ECR International Pennco FSB II Series Instruction manual

FSB Series II
Gas-Fired Hot Water
Induced Draft Boilers
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
P/N 240009022 Rev. B [04/2012]
An ISO 9001-2008 Certified Company
Tested for 50 psi.
ASME Working
Pressure
C.S.A. Certified for
Natural gas or
Propane
Manufacturedby:
ECRInternational,Inc.
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com
Models
FSB-2
FSB-3
FSB-4
FSB-5
FSB-6
FSB-7

2
TABLE OF CONTENTS
Safety Symbols & Warnings
The following defined 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 flammable vapors
and liquids.
DO NOT obstruct air openings to the boiler room.
Modification, substitution or elimination of factory
equipped, supplied or specified components may
result in personal injury or loss of life.
TO THE OWNER - Installation and service of this
boiler must be performed by a qualified 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.
!
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

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
Vent Diameter (Inches)
To Chimney
(Category I)
Horizontal Vent
(Category III)
FSB-2 42.5 36 31 84.4 4 3
FSB-3 75.0 63 55 83.4 4 3
FSB-4 112.5 94 82 83.0 4 3
FSB-5 150.0 125 109 82.7 4 3
FSB-6 187.5 155 135 82.3 4 4
FSB-7 225.0 186 162 82.0 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 certified
field 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 Certified 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 floor. If installed on combustible floor, 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 orifice size. U.S.A. 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
(NFPA54/ANSI Z223.1), or manufacturer for correct orifice sizing information. High altitude orifices are available from
boiler manufacturer.

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

5
INSTALLATION PROCEDURE
WARNING
Improper installation, adjustment, alteration, service
or maintenance could result in death or serious
injury.
!
1. Installation must conform to requirements of authority
having jurisdiction or, in absence of such requirements,
to the National Fuel Gas Code, ANSI Z223.1/NFPA 54.
2. Where required by authority having jurisdiction,
installation must conform to the Standard for Controls
and Safety Devices for Automatically fired Boilers,
ANSI/ASME CSD-1.
3. Boiler series is classified as Category I. Vent
installation shall be in accordance with "Venting of
Equipment ," of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54, or applicable provisions of 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 fiberglass insulation can
clog burner ports and cause incomplete combustion and
sooting.
WARNING
Fire hazard. Do not install boiler on combustible
flooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
10. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
flooring 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.
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 floor. DO NOT INSTALL ON CARPETING.
Figure 1 - Minimum Clearances To Combustible
Construction
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
infiltration 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 ft3x Total Input [Mbh]
оKnown Air Infiltration Rate. See Table 3 for
space with boiler only. Use equation for multiple
appliances. Do not use an air infiltration rate
(ACH) greater than 0.60.
Volume ≥15 ft3/ACH x Total Input [Mbh]
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 in2per 4 Mbh of total
input rating of all appliances in enclosure.
Communicating through horizontal ducts.
Provide minimum free area of 1 in2per 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 specific air supply requirements for enclosure
or structure where boiler is installed, including air
supply openings and ducts.
Table 2 - Air Infiltration
Input Mbh Standard
Method
Known Air Infiltration 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
1. Refer to local codes and appropriate ASME Boiler
and Pressure Vessel Code for additional installation
requirements.
2. Install relief valve on 3/4” pipe nipple in tapped boiler
opening.
A. Pipe discharge line following guidelines in preceding
Warning. See Figure 2, Page 7.
B. Discharge line pipe size shall be equal or greater
than that of relief valve outlet over entire length
of discharge line with no intervening shutoff valve
between safety relief valve and discharge to
atmosphere.
C. Discharge line shall terminate with plain end to
atmosphere where any discharge will be clearly
visible and is at no risk of freezing.
D. Discharge line shall be independently supported to
avoid applied stress on relief valve.
E. Installation shall allow complete drainage of relief
valve and discharge line.
3. Install Drain Valve on lower left side of boiler as
marked.
4. Install Temperature and Pressure Gauge into ¼”
bushing threaded in tee furnished with supply piping.
See Figure 3 & 4.
5. Connect Supply and Return Lines to boiler. See Figures
3 and 4. Connections may require certain additional
fittings and parts.
INSTALLATION SYSTEM PIPING
WARNING
Burn or Scald Hazard. Discharge line shall be installed to relief valve outlet connection to avoid burns,
scalding, or water damage due to discharge of steam and/or hot water during operation.
Discharge line shall:
• connect to relief valve outlet and piped down to safe point of disposal. Check local codes for maximum
distance from floor or allowable safe point of discharge.
• be of pipe size equal to or greater than that of the relief valve outlet over the entire length of discharge
line;
• have no intervening shutoff valve between safety relief valve and discharge to atmosphere (do not plug or
place any obstruction in discharge line.
• terminate freely to atmosphere where any discharge will be clearly visible and at no risk of freezing;
• allow complete drainage of the valve and the discharge line;
• be independently supported and securely anchored to avoid applied stress on the relief valve;
• be as short and straight as possible;
• terminate with plain end (not threaded);
• be constructed of material suitable for exposure to temperatures of 375° F; or greater.
Refer to local codes and appropriate ANSI/ASME Boiler and Pressure Vessel Code, Section IV, or Boiler,
Pressure Vessel and Pressure Piping Code, CSA B51 for additional installation requirements.
!
Check local codes
for maximum
distance from
floor or other
allowable safe
point of discharge
RELIEF VALVE
DISCHARGE
PIPING
Figure 2 - Safety Relief Valve Discharge Piping

8
INSTALLATION SYSTEM PIPING
Figure 3 - Forced Hot Water Typical Piping
Figure 4 - Forced Hot Water Typical Piping
With Zone Control Valve

9
• Install radiation units (panels, radiators or cabinets) and
supply and return mains first 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 necessary, as is flushing of float type devices, per
manufacturers specific 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 flow 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 floor
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 .
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.
2. Boiler’s induced draft blower has 3” outlet. 3” X
4” increaser fitting is included in parts bag. Locate
increaser fitting on outlet of induced draft blower, and
secure gas-tight with bead of furnished silicone sealant.
Increaser fitting is required on this boiler for Category I
venting, and 4” is minimum permissible vent diameter.
This does not imply vent connector is intended to be 4”
diameter pipe. Vent connector shall be sized according
to appropriate venting tables in the National Fuel
Gas Code and may be required to be larger than 4”
diameter.
NOTICE
Boiler installation for chimney venting is not
complete unless increaser fitting is located and
secured.
3. These are high efficiency 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 flexible 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 flexible vent liner
D. Use certified 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 specific
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 flush with inside face of
chimney flue. 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 fireplace flue.
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 flexible liner must be
installed in accordance with instructions furnished with
vent. Maintain clearances as specified for vent pipe.
• Verify vent pipe is fire-stopped where it goes through
floor or ceiling. It should have approved vent cap with
clearances from roof. If clearances are less than shown,
have vent checked by local authorities. Figure 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

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 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 deficiencies
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 fireplace 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 flame 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, fireplace dampers and any
other gas-burning appliance to their previous conditions
of use.
7. Any improper operation of the common venting sys-
tem should be corrected so the installation conforms
with the National Fuel Gas Code, ANSI Z223.1/NFPA
54. When re-sizing any portion of the common venting
system, the common venting system should be re-sized
to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
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 Efficiency Boilers
(21mm/m)
(300mm)
(21mm/m)
(300mm)

14
1. Boilers may be vented horizontally as shown in
Figure 8, Page 13. Vent pipe is pitched down from
boiler to 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 fitting.
B. Minimum horizontal vent length for all vent
materials is 2 feet plus one 90° elbow plus
termination fitting.
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 fitting. 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, fitted with a minimum
1/4” mesh screen to keep out rodents and birds.
The elbow shall be of the same material and size
as vent pipe. The elbow exit should be at least 6”
away from exterior wall 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, 7 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. If the 90° elbow is the termination fitting of choice,
then the single wall pipe will be passing through
the side wall. For combustible walls, a UL listed
thimble shall be used where the single wall pipe
passes through the wall. 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 the pitch of the vent pipe, and
provide proper sealing. A thimble is not required
for single wall pipe passing through noncombustible
walls.
HORIZONTAL VENTING INSTRUCTIONS

15
D. The venting system shall terminate at least 3 feet
(0.9m) above any forced air inlet located within
10 feet (3m). The venting system shall terminate
at least 4 feet (1.2m) below, 4 feet (1.2m)
horizontally from, or 1 foot (300 mm) above any
door, window, or gravity air inlet into any building.
The bottom of the vent shall be located at least 12
inches (300mm) above grade. Termination of the
vent shall be not less than 7 feet (2.13m) above
adjacent public walkway. The vent terminal shall
not be installed closer than 3 feet (0.9m) from the
inside corner of an L shaped structure. Termination
of the vent should be kept at least 3 feet (0.9m)
away from vegetation. The venting system shall
terminate at least 4 feet horizontally from, and in
no case above or below, unless a 4 foot horizontal
distance is maintained, from electric meters, gas
meters, regulators, and relief equipment. See
Figure 9.
United States - Terminate vent system at least
4 feet (1.22m) horizontally from, and in no
case above or below, unless a 4 feet (1.22m)
horizontal distance is maintained, from electric
meters, gas meters, regulators and relief
equipment.
HORIZONTAL VENTING INSTRUCTIONS
Figure 9 - Horizontal Venting Clearances
A. The venting system shall terminate at least 4 feet
below any eave, soffit, or roof overhang.
B. The venting system shall not terminate underneath
any deck, patio, or similar structure.
C. Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to prevent
accidental contact with people or pets.
D. Terminate the vent above normal snow-line. Avoid
locations where snow may drift and block the vent.
Ice or snow may cause the boiler to shut down if
the vent becomes obstructed.
E. Under certain conditions, flue gas will condense,
forming moisture. In such cases, steps should be
taken to prevent building materials at the vent
terminal from being damaged by exhaust of flue
gas.

16
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. 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
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
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 fitting. When using
the Tjernlund VH-1 vent hood, the female end
(flared 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
fit over the outlet. After crimping is completed fol-
low the instructions for applying silicone sealant.
For 4” vent pipe runs, begin with a Saf-T-Vent 3”
to 4” increaser fitting 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 con-
necting 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 flow must be
in the direction indicated on the vent pipe. When
using the Tjernlund VH-1 vent hood, the female
end (flared 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 connect-
ing 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 finger or flat 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 flue 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 fitting 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
end of vent pipe going over the blower’s outlet.
When using the Tjernlund VH-1 vent hood,
the female end (flared end) of the vent pipe
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
hood’s connecting vent pipe. Now fill 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 flat 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 fluid 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
the vent pipe run with 3” FasNSeal vent pipe.
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 fitting, 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-
DUN-3. This adapter has no internal sealing gasket.
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 the locking
band, finish creating a complete seal by filling
the 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 the 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
fitting 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
fitting 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 fitting 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 flue gases to continuously condense
inside the vent pipe. Do not insulate the vent pipe. It
must be visible for monthly inspection. Insure that the
vent pipe is properly pitched away from the boiler, with
no low spots, so that condensate in the vent will drain
away from the boiler. An insulated enclosure or chase,
with access for inspection and servicing of the vent,
may be required to prevent freezing of liquid conden-
sate. Consult the vent pipe manufacturer’s instructions
for specific guidelines.
11. At beginning of each heating season and monthly
during the heating season, check all vent pipes and
vent terminal to make sure there are no obstructions.
Periodically clean the screen in the vent terminal.
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 specifically 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.
Confirm that installing a power venter is an option allowed
by local codes. Follow the specific 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, flue 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 flue
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 flue gas.
When installing single wall galvanized vent pipe for power
venting follow the specific 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, begin
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 fitting (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 fitting.
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 fire
department.
!
!
Table 4 - Supply Piping Size
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 National Fuel gas Code, ANSI Z223.1/
NFPA 54
• All pipe compound must be resistant to liquefied
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 floor. 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 Gas 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
flames, 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 Figure 5 & 6, Page 9.
• Locate leakage using gas detector, noncorrosive
detection fluid, 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