ECR International Green Mountain GMPVB 3 Series Instruction manual
Manufactured by:
ECR International Inc.
2201 Dwyer Avenue, Utica, NY 13501
Tel.
800 325 5479
www.ecrinternational.com
PN 240013105 REV. A [08/15/2020]
GMPVB SERIES 3
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Models
GMPVB-42
GMPVB-75
GMPVB-112
GMPVB-150
GMPVB-187
Tested For 50 psi
ASME
Working Pressure
For Natural Gas Or Propane
2
1 - Physical Data ������������������������������������������������������������������������������������������������������������� 4
2 - Safety Symbols and Warnings������������������������������������������������������������������������������������ 5
2.1. Safety Symbols & Warnings ......................................................................................5
2.2 For Your Safety ........................................................................................................6
3 - Locating the boiler ����������������������������������������������������������������������������������������������������� 7
3.1 Installation Requirements..........................................................................................7
3.2 Boiler Location Considerations....................................................................................8
4 - Connecting supply and return piping�������������������������������������������������������������������������� 9
4.1 Safety Relief Valve Installation ...................................................................................9
4.2 Supply and Return Requirements..............................................................................10
5 - Ventilation & Combustion Air ����������������������������������������������������������������������������������� 12
6 - Vent system modification����������������������������������������������������������������������������������������� 13
7 - Vent Installation ������������������������������������������������������������������������������������������������������ 14
7.1
Chimney Venting (Category I)
......................................................................................14
7.2 Minimum Vent Pipe Clearance ..................................................................................14
8 - Horizontal Venting (Category III) �������������������������������������������������������������������������� 16
9 -
Optional Horizontal Venting Instruction
��������������������������������������������������������������������� 21
10 - Gas supply Piping��������������������������������������������������������������������������������������������������� 22
11 - Electrical Wiring����������������������������������������������������������������������������������������������������� 24
11.1 Electrical Wiring Requirements................................................................................24
11.2 Thermostat Installation..........................................................................................24
12 - Wiring Diagrams ���������������������������������������������������������������������������������������������������� 25
13 - Sequence of Operation������������������������������������������������������������������������������������������� 26
14 - Starting Your Boiler������������������������������������������������������������������������������������������������ 27
14.1 Filling System.......................................................................................................27
14.2 Operating Instructions...........................................................................................28
14.3 Turn Off Gas To Appliance ......................................................................................28
15 - Checking and Adjusting������������������������������������������������������������������������������������������ 29
15.1 Gas Valve Safety Shutdown Test .............................................................................29
15.2 Pilot Burner Adjustment.........................................................................................29
15.3 Main Burner(s) Inspection......................................................................................29
15.4 Adjusting Limit Controls.........................................................................................29
15.5 Thermostat Heat Anticipator Setting........................................................................30
16 - Maintaining Your Boiler������������������������������������������������������������������������������������������ 31
17 - Service Hints���������������������������������������������������������������������������������������������������������� 32
18 - Boiler Ratings & Capacities ������������������������������������������������������������������������������������ 33
Appendix A - Control Module ����������������������������������������������������������������������������������������� 34
A.1
Installation Environment Considerations
......................................................................34
A.2 Electrical Connections .............................................................................................34
A.3 Adjusting Settings ..................................................................................................34
A.4 Display .................................................................................................................34
A.5 Operation..............................................................................................................35
A.6
Boiler High Limit Temperature Controller
......................................................................36
A.7 Troubleshooting......................................................................................................36
A.8 Troubleshooting Error Codes ....................................................................................37
A.9 Intermittent Pilot....................................................................................................38
TABEL OF CONTENTS
PN 240013105 Rev. A [08/15/2020]
3
VERIFY CONTENTS RECEIVED
Fully Assembled Boiler *Vent Adapter
*Fuse Link
Pump (Optional)
*Drain Valve *ASME Safety Relief Valve *Tridicator *Black Iron Fittings
(see parts list for sizes
and use)
Includes Essential
Documents and Warranty
11x17 Wire Diagrams
Document Package
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
time of printing of this manual� Manufacture reserves the right to
* Items found in parts box included with your boiler.
PN 240013105 Rev. A [08/15/2020]
4
1 - PHYSICAL DATA
Model
GMBVB-42 GMPVB-75
GMPVB-112
GMPVB-150 GMPVB-187
# Sections 2 3 4 5 6
A Width 11"14-¹/"17-/""24"
279 mm 362 mm 445 mm 527 mm 610 mm
BHeight 29” 29” 29” 29” 29”
737 mm 737 mm 737 mm 737 mm 737 mm
CDepth
591 mm 591 mm 591 mm 591 mm 591 mm
DVent Location 2-
/
"2-
/
”2-
/
”2-
/
”2-
/
”
59 mm 59 mm 59 mm 59 mm 59 mm
E Flue Diameter (Sidewall) 3” 3” 3” 3” 4”
76 mm 76 mm 76 mm 76 mm 102 mm
F Flue Diameter (Chimney)
102 mm 102 mm 102 mm 102 mm 102 mm
Supply & Return Tappings 1-
¹/
1-
¹/
1-
¹/
1-
¹/
1-
¹/
Heating Water Content, Gal (Liters) 1.75 (6.6) 3 (11.4) 4.25 (16.1) 5.5 (20.9) 6.75(25.6)
Boiler Weight, less pkg - Lbs (KG) 225 (102.1) 265 (120.2) 322 (146.1) 370 (167.8) 431 (195.5)
"
(313.1 mm)
"
(592.6 mm)
GAS SUPPLY
(184mm)
(83mm)
" (516 mm)
" (419 mm)
"
(117.8mm)
SUPPLY
ASME RELIEF
VALVE
PN 240013105 Rev. A [08/15/2020]
5
2 - SAFETY SYMBOLS AND WARNINGS
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.
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.
!!
NOTICE
Used to address practices not related to personal
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
tap or draw their own bath.
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
Seng
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.
2�1� Safety Symbols & Warnings
WARNING
Adding water to a hot boiler may result in heat
exchanger is not hot. Failure to follow these
instructions could result in death or serious injury.
!
PN 240013105 Rev. A [08/15/2020]
6
WARNING
Keep boiler area clear and free from combustible
liquids.
result in personal injury or loss of life.
Installation and service of this boiler shall be performed
When this product is installed in the Commonwealth
of Massachusetts the installation shall be performed
by a Licensed Plumber or Licensed Gas Fitter.
!
WARNING
Combustion chamber insulation in this product
can be converted to cristobalite in very high
temperature applications. The International Agency
for Research on Cancer (IARC) has concluded,
Crystalline silica inhaled in the form of quartz
or cristobalite from occupational sources is
carcinogenic to humans (Group1). Avoid breathing
respirator is based on the OSHA requirements
for cristobalite at the time this document was
written. Other types of respirators may be needed
depending on the job site conditions. Current
https://www.cdc.gov/niosh/topics/
silica/.
and phone numbers are also listed on this website.
and eye protection. Apply enough water to the
combustion chamber lining to prevent dust. Wash
potentially contaminated clothes separately from
other clothing. Rinse clothes washer thoroughly.
Breathing: Fresh air.
!
2 - SAFETY SYMBOLS AND WARNINGS
Manufacturer recommends a carbon monoxide detectorManufacturer recommends a carbon monoxide detector
jurisdictions may, by law, require.jurisdictions may, by law, require.
2�2 For Your Safety
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
as excess of water or other liquid, shall be
replaced. Failure to follow these directions will
result in a Hazardous Situation.
!
PN 240013105 Rev. A [08/15/2020]
7
3 - LOCATING THE BOILER
1.
Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code
2.
Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
3.
Equipment”, of the National Fuel Gas Code
building codes.
4.
Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on
5.
Install such that gas ignition system components are
protected from water (dripping, spraying, rain, etc.)
during appliance operation and service, (circulator
replacement, condensate trap, control replacement,
etc.).
6.
Locate boiler on level, solid base as near chimney as
possible and centrally located with respect to heat
distribution system as practical.
7.
Verify you have the right size boiler before starting
installation. See rating and capacity table.
8.
When installed in utility room, door should be wide
enough to allow largest boiler part to enter, or to
permit replacement of another appliance such as water
heater.
9.
Boiler installed in building under construction, take
care to insure clean combustion air supply during
construction process. Airborne particulates such as
clog burner ports and cause incomplete combustion and
sooting.
10.
FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
NOTICE
Follow local regulations with respect to installation
of CO detectors.
Table 1 - BOILER MINIMUM CLEARANCE TO
COMBUSTIBLES
Unit Minimum
Clearances
Top 6” (152 mm)
Rear 6” (152 mm)
Right 8” (203 mm)
Left 6” (152 mm)
Front (Alcove) 18” (457 mm)
Flue/Vent Connector 6” (152 mm)
1” (24 mm)
Set unit on concrete or other noncombustible material base or
oor. DO NOT INSTALL ON CARPETING.
Figure 1 - Minimum Clearances To Combustible
Construction
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
above.
8”
Boiler
Rear
Front
Right
LEFT
18”
6” 8”
6”
CAUTION
Bolier weight exceeds 200 pounds (90.7 kg). Do not
lift boiler without assistance.
!!
WARNING
Fire hazard. Do not install boiler on combustible
Addendum) included in literature envelope provide
with boiler. Failure to follow these instructions could
result in death or serious injury.
!
3�1 Installation Requirements
(Combustible Floor Addendum) included in literature
envelope provide with boiler and outlined in National
Fuel Gas CodeDo Not Install
Boiler on carpeting�
11.
Verify boiler is supplied with correct type of gas, fresh
air for combustion, and suitable electrical supply.
PN 240013105 Rev. A [08/15/2020]
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3 - LOCATING THE BOILER
• Ambient room temperature always above 32°F (0°C) to
prevent the potential of freezing.
• Drainage of water (or water/ antifreeze solution) during
boiler service or from safety relief valve discharge.
• Access to system water piping, gas supply, and
electrical service.
•
capable of supporting the weight of the boiler, water,
and equipment.
•
wet.
• Water, gas, and electrical connect to right side of
boiler.
Table 2 - CONTAMINANTS
Items to Avoid Products Which May Contain These
Items Areas Where These Items May Be
Found
Chlorine, Fluorine, and Compounds
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Swimming pool or spa chemicals
De-icing salts or chemicals
Carbon Tetrachloride
Swimming pools and pool storage areas
Airborne Particulates
Drywall dust
Road or gravel dust
Dryer lint
Cat litter
Acids, Solvents, etc.
Paint, Varnish, Turpentine, etc.
Cleaning Solvents
Hydrochloric acid/muriatic acid
Cements, adhesives and glues
Photo processing plants
Garages with workshops
establishments
Laundry Chemicals Laundry detergents, bleaches, fabric
softeners, etc.
Antistatic fabric softeners (dryer sheets)
Dry cleaning/laundry areas and
establishments
Other
Permanent wave solutions
Refrigerants (Freon, etc) (only where
the refrigerant may be leaking from the
appliance)
Beauty shops
Refrigeration repair shops
passages possibly resulting in unsafe operation. In this case, unit servicing shall include
the room be generously ventilated (well in excess of combustible air requirements), and
homeowner seal laundry supply containers, and minimize room vapors.
. Piping allowing fresh air in should also be considered. See Section 5-1.
• Horizontal run to chimney shall be as short as possible.
• System piping exposed to freezing conditions: Use
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
3�2 Boiler Location Considerations
PN 240013105 Rev. A [08/15/2020]
9
4 - CONNECTING SUPPLY AND RETURN PIPING
Check local codes
for maximum
distance from
allowable safe
point of discharge
ASME RELIEF VALVE
DISCHARGE
PIPING
Figure 2 - Safety Relief Valve Discharge Piping
1.
Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements. Install safety relief valve using pipe
2.
Install safety relief valve with spindle in vertical
position.
3.
relief valve.
4.
Install discharge piping from safety relief valve. See
Figure 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).
WARNING
Burn and scald hazard! Safety relief valve shall be
installed with spindle in upright position only,
following ASME BPV code. Failure to follow these
instructions could result in death or serious injury.
!
4�1 Safety Relief Valve Installation
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions. Failure
to follow these instructions could result in death or
serious injury.
!
PN 240013105 Rev. A [08/15/2020]
10
LIMIT SENSOR
MINIMUM HEIGHT FOR
LOW WATER CUTOFF
PROBE
Figure 3 -
Forced Hot Water Typical Piping
LIMIT SENSOR
MINIMUM HEIGHT
FOR LOW WATER
CUTOFF PROBE
Figure 4 - Forced Hot Water Typical Piping
With Zone Control Valve
4 - CONNECTING SUPPLY AND RETURN PIPING
PN 240013105 Rev. A [08/15/2020]
11
• Install radiation units (panels, radiators or cabinets) and
boiler.
• Verify clean water supply is available when connecting
cold water supply to water valve. Install sand strainer at
pump when water supply is from well or pump.
•
above radiation level or as required by the Authority
having jurisdiction, either provide as part of boiler
or at time of boiler installation. Periodic inspection
& 4 for minimum height for installation of LWCO. Refer
to parts manual for LWCO kit. When using LWCO other
manufacturer instructions.
• Boiler used in connection with refrigeration systems
shall be installed so chilled medium is piped in parallel
with heating boiler with appropriate valves to prevent
chilled medium from entering heating boiler.
See
Figure 5
.
• Boiler connected to heating coils located in air handling
units exposed to refrigerated air circulation, piping
other automatic means to prevent gravity circulation of
boiler water during cooling cycle.
Figure 5
- Piping Arrangements For Boiler When
Used In Connection With Refrigeration
System
150°F) And Large Water Content Systems
Condensation is corrosive and can eventually cause severe
damage to boiler and venting system.
• Minimum design return water temperature to prevent
condensation in boiler and venting is 130°F. Minimum
high limit setting is 150°F.
• Boiler used in heating systems where design water
heating), a 3-way or 4-way mixing valve or suitable
alternative is required to prevent low temperature return
water from entering boiler. When using mixing valve,
follow manufacturer’s installation instructions.
• Boiler connected to system having large water content
(such as former gravity system), suggest use of bypass
piping. See
Figure
6
.
Adjust two throttling valves to maintain at
least 130° F (54° C) in boiler return.
Figure 6
- Bypass Piping
4 - CONNECTING SUPPLY AND RETURN PIPING
WARNING
resulting from condensate induced corrosion may
block boiler passages, resulting in carbon monoxide
temperature is under 130°F. Failure to follow these
instructions could result in death or serious injury.
!
4�2 Supply and Return Requirements
PN 240013105 Rev. A [08/15/2020]
12
5 - VENTILATION & COMBUSTION AIR
Provide combustion air and ventilation air in accordance
with the section “Air for Combustion and Ventilation,” of
the National Fuel Gas CodeProvide
make-up air where exhaust fans, clothes dryers, and
kitchen ventilation equipment interfere with proper
operation. If inadequate makeup air is suspected it is
always acceptable to add additional ventilation.
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 jurisdiction.
• Mechanical Air Supply. Provide minimum of 0.35 cfm
per (Btu/hr)/1000 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
minimum volume not available.
A. Standard Method. Cannot be used if known air
Table 3 for space with boiler only. Use equation for
multiple appliances.
3x Total Input (Btu/hr)/1000
B.
space with boiler only. Use equation for multiple
(ACH) greater than 0.60.
21 ft3
C.
requirements between connected indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
A. Two Permanent Opening Method. Provide opening
commencing within 12 inches of top and second
opening commencing within 12 inches of bottom of
enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in² per 4,000 Btu/hr of
total input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in² per 2,000
Btu/hr of total input rating of all appliances in
enclosure.
B. One Permanent Opening Method. Provide opening
commencing within 12 inches of top of enclosure.
Provide minimum clearance of 1 inch on sides/back
and 6 inches on front of boiler (does not supersede
clearance to combustible materials).
•
requirements for louvers, grilles, screens and air ducts.
•
Fuel Gas Code for application information.
providing air supply in accordance with:
• Section 8.2 and 8.3 when combination of
appliances has a total input of up to and including
400,000 Btu/hr (120 kW).
• Section 8.4 when combination of appliances has total
input exceeding 400,000 Btu/hr (120 kW).
•
or structure where boiler is installed, including air
supply openings and ducts.
Table 3 ( ft
Input
Standard
Method
0�1 0�2 0�3 0�4 0�5 0�6
42,500 2125 6375 3188 2125 1594 1275 1063
75,000 3750 11250 5625 3750 2813 2250 1875
112,500 5625 16875 8438 5625 4219 3375 2813
150,000 7500 22500 11250 7500 5625 4500 3750
187,500 9375 28125 14063 9375 7031 5625 4688
WARNING
Asphyxiation Hazard! Provide enough air openings
and allow for consistent, quality combustion.
Do not obstruct air openings. Follow instructions
below, to maintain adequate combustion air.
Failure to follow these instructions could result in
ignition failure, overheating, carbon monoxide, and
!
5�1 Requirements
PN 240013105 Rev. A [08/15/2020]
13
When an existing boiler is removed from a common
venting system, the common venting system is likely to be
too large for proper venting of the appliances remaining
connected to it. If this occurs, follow this test procedure:
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.
1.
Seal any unused openings in the common venting
system.
2.
Visually inspect the venting system for proper size and
horizontal pitch and determine there is no blockage or
which could cause an unsafe condition.
3.
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
4.
Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
5.
Test for spillage at the draft hood relief opening after 5
or candle, or smoke from a cigarette, cigar, or pipe.
6 - VENT SYSTEM MODIFICATION
6.
After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
other gas-burning appliance to their previous conditions
of use.
7.
Any improper operation of the common venting system
should be corrected so the installation conforms with
the National Fuel gas Code
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
8.
The existing venting system shall be checked to ensure
it meets local codes.
6�1 Removal of Existing Boiler From Venting
System
PN 240013105 Rev. A [08/15/2020]
14
Chimney must be clean, right size, properly constructed
and in good condition. A chimney shall be lined in a manner
acceptable to the authority having jurisdiction.
1.
Installation must conform to requirements of the
authority having jurisdiction or, in absence of such
requirements, to the National Fuel Gas Code
building codes.
2.
Boiler’s induced draft blower has 3” outlet. 3” X
secure gas-tight with bead of furnished silicone sealant.
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
Gas Code and may be required to be larger than 4”
diameter.
3.
exhaust temperature.
4.
Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe
B.
C. Poured ceramic liner.
5.
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.
D.
6.
Vent connector from boiler to chimney should run as
directly as possible with as few elbows as possible.
7.
Where possible, it is recommended to common vent
water heater and boiler. Consult appropriate Vent
Sizing Tables in National Fuel Gas Code
requirements of multiple appliance venting.
8.
When boiler is only appliance connected to vent, Type
B vent pipe is recommended for vent connector.
9.
For horizontal runs slope pipe up from boiler to vent
terminal not less than 1/4” in/ft (21 mm/m).
10.
connection.
11.
Fasten sections of vent pipe with 3 sheet metal screws
at each joint to make rigid.
12.
Use stovepipe wires or metal strapping every 5’ to
support pipe from above.
13.
14.
Do not install damper on this boiler.
• 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
installed in accordance with instructions furnished with
•
clearances from roof. If clearances are less than shown,
have vent checked by local authorities. Figure 7.
7 - VENT INSTALLATION
WARNING
Boiler and venting installations shall be performed
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
as carbon monoxide which is odorless and invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!
NOTICE
Minimum Vent Pipe Clearance - Wood and other
combustible materials shall not be closer than 6”
from any surface of single wall metal vent pipe.
Listed Type B vent pipe or other listed venting
systems shall be installed in accordance with their
listing.
NOTICE
Boiler installation for chimney venting is not
secured.
7�1 Chimney Venting (Category I)
7�2 Requirements
PN 240013105 Rev. A [08/15/2020]
15
WARNING
3” x 4” increaser is required for Category I venting.
Failure to follow these instructions could result in
asphyxiation from poisonous gases such as carbon
monoxide which is odorless and invisible and may
result in serious injury or death.
!
7 - VENT INSTALLATION
Liner
Chimney
Thimble
Vent System
Cleanout
Boiler
Vent pipe must be:
At lease 2 ft.
(610mm) higher
than any part of
the roof, but not
less than 3 ft.
(915mm) tall, and
within a 10 ft.
within a 10 ft.
(3m) radius of the
apex.
CHECK YOUR CHIMNEY
For boilers connection to gas vents or chimneys,
vent installations shall be in accordance with
“Venting of Equipment”, of the National Fuel
Gas Code
provisions of the local building codes.
Figure 7 - Type B Gas Vent
3”x4” Increaser
PN 240013105 Rev. A [08/15/2020]
16
Horizontal Requirements (Category III) venting
these instructions�
Maximum Horizontal Vent Length For Stainless Steel Vent
Pipe - 30’ Plus One 90º Elbow Plus Vent Terminal.
Minimum Horizontal Vent Length - 2’ Plus One 90º Elbow
Vent Termination.
Additional elbows are equivalent to 6 feet of straight pipe
for 4” diameter 90° elbow or 3 feet of straight pipe for 3”
diameter 90° elbow. 2, 3, 4, 5, Section Boilers use 3” vent
pipe; for 6 Section Boilers use 4” vent pipe.
CHOICE OF VENT PIPE MATERIAL
•
• U. L. Listed Heat-Fab Saf-T-Vent Stainless Steel Vent
Pipe.
• U. L. Listed Flex-L Star-34 Stainless Steel Vent Pipe.
•
Vent Pipe.
INDUCED DRAFT HIGH EFFICIENCY BOILERS
8 - HORIZONTAL VENTING INSTRUCTIONS
Figure 8
(21 mm/m)
(300 mm)
(21 mm/m)
(300 mm)
8�1 Horizontal Venting (Category III)
PN 240013105 Rev. A [08/15/2020]
17
1.
Boilers may be vented horizontally as shown in
Figure 8�
Vent pipe is pitched
from boiler to
vent termination. Do not connect other appliances to
this vent.
2.
Vent Pipe Material:
A.
from boiler to vent termination,
-or-
B. UL Listed Heat-FabSaf-T-Vent stainless steel vent
pipe from boiler to vent termination,
-or-
C. UL Listed Flex-L StaR-34 stainless steel vent pipe
from boiler to vent termination,
-or-
D.
pipe from boiler to vent termination.
3.
Clearance to Combustible Materials: For stainless steel
vent pipe maintain 6” minimum air space clearance to
combustible materials.
4.
Vent Pipe Size:
A. 2, 3, 4 and 5 section boilers use 3” vent pipe
connected directly to the outlet of the induced draft
blower.
B. 6 section boilers use 4” vent pipe, starting with
a 3” to 4” stainless steel vent pipe transition that
is connected directly to the outlet of the induced
draft blower. Do not use 3” vent pipe on 6 section
boilers.
5.
Vent Pipe Length:
A. For stainless steel vent pipe, the maximum
horizontal vent length is 30 feet plus one 90°elbow
B. Minimum horizontal vent length for all vent
materials is 2 feet plus one 90° elbow plus
C. For additional elbows reduce the maximum vent
length as shown:
• 3” - 90° elbow - reduce vent length 3 feet per
each 3” elbow
• 4” - 90° elbow - reduce vent length 6 feet per
each 4” elbow
Example:
6 section boiler has 3 elbows plus the
be used, at 6 feet per elbow. This is equivalent to 12 feet
of pipe (2 x 6 =12), therefore maximum vent length is now
18 feet (30 -12 =18).
6.
Vent Termination Fitting: For all vent pipe materials,
you may use either:
A.
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 as shown in
Figure 8
.
-or-
B. Tjernlund VH-1 Series side wall vent hood. For 2,
3, 4, 5 section boilers use VH-1-3”. For 6 section
boilers use VH-1-4”.
7.
Vent Pipe Termination Location
See Figure 9
:
A. When venting through combustible walls,
combustible clearances must be considered. The
VH-1 Side wall vent hood provides both the outside
vent termination and a double wall pipe for passing
through a combustible wall up to 8” thick (VH-
1-4”) or 9” thick (VH-1-3”). The hole in the wall
must be 6¼” square for 3” vent pipe and 7 1/2”
square for 4” vent pipe, in order to insert the VH-1
side wall vent hood. The VH-1 may also be used in
noncombustible walls.
B.
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. For combustible walls
use the following:
• 3” vent pipe - use Simpson’s Duravent 3” thimble
• 4” vent pipe - use Simpson’s Duravent 4” thimble.
Maximum wall thickness with this thimble is 7
inches.
single wall vent pipe must pass through the side wall, a UL
maximum wall thickness of 7 inches. Seal the thimble along
the outside edge of the plate with caulk or silicone and
fasten to the wall with screws or nails.
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 noncombustible
walls.
8 - HORIZONTAL VENTING INSTRUCTIONS
PN 240013105 Rev. A [08/15/2020]
18
D. Vent Termination
оVenting system shall terminate at least 3 feet
(0.9 m) above any forced air inlet located within
10 feet (3 m).
оVenting system shall terminate at least 4 feet
(1.2 m) below, 4 feet (1.2 m) horizontally from,
or 1 foot (300 mm) above any door, window, or
gravity air inlet into any building.
оBottom of vent shall be located at least 12
inches (300 mm) above grade.
оTermination of vent shall be not less than 7 feet
(2.13 m) above adjacent public walkway.
оVent terminal shall not be installed closer than
3 feet (0.9 m) from inside corner of L shaped
structure.
оTermination of vent should be kept at least 3
feet (0.9 m) away from vegetation.
оVenting system shall not terminate underneath
any deck, patio, or similar structure.
8 - HORIZONTAL VENTING INSTRUCTIONS
Figure 9 - Horizontal Venting Clearances
оUnited States - Terminate vent system at least
4 feet (1.22 m) 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. See Figure 9.
оCanada - Terminate vent system at least 6
feet (1.83 m) horizontally from, and in no case
above or below,unless 6 feet (1.83 m) horizontal
distance is maintained, from gas and electric
meters, regulators and relief equipment.
оVenting system shall terminate at least 4 feet
оPlace vent on wall away from prevailing winter
wind. Locate or guard vent to prevent accidental
contact with people or pets.
оTerminate vent above normal snow-line. Avoid
locations where snow may drift and block vent.
Ice or snow may cause boiler to shut down if
vent becomes obstructed.
о
forming moisture. Take steps to prevent building
materials at vent terminal from being damaged
PN 240013105 Rev. A [08/15/2020]
19
8.
Joining and Sealing the Vent Pipe:
The vent pipe needs to be both watertight and gas
tight. Seal all joints and seams as follows:
A.
a high temperature silicone sealant rated for
550°F. The outside of the male end and inside
of the female end of the pipe must be cleaned
with brake cleaner before applying silicone bead.
For 3” vent pipe runs begin with the male end
of the vent pipe over the boilers induced draft
blower outlet. For 4” vent pipe runs begin with a
draft blower outlet, to which an even bead of high
temperature silicone sealant should be applied.
reducer. (A locking band may be used around this
joint for additional support.) Then following the
sealing instructions, push the 4” male end of the
the Tjernlund VH-1 vent hood, the female end
the termination hood. The male end of the vent
over the vent hood’s connecting pipe. Before the
pipes are joined, apply a ¼” bead of silicone one
inch from the end of the male end. Then push the
pipes together as far as they will go making sure
apply another bead of silicone around this joint and
the center of the joint.
1. Apply the high temperature silicone
approximately one inch from the end, around
the male end of the pipe in an even ¼” bead.
2. Pipes can now be pushed together as far as they
will go. The seams on pipe should be aligned
and oriented upward in all horizontal appliances.
Apply another bead of silicone around this joint
and smooth out.
3. Slide locking band over center of joint and
tighten gear clamps. Make sure locking band is
centered on joint.
4. Check all joints and seams for gas tightness.
5. Horizontal venting shall have slope not less
than ¼” every 12 inches (21 mm/m) downward
away from the boiler to prevent collection of
condensate throughout the assembly.
6. Allow sealant to cure for 24 hours before
operating appliance.
B. For Heat-Fab Saf-T-Vent stainless steel vent pipe
use a high temperature silicone sealant rated for
550°F The outside of the male end and inside
of the female end of the pipe must be cleaned
before applying the silicone bead. For 3” vent
pipe runs, the male end of the vent pipe which
goes over the outlet of the boiler’s induced draft
blower must be crimped. The vent pipe should be
crimped as minimal as possible to provide a tight
follow the instructions for applying silicone sealant.
For 4” vent pipe runs, begin with a Saf-T-Vent 3”
draft blower outlet, to which an even bead of high
temperature silicone sealant should be applied.
Then continue the 4” Saf-T-Vent pipe run by
connecting the 4” male end of the Saf-T-Vent to the
increaser. (A locking band may be used around this
in the direction indicated on the vent pipe. When
using the Tjernlund VH-1 vent hood, the female
to the termination hood. Apply high temperature
silicone in an even ¼” bead approximately ¼” to
vent pipe. Also, run a similar size bead of silicone
sealant down the seam weld of the vent pipe.
Then push the female end over the vent hood’s
connecting vent pipe.
1. Apply the high temperature silicone around
the male end of the pipe (without the tabs)
in an even ¼” bead. Silicone bead should be
male end. Also, run a similar size bead of
silicone sealant down the seam weld at the end
of each joint.
2. Pipes can now be pushed together as far as they
will go. The seams on the vent pipe should be
aligned and oriented upward in all horizontal
spread any sealant that squeezes out around the
circumference of the joint.
3. Attach the sections together with the locking
rings and tabs (except at the blower outlet
where no locking ring exists.) Inspect the
necessary apply additional sealant around the
joint.
4. Horizontal venting shall have a slope not less
than ¼” every 12 inches (21 mm/m) downward
away from the boiler to prevent collection of
condensate throughout the assembly.
5. Allow the sealant to cure for 24 hours before
operating the appliance.
8 - HORIZONTAL VENTING INSTRUCTIONS
PN 240013105 Rev. A [08/15/2020]
20
C. For Flex-L StaR-34 stainless steel vent pipe use
a high temperature silicone sealant rated for
550°F. Before applying silicone, the outside of
the male end and inside of the female end of the
pipe must be cleaned using a cleaner, such as
methyl ethyl ketone (MEK) or naphtha. For 3”
vent pipe runs, begin with the male end of the
vent pipe over the boiler’s induced draft blower
outlet. For 4” vent pipe runs begin with a StaR-34
draft blower outlet. For both 3” and 4” vent pipe
runs, apply a bead of silicone sealant around the
blower outlet and around the inside of the male
end of vent pipe going over the blower’s outlet.
When using the Tjernlund VH-1 vent hood,
will be connected to the termination hood.
Apply high temperature silicone in an even ¼”
bead approximately ¼” from the end of the vent
hood’s connecting vent pipe. Also, run a similar size
bead of silicone sealant down the seam weld of the
vent pipe. Then push the female end over the vent
inlet with silicone sealant. Do not try to insert the
joiner band, instead fasten the vent pipe to the
vent hood’s pipe with a steel gear clamp.
1. Apply the high temperature silicone around
the male end of the pipe in an even ¼” bead.
Silicone bead should be approximately ¼” from
the end of the male end. Also, run a similar size
bead of silicone sealant down the seam weld at
the end of each joint.
2. The seams on the vent pipe should be aligned
and oriented upward in all horizontal vent pipe
runs.
3. Insert the male end of one into the female end
of the other. Push the pipe together so the
female end rests up against the stop bead of the
male end.
4. Insert a StaR-Joiner Band into the inlet of the
beaded channel. Feed the Joiner Band in so
it makes its way around the pipe, back to the
channel inlet and it overlaps itself by about ½”.
5.
beaded channel. Fill the inlet of the beaded
channel with high temperature silicone. Smooth
out the silicone over the channel inlet and the
silicone between the female end and the stop
bead of the male end.
6. Horizontal venting shall have a slope not less
than ¼” every 12 inches (21 mm/m) downward
away from the boiler to prevent collection of
condensate throughout the assembly.
7. Allow the sealant to cure for 24 hours before
operating the appliance.
D.
vent pipe runs on 2, 3, 4 and 5 section boilers,
over the boiler’s induced draft blower. Continue
For 6 section boilers, begin by locating the
increaser to the 3” adapter outlet. Continue the
use of an internal sealing gasket and a locking
band on the female end of each vent pipe. All
components should be examined for possible
shipping damage prior to installation. Align all vent
pipe seams and orient upward in all horizontal
applications. Adjustable vent lengths are available
for 4” diameter vent piping. For 3” diameter vent
piping, square cut male end at the desired length.
For 2, 3, 4 and 5 section boilers using the VH-1-
To attach the adapter to the vent hood, crimp
the 3” vent hood pipe, apply a ¼” bead of high
temperature silicone sealant around the outside
of the vent hood’s crimped connecting pipe and a
similar bead of high temperature silicone around
the two pipes together and tightening the locking
temperature silicone. For 6 section boilers using the
VH-1 - 4” vent hood, an adapter is not required.
VH-1- 4” vent hood, and is joined and sealed by the
internal gasket and locking band.
1. Insert male end into female section.
2. Push the units together as far as possible.
3. Firmly tighten locking band with a nut driver.
4.
fasteners.
5. Horizontal venting shall have a slope of not less
than ¼” every 12 inches 21 mm/m) downward
away from the boiler to prevent the collection of
condensate throughout the assembly.
8 - HORIZONTAL VENTING INSTRUCTIONS
PN 240013105 Rev. A [08/15/2020]
This manual suits for next models
5
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