ECR GreenMountain GMGWB045FE User manual

An ISO 9001-2008 Certified Company
P/N# 240009305, Rev. C[07/2013]
GMGW
Cast Iron
Gas Fired Boilers
For Forced Hot Water
INSTALLATION, OPERATIONS AND MAINTENANCE
MANUAL
Manufactured by:
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
web site: www.ecrinternational.com
Models
GMGWB045FE GMGWB120FE
GMGWB070FE GMGWB145FE
GMGWB096FE GMGWB170FE
GMGWB195FE GMGWB245FE
GMGWB295FE
Tested For 100 psi
ASME
Working Pressure
C.S.A. Certied
For Natural Gas Or Propane

2
1 - Ratings & Data - Natural Gas & Propane Gas...........................................................4
2 - Dimensions .............................................................................................................5
3 - Installation Procedure ............................................................................................6
4 - Ventilation & Combustion Air ..................................................................................7
5 - Connecting Supply & Return Piping.........................................................................8
6 - Vent Installation ...................................................................................................14
7 - Vent System Modication......................................................................................14
8 - Vent Damper Installation & Instructions...............................................................15
9 - Connecting Gas Service .........................................................................................16
10 - Electrical Section.................................................................................................17
11 - Wiring Diagram ...................................................................................................20
12 - Lighting Instructions...........................................................................................22
13 - Normal Sequence Of Operation ...........................................................................23
14 - General Instructions ...........................................................................................24
15 - Checking Gas Input Rate To Boiler ......................................................................25
Appendix A - Control Module ..................................................................................... 26
A.1 Installation Environment Considerations ................................................................ 26
A.2 Electrical Connections ......................................................................................... 26
A.3 Adjusting Settings .............................................................................................. 26
A.4 Display ............................................................................................................. 26
A.5 Operation .......................................................................................................... 27
A.6 Boiler High Limit Temperature Controller................................................................ 28
A.8 Troubleshooting Error Codes ................................................................................ 28
A.9 Intermittent Pilot Ignition System Verification.........................................................29
TABLE OF CONTENTS

3
SAFETY MESSAGES
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
!
Safety Symbols & Warnings
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
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.
!

4
Table 1 - Ratings and Capacities
Model No.
Input
Mbh (1)
Heating
Capacity
Mbh (1)
Net AHRI
Rating Water
Mbh (2) **
AFUE Elect.
Ign.
No. Of
Burners
Recommended Air
Cushion Tank (3)
Water
Content
(Gals.)
GMGWB045FE 45 37 32 82.0% 1 15 2.4
GMGWB070FE 70 57 50 82.0% 2 15 4.0
GMGWB096FE 96 79 69 82.0% 2 30 4.0
GMGWB120FE 120 98 85 82.0% 3 30 5.6
GMGWB145FE 145 119 103 82.0% 3 30 5.6
GMGWB170FE 170 140 122 82.0% 4 30 7.2
GMGWB195FE 195 160 139 82.0% 4 30 7.2
GMGWB245FE 245 201 174 82.0% 5 30 8.8
GMGWB295FE 295 242 210 82.0% 6 60 10.4
1 - RATINGS & DATA - NATURAL GAS & PROPANE GAS
EXPLANATORY NOTES
-- All boilers are design certied for installation on noncombustible oor.
-- Recommended chimney height 20 feet. In special cases where conditions permit, chimney height may be
reduced to 10 feet. Refer to the latest revision of NFGC part 11.
-- Electric service to be 120 Volts, 15 Amps, 60 Hz.
-- The MEA number for the this boiler is 19-79-E.
(1) Input rating for sea level to 2,000 ft. (610m) above sea level.
United States, over 2000 ft (610m) above sea level. Reduce input rate 4% for every 1,000 ft (304m) above sea
level.
(2) Net AHRI Water Ratings shown based on piping and pickup allowance of 1.15. Consult manufacturer before selecting
boiler for installations having unusual piping and pickup requirements, such as intermittent system operation,
extensive piping systems, etc.
For forced hot water systems where boiler and all piping within area to be heated, boiler may be selected on basis of
its heating capacity.
(3) Tank sized for non-ferrous baseboard or radiant panel systems. Increase size for cast iron baseboard and
radiation.
STANDARD EQUIPMENT: Boiler Jacket, Cast Iron Boiler Battery, High Limit Control, Intermittent Electric Ignition Pilot
System, Vent Damper Relay, Circulator With Return Piping To Boiler, Main Gas Burners, Gas Control (Includes Automatic Gas
Valve, Gas Pressure Regulator, Intermittent Pilot, Safety Shutoff, Pilot Flow Adjustment, Pilot Filter), A.S.M.E. Relief Valve, Drain
Valve, Spill Switch, Rollout Switch, Combination Gas Control, Automatic Vent Damper. Not Shown Are: Wiring Harness,, Non-
linting Safety Pilot.

5
Table 2 - Dimensions
Model No. Natural Gas
Inlet*
Dimensions (Inches) Pump Size Supply &
Return Tappings
A B C D E F
GMGWB045FE ½" 11¼ 5⅝ 427⅛ 20
7
/
16
4
15
/
16
1¼"
GMGWB070FE ½" 15⅛ 7 5 28⅛ 20
15
/
16
4
15
/
16
1¼"
GMGWB096FE ½" 15⅛ 7 5 28⅛ 20
15
/
16
4
15
/
16
1¼"
GMGWB120FE ½" 19 9½ 6 29⅛ 21
7
/
16
5
7
/
16
1¼"
GMGWB145FE ½" 19 9½ 6 29⅛ 21
7
/
16
5
7
/
16
1¼"
GMGWB170FE ½" 22⅞ 11
3
/
16
730⅛ 21
15
/
16
5
15
/
16
1¼"
GMGWB195FE ½" 22⅞ 11
3
/
16
730⅛ 21
15
/
16
5
15
/
16
1¼"
GMGWB245FE ¾” 26¾ 13
6
/
16
831⅛ 22
7
/
16
6
15
/
16
1¼"
GMGWB295FE ¾” 30⅝ 15
5
/
16
932⅛ 22
15
/
16
8
15
/
16
1¼"
* Propane Gas Inlet (All Units) 1/2”
2 - DIMENSIONS
Dimensions

6
1 - Ratings & Data - Natural Gas & Propane Gas...........................................................4
2 - Dimensions .............................................................................................................5
3 - Installation Procedure ............................................................................................6
4 - Ventilation & Combustion Air ..................................................................................7
5 - Connecting Supply & Return Piping.........................................................................8
6 - Vent Installation ...................................................................................................14
7 - Vent System Modication......................................................................................14
8 - Vent Damper Installation & Instructions...............................................................15
9 - Connecting Gas Service .........................................................................................16
10 - Electrical Section.................................................................................................17
11 - Wiring Diagram ...................................................................................................18
12 - Lighting Instructions...........................................................................................20
13 - Normal Sequence Of Operation ...........................................................................21
14 - General Instructions ...........................................................................................21
15 - Checking Gas Input Rate To Boiler ......................................................................23
Appendix A - Control Module ..................................................................................... 24
A.1 Installation Environment Considerations ................................................................ 24
A.2 Electrical Connections ......................................................................................... 24
A.3 Adjusting Settings .............................................................................................. 24
A.4 Display ............................................................................................................. 24
A.5 Operation .......................................................................................................... 25
A.6 Boiler High Limit Temperature Controller................................................................ 26
A.8 Troubleshooting Error Codes ................................................................................ 26
A.9 Intermittent Pilot Ignition System Verication......................................................... 27
TABLE OF CONTENTS

7
SAFETY MESSAGES
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
!
Safety Symbols & Warnings
The following dened symbols are used throughout this
manual to notify the reader of potential hazards of varying
risk levels.
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.
!

8
3 - 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 red Boilers,
ANSI/ASME CSD-1.
3. Boiler series is classied 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. Boiler shall be installed 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. Allow 24 inches (610mm) at front and right side for
servicing and cleaning.
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.
WARNING
Fire hazard. Do not install boiler on combustible
ooring or carpeting. Failure to follow these
instructions could result in death or serious injury.
!
TOP ....................................18 IN. (457mm)
FRONT .........................................ALCOVE *
FLUE CONNECTOR ................. 6 IN. (152mm)
REAR....................................8 IN. (229mm)
CONTROL SIDE ................... ..9 IN. (76mm)
OTHER SIDE............................3 IN. (76mm)
HOT WATER PIPING ................. 2 IN. (51mm)
NOTE: Greater clearances for access should supersede fire
protection clearances.
* Denition of Alcove is three sided space with no wall in
front of boiler. ANSI standard for alcove is 18 inches from
front of appliance to leading edge of side walls as shown
below.
9. FOR INSTALLATION ON NON-COMBUSTIBLE
FLOORS ONLY - For installation on combustible
ooring special base must be used. (See Replacement
Parts Section.) Boiler can not be installed on
carpeting. Minimum clearances to combustible
construction are:
Minimum Clearances To Combustible
Construction (As Seen From Above)
3"
8"
BOILER
18"
9"
Control
Side
Front

9
Table 1 - Minimum Room Volume, Indoor Air Only*
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
45 2250 9450 4725 3150 2363 1890 1575
70 3500 14700 7350 4900 3675 2940 2450
96 4800 20160 10080 6720 5040 4032 3360
120 6000 25200 12600 8400 6300 5040 4200
145 7250 30450 15225 10150 7613 6090 5075
175 8750 36750 18375 12250 9188 7350 6125
195 9750 40950 20475 13650 10238 8190 6825
245 12250 51450 25725 17150 12863 10290 8575
295 14750 61950 30975 20650 15488 12390 10325
* Table values based on boiler only. Add volume for any additional appliances.
4 - 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
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 jurisdiction.
• 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.
A. Standard Method. Cannot be used if known air
inltration rate is less than 0.40 air changes per
hour. See Table 1 for space with boiler only. Use
equation for multiple appliances.
Volume ≥ 50 ft3x Total Input [Mbh]
B. Known Air Inltration Rate. See Table 1 for
space with boiler only. Use equation for multiple
appliances. Do not use an air inltration rate
(ACH) greater than 0.60.
Volume ≥ 21 ft3⁄ACH x Total Input [Mbh]
C. Refer to National Fuel Gas Code for opening
requirements between connected indoor spaces.
• All Outdoor Air. Provide permanent opening(s)
communicating directly or by ducts with outdoors.
A. Two Permanent Opening Method. Provide
opening commencing within 12 inches of top and
second opening commencing within 12 inches of
bottom of enclosure.
Direct communication with outdoors or
communicating through vertical ducts. Provide
minimum free area of 1 in² per 4 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.
B. One Permanent Opening Method. Provide
opening commencing within 12 inches of top of
enclosure. Provide minimum clearance of 1 inch on
sides/back and 6 inches on front of boiler (does not
supersede clearance to combustible materials).
C. 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.

10
Figure 1 - Safety Relief Valve
Check local codes
for maximum dis-
tance from oor or
allowable safe point
of discharge.
Discharge Line
Safety Relief Valve
5 - CONNECTING SUPPLY & RETURN 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 oor 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 (191°C); or greater.
Refer to local codes and appropriate ASME Boiler and Pressure Vessel Code for additional installation
requirements.
!

11
Hydronic Piping - General
• Install piping in accordance with authority having
jurisdiction.
• Support system piping and safety relief valve discharge
piping.
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). Install low water cutoff.
• Boiler used in connection with refrigeration system.
Install piping in parallel with boiler, with appropriate
valves to prevent chilled medium from entering boiler.
See Figure 2, Page Sec1:12.
• 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.
Safety Relief Valve
WARNING
Burn and scald hazard. Safety relief valve could
discharge steam or hot water during operation.
Install discharge piping per these instructions.
!
NOTICE
Boiler rated at 100 psig maximum allowable working
pressure. Boiler provided with 30 psig safety relief
valve. Field source safety relief valve for system
pressures greater than 30 psig. Temperature-
pressure gauge provided with boiler is satisfactory
for 30-50 psig operation. Replace temperature-
pressure gauge for system pressure over 50 psig.
Scale on dial must be graduated to not less than 1½
nor more than 3½ time safety relief valve pressure
settings.
• Do not install shutoff valve between boiler and safety
relief valve.
• Systems with automatic ll valves require back ow
prevention device.
• Install discharge piping from safety relief valve. See
Warning, Page 8.
• When boiler is connected to heating system utilizing
multiple zoned circulators, each circulator must be
supplied with ow control valve to prevent gravity
circulation.
• Hot water boilers and system must be lled with water
and maintained to minimum pressure of 12 psi.
• Bypass piping is an option which gives ability to adjust
the supply boiler water temperature to t the system or
condition of installation. This method of piping, however,
is not typically required for baseboard heating systems.
Typical installations where bypass piping is used are as
follows:
A. This method is used to protect boilers from
condensation forming due to low temperature
return water. Generally noticed in large converted
gravity systems or other large water volume
systems. Figures 3 & 4, Page 11.
B. These methods are used to protect systems using
radiant panels and the material they are encased
in from high temperature supply water from the
boiler and protect boiler from condensation.
NOTE#1: When using bypass piping, adjust valves V1 & V2
until desired system temperature is obtained.
NOTE#2: Bypass loop must be same size piping as the
supply and return piping.
• Installation using circulators and zone valves are shown
in Figures 3-8 . For further piping information refer to
AHRI Installation and Piping Guide.
• For zone controls and indirect hot water, refer to
appropriate manufacturer instructions.
5 - CONNECTING SUPPLY & RETURN PIPING

12
5 - CONNECTING SUPPLY AND RETURN PIPING
EXPANSION
TANK
CHECK
VALVE
B
D
FEED
WATER
C
RETURN PIPING
FROM HEATING
AND COOLING
ELEMENT
WATER
CHILLER
SUPPLY PIPING
TO HEATING
AND COOLING
ELEMENT
CIRCULATOR
A
PRESSURE
REDUCING
VALVE
PROPER
BACKFLOW
PROTECTION
DEVICE
GATE
VALVE
PURGE
VALVE
NOTICE
Circulators in following illustrations are mounted on
system supply side, mounting on system return side
is also acceptable practice.
Figure 2 - Circulators Mounted on Supply System, Boiler Used In Conguration to Chiller System.
See Special Conditions, Page 9

13
BOILER ALTERNATE
CIRCULATOR
LOCATION
TO SYSTEM FROM SYSTEM
V2V1
CIRCULATOR
SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE AIR SEPARATOR
ZONE VALVE
EXPANSION
TANK
WATER INLET
SYSTEM
CIRCULATOR
Figure 4 - Bypass Piping - Fixed Low Temp Only, See Bypass Piping Options, Page 9
5 - CONNECTING SUPPLY AND RETURN PIPING
Figure 3 - Bypass Piping -Automatic Mixing Valve, See Bypass Piping Options, Page 9
BOILER
WATER INLET
ALTERNATE
CIRCULATOR
LOCATION
TO SYSTEM FROM SYSTEM
CIRCULATOR
SHUT-OFF
VALVE
PRESSURE
REDUCER VALVE
CHECK VALVE
BALL VALVE
3 WAY MIXING
VALVE
AIR SEPARATOR
HOSE BIB
EXPANSION
TANK
Note: Bypass
connection not showing
primary/secondary
piping
Note: Bypass
connection not showing
primary/secondary
piping

14
5 - CONNECTING SUPPLY AND RETURN PIPING
Figure 5 - Single Zone System With DHW Priority
Figure 6 - Multi-Zone System with Circulators and DHW Priority

15
5 - CONNECTING SUPPLY AND RETURN PIPING
Figure 7 - Multi-zone System With Zone Valves And DHW Priority (With Circulator)
Figure 8 - Multi-zone System With Zone Valves And DHW Priority (With Zone Valve)

16
When existing boiler is removed from a common venting
system, the system is likely to be too large for the proper
venting of the appliances still connected to it.
Removal Of Boiler From Venting System
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 appliances remaining connected
to the common venting system are not in operation.
1. Seal any unused opening 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 other appliance not
connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they 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.
5. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the 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 a common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, replace dampers and
any other gas burning appliances to their previous
condition 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.
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.
1. Vent pipe must slope upward from boiler not less then
¼ inch per 1 foot to the vent terminal.
2. Horizontal portions of venting system shall be
supported rigidly every 5 feet and at elbows. No portion
of vent pipe should have any dips or sags.
3. This boiler series is classied 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 the local
building codes.
4. Vent connectors serving appliances vented by natural
draft shall not be connected into any portion of
mechanical draft systems operating under positive
pressure.
5. Connect ue pipe from draft hood to chimney. Bolt or
screw joints together to avoid sags. Flue pipe should
not extend beyond inside wall of chimney. Do not
install manual damper in ue pipe or reduce size of
ue outlet except as provided by the latest revision
of ANSI Z223.1. Protect combustible ceiling and walls
near ue pipe with reproof insulation. Where two or
more appliances vent into a common ue, the area of
the common ue must be at least equal to the area
of the largest ue plus 50 percent of the area of each
additional ue.
6 - VENT INSTALLATION
7 - VENT SYSTEM MODIFICATION
WARNING
Boiler and venting installations shall be performed
by a qualied expert and in accordance with the
appropriate manual. Installing or venting boiler
or other gas appliance with improper methods or
materials may result in serious injury or death due
to re or to asphyxiation from poisonous gases such
as carbon monoxide with is odorless and invisible.
!
WARNING
Do not connect boiler to any portion of mechanical
draft system operating under positive pressure.
!

17
REFER TO DAMPER MANUFACTURER'S
INSTALLATION INSTRUCTIONS FOR
POSITION OF DAMPER
CONTROL BOX
ACCEPTABLE VENT
DAMPER LOCATIONS
BOILER
HOT WATER HEATER
CHIMNEY
UN-ACCEPTABLE
DAMPER LOCATIONS
1. Verify only boiler is serviced by vent damper. See
Figure 10 .
2. Clearance of not less than 6 inches between vent
damper and combustible material must be maintained.
Additional clearance should be allowed for service of
Vent Damper.
3. Vent damper must be in open position when appliance
main burners are operating.
4. Vent damper position indicator must be in visible
location following installation.
5. Thermostat's heat anticipator must be adjusted to
match total current draw of all controls associated with
boiler during heating cycle.
8 - VENT DAMPER INSTALLATION & INSTRUCTIONS
Figure 9 - Damper Installation Figure 10 - Damper Location
NOTE: Refer to Figure 9 for steps 1-6.
1. Place Vent Damper on or as close to vent outlet of
boiler as possible. Do not modify draft hood or vent
damper during installation.
2. Remove Vent Damper Motor cover.
3. Feed damper wire harness connector through bracket
hole on damper motor frame.
4. Tighten locknut onto Damper wire harness connector.
5. Plug Damper connector into socket on damper motor
frame.
6. Replace damper motor cover and wire damper as.

18
9 - CONNECTING GAS SERVICE
Figure 11 - Drip Leg
Maximum Capacity Of Pipe In Cubic Feet Of Gas/Hour
(Gas Pressure = 0.5 psig or less, Pressure Drop = 5 in.
w/c)
Table 2 - Gas Piping
Length of
Pipe (Feet)
Nominal Iron Pipe Size
½” ¾” 1” 1¼”
10 175 360 680 1400
20 120 250 465 950
30 97 200 375 770
40 82 170 320 660
60 66 138 260 530
80 57 118 220 460
100 50 103 195 400
For additional information refer to the National Fuel Gas
Code Handbook.
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.
!General
•Use piping materials and joining methods acceptable
to authority having jurisdiction. In absence of such
requirements of National Fuel gas Code, ANSI Z223.1/
NFPA 54
• Size and install gas piping system to provide sufcient
gas supply to meet maximum input at not less than
minimum supply pressure. See Table 3.
•Support piping with hooks straps, bands, brackets,
hangers, or building structure components to prevent or
dampen excessive vibrations and prevent strain on gas
connection. Boiler will not support piping weight.
•Use thread (joint) compound (pipe dope) suitable for
liqueed petroleum gas.
• Install eld sourced manual main shutoff valve, ground
joint union, and sediment trap upstream of gas valve.
See Figure 11.
Table 3 - Gas Pressure
Natural Gas Propane
Min. Supply Pressure 5" w.c. 11" w.c.
Max. Supply Pressure 13.5" w.c. 13.5" w.c.
Manifold Pressure 3.5" w.c. 10.5" w.c.
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.
!
Leak 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.
• Locate leakage using gas detector, noncorrosive
detection uid, or other leak detection method
acceptable to authority having jurisdiction. Do not
use matches, candles, open ames, or other methods
providing ignition source.
• Correct leaks immediately and retest.

19
10 - ELECTRICAL SECTION
WARNING
Electrical shock hazard. Turn OFF electrical power
supply at service panel before making electrical
connections. Failure to do so could result in death
or serious injury.
!
Electrical Wiring
See wiring diagrams on the following two pages for
details.
Electrically bond boiler to ground in accordance with
requirements of authority having jurisdiction. Refer to
National Electrical Code, ANSI/NFPA 70.
Thermostat Installation
1. Install thermostat on inside wall about four feet above
oor.
2. NEVER install thermostat on outside wall.
3. Do not install a thermostat where it will be affected
by drafts, hot or cold pipes, sunlight, lighting xtures,
televisions, a replace, or a chimney.
4. Check thermostat operation by raising and lowering
thermostat setting as required to start and stop
burners.
5. Instructions for nal adjustment of thermostat
are packaged with thermostat (adjusting heating
anticipator, calibration, etc.)

20
11 - WIRING DIAGRAM
I
Figure 12 - Integrated High Limit & Electronic Ignition Control (240008781)
WARNING
result in personal injury or loss of life.
!