ECR International Olsen OSVB II Series Instruction manual

P/N 240009138, Rev. D [10/2014]
An ISO 9001-2008 Certified Company
OSVB SERIES II
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
Models
OSVB-2
OSVB-3
OSVB-4
OSVB-5
OSVB-6
OSVB-7
An ISO 9001-2008 Certied Company
C.S.A. Certied
For Natural Gas Or Propane
Tested For 50 psi.
ASME
Working Pressure

2
Boiler Ratings & Capacities...................... 3
Dimensions ............................................. 4
Installation Procedure............................. 5
Ventilation & Combustion Air .................. 6
Installation System Piping ...................... 7
Vent Installation ................................... 10
Horizontal Venting Instructions .......... 13
Optional Horizontal Venting Instruction 18
Gas supply Piping .................................. 19
Electrical Wiring .................................... 21
Sequence of Operation .......................... 22
Wiring Diagrams ................................... 23
Starting Your Boiler............................... 24
Checking and Adjusting......................... 26
Maintaining Your Boiler ......................... 28
Service Hints ......................................... 29
Equipment & Optional Accessories ........ 30
Appendix A - Control Module ................. 32
A.1 Installation Environment Considerations . 32
A.2 Electrical Connections .......................... 32
A.3 Adjusting Settings ............................... 32
A.4 Display .............................................. 32
A.5 Operation .......................................... 33
A.6 Boiler High Limit Temperature Controller 34
A.7 Troubleshooting .................................. 34
A.8 Troubleshooting Error Codes ................. 34
A.9 Intermittent Pilot ................................ 35
TABLE OF CONTENTS
Safety Symbols & Warnings
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
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
!
IMPORTANT: Read the following instructions
COMPLETELY before installing!!
KEEP THIS MANUAL NEAR BOILER
RETAIN FOR FUTURE REFERENCE
WARNING
Keep boiler area clear and free from combustible
materials, gasoline and other ammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modication, substitution or elimination of factory
equipped, supplied or specied components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualied installer.
TO THE INSTALLER - Leave all instructions with
boiler for future reference.
When this product is installed in the
Commonwealth of Massachusetts the installation
must be performed by a Licensed Plumber or
Licensed Gas Fitter.
!
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.
!

3
New York City MEA Number 484-84-E Vol. IV.
BOILER RATINGS & CAPACITIES
Table 1 - RATINGS NATURAL AND PROPANE GASES
Model
Input
*Mbh
Heating
Capacity
*Mbh
**Net
AHRI
Rating
Water
*Mbh
AFUE
High Altitude
Input *Mbh
Vent Diameter (Inches)
To Chimney
(Category I)
Horizontal Vent
(Category III)
OSVB-2 42 36 31 84.4 38 43
OSVB-3 75 63 55 83.4 67 4 3
OSVB-4 112 94 82 83.0 101 43
OSVB-5 150 125 109 82.7 135 4 3
OSVB-6 187 155 135 82.3 168 4 4
OSVB-7 225 186 162 82.0 202 4 4
* MBH = 1,000 Btuh = British Thermal Unit Per Hour. Boilers are equipped for altitudes up to 2,000 feet only.
• U.S.A. Only - For altitudes above 2,000 feet, ratings should be reduced at the rate of 4% for each
1,000 feet above sea level.
• Canada Only - Boilers may be used at high altitude (2,000-4500 feet/640-1350m) by using a certied
eld conversion kit, resulting in a 10% de-rate. Contact Provincial authority having jurisdiction for installations
above 4500 ft (1350m)above sea level.+ Heating Capacity based on D.O.E. (Department of Energy) test
procedure.
** Net AHRI Water Ratings i ndicate amount of remaining heat input that can be used to heat the radiation
or terminal units. Net AHRI Ratings shown are based on an allowance of 1.15 Selection of
boiler size should be based upon “Net AHRI Rating” being equal to or greater than calculated
heat loss of building.
Manufacturer should be consulted before selecting a boiler for installations having unusual piping
and pickup requirements.
This boiler cannot be used with all types of chimneys. Read these instructions carefully before installing.
These Gas-Fired Hot Water Boilers are low pressure, sectional cast iron boilers Design Certied by C.S.A. (Canadian Standards
Association) for use with Natural and Propane Gases. Constructed and hydrostatically tested for maximum working pressure of 50 psi in
accordance with A.S.M.E. Boiler and Pressure Vessel Code Section IV Standards for cast iron heating boilers.
Boilers must stand on noncombustible oor. If installed on combustible oor, please refer to Repair Parts manual for appropriate
Combustible Floor Base part number.
Boilers For Use At High Altitude
Boiler is factory equipped for use at altitudes of 0-2,000 feet above sea level. For use at altitudes above 2,000 feet above sea level,
input ratings are reduced by change in main burner orice size.
U.S.A. Only - For altitudes above 2,000 feet above sea level, input ratings should be reduced at rate of 4% for each 1,000 feet above
sea level. Consult National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1,
or manufacturer for correct orice sizing information.
Canada Only - For altitudes in the range of 2,000-4,500 feet (610 - 1350m) above sea level, boilers may be eld equipped for use
at high altitude by using a certied eld conversion kit. The change in main burner orice size results in the boiler’s input rating
being reduced by 10%.The conversion shall be carried out by a manufacturer’s authorized representative, in accordance with the
requirements of the manufacturer, provincial or territorial authorities having jurisdiction and in accordance with the requirements of
CSA-B149 Natural Gas and Propane Installation Code. The certied eld conversion kit includes a conversion data plate, which must be
attached to the boiler adjacent to the rating plate, indicating that the boiler has been converted for high altitude use. The conversion
data plate must be lled in with the correct conversion information.
For altitudes over 4500 feet (1350m), contact Provincial authority having jurisdiction.

4
DIMENSIONS
Model Width (A)
OSVB-2 11
OSVB-3 14-1/4
OSVB-4 17-1/2
OSVB-5 20-3/4
OSVB-6 24
OSVB-7 27-1/4

5
INSTALLATION PROCEDURE
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
!
1. The installation must 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
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically red Boilers,
ANSI/ASME CSD-1.
3. This boiler series is classied as a Category I. Vent
installation shall be in accordance with “Venting of
Equipment ,” of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or “Venting Systems and Air Supply
for Appliances,” of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes.
4. Boiler has met safe lighting and other performance
criteria with gas manifold and control assembly on
boiler per latest revision of ANSI Z21.13/CGA 4.9.
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
from drywall dust and from berglass insulation can
clog burner ports and cause incomplete combustion and
sooting.
NOTICE
Follow local regulations with respect to installation
of CO detectors.
Table 1 - BOILER MINIMUM CLEARANCE TO
COMBUSTIBLES
Unit Minimum
Clearances
Top 6” (152mm)
Rear 6” (152mm)
Control Side 8” (203mm)
Opposite Side 6” (152mm)
Front (Alcove) 18” (457mm)
Flue/Vent Connector 6” (152mm)
Near Boiler Piping 1” (24mm)
Set unit on concrete or other noncombustible material base or
oor. DO NOT INSTALL ON CARPETING.
Figure 1 - Minimum Clearances To Combustible
Construction
10. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
ooring special base must be used. (See Replacement
Parts Section.) Do Not Install Boiler on carpeting.
11. Verify boiler is supplied with correct type of gas, fresh
air for combustion, and suitable electrical supply.
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
8”
Boiler
Rear
Front
Control Side
Opposite Side
18”
6”
6” 8”

6
VENTILATION & COMBUSTION AIR
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.
оStandard Method. Cannot be used if known air
inltration rate is less than 0.40 air changes per
hour. See Table 3 for space with boiler only. Use
equation for multiple appliances.
Volume ≥ 50 ft3 x Total Input [Mbh]
оKnown Air Inltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air inltration rate
(ACH) greater than 0.60.
Volume ≥ 15 ft3/ACH x Total Input [Mbh]
оRefer 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.
оTwo 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 in2 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.
оOne 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).
оCombination 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 to
National 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 appliances
has a total input of up to and including 400 Mbh (120
kW).
оDoes 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 specic air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
Table 2 - Air Inltration Rate
Input Mbh Standard
Method
Known Air Inltration Rate Method (Air Changes Per Hour)
0.1 0.2 0.3 0.4 0.5 0.6
42.5 2125 6375 3188 2125 1594 1275 1063
75 3750 11250 5625 3750 2813 2250 1875
112.5 5625 16875 8438 5625 4219 3375 2813
150 7500 22500 11250 7500 5625 4500 3750
187.5 9375 28125 14063 9375 7031 5625 4688
225 11250 33750 16875 11250 8438 6750 5625

7
INSTALLATION SYSTEM PIPING
Check local codes
for maximum
distance from
oor or other
allowable safe
point of discharge
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 require-
ments. Install safety relief valve using pipe ttings
provided with boiler. See Figure 2
2. Install safety relief valve with spindle in vertical posi-
tion.
3. Do not install shutoff valve between boiler and safety
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 loca-
tion 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 could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!

8
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
INSTALLATION SYSTEM PIPING

9
• Install radiation units (panels, radiators or cabinets) and
supply and return mains rst then make connections at
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.
• Provide low water cutoff device when boiler is installed
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 is neces-
sary, as is ushing of oat type devices, per manufac-
turers specic instructions. Refer to Figures 3 & 4 for
minimum height for installation of LWCO. Use kit #
550002998 and follow instructions included with kit.
When using LWCO other than kit listed follow specic
LWCO 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
system shall be equipped with ow control valves or
other automatic means to prevent gravity circulation of
boiler water during cooling cycle.
INSTALLATION SYSTEM PIPING
Figure 5 - Piping Arrangements For Boiler When
Used In Connection With Refrigeration
System
Low Design Water Temperature Systems (Below
140°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 120°F. Minimum
high limit setting is 140°F.
• Boiler used in heating systems where design water
temperatures below 140°F are desired (e.g. radiant oor
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 120° F (49°C) in boiler return.
Figure 6 - Bypass Piping

10
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 or of the Natural Gas and Propane
Installation Code, CAN/CSA B149.1, or applicable
provisions of the local building codes..
2. Boiler’s induced draft blower has 3” outlet. 3” X
4” increaser tting is included in parts bag. Locate
increaser tting on outlet of induced draft blower, and
secure gas-tight with bead of furnished silicone sealant.
Increaser tting 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 tting is located and secured.
3. These are high efciency boilers with low stack or
exhaust temperature.
4. Venting into masonry chimney without liner, line
chimney from top to bottom with either:
A. Listed Type B vent pipe
B. Listed exible vent liner
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. Use listed exible vent liner
D. Use certied chimney lining system
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 for specic
requirements of multiple appliance venting.
8. Boiler is only appliance connected to vent, Type B vent
pipe is recommended for vent connector.
9. Slope pipe up from boiler to chimney not less than 1/4”
per foot (21mm/m).
10. End of vent pipe must be ush with inside face of
chimney ue. Use sealed-in thimble for chimney
connection.
11. Fasten sections of vent pipe with sheet metal screws to
make piping rigid. Use stovepipe wires to support pipe
from above.
12. Do not connect to replace ue.
13. Do not install damper on this boiler.
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 exible liner must be
installed in accordance with instructions furnished with
vent. Maintain clearances as specied for vent pipe.
• Verify vent pipe is re-stopped where it goes through
oor or ceiling. It should have approved vent cap with
clearances from roof. If clearances are less than shown
in have vent checked by local authorities. See Figure 7,
Page 11.
• Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.
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.
Boiler
Water Heater
Chimney
CHECK YOUR CHIMNEY
For boilers for connection to gas vents or
chimneys, vent installations shall be in
accordance with “Venting of Equipment”, of the
National Fuel Gas Code, ANSI Z223.1/NFPA 54,
or of the Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable provisions
of the local building codes.
Figure 7 - Type B Gas Vent
11
VENT INSTALLATION

12
Removing Existing Boiler From Common Venting
System
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.
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
restriction, leakage, corrosion and other deciencies
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
summer exhaust fan. Close replace dampers.
4. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
VENT INSTALLATION
5. Test for spillage at the draft hood relief opening after 5
minutes of main burner operation. Use ame of a match
or candle, or smoke from a cigarette, cigar, or pipe.
6. 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, replace dampers and any
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, 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.
8. It is recommended that existing gas vents be checked
to be sure they meet local codes.

13
Horizontal (Category III) venting systems must be installed
in accordance with 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, 7 Section Boilers use 4” vent pipe.
CHOICE OF VENT PIPE MATERIAL
• U. L. Listed Z-Flex Z-Vent Stainless Steel Vent Pipe.
• U. L. Listed Heat-Fab Saf-T-Vent Stainless Steel Vent
Pipe.
• U. L. Listed Flex-L Star-34 Stainless Steel Vent Pipe.
• U. L. Listed ProTech Systems FasNSeal Stainless Steel
Vent Pipe.
INDUCED DRAFT HIGH EFFICIENCY BOILERS
HORIZONTAL VENTING INSTRUCTIONS
Figure 8 - Induced Draft High Efciency Boilers
(21mm/m)
(300mm)
(21mm/m)
(300mm)

14
1. These boilers may be vented horizontally as shown in
Figure 8, Page 13 . The vent pipe is pitched down
from the boiler to the vent termination. Do not connect
other appliances to this vent.
2. Vent Pipe Material:
A. UL Listed Z-Flex Z-Vent stainless steel vent pipe
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. UL Listed ProTech FasNSeal stainless steel vent
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 and 7 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
or 7 section boilers.
5. Vent Pipe Length:
A. For stainless steel vent pipe, the maximum
horizontal vent length is 30 feet plus one 90° elbow
plus termination tting.
B. Minimum horizontal vent length for all vent
materials is 2 feet plus one 90° elbow plus
termination tting.
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
termination tting. This means 2 additional 4” elbows will
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. A 90° elbow pointing down, tted 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 as shown in Figure 7,
Page 11 .
-or-
B. Tjernlund VH-1 Series side wall vent hood. For 2,
3, 4, 5 section boilers use VH-1-3”, For 6, 7 section
boilers use VH-1-4”.
7. Vent Pipe Termination Location (Figure 8, Page 13) :
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. If the 90° elbow is the termination tting 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. For combustible walls
using Z-Vent, Saf-T-Vent, or StaR-34 vent pipe,
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.
For combustible walls using ProTech FasNSeal where the
single wall vent pipe must pass through the side wall, a UL
Listed FasNSeal wall thimble shall be used.
The thimble is adjustable for different wall thickness, with a
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 pitch of vent pipe, and provide
proper sealing. Thimble is not required for single
wall pipe passing through noncombustible walls.
HORIZONTAL VENTING INSTRUCTIONS

15
D. Vent Termination
оVenting system shall terminate at least 3 feet
(0.9m) above any forced air inlet located within
10 feet (3m).
оVenting 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.
оBottom of vent shall be located at least 12
inches (300mm) above grade.
оTermination of vent shall be not less than 7 feet
(2.13m) above adjacent public walkway.
оVent terminal shall not be installed closer than
3 feet (0.9m) from inside corner of L shaped
structure.
оTermination of vent should be kept at least 3
feet (0.9m) away from vegetation.
оUnited 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. See Figure 9.
HORIZONTAL VENTING INSTRUCTIONS
Figure 9 - Horizontal Venting Clearances
оCanada - Terminate vent system at least 6
feet (1.83m) horizontally from, and in no case
above or below,unless 6 feet (1.83m) horizontal
distance is maintained, from gas and electric
meters, regulators and relief equipment.
оVenting system shall terminate at least 4 feet
below any eave, soft, or roof overhang.
оVenting system shall not terminate underneath
any deck, patio, or similar structure.
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.
оUnder certain conditions, ue gas will condense,
forming moisture. Take steps to prevent building
materials at vent terminal from being damaged
by exhaust of ue gas.

16
8. Jo i n i ng an d S e alin g t h e Ven t P i pe:
The vent pipe needs to be both watertight and gas
tight. Seal all joints and seams as follows:
A. For Z-Flex Z-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
w i t h b r a k e c l e a n e r b e f o r e a p p l y i n g s i l i c o n e b e a d .
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
6” length of 3” Z-Vent over the boiler’s induced
draft blower outlet, to which an even bead of high
temperature silicone sealant should be applied.
Then connect the 3” Z-Vent to a Z-Vent 3” to 4”
reducer. Then continue the 4” Z-Vent pipe run by
connecting the 4” male end of the Z-Vent to the
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
Z-Vent over the 4” increaser tting. When using
the Tjernlund VH-1 vent hood, the female end
(ared end) of the vent pipe will be connected to
the termination hood. The male end of the vent
hood must be crimped before pushing the Z-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
any seams are aligned and oriented upward. Now
apply another bead of silicone around this joint and
smooth out. Then use a Z-Flex locking band around
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 (21mm/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
t over the outlet. After crimping is completed
f o l l o w t h e i n s t r u c t i o n s f o r a p p l y i n g s i l i c o n e s e a l a n t .
For 4” vent pipe runs, begin with a Saf-T-Vent 3”
to 4” increaser tting over the boiler’s induced
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
joint for additional support.) The vent ow must be
in the direction indicated on the vent pipe. When
using the Tjernlund VH-1 vent hood, the female
end (ared end) of the vent pipe will be connected
to the termination hood. Apply high temperature
silicone in an even ¼” bead approximately ¼” to
⅜” 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 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
approximately ¼” to ⅜” 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. 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
appliances. With a moistened nger or at tool,
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
joint to ensure that ue gases will not leak. If
necessary apply additional sealant around the
joint.
4. Horizontal venting shall have a slope not less
than ¼” every 12 inches (21mm/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.
HORIZONTAL VENTING INSTRUCTIONS

17
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
3” to 4” increaser tting over the boiler’s induced
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
e n d o f v e n t p i p e g o i n g o v e r t h e b l o w e r ’ s o u t l e t .
When using the Tjernlund VH-1 vent hood,
the female end (ared end) of the vent pipe
w i l l b e c o n n e c t e d t o t h e t e r m i n a t i o n h o o d .
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
hood’s connecting vent pipe. Now ll in the channel
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. Cut the excess Joiner Band so it lays at in the
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 (21mm/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. For ProTech Systems FasNSeal stainless steel
vent pipe no cleaning uid is required. For 3”
vent pipe runs on 2, 3, 4 and 5 section boilers,
begin by locating the FasNSeal Ametek Adapter
over the boiler’s induced draft blower. Continue
t h e v e n t p i p e r u n w i t h 3 ” F a s N S e a l v e n t p i p e .
For 6 and 7 section boilers, begin by locating the
FasNSeal Ametek Adapter over the boiler’s induced
draft blower. Then connect a FasNSeal 3” to 4”
increaser to the 3” adapter outlet. Continue the
vent pipe run with 4” FasNSeal vent pipe. Other
than the Ametek Adapter and increaser tting, DO
NOT use 3” vent pipe on 6 or 7 section boilers.
FasNSeal vent pipe is joined and sealed by 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-
3” vent hood, connect the FasNSeal Vent to the
VH-1-3” vent hood using FasNSeal Adapter #FSC-
D U N - 3 . T h i s a d a p t e r h a s n o i n t e r n a l s e a l i n g g a s k e t .
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 inside of the FasNSeal adapter. After pressing
the two pipes together and tightening locking band,
nish creating a complete seal by lling FasNSeal
adapter’s notched hole with high temperature
silicone. For 6 and 7 section boilers using the VH-1
- 4” vent hood, an adapter is not required. The 4”
FasNSeal vent pipe connects directly to the VH-1-
4” vent hood, and is joined and sealed by internal
gasket and locking band.
To join and seal the FasNSeal vent pipe:
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. DO NOT penetrate the FasNSeal vent pipe with
fasteners.
5. Horizontal venting shall have a slope of not less
than ¼” every 12 inches 21mm/m) downward
away from the boiler to prevent the collection of
condensate throughout the assembly.
HORIZONTAL VENTING INSTRUCTIONS

18
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 as follows:
A. Z-Flex stainless steel vent piping requires a loose
tting metal strap or similar support at each joint
at a maximum of 4 feet between supports.
B. Heat-Fab stainless steel vent piping requires a
support for every 6 feet of horizontal piping run.
The support must be secured using at least #10
fasteners to a solid material (solid masonry or
wood framing or blocking.) Do not fasten to drywall
sheathing using hollow wall anchors. Each support
will be 1½ inch lower than the previous support
when spaced 6 feet apart.
C. Flex-L stainless steel vent piping requires a loose
tting metal strap or similar support at each joint
at a maximum of 4 feet between supports.
D. ProTech stainless steel vent piping requires one
loose tting FasNSeal support strap for every 6’ of
horizontal vent.
10. If the horizontal vent must go through a crawl space
or other unheated space, the cool temperatures will
likely cause the ue 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 conden-
sate. Consult the vent pipe manufacturer’s instructions
for specic guidelines.
11. At the beginning of each heating season and monthly
during the heating season, check all vent pipes and the
vent terminal to make sure there are no obstructions.
Periodically clean the screen in the vent terminal.
OPTIONAL HORIZONTAL VENTING INSTRUCTION
HORIZONTAL VENTING INSTRUCTIONS
Horizontal venting with a power venter is an alternate
method of sidewall venting. This boiler is CSA listed for
sidewall venting with standard single wall galvanized or
Type B vent pipe when using the following power venter
kits, which were specically sized for these boilers:
Table 3 - Field Controls
Number Of
Boiler Sections
Field Controls
Power Venter
2, 3, 4, 5 SWG-4D
6, 7 SWG-5D
Some possible reasons for using a power venter for
sidewall venting:
1. May be preferred by local codes.
2. Need a vent piping run beyond 30’ (9.1m) (but not
more than 50’ (15.2m)).
3. The boiler installation site experiences gusting or high
winds. A power venter can help prevent the boiler from
short cycling due to gusting or high winds by providing
vent exhaust pressures greater than the boiler’s
induced draft blower alone.
4. When installers or homeowners prefer a negative
pressure vent system instead of a positive pressure
vent system.
5. May be more cost effective than stainless steel
venting, particularly at longer vent length.
The Field Controls power vent kit includes either a
SWG-II-4HD or SWG-II-5 power venter, a MG-1 4”
barometric draft controller, and the CK-43D controls kit.
Conrm that installing a power venter is an option allowed
by local codes. Follow the specic power venter installation
instructions issued with the power venter kits. Although
the power venter is equipped with its own fan, the fan on
the boiler remains in place and is unaltered when a power
venter is used.
When sidewall venting, ue gases must be vented to a
point in relation to the prevailing wind so that they may
freely disperse without being blown back at the building
causing discoloration, or into the building through doors or
windows causing odors. Also, under certain conditions ue
gases will condense, forming moisture. In such cases, steps
should be taken to prevent building materials at the vent
terminal from being damaged by the exhausted ue gas.
When installing single wall galvanized vent pipe for power
venting follow the specic power venter installation
instructions for layout, location of the barometric draft
control and termination connections.
When joining and sealing the single wall galvanized or Type
B vent piping, use RTV silicone sealant with a minimum
temperature rating of 400°F. For 3” vent pipe runs, be-
gin with the female end of the vent pipe over the boiler’s
induced draft blower outlet. For 4” vent pipe runs begin
with the galvanized 3” to 4” increaser tting (included in
the boiler’s parts bag) over the induced draft blower outlet.
Then follow by placing the female end of the 4” vent pipe
over the increaser tting.
When joining pieces of single wall galvanized vent pipe, a
substantial bead of silicone should be used at the joint to
insure a leak proof connection.

19
CAUTION
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electrical switch; do not use
any phone in your building.
• Immediately call your gas supplier from a
neighbor’s phone. Follow gas supplier’s
instructions.
• If you cannot reach your gas supplier, call the re
department.
!
3” Minimum
Sediment
Trap
Manifold
Floor Line
Automatic
Gas Valve
Ground
Joint
Union
Table 4 - Gas Pressures
PRESSURE GAS
NATURAL PROPANE
MIN. SUPPLY 5" w.c. 11" w.c.
MAX. SUPPLY 13.5" w.c. 13.5" w.c.
MANIFOLD 3.5" w.c. 10" w.c.
Verify minimum pressure while boiler is operating.
Verify maximum prssure when boiler is not operating
Connecting Gas Piping
Gas line enters boiler from right side. Flexible gas
connectors must never breach any boiler openings.
• Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements:
• USA - National Fuel gas Code, ANSI Z223.1/NFPA 54
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
• All pipe compound must be resistant to liqueed
petroleum gas.
• Install ground joint union in gas supply line between
shut-off valve and boiler controls.
• Install sediment trap upstream of gas controls.
• Use two pipe wrenches when making connection to gas
valve to keep it from turning.
• Install manual shut-off valve in vertical pipe about 5 feet
(1.5m) above oor. See Figure 10.
• Tighten all joints securely.
• Propane gas connections should only be made by
licensed propane installer.
• Two-stage regulation should be used by propane
installer.
• Propane gas piping should be check by propane installer.
Check Gas Supply
Gas pipe must be correct size for length of run and for
total BTU per hour input of all gas utilization equipment
connected to it. See Table 6 & 7, Page 20 for proper size.
Be sure your gas line complies with local codes and gas
company requirements.
DANGER
Fire Hazard. Do not use matches, candles, open
ames, or other methods providing ignition source.
Failure to comply will result in death or serious
injury.
!
Check Gas Piping
Pressure test boiler and gas connection before placing
boiler in operation.
• Pressure test over 1/2 psig (3.5 kPa). Disconnect
boiler and its individual gas shutoff valve from gas
supply system.
• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate
boiler from gas supply system by closing manual gas
shutoff valve. See Figures 5-6 Page 9.
• Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction.
• Correct leaks immediately and retest.
GAS SUPPLY PIPING
Figure 10 - Gas Piping At Boiler

20
GAS SUPPLY PIPING
*Outside diameter:
Measure length of pipe or tubing from gas meter or propane
second stage regulator.
Table 5 - NATURAL GAS
Length of
Pipe - Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
½" ¾" 1" 1¼"
20 92,000 190,000 350,000 625,000
40 63,000 130,000 245,000 445,000
60 50,000 105,000 195,000 365,000
Table 6 - PROPANE GAS
Length
of
Pipe - Ft.
Pipe Capacity - BTU Per Hour Input
Includes Fittings
Copper Tubing* Iron Pipe
⅝" ¾" ½" ¾"
20 131,000 216,000 189,000 393,000
40 90,000 145,000 129,000 267,000
60 72,000 121,000 103,000 217,000