ECR 075 97gb Instruction manual

An ISO 9001-2008 Certied Company
ECR International, Inc.
2201 Dwyer Ave
Utica, NY 13501
P/N # 240008282, REV J [03/2014]
CONDENSING
GAS BOILER
Models 075 & 100
WALL MOUNTED
GAS BOILER
INSTALLATION, OPERATION &
MAINTENANCE MANUAL

2
Description
Item No. Illustration
Fully Assembled Boiler 1
Metal Wall Bracket 2
Lag Bolt, 3/8" x 3" Hex (4 ea) 3
*Safety Relief Valve 4
3/4" Elbow 90° 5
3/4" Close Nipple 6
3/4" F x 3/4" M NPT Tee 7
3/4" x 1/4" NPT 90° Elbow 8
Air Vent 9
**Temperature Pressure Gauge 10
Bushing 3/4" x 1/4" 11
3/4" Tee (Same as No. 11) 12
Nipple 1¼ x 5½ 13
Drain Valve, 3/4" 14
3/4" Tee 15
Nipple 1¼ x 5½ 16
Bushing 7/8" OD, Heyco (2 ea) 17 Used for electrical wire knockouts.
Outdoor Sensor 18 Used for measuring outside temperature.
Stopper, Rubber 5/16" (2 ea) 17 Used for packaging holes on back of boiler.
Plastic Plug (2 ea) 18 Used for packaging holes on back of boiler.
Outdoor Sensor 19 Used for measuring outside temperature.
Document Package 20 Includes essential documents.
4
7
6
5
9
2
3
10
11
13
14
15
12
16
* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure greater
than 25 psig.
** Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system
pressure greater than 60 psig.
VERIFY CONTENTS RECEIVED
8

3
DIMENSIONS
FIGURE 1-1 Dimensions
Wall Hanging
Bracket
(D)
Gas
Connection
(G)
Supply Water
(E) Return Water
(E)
User Interface
(B)
(A)
Alternate
Return Water
(E)
Alternate
Supply Water
(E)
Alternate Gas
Connection
(F)
(C)
(B)
(F)
Table 1 : Physical Data
Size Width
(A)
Height
(B)
Depth
(C)
Bracket
(D)
Water Connections Gas
Connection
(G)
Condensate Drain Weight
Shipping Unit
Size
(E)
Height
(F) (H) (I)
075
/100
22-1/16"
(560mm)
35-5/8"
(905mm)
16-3/16"
(411mm)
27-1/2"
(969mm)
1-1/4"
NPT
31-1/16"
(789mm) 1/2" NPT 7-1/2" 5" 140 lb (63.5 kg)
115 lb
(51.2 kg)
Vent Connection Combustion Air
Floor
(D)
(H)
(I)
Condensate
Drain

4
1 - Introduction............................................................................................................................... 5
2 - Important Safety Information.................................................................................................... 6
3 - Component Listing ..................................................................................................................... 7
4 - Locating Boiler ......................................................................................................................... 11
5 - Hydronic Piping........................................................................................................................ 13
5.2 Special Conditions ................. .................................................................................................13
5.3 Safety Relief Valve And Air Vent.................................................................................................13
5.4 Trim Piping ............................................................................................................................ 14
5.5 System Piping........................................................................................................................ 14
6 - Combustion Air And Vent Piping............................................................................................... 19
6.2 Removal Of Existing Boiler From Common Vent System.................................................................19
6.3 Venting Materials ................................................................................................................... 19
6.4 Pipe Installation ..................................................................................................................... 20
6.5 Termination........................................................................................................................... 20
6.7 Venting Congurations ............................................................................................................ 21
6.8 SideVentingTerminalRequirements..............................................................................................26
6.9 Condensate Piping.................................................................................................................. 28
7 - Gas Supply Piping .................................................................................................................... 29
8 - Electrical Connections .............................................................................................................. 31
8.2 Line Voltage Connections......................................................................................................... 31
8.3 External Connections .............................................................................................................. 31
9 - Start Up Procedure................................................................................................................... 33
9.6 Perform Csd-1 Compliance Test..................................................................................................37
9.7 Complete Start Up Procedure..................................................................................................... 38
10 - Operating Instructions ........................................................................................................... 39
11 - General Maintenance And Cleaning ........................................................................................ 40
12 - Ratings And Capacities........................................................................................................... 43
13 - Trouble Shooting.................................................................................................................... 44
14 - Wiring Diagram ...................................................................................................................... 61
15 - Glossary ................................................................................................................................. 63
Appendix A - Control Module ������������������������������������������������������������������������������������������� 65
1.1 Introduction .......................................................................................................................... 65
1.2 Operation.............................................................................................................................. 65
1.3 Status Indication.................................................................................................................... 65
1.4 Sequence Of Operation ........................................................................................................... 66
1.5 User Menu............................................................................................................................. 68
TABLE OF CONTENTS

5
Information and specications outlined in this manual in effect at the
time of printing of this manual. ECR International reserves the right to
discontinue, change specications or system design at any time without
notice and without incurring any obligation, whatsoever.
Check our website frequently for updates: www.ecrinternational.com
1.1 Designated Use
• Hot water heating boiler.
• Indoor installation.
• Closet or alcove installation.
• Direct vent boiler.
• For use with natural gas or liqueed petroleum gases
(LP/propane).
1.2 The unit MUST NOT:
• Directly heat potable water. Indirect heating is acceptable.
• Heat water with non-hydronic heating system chemicals
present (example, swimming pool water).
• Exceed 150 psig (1.03 MPa) system pressure.
• Exceed 195°F (90.5°C) system design temperature.
1.3 Operational Features
• Modulating: 20-100%.
• Integral Dual Limit.
• Integral Low Water Cutoff (with test button).
• Outdoor Temperature Reset.
• Integral Multiple Boiler Control.
• Heat exchanger over heat protection.
1 - INTRODUCTION

6
NOTICE
Used to address practices not related to personal
injury.
2.3 Installation shall conform to requirements of
authority having jurisdiction or in absence of such
requirements:
• United States
• National Fuel Gas Code, ANSI Z223.1/NFPA 54 .
• National Electrical Code, NFPA 70.
• Canada
• Natural Gas and Propane Installation Code,
CAN/CSA B149.1.
• Canadian Electrical Code, Part I, Safety Standard
for Electrical Installations, CSA C22.1
2.4 Where required by authority having jurisdiction,
installation shall conform to Standard for Controls
and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD-1�
Additional manual reset low water cutoff may be required.
2.5 Requirements for Commonwealth of
Massachusetts:
Boiler installation must conform to Commonwealth of
Massachusetts code 248 CMR which includes but is not
limited to:
• Installation by licensed plumber or gas tter.
CAUTION
Indicates a hazardous situation which, if not avoided,
could result in minor or moderate injury.
!
WARNING
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury.
!
DANGER
Indicates a hazardous situation which, if not avoided,
WILL result in death or serious injury
!
This is the safety alert symbol. Symbol alerts you to
potential personal injury hazards. Obey all safety messages
following this symbol to avoid possible injury or death.
2.2 Become familiar with symbols identifying
potential hazards�
2.1 General
Boiler installation shall be completed by qualied agency.
See glossary for additional information.
WARNING
Fire, explosion, asphyxiation and electrical shock
hazard. Improper installation could result in death
or serious injury. Read this manual and understand
all requirements before beginning installation.
!
2 - IMPORTANT SAFETY INFORMATION

7
3.1 Component Listing
1. User Interface - Displays information regarding
boiler condition. Allows adjustment of boiler operating
parameters. NOTE: Does not replace thermostat used
to control central heating space.
2. Combustion Air Inlet (2" PVC) (see Section 6)
3. Return Water From Heating System (In) 1-1/4"
NPT - Connections supplied to connection top and/or
bottom of boiler. See Section 5.
4. Low Voltage Terminal Strip Connection of all low
voltage wiring, including thermostat. See section 8.
5. Igniter
6. Flame Sensor
7. Sight Glass Permits observation of burner ame.
8. Burner
9. Heat Exchanger
10. Condensate Collector
11. Return Water Temperature Sensor
12. Drain Valve
13. Heat Exchanger Ball Valve
14. Supply Water Outlet to Heating System (Out)
1-1/4"NPT Connections supplied for connecting from
either top or bottom of boiler. See section 5.
15. Vent Temperature Sensor
16. Condensate Drain) Boiler produces a liquid
(condensate) as a by-product of combustion. Condensate
must be piped to appropriate drain. See section 6.
17. Heat Exchanger Pump
18. Gas Shutoff Valve - Fuel supply isolation during
servicing. See section 7
19. Combustion Air Blower Delivers proper quantity of
combustion air, receives fuel from gas valve, mixes air
and fuel sending mixture to burner for combustion.
20. Gas (Control) Valve Delivers proper quantity of
fuel to Combustion Air Blower. See section 7.
21. Supply Water Temperature Sensor and High Limit
Switch
22. Low Water Cutoff Senses inadequate quantity of
water. Turns off boiler before damage can occur.
23. Safety Relief Valve Factory supplied, Field installed.
See section 5.
24. High Voltage Junction Box For connection of 120V
components. See section 8.
25. Vent Connector See section 6.
26. Gas Connection (See section 7.
27. Wall Hanging Support Bracket (see page 7) -
Integral to boiler. Allows optional wall mounting when
used with supplied wall mounting bracket. See section 4.
28. Auxiliary Power Outlet Convenience outlet for
condensate pump or service. Controlled by Service
Switch (29)
29. Service Switch
30. Air Vent
31. Central Heating Pump Circuit Breaker 5 amp
circuit breaker protects control module.
32. Boiler Control Module
33. Internal Access Panel (see page 9) - Gently pull
upward then forward to access control module.
Removable for access to internal components of boiler.
34. Central Heating Pump Relay (see page 9)
35. Transformer Supplies 24V power to low water cutoff.
36. Air Pressure Switch (not shown)
37. Test Port - (see page 8)
38. Combustion Analysis Test Port - (see page 8)
3 - COMPONENT LISTING

8
3 - COMPONENT LISTING
FIGURE 3-1 Boiler Components
(4) LOW VOLTAGE
TERMINAL
STRIP
(2) COMBUSTION
AIR INLET- 2" PVC (25) VENT
CONNECTOR - 2" PVC
(23)
SAFETY
RELIEF
VALVE
(30) AIR
VENT
(3) RETURN WATER
FROM HEATING
SYSTEM (IN)
(24) HIGH
VOLTAGE
JUNCTION BOX
(14) SUPPLY WATER TO
HEATING SYSTEM (OUT)
(26) GAS
CONNECTION
(29) SERVICE
SWITCH
(28) AUXILIARY
POWER OUTLET
(31) CENTRAL HEATING
PUMP CIRCUIT BREAKER
(27) BRACKET FOR
OPTIONAL WALL MOUNT
NOTE:
See Section 5-3
For Safety Relief
Valve Piping
Instructions

9
3 - COMPONENT LISTING
FIGURE 3-2 Boiler Components
(4) LOW
VOLTAGE
TERMINAL
STRIP
(24) HIGH VOLTAGE
JUNCTION BOX
(3) RETURN
WATER FROM
HEATING SYSTEM
(IN) 1-1/4" NPT
(5)
IGNITER
(7) SIGHT
GLASS
(13) HEAT
EXCHANGER
BALL VALVE
(16)
CONDENSATE
DRAIN 1/2" PVC
(18) GAS
SHUTOFF VALVE
(22) LOW
WATER CUTOFF
(19)
COMBUSTION
AIR
BLOWER
(9) HEAT
EXCHANGER
(20) GAS
(CONTROL)
VALVE
(1) USER INTERFACE
(3)
RETURN WATER
FROM HEATING
SYSTEM (IN)
1-1/4" NPT
(14) SUPPLY WATER
TO
HEATING SYSTEM
(OUT) 1-1/4" NPT
(13) HEAT
EXCHANGER PUMP
(10)
CONDENSATE
COLLECTOR
(12) DRAIN
VALVE
(6) FLAME
SENSOR
(SHOWN IN OPEN
POSITION)
(15) VENT
TEMPERATURE
SENSOR
(23) SAFETY
RELIEF VALVE
(25) VENT CONNECTOR
(2" PVC)
(21) HIGH
TEMPERATURE
SUPPLY SWITCH
(11) RETURN
TEMPERATURE
SENSOR
(38)
COMBUSTION
ANALYSIS TEST
PORT
(37)
PRESSURE
TEST PORT
NOTE:
See Section 5
For Piping
Instructions

10
3 - COMPONENT LISTING
(33) INTERNAL ACCESS
PANEL - CLOSED
(33) INTERNAL ACCESS
PANEL - OPEN
(32) CONTROL
MODULE
(34) CENTRAL HEATING
PUMP RELAY
(35)TRANSFORMER
Control Module
Fuse and holder
Note: To open
Lift panel up
then pull forward

11
TABLE 2: BOILER CLEARANCES
Dimension Combustible
Materials (1) Service(1)(2)
Top (A) 0" (0 cm) 14" (36 cm)
Left Side (B) 6" (16 cm) 6" (16 cm)
Right Side (C) 0" (0 cm) 1½" (4 cm)
Front (D) 0" (0 cm) 6" (16 cm)
Back (E) 0" (0 cm) 0" (0 cm)
Bottom (F) 0" (0 cm)
0" (0 cm) Floor
12" (32 cm) for
Bottom Piped
Combustion
Air/Vent piping
0" (0 cm) 6" (16 cm)
Hot Water
Piping
See local code 6" (16 cm)
(1) Required distances measured from boiler.
(2) Service, proper operation clearance recommendation.
4 - LOCATING BOILER
FLOOR FLOOR
A
E
E
D
B
FIGURE 4-1 Clearance to Combustible Materials
4.1 Boiler Location Considerations
• Ambient room temperature always above 32°F (0°C) to
prevent freezing of liquid condensate.
• Approved for installation in closets and on combustible
oors. Do not install boiler on carpeting.
• Protection of gas ignition system components from
water (dripping, spraying, rain, etc.) during operation
and service (circulator replacement, condensate trap,
control replacement, etc.).
• Floor or wall mounting.
• Wall must be plumb and capable of supporting boiler
weight plus 60 lbs (28 kg). See Table 1.
• Floor must be level. Leveling feet allow adjustment
up to 1/4" (6 mm).
• Wall mounting. See section 4.3.
• Access to outdoors to meet minimum and maximum
pipe lengths for combustion air and vent piping. See
section 6.
• Disposal of condensate. See section 6.
• Drainage of water (or water - antifreeze solution) during
boiler service or from safety relief valve discharge. See
section 5.
• Access to system water piping, gas supply, and electrical
service. See sections 5, 7 and 8.
• Clearances to combustible materials and service
clearances. See Table 2 and gure 4-1.
• Multiple Boilers can be placed side by side, back to back
or wall mounted.
B
AA
C
C

12
4 - LOCATING BOILER
FIGURE 4-2 Wall Mount Bracket Engaged with
Bracket on Boiler
4 Slots for attaching Wall
Mount Bracket to Studs
Center brackets. Avoid
overhang on sides of wall
mount bracket.
4.2 Pre-pipe supply and return water connections
with factory ttings before wall mounting.
4.3 Wall Mounting
Mount boiler on wall using wall mounting bracket included
with unit.
• Structure must be capable of supporting boiler weight
plus 60 lbs (28 kg). See Table 1, page 2.
• Wall mount bracket has 4 slots allowing mounting on
two (2) wall studs spaced at 11½" to 16½" on center.
See gure 4-2.
• Boiler includes (4) 3/8" x 3" lag screws and (4) washers
for attaching wall mount bracket to wood studs. Field
source appropriate fasteners for other wall constructions
(masonry, concrete).
• Attach wall mount bracket level on wall.
• Boiler must engage with wall mount bracket.
• Avoid overhang on sides of wall mount bracket. Verify
boiler bracket is centered on wall bracket. See gure
4-2.
WARNING
Fire, explosion hazard. Mount boiler vertically or
slightly tilted backward to insure proper function of
low water cutoff. Failure to follow these instructions
could result in death or serious injury.
• When mounting boiler onto wall insert two plastic
stoppers and two plastic plugs to packaging holes on
back of boiler.
• Mount boiler vertically or slightly tilted backward to
insure the low water cutoff functions properly. See
gure 4-3 for low water cutoff orientation.
!
CAUTION
Boiler weight exceeds 115 pounds (51.2 kg). Do
not lift boiler onto wall without assistance.
!
NOTICE
Lift boiler using chassis. Using front jacket, vent
piping, water or gas ttings to lift boiler may cause
damage to the boiler.
FIGURE 4-3 Low Water Cutoff Orientation
5° ~ 15°
Factory Default 10°

13
5.1 General
• Install piping in accordance with authority having jurisdiction.
NOTICE
Use two (2) wrenches when tightening and tting
to pipe boiler's threaded ttings. Boiler's internal
piping can be damaged if subjected to excessive
torque.
• Support system piping and safety relief valve discharge
piping. Boiler's internal piping and wall mount bracket can
be damaged if subjected to excessive weight.
• Size central heating pump (and domestic hot water pump,
if used) for system requirements only. Heat exchanger
pump compensates for pressure drop through boiler
internal piping and heat exchanger.
• Thoroughly clean and ush system before connecting to
boiler.
• If oil is present in system water, use approved detergent to
wash system.
• Flush system to remove any solid objects such as metal
chips, bers, or Teon tape, etc.
5.2 Special Conditions
• System piping exposed to freezing conditions: Use
inhibited proplyene glycol solutions certied by uid
manufacturer for use with closed water heating system.
Do not use automotive or ethylene glycol.
• Boiler installed above radiation level (or as required by
authority having jurisdiction). Integral low water cutoff
provided in boiler. See pages 7 & 9.
• Boiler used in connection with refrigeration system.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
• System piping connected to heating coils located in air
handling unit exposed to refrigerated air circulation. Install
ow control valves or other automatic means to prevent
gravity circulation of boiler water during cooling cycle.
5.3 Safety Relief Valve and Air Vent
NOTICE
Boiler rated at 150 psig (1.03 MPa) maximum
allowable working pressure. Boiler provided with
30 psig (206 kPa) safety relief valve. Field source
safety relief valve for system pressures greater than
25 psig. Temperature Pressure Gauge satisfactory
for 60 psig operation. Field source temperature
pressure gauge for system pressures greater than
60 psig.
• Install safety relief valve and air vent using pipe ttings
provided with boiler. See gure 5-1
• Install safety relief valve with spindle in vertical position.
• Do not install shutoff valve between boiler and safety
relief valve.
WARNING
• Poison hazard. Ethylene glycol is toxic. Do not
use ethylene glycol.
• Never use automotive or standard glycol antifreeze,
even ethylene glycol made for hydronic systems.
• Ethylene glycol can attack gaskets and seals used
in hydronic systems.
• Use only inhibited proplyene glycol solutions
certied by uid manufacturer as acceptable for
use with closed water heating system.
• Thoroughly clean and ush any system that used
glycol before installing new Boiler.
• Provide user with Material Safety Data Sheet
(MSDS) on uid used.
!
5 - HYDRONIC PIPING
NOTICE
Do not expose boiler and condensate piping to
freezing temperatures.
FIGURE 5-1 Safety Relief Valve & Air Vent
3/4" NPT
Close Nipple
3/4"F x 3/4"M
NPT Tee
3/4" x 1/4" NPT
90° Elbow
Air Vent
3/4 NPT
Safety Relief
Valve
3/4" NPT
90° Elbow

14
• Systems with automatic ll valves require back ow
prevention device.
• Install discharge piping from safety relief valve. See
gure 5-2.
• Use ¾" or larger pipe.
• Use pipe suitable for temperatures of 375°F (191°C)
or greater.
• Individual boiler discharge piping shall be independent
of other discharge piping.
• Size and arrange discharge piping to avoid reducing
safety relief valve relieving capacity below minimum
relief valve capacity stated on rating plate.
• Run pipe as short and straight as possible to location
protecting user from scalding and properly drain
piping.
• Install union, if used, close to safety relief valve outlet.
• Install elbow(s), if used, close to safety relief valve
outlet and downstream of union (if used).
• Terminate pipe with plain end (not threaded).
5.4 Trim Piping
• Supply and Return Piping
• Supply - Select either top, bottom or both.
• Return - Select either top, bottom, or both.
• Use second temperature pressure gauge when piping
top and bottom.
• Install brass plug(s) provided with boiler in unused
tapping(s). Use provided sealant.
• Temperature - Pressure Gauge. Install temperature
pressure gauge using nipple, bushing and tee provided
with boiler. See gure 5-3.
5.5 System Piping
• See Table 3 for basic system piping congurations.
• Systems with automatic ll valves require back ow
prevention device.
• Single boiler system. See gures 5-4, 5-5, 5-6, 5-7 for
general guidance. Additional considerations:
• Boiler control is designed for single central heating
pump. Installer responsible for integration of
multiple central heating pumps.
• Boiler control allows domestic hot water
prioritization. Function could be lost if central
heating pump not directly connected to control
system.
• Multiple boiler system. See gure 5-8 for general
guidance. Additional considerations:
• Control system requires equivalent water
temperatures entering each boiler to properly
sequence and adjust system supply temperature.
• Install multi boiler sensor kit. See "Parts, Kits &
Optional Accessories" manual for part number.
• Heating system with existing primary loop, close internal
primary loop ball valve.
• Heating system without existing primary loop, leave internal
primary loop ball valve open to use internal primary loop.
5 - HYDRONIC PIPING
FIGURE 5-3 Temperature Pressure Gauge Installation
To use this format set your tiff output to
Print capture, 150dpi, C -Landscape, Scale to fit
for best results
Temperature Pressure Gauge
shown at Optional Bottom
Supply Connection to Boiler
FIGURE 5-2 Safety Relief Valve Discharge Piping
Check Local Codes
For Maximum
Distance To Floor
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!

15
Piping Legend
FIGURE 5-4 System Piping
5 - HYDRONIC PIPING
NOTICE
Illustrations are meant to show system piping
concept only. Installer responsible for all equipment
and detailing required by authority having
jurisdiction.
System
Return
System
Supply
FLOOR
Table 3 - System Piping Congurations
Single Boiler
Two Pipe Zoned System With Zone Valves gure 5-5
With Zone Pumps gure 5-6
Primary/Secondary Pumping Closed External Primary Loop or gure 5-7
Open External Primary Loop gure 5-7
Multiple Boilers
Typical Mulitple Boiler Piping With Zone Valves gure 5-8
With Zone Pumps Not Shown
Primary/Secondary Pumping
Closed External Primary Loop Not Shown
Open External Primary Loop Not Shown
Pipe to
condensate
drain

16
5 - HYDRONIC PIPING
FIGURE 5-5 Single Boiler Two-Pipe Zoned System With Zone Valves
FIGURE 5-6 Single Boiler Two-Pipe Zoned System With Zone Pumps
Heat exchanger
ball valve open
(as shipped)
Heat exchanger
ball valve open
(as shipped)
DHW
Pump
CH/System
Pump
DHW
Pump
Zone
Pump
3/8"/9.5 mm
Open End
Wrench
3/8"/9.5 mm
Open End
Wrench
Heat exchanger ball
valve open

17
5 - HYDRONIC PIPING
FIGURE 5-7 Single Boiler Using Primary/Secondary Pumping With Closed External Primary Loop or Single
Boiler Using Primary/Secondary Pumping With Open External Primary Loop
12"/305mm Max. apart
12"/305mm
Max. apart
Limit length
to
5'/1.6 m
Existing closely
spaced tees
in primary
system loop
CH/System
Pump
Heat exchanger ball
valve open Heat exchanger
ball valves closed
3/8"/9.5 mm Open
End Wrench 3/8"/9.5 mm Open
End Wrench

18
5 - HYDRONIC PIPING
5-8 Typical Multiple Boiler Piping - (See Multiple Boiler Guide)
CH/
System
Pump 12"/305mm Max. apart
System
Temperature
Sensor Size common piping
according to
maximum heat
capacity of
entire system
Up to 16
boilers
All heat exchanger
ball valves closed
3/8"/9.5mm Open
End Wrench
DHW
Pump
(See Multiple Boiler Guide)

19
6.1 General
This boiler requires a dedicated direct vent system.
Install combustion air and vent piping in accordance
with these instructions, authority having jurisdiction,
and:
• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.
• Canada - Natural Gas and Propane Installation Code,
CAN/CSA B149.1
Vent connections serving appliances vented by natural draft
shall not be connected into any portion of mechanical draft
systems operating under positive pressure.
Install vent system in accordance with these instructions.
6.2 Removal of Existing Boiler From Common
Vent System
When existing boiler is removed from common venting
system, common venting system is likely to be too large for
proper venting of appliances remaining connected to it.
After removal of existing boiler, following steps shall
be followed with each appliance remaining connected to
common venting system placed in operation, while other
appliances remaining connected to common venting system
are not in operation:
• Seal any unused openings in common venting system.
• Visually inspect venting system for proper size and
horizontal pitch. Determine there is no blockage or
restrictions, leakage, corrosion and other deciencies
which could cause an unsafe condition.
• When practical, close all building doors, windows, and
all doors between space in which appliances remaining
connected to common venting system are located
and other spaces of building. Turn on clothes dryer
and any appliance not connected to common venting
system. Turn on exhaust fans, such as range hoods and
bathroom exhaust so they will operate at maximum
speed. Do not operate summer exhaust fan. Close
replace dampers.
• Turn on appliance being inspected. Follow lighting
instructions. Adjust thermostat so appliances will operate
continuously.
• Test for spillage at draft hood relief opening after 5
minutes of main burner operation. Use ame of match or
candle, smoke from cigarette, cigar or pipe.
• Determine each appliance remaining connected to
common venting system properly vents when tested
as outlined above. Then return doors, windows,
exhaust fans and any other gas-burning appliance to
their previous condition of use.
6 - COMBUSTION AIR AND VENT PIPING
• Any improper operation of common venting system
should be corrected so installation conforms with National
Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas
and Propane Installation Code, CAN/CSA B149.1.
When re-sizing any portion of common venting system,
common venting system should be re-sized to approach
minimum size as determined using appropriate tables in
Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/
NFPA 54 and/or Natural Gas and Propane Installation
Code, CAN/CSA B149.1.
6.3 Venting Materials
• See Table 4
WARNING
Use of cellular core PVC for venting ue gas could
result in death, serious injury.
!
Table 4 - Combustion air and vent pipe ttings
must conform with the following:
Item Material Standards
Vent Pipe
and Fittings
PVC schedule 40 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC schedule 40 ANSI/ASTM D1784/
F441
SDR-21 & SDR-26 PVC ANSI/ASTM D2241
ABS-DWV ANSI/ASTM D2661
Schedule 40ABS ANSI/ASTM F628
PP (Polypropylene)
Pipe and Components
UL 1738
ULC S636-08
Pipe
Cement/
Primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
Schedule 40 ABS ANSI/ASTM D2235
IPEX is approved vent manufacturer in Canada listed to
ULC-S636.
IPEX System 636 Cements and Primers are approved in
Canada listed to ULC-S636.
Use of cellular core PVC (ASTM F891), cellular core CPVC,
or Radel® , (Polyphenolsulfone) in venting systems shall
be prohibited.
WARNING
Covering non-metallic vent pipe and ttings with
thermal insulation shall be prohibited.
!

20
6 - COMBUSTION AIR AND VENT PIPING
WARNING
Vent extending through exterior wall shall not
terminate adjacent to wall or below building
extensions such as eaves, balconies, parapets or
decks. Failure to comply could result in death or
serious injury.
!
6.4 Pipe Installation
• Minimum and maximum combustion air and vent pipe
lengths listed in Table 5. Pipe length counted from
combustion air connector to termination.
• Install eld-sourced 2" to 3" transition, if used, in
vertical section at combustion air inlet and vent
connector.
• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows
equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no
equivalent length.
• Slope vent pipes minimum 1/4" per foot (21 mm/m)
back toward boiler. Support horizontal sections to
prevent sags capable of accumulating condensate.
• Support piping in accordance with pipe manufacturer's
instruction and authority having jurisdiction. In absence
of manufacturer's instruction use pipe hooks, pipe
straps, brackets, or hangers of adequate and strength
located at intervals of 4 ft (1.2m) or less. Allow for
expansion/contraction of pipe.
• Combustion air and vent piping must be air tight and
water tight.
• Certied vent system components must NOT be
interchanged with other vent systems or unlisted pipe/
ttings.
• Canadian installations only. All venting material, primer
and glue must be listed to ULC S636.
• Canadian installations only. First 3 ft (0.9 m) of
plastic vent pipe from vent connector must be readily
accessible for visual inspection.
6.5 Termination
• Terminate combustion air and vent pipes with ttings or
concentric vent kit.
• See "Parts, Kits and Optional Accessory" manual for
concentric vent kit part numbers.
• Use horizontal pipe for vent and 90° elbow for
combustion air termination when using ttings.
• Terminate combustion air and vent pipes in same
atmospheric pressure zone through exterior sidewall or
roof.
• Locate combustion air termination as far as possible from
swimming pool, swimming pool pump house, and other
sources of airborne chlorine.
• Locate combustion air and vent as required by authority
having jurisdiction.
Table 5 - Combustion Air and Vent Piping Length
Minimum/Maximum Vent Lengths
2” Pipe 3” Pipe
Model 075/100 075/100
Min. 6 ft.
(1.8 m)
6 ft.
(1.8 m)
Max. 50 ft.
(15.2 m)
100 ft.
(30.5 m)
Table 6 -Equivalent Length of Venting Components
Equivalent Length of Venting Components
Component Feet Meters
90° Elbow 5 1.6
45° Elbow 3 1/2 1.1
2" x 4" Adapter 0 0
3" x 4" Adapter 0 0
Concentric Vent Kit 5 1.6
Polypropylene Flexible Pipe per Foot 2 5/8 0.8