
installed in a vertical position with spindle at top.
TP GaugeTP Gauge
SystemSystem
SupplySupply SystemSystem
ReturnReturn
PN 240011656 REV. K [11/01/2020]

System
Return
System
Supply
MINIMUM
ACCEPTABLE
HEIGHT FOR
LWCO PROBE
Check Local Codes
For Maximum
Distance To Floor
12
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
FIGURE 5-2 Safety Relief Valve Discharge Piping
5 - HYDRONIC PIPING
5.3 Safety Relief Valve and Air Vent
• 

• Install safety relief valve with spindle in vertical position.
• 
relief valve.
• Install discharge piping from safety relief valve.
• 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).
Check Local Codes ForCheck Local Codes For
Maximum Distance ToMaximum Distance To
FloorFloor
5.4 Low Water Cuto
• Boiler is equipped with Low Water Pressure Switch.
• 

between boiler and LWCO probe.
• If using separate stand pipe, install air vent using tee to
avoid nuisance shutdowns.
• Arrange piping to prevent water dripping onto boiler.
• Connect probe signal wires to shutdown terminal (BL)
on control board so LWCO operation does not interfere
with post purge.
WARNING
Fire, explosion hazard. Mount boiler vertically or
slightly tilted backward to insure proper function of

could result in death or serious injury.
!
Safety Relief Valve
FIGURE 5-3 System Piping - LWCO Probe Location
PN 240011656 REV. K [11/01/2020]

13
5.5 Trim Piping
• Temperature - Pressure Gauge. Install temperature
pressure gauge using piping provided with boiler. See


• Boiler has integral drain valve located inside jacket directly
underneath pump. Install provided external drain valve.
5.6 System Piping
• 
• 
prevention device.
•  for general
guidance. Additional considerations:
• Boiler control is designed for single central heating
pump. Installer responsible for integration of
multiple central heating pumps.
• Boiler control allows domestic hot water
prioritization. Function could be lost if central heating
pump not directly connected to control system.
• Multiple boiler system.  for
general guidance. Additional considerations:
• Control system requires equivalent water
temperatures entering each boiler to properly sequence
and adjust system supply temperature.
WARNING
Burn and scald hazard. Verify all plastic caps are
removed from boiler connections. Failure to follow
these instructions could result in death or serious
injury.
!
• 
• 
• Ensure washers supplied are utilized.
• Fit union connections to supply and return on boiler.
A. If soldering to boiler, ensure unions are not connected
to supply and return piping, otherwise internal seals
may be damaged.
B. 

C. Fit pressure relief valve connection vertically before
heating isolating valve.
• Connect system valve pipe work to the boiler.
• 
Follow local code with respect to necessary distance to the

• Verify all valves are closed.
5 - HYDRONIC PIPING
• Connect supplied condensate trap to a drain. Verify there is
continuous slope towards the drain, avoid level horizontal
sections of tubing.
• Manufacturer recommends installing an isolation and purge
valve to use during commissioning to ensure the boiler does
not shut down due to over temperature.
• 
installed LWCO.
5.7 Heating System And Refrigeration
Boiler when used in connection with refrigeration system,
must be installed so chilled medium is piped in parallel with
the boiler with appropriate valves to prevent chilled medium
from entering the boiler.
Boiler piping system of hot water boiler connected to heating
coils located in air handling units where they may be exposed

control valves or other automatic means to prevent gravity
circulation of the boiler water during the cooling cycle.
5.8 Labor Savor Manifold Installation (supplied) See
Figure 5-1
1. Boiler is supplied with union connection installed on boiler
piping for connection to manifold.
2. 
Note Identify BOILER supply and return when
installing manifold.
3. Apply sealant and tighten manifold in place. Check for
leaks.
PN 240011656 REV. K [11/01/2020]

14
Table 4 - System Piping Congurations
Single Boiler Primary/Secondary Pumping Zone Valves Figure 5-4 / 5-6
Zone Pumps Figure 5-5 / 5-7
Multiple Boilers See Application Guide 240012832
5 - HYDRONIC PIPING
Note Illustrations are meant to show system piping
concept only. Installer responsible for all
equipment and detailing required by authority
having jurisdiction.
WARNING
Burn, Scald Hazard! Water temperature over 125°F
(51°C) can cause severe burns and scalding. See
User's Manual before setting water temperature.
Failure to follow these instructions could result in
death or serious injury.
!
Piping Legend
Boiler
PN 240011656 REV. K [11/01/2020]

15
5 - HYDRONIC PIPING
FIGURE 5-4 - Primary/Secondary, Zoned, WITH ZONE VALVES, (Optional) Indirect Tank
T & P Relief
Valve to
Drain
Cold
Water
Supply
Optional
Indirect
DHW Tank BOILER
Make-up
Water
Supply
Tank
Sensor
CH /System
Pump
ASME
Relief
Valve
1
DHW Pump
112” (305mm) Maximum
Separation
Note
Note * Manufacturer requires all domestic
hot water (DHW) installations use
an anti-scald valve. Local codes
may require additional equipment
(expansion tank, relief valves,
etc.) Select and size equipment
to suit installation and meet code
requirements.
* Hot
Water
Supply
Tempered
S
Note
Refer to pump manufacturer
literature for proper pump sizing.
PN 240011656 REV. K [11/01/2020]

16
5 - HYDRONIC PIPING
FIGURE 5-5 - Primary/Secondary, Zoned, WITH ZONE PUMPS, (Optional) Indirect Tank
112” (305mm) Maximum
Separation
Note
Note * Manufacturer requires all domestic
hot water (DHW) installations use
an anti-scald valve. Local codes
may require additional equipment
(expansion tank, relief valves,
etc.) Select and size equipment
to suit installation and meet code
requirements.
T & P Relief
Valve to
Drain
Cold
Water
Supply
Optional
Indirect
DHW Tank
BOILER
Make-up
Water
Supply
Tank
Sensor
CH /System
Pump
ASME
Relief
Valve
1
DHW Pump
1
* Hot
Water
Supply
Tempered
S
Note Use external pump relay or Argo Zone
Control to interface system pump to boiler.
Note
Refer to pump manufacturer
literature for proper pump sizing.
PN 240011656 REV. K [11/01/2020]

17
6.1 General
• Installations shall comply with Authority having jurisdiction
and in absence of such with:
»U.S. ANSI Z223.1 /NFPA 54 in the United States
»CSA B149.1 in Canada.
• This boiler requires a dedicated direct vent system or may
be category IV Indoor air.
• Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
• Materials used in the U.S. shall comply with Authority
having jurisdiction and in absence of such with: ANSI/
ASTM D1785, ANSI/ASTM F441, ANSI/ASTF493, UL1738 or
ULC S636.
• Canadian installations only: All venting material, primer
and glue must be listed to ULC S636.
• Canadian installations only: First 3 ft. (0.9m) of plastic vent
pipe from vent connector must be readily accessible for
visual inspection.
• 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 3 ft (1.0 m) or less. Allow for expansion/
contraction of pipe.
• Venting system must be free to expand and contract.
6 - COMBUSTION AIR AND VENT PIPING
WARNING
Fire, explosion, and asphyxiation hazard. Improper
installation could result in death or serious
injury. Read these instructions and understand all
requirements before beginning installation.
!• Vent system shall have unrestricted movement through
walls, ceilings and roof penetrations.
• Wall and roof openings must be framed to provide support
attachment of termination assemblies.
• 


• 

• Assemble piping in accordance with pipe manufacturer's
instructions.
• 
slope exhaust pipe minimum of 1/4" per foot; or vent
manufacturer's recommendation whichever is greater, back
toward the boiler.
• Support horizontal sections of vent pipe to prevent sags
capable of accumulating condensation. Unless otherwise

or equivalent.
• 

lubrication during assembly of vent pipe.
• Check for proper joint construction when joining pipe to
.
• Manufacturer requires use of an approved mechanical
fastener, which may vary per vent pipe manufacturer, at

polypropylene vent system.
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

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 bathroom
exhaust so they will operate at maximum speed. Do not

WARNING
ABS/PVC venting shall not to be used this product.
Use of DWV plumbing pipes to vent this boiler shall
be prohibited.
Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in venting
systems shall be prohibited.

thermal insulation shall be prohibited.
Failure to follow these instructions could result in
death or serious injury.
!
Note Follow venting manufacturer's equivalent lengths
for specialty ttings.
PN 240011656 REV. K [11/01/2020]

18
6 - COMBUSTION AIR AND VENT PIPING
• 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

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 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, common
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 Denitions
1. Coaxial piping – Exhaust and air intake pipe have a
common axis.
2. Twin Pipe – Exhaust and intake air are separate pipes,
can be terminated using single wall terminals from the

or tees.
PN 240011656 REV. K [11/01/2020]

19
WARNING
Manufacturer recommends this condensing boiler
be vented with approved polypropylene venting
material. Use only materials listed below for vent

could result in death or serious injury.
!
WARNING
ABS/PVC venting shall not to be used this product.
Use of DWV plumbing pipes to vent this boiler shall
be prohibited.
Use of cellular core PVC (ASTM F891), cellular core
CPVC, or Radel® (polyphenolsulfone) in venting
systems shall be prohibited.

thermal insulation shall be prohibited.
Failure to follow these instructions could result in
death or serious injury.
!
6.4 Approved Venting Materials
Installation shall conform to requirements of authority having
jurisdiction or in absence of such requirements:
• USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54.
A. Vent Material Options:
1. 80 mm/125 mm Polypropylene coaxial (5 inch / 3 inch)
or
• Natalini
• DuraVent
®
• Centrotherm
• Z-Flex
®
Note: Maximum equivalent length may vary between
manufacturers.
C. Vent Termination
• Do not include termination for equivalent length
calculations.
• 
concentric vent kit.
Use horizontal pipe for vent and 90° elbow for

• Separate vent terminal from air inlet terminal to prevent

at sidewall, air inlet terminal shall be at least 36" or more
away from vent terminal.
• Locate combustion air termination as far as possible from
swimming pool, swimming pool pump house, and other
sources of airborne chlorine.
• Locate combustion air intake and vent terminals as
required by authority having jurisdiction.
• Use black ultra violet stabilized polypropylene when
exposed to sunlight, wind, or prone to freeze ups.
6.5 Coaxial
A. Coaxial Vent Screw Placement (See Figure 6-1)
6 - COMBUSTION AIR AND VENT PIPING
Note Follow venting manufacturer's equivalent lengths

FIGURE 6-1 - Coaxial Vent Screw Placement
2. 80 mm polypropylene twin pipe (MUST be polypropylene
on BOTH intake and exhaust) ("3 inch")- conversion kit
required.
or
3. 3" Twin pipe CPVC (PVC optional on intake ONLY).
B. Approved Polypropylene Manufacturers:
Must comply with UL 1738 or ULC S636. The following
manufacturers have been evaluated:
Fasten two (2) screws through the outer intake pipe behind
the gaskets at equal distances approximately 180º apart.
Use zinc coated sheet metal screws in accordance with vent
pipe manufacturer's instructions.
1. Before securing the screws, verify pipe is inserted in
accordance with pipe manufacturer's instructions.
2. When connecting vent pipes, follow vent pipe
manufacturer's instructions regarding lubrication.
WARNING
Asphyxiation hazard. Before securing the screws
ensure the pipe has been pushed in a minimum of
1-3/4" (45 mm) into the gasketed end of the other
pipe. Failure to follow these instructions could result
in death or serious injury.
!
PN 240011656 REV. K [11/01/2020]

20
6 - COMBUSTION AIR AND VENT PIPING
FIGURE 6-2 Side Wall Coaxial Venting
WARNING
• 
thermal insulation shall be prohibited.
• 
result in death, or serious injury.
• Concentric venting shall be fastened with screws.

!
FIGURE 6-3 Roof Mount Coaxial Venting
2” (50 mm) XMin. 8" (181 mm)
Max. 14" (356 mm)
Slope vent pipes
min. 3/4" (2 cm)
for every 3¹/₂ft.
(1.0m) back to
boiler
Maintain 12"(305mm)
US (18"(457mm)
Canada) clearance
above highest
anticipated snow level
24" (610mm) above
roof or ground
Ground
Anticipated
Snow Line
Ground
Anticipated
Snow Line
Maintain 12"(305mm)
US (18"(457mm)
Canada) clearance
above highest
anticipated snow level
24" (610mm) above
roof or ground
Anticipated
Snow Line
18" Vertical
Clearance to

Maximum Length = L
A B 21’ (6.4 m)
E F 21’ (6.4 m)
L1
L2
L = L1 + L2
Illustration shows examples of maximum equivalent lengths.
Coaxial Elbows - Equivalent length
Elbow Total Length Reduction
45° 1' 8" (0.5 m)
90° 3' 4" (1.0 m)
B. Coaxial Flue Options
• Standard horizontal termination is suitable only for
horizontal applications.
• Maximum permissible equivalent vent length is 21 ft.
(6.4 m)
• 
consideration.
• 
equivalent length calculations
Elbow Total Length Reduction
45° 1' 8" (0.5 m)
90° 3' 4" (1.0 m)
PN 240011656 REV. K [11/01/2020]