Kenmore K90-150 User manual

Gas-FiredDirectVent
Condensing
HOTWATERBOILER
• Installation
•Operation
•Maintenance
WARNING: Improper installation, adjustment, alteration, service
or maintenancecan cause injury or property damage.Refer to this
manual. For assistance or information consult a qualified installer,
service agency or thegas supplier.

INSTALLATION MANUALAND OPERATING INSTRUCTIONS
PIN# 240004826K, Rev. 1.1 [08/05] • Printed in USA • Made In USA
I. Introduction ........................................................ 2
I1.Safety Symbols ................................................ 2
Ill. Rules For Safe Installation and Operation ......... 3
IV. Boiler Ratings and Capacities ......................... 4
V. Before Installing The Boiler .............................. 5
VI. Placing The Boiler ........................................... 9
VII. Near Boiler Piping .......................................... 9
VIII. Combustion Air and Vent Pipe .................... 11
IX. Gas Supply Piping ........................................ 13
X. Electrical Wiring ............................................. 15
XI. Controls and Accessories ............................. 17
XII. Startup ......................................................... 19
XIII. Checkout Procedures and Adjustments ........ 22
XIV. Maintenance and Cleaning ......................... 25
XV. Detailed Sequence of Operation .................. 27
XVI. Troubleshooting .......................................... 32
XVII. Installation and Checkout Certificate ......... 39
forces the resulting flue gases from the boiler unit
and provides a positive removal of the flue gases
from the building through inexpensive and readily
available PVC and CPVC vent pipes.
The following defined symbols are used throughout
this manual to notify the reader of potential hazards
of varying risk levels.
KEEP THIS MANUAL NEAR BOILER AND
RETAIN FOR FUTURE REFERENCE.
_WARNING
IA CAUT,O.A I
This appliance is a gas-fired direct vent cast
aluminum hot water boiler. A revolutionary cast
aluminum heat exchanger means better heat
transfer and thermal storage than similarly sized
cast iron boilers, which results in higher efficiency.
The heating system water absorbs large amounts
of heat from the cast aluminum heat exchanger,
cooling the flue gases and causing condensation.
Sealed combustion, premix gas burner, and low
flame temperature means drastically reduced CO
and NOx emissions, which contribute to a cleaner
and healthier environment.
Indicates a potential hazardous situation
which, if not avoided, MAY result in minor or
moderate injury. It may also be used to alert
against unsafe practices. ,,
/cMPORTANT: Read the following instructions_
OMPLETELY before installing!!
This appliance, unlike normal residential atmospheric
and induced draft units, takes its combustion air
directly from the outdoors (sealed combustion) and
does not compete with building occupants for fresh
air. Sealed combustion (also known as "direct vent")
is the safest and best way to obtain plenty of clean
combustion air. The forced draft fan draws in the
outside combustion air to mix with gas, which flows
into the pre-mix burner and combusts. The fan then

_WARNING
O_Pt'NING FOR AIR YENT
OPENING FOR REIJI_ VALVE AND EXPANSION TANK
OISCHARG£ PIPE _CONNECTIOH STANDARD
SUPPLY _RL'TURNOFTNINGS
114 NPT CONNECTIONS
JU_1_q 80X FOR 120V._ --__BIN_.
i\
_'-- "'-_ C:::::l
S '1/4
_tl/'
(2"C_C)
C_ DRAIN'
_NG (1/2"
fIMPORTANT: Failure to follow these _nstructions
could cause a malfunction of the boiler and result
in death, serious bodily injury, and/or property
damage.
For assistance or additional information, consult
a qualified installer, service agency, or the gas
supplier, t
1. Check all applicable state and local building
codes and utility company requirements before
installation. This installation must conform with
these requirements in theirentirety. Inthe absence
of these codes, use NFPA installation codes and
good industry practice.
2. Before servicing the boiler, allow it to cool.
Always shut off any electricity and gas supply
connected to the boiler prior to servicing.
3. Inspect gas line for leaks.
VENTCONN(CTI0_(2" c_wc)-
----"'______
may result in too much air for the pre-mix bumer
causing poor or loss of combustion•
5. Never vent the products of combustion from
this boiler to an enclosed space. Always vent to
the outdoors. Never vent to another room or to
inside a building.
6. Be sure there is adequate outdoor air supply
to boiler for complete combustion.
7. Follow a regular service and maintenance
schedule for efficient and safe operation.
8. Keep boiler area clean of debris and free of
combustible and flammable materials.
9. Proper through-the-wall or through-the-roof
combustion venting shall be in accordance with the
materials and methods described in this manual•
Installation must comply with local codes.
4. Be certain gas input rate is correct. Overfiring
may result in early failure of the boilercomponents.
This may cause dangerous operation. Underfiring
10. This boiler and related hot water heating
systems are not do-it-yourself items. They must be
installed and serviced by qualified professionals.

112.5 98
135 117
157.5 137
200 180 157
c_)1MBH = 1,000Btuh(British ThermalUnits PerHour)
M
284 90
284 90
284 90
284 90
2" CPVC & 3" PVC
2" CPVC & 3" PVC
2" CPVC & 3" PVC
2" CPVC & 3" PVC
(2)AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on Department of Energytest procedure.
Ratings shown are for sea level applications. The boiler automatically derates input as altitude increases.
No alterations to boiler are required for altitudes above sea level.
Altitude
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
Vent Lengths
200,000 200,000
197,000 196,500
194,000 193,000
191,000 189,500
188,000 186,000
185,000 182,500
182,000 179,000
179,000 175,500
176,000 172,000
173,000 168,500
170,0001 165,000
Vent Lengths
175,000 175,000
172,400 172,200
169,800 169,400
167,200 i 166,600
164,6001 163,800
162,000 161,000
159,400 158,200
156,800 155,40C
154,200 152,600
151,600 149,800
149,000 147,000
Vent Lengths
150,000 150,000
147,800 147,400
145,600 144,800
143,400 142,200
141,2001 139,600
139,000 137,000
136,800 134,400
134,600 131,800
132,400 129,200
130,200 126,600
128,000 124,000
Vent
125,000
123,500
122,000
120,500
119,000
117,500
114,500
113,000
111,500
110,000
125,000
123,000
121,000
119,000
117,000
115,000
113,000
111,000
109,000
107,000
105,000
Altitude
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
9,000
10,000
200,000
195,900
191,800
187,700
183,600
179,500
175,400
171,300
167,200
163,100
159,000
200,000
195,750
191,500
187,250
183,000
178,750
174,500
170,250
166,000
161,750i
157,500
175,000
171,900
168,800
165,700
162,600
159,500
156,400
153,300
150,200
147,100
144,000
175,000
171,200
167,400
163,600
159,800
156,000
152,200
148,400
144,600
140,800
137,000
150,000
146,900
143,800
140,700
137,600
134,500
131,400
128,300
125,200
122,100
119,000
150,000
146,700
143,400
140,100
136,800
133,500
130,200
126,900
123,600
120,300
117,000
125,000
123,050
121,100
119,150
117,200
115,250
113,300
111,350
109,400
107,450
105,500
125,000
122,250
119,500
116,750
114,000
111,250
108,500
105,750
103,000
100,250
97,500

These low pressure gas-fired hot water boilers are design certified by CSA International, for use with
natural and propane gases. The boilers are constructed and hydrostatically tested for a maximum work-
ing pressure of 50 psig (pounds per square inch gauge) in accordance with A.S.M.E. (American Society
of Mechanical Engineers) Boiler and Pressure Vessel Code, Section IV Standards for heating boilers.
The Boilers are certified in accordance with ANSI (American National Standards Institute) Z21.13
standards as gas-fired, direct vent, condensing, hot water boilers.
The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small portion is heat loss from the jacket and surfaces of
the boiler, and it is assumed that this heat stays in the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied to heat the radiation or terminal units (i.e. finned tube
baseboard, cast iron radiators, radiant floor, etc.). The difference between the Heating Capacity and the
Net I=B=R Rating, called the piping and pickup allowance, establishes a reserve for heating the volume
of water in the system and offsetting heat losses from the piping. The Net I=B=R Ratings shown are
based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as published by the
Hydronics Institute. The Net t=B=R Rating of the boiler selected should be greater than or equal to the
calculated peak heating load (heat toss) for the building or area(s) served by the boiler and associated hot
water heating systems. The manufacturer should be consulted before selecting a boiler for installations
having unusual piping and pickup requirements.
Complete all of _e following prior to installing the boiler.
This boiler product is a gas-fired, direct vent, con-
densing boiler and must be installed in accordance
with all applicable federal, state and local building
codes including, but not limited to the following:
United States -Installation shall conform
with National Fuel Gas Code (NFPA-54/ANSI
Z223.1 - latest revision)
Canada - Installation shall be in accordance
with CSA-B149.1 and .2 installation codes.
• Check to be sure you have selected the boiler
with the proper capacity before continuing the in-
stallation. The I=B=R Rating of the boiler selected
should be greater than or equal to the calculated
peak heating load (heat loss) for the building or
area(s) served by the boiler and associated hot
water heating systems. See Section IV, "Boiler
Ratings and Capacities, "for more information.
• Heat loss calculations should be based on
approved industry methods.
Where required by the authority having jurisdiction,
the installation must conform to the American Soci-
ety of Mechanical Engineers Safety Code for Con-
trols and Safety Devices for Automatically Fired
Boilers, No.CSD-I.
The installation must conform to the requirements
of the authority having jurisdiction or, in the ab-
sence of such requirements, to the National Fuel
Gas Code, ANSI Z223.1 - latest revision.
Installers- Follow local regulations with re-
spect to installation of CO (Carbon Monox-
ide) Detectors. Follow maintenance recom-
mendations in this manual.
Before selecting a location for the boiler, the follow-
ing should be considered. Each boiler considered
for installation must be:
•Supplied with the correct type of gas (natural
gas or propane).
•Connected to a suitable combustion air intake pip-
ing system to supply the correct amounts of fresh
(outdoor) air for combus_on (max. leng_ 60').
• Connected to a suitable venting system to re-
move the hazardous products of gas combus-
tion (max. length 60').

• Connectedto a suitable hot water heating
system.
• Suppliedwith a suitableelectricalsupplyfor
allboilermotorsandcontrols.
• Connectedto a properlylocatedthermostat
oroperatingcontrol.(notincludedwithboiler)
• Placedon level surface (mustNOT be in-
stalledon carpeting)
• Condensatedrainline must be pitched down
to floor drain or external condensate pump with
reservoir at ¼"per foot (wood frame or blocks
may be used to raise boiler).
1. Select a location which is level, central to the
piping systems served and as close to the vent
and air intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e.
larger clearances) than required fire protection
clearances, must be used for the boiler installa-
tion. Accessibility clearances may be achieved
with the use of removable walls or partitions.
3. The boiler is approved for installation in clos-
ets and on combustible floors. This boiler shall
NOT be installed on carpeting.
the front where passage is required for cleaning or
servicing, inspection or replacement of any parts
that normally may require such attention. Allow at
least 24" at the front and left side and 8" at the top
for servicing. No combustible clearances are re-
quired to venting or combustion air intake piping.
5. Equipment shall be installed in a location
which facilitates the operation of venting and
combustion air intake piping systems as de-
scribed in this manual.
6. Advise owner of boiler to keep venting and
combustion air intake passages free of obstruc-
tions. Both the venting and combustion air intake
piping systems connected to the outdoors must
permit flow through the piping systems without
restrictions for the boiler to operate.
7. The boiler shall be installed such that the
automatic gas ignition system components are
protected from water (dripping, spraying, rain,
etc.) during operation and service (circulator re-
placement, control replacement, etc.).
8. The boiler must be located where ambient
temperatures (minimum possible room temper-
atures where boiler is installed assuming boiler
is not in operation and therefore contributes no
heat to the space) are always at or above 32°F
to prevent freezing of liquid condensate.
Top 1" 8"
Left Side 8" 24"
Right Side 1"
Base 1"
Front 0" 24"
Back 1"
IntakeNent 0"
Piping
_lear Boiler Hot 1"
Water Piping
All distances measured from the cabinetof the boiler.
4. The clearances shown in Table 4 indicate re-
quired clearances per CSA listing. A min. 1" clear-
ance must be maintained between combustible
construction and each of the right, top and back
surfaces of the boiler. A min. 8" clearance is re-
quired on the left side, to allow room for the inlet
air pipe. An 18" clearance must be maintained at
This boiler requires a dedicated direct vent system.
In a direct vent system, all air for combustion is
taken directly from outside atmosphere, and all flue
products are discharged to outside atmosphere.
ROOF VENT/INTAKE TERMINATIONS
iFigure 1 ]
Combustion air and vent pipe connections must
terminate together in the same atmospheric pres-
sure zone, either through the roof or sidewall (roof
termination preferred). See Figures 1 and 2 for re-
quired clearances.

CONCENTRIC VENT ROOF INSTALLATION
, AIIOv_E_6NEST
3" Dia. PVC Vent/Exhaust !
-
! _1 46%" I,-
n 3" Dia. PVC Intake/Combustion Air
[ Figure 5 ]
remaining connected to it. At the time of removal of
an existing boiler, the following steps shall be fol-
lowed 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 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 or
other deficiencies which could cause an unsafe
condition.
3. When it 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 oth-
er spaces of the building. Turn on clothes dryer
and any appliance not connected to the common
venting system. Turn on any exhaust fans, such
as range hoods and bathroom exhaust, so they
will operate at maximum speed. Do not operate
a summer exhaust fan. Close fire dampers.
4. Place in operation the appliance being in-
spected. Follow the lighting instructions. Adjust
thermostat so appliances will operate continu-
ously.
5. Test for spillage at the draft hood relief open-
ing after 5 minutes of main burner operation. Use
the flame of a match or candle, or the smoke
from a cigarette, cigar or pipe.
Boiler must be placed on level surface. Boiler is
NOT to be installed on carpeting.
NOTES
1. Ifboiler is not level condensate drain lines will not function
properly, Adjustable feet are located on the boiler to make
up for minor surface irregularities or tilt,
2. Wood frame of blocks may be used to raise boiler to maintain
_drain pitch or to be above extemal condensate pump reservoir.J
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
6. After it has been determined that each ap-
pliance remaining connected to the common
venting system properly vents when tested as
outlined above, return doors, windows, exhaust
fans and any other gas-burning appliance to their
previous condition of use.
7. Any improper operation of the common vent-
ing system should be corrected so the installation
conforms with the National Fuel Code, NFPA-
54/ANSI -Z223.1-1atest revision, or section 5 of
CSA-B149 for Canadian standards. When resiz-
ing any portion of the common venting system,
the common venting system should be resized to
approach the minimum size as determined using
the appropriate tables in part 11 in the National
Fuel Gas Code, NFPA-54/ANSI- Z223.1-1atest
revision, or section 5 of CSA-B149 for Canadian
standards.

Theboiler should be placed to providethe most
directconnectionsto the combustionair,ventand
systempipingaspossible.
Placecrated boiler as close to selectedlocation
aspossibleanduncrateboiler.Theuncratedboiler
maybemovedinto positionwithan appliancedol-
ly or 2-wheelhandtruck.The dolly or handtruck
shouldbe insertedunderthe right hand side of
theboiler.Itispossibletoslidetheboilerforashort
distanceonasmoothfloororsurface.
NuOTE: Refer to "Locating The Boiler" in Section V for re-_
ired clearances for servicing and maintenance. J
fiA cAo.,-,o,AI
Copper supply and return piping must NOT be in-
stalled directly into aluminum boiler section castings
due to galvanic corrosion between dissimilar met-
als. Iron or steel bushings or pipe nipples should
be used between copper system piping and boiler
to make final connection to boiler. Also, the use of
dielectric unions is acceptable. The packaged boiler
is furnished with iron piping in the front boiler sec-
tion for the supply and return connections.
When the installation of the boiler is for a new heat-
ing system, first install all of the radiation units (pan-
els, radiators, baseboard, or tubing) and the supply
and return mains. After all heating system piping and
components have been installed, make final con-
nection of the system piping to the boiler.
Ahot water boiler installed above radiation level must
be equipped with a low water cut off device (included
with boiler). A periodic inspection is necessary, as is
flushing of float type devices, per low water cut off
manufacturers specific instructions.
DIAPHRAGM TYPE EXPANSION TANK PIPING
E_C_ T_f_ _VICE VAL_
--(_,_n[ VALOIS C_ FULL
PORT B_ VAL'_
_J TO_ATIC _R
V_. _/'_"X'/8"_F_t_i_O_J_'_i_°iN
.... ?ST _°_1_4 FC_ F_ WA_R
Figure 6 ]
Determine required system fill pressure, system de-
sign temperature, and system water content. Boiler
contains 2.6 gallons (U.S.). Size expansion tank ac-
cordingly. Consult expansion tank manufacturer for
proper sizing information. Connect properly sized
expansion tank (not furnished) as shown in Figure 6
for diaphragm type expansion tank. For diaphragm
type expansion tanks, adjust the tank air pressure
to match the system fill pressure. Install air vent
(fumished) as shown for diaphragm type expansion
tank system only. install make-up water connec-
tions as shown and per local codes. If a pressure
reducing valve is used, adjust to match the system
fill pressure. In connecting the cold make-up water
supply to the boiler, make sure that clean water sup-
ply is available. When the water supply is from a well
or pump, a sand strainer should be installed at the
pump.
RELIEF VALVE DISCHARGE PIPING
fPRESSUR[ REUEF0EVlC[
[FigureTI
The boiler is furnished with a relief valve and tem-
perature pressure gauge in the boiler parts bag. In-
stall vent retief valve as shown in Figure 7. Provide
¾" piping from the relief valve to a local floor drain,

but leave an air gap betweenpiping and drain.
No shutoffof any descriptionshall be placed be-
tween safetyreliefvalve andthe boiler,or on the
dischargepipesbetweensuchsafetyvalveandthe
atmosphere.Installationof the safety reliefvalve
shall conformtoANSl/ASMEBoilerand Pressure
VesselCode, SectionIV.The manufactureris not
responsiblefor anywaterdamage.
SINGLE ZONE BOILER PIPING
SUPPLY TD
VALVE
VALVE
CAN VENT-
SHUT OFF LFEE_
VATER
PURGE RE_UCED PRESSURE
BACKFI.I]V PREVENTER
PRESSURE
SERVICE
RETURN FROH
SYSTEN
TANK
MULTIZONE BOILER PIPING
WITH CIRCULATORS
,GAE VAL_E
NOTE: When zoning with circulators, the furnished circulator pump
should be used as one of the zone pumps. Each stripped end of
the electrical wires for the circulator pump inside the junction box
should be taped or wire nutted to prevent short circuits. Unplug the
circulator pump wiring at the integrated boiler control.
MULTIZONE BOILER PIPING
WITH ZONE VALVES
The packaged boiler unit is set up to receive 11¼"
NPT supply and return piping from top access.
frNiOTE: The circulator and isolation valves fur-_
pump are
shed within acarton inside the boiler cabinet and can beJ
/
_nstalled at the installer preferred location. J
CONDENSATE DRAIN PIPING
lo INWJI_ ,¢m't
Condensate drain line to be pitched down to floor
drain at a minimum of '/_"per foot. An external con-
densate pump (not furnished) may be used if floor
drain is not available. The condensate pump must
be designed for flue gas condensate application.

fNOTES
1. Condensate trap is to be built in the field per Figure 10
2. Wood frame or blocks may be used to raise the boiler
to maintain drain pitch or to be above external condensate
pump reservoir.
3. There is a 115 volt AC receptacle provided on the service
switch junction box which.is located at the boiler right side, to
provide power for an external condensate pump (if needed).
,. j
The condensate trap is to be field installed as previ-
ously shown in Figure 10. Provided are ½" PVC fit-
tings for the condensate drain trap (assembled in the
field). The condensate drain is to be pitched down to
the floor drain at a minimum of 1¼,,per foot.
The ½" diameter schedule 40 PVC condensate
drain piping and pipe fittings must conform toANSI
standards and ASTM D1785 or D2846. Schedule
40 PVC cement and primer must conform to ASTM
D2564 or F493. In Canada, use CSA or ULC certi-
fied schedule 40 PVC drain pipe and cement.
A condensate pump with a reservoir (not furnished)
may be used to remove condensate to a drain line
(sanitary line) above boiler if a floor drain is not
available or is inaccessible.
ON INITIAL START UP THE CONDENSATE TRAP
MUST BE MANUALLY FILLED WITH WATER.
The following are the steps required to initially fill
the condensate trap for start up, these steps are
only required at the initial start up or if maintenance
requires draining of the condensate trap:
1. Pour about 1 cup of cold tap water into the
condensate trap vent.
2. Excess water should go through the conden-
sate drain line. Verify proper operation of the drain
line (and external condensate pump if used).
The boiler, when used in connection with a refrig-
eration system, must be installed so the chiller me-
dium is piped in parallel with the boiler with appro-
priate valves to prevent the chilled medium from
entering the boiler.
The boiler piping system of a hot water boiler con-
nected to heating coils located in air handling units
where they may be exposed to refrigerated air cir-
culation must be equipped with flow control valves
or other automatic means to prevent gravity circu-
lation of the boiler water during the cooling cycle.
/ibMPORTANT: To prevent damage to the gas_
urner and ensure proper operation of the unit, I
I installer must clean and remove all shavings from I
k_he interior of all PVC pipe used on the air intake.,,,/
For boilers connected to gas vents or chimneys, vent
installations shall be in accordance with part 7,Venting
of Equipment, of the National Fuel Gas Code, ANSI
Z223.1-1atest revision, CSA-B149.1 and B149.2, and
applicable provisions of the local building codes.
Provisions for combustion and ventilation air must
be in accordance with section 5.3, Air For Com-
bustion and Ventilation, of the National Fuel Gas
Code, ANSI Z223.1-1atest revision, CSA-B149.1
and B149.2, or applicable provisions of the local
building code.
outdoors through the combustion air intake pipe.
All flue products are discharged to the outdoors
through the vent pipe.
1. See Figures 1-2 in Section V, "Combustion Air
and Vent Pipe Requirements," for standard two-
pipe roof and sidewall terminations and Figures
3-5 (same section) for concentric vent termina-
tions (roof termination is preferred). Combus-
tion air and vent pipes must terminate together
in same atmospheric pressure zone as shown.
Construction through which vent and air intake
pipes may be installed is a minimum ¼" and max-
imum 24" thickness.
2. Combustion air and vent pipe fittings must con-
form to one of the following American National
Standards Institute (ANSI) and American Society
for Testing and Materials (ASTM) standards:
•D1784 (schedule-40 CPVC)
These boilers require a dedicated direct vent sys-
tem. All air for combustion is taken directly from • D1785 (schedule-40 PVC)

•D2665 (PVC-DWV)
• D2241 (SDR-21 and SDR-26 PVC)
• D2661 (ABS-DWV)
• F628 (schedule-40 ABS).
Pipe cement and primer must conform to ASTM
standards D2564 (PVC) or D2235 (ABS).
In Canada construct all combustion air and vent
pipes for this unit of CSA or ULC certified sched-
ule-40 CPVC, schedule-40 PVC, PVC-DWV or
ABS-DWV pipe and pipe cement. SDR pipe is
NOT approved in Canada.
3. Combustion air and vent piping connections
on boiler are 2", but must increase to 3". Due to
potential for flue gas temperatures over 155°1,
the first 5 feet of vent pipe must be CPVC (fur-
nished), the remaining vent pipe can be PVC.
If any elbows are employed within the first 2 ½'
feet of vent, they must be CPVC. Two 30" pieces
of 2" CPVC pipe and one 2" CPVC coupling are
furnished with the boiler. (Figure 11)
COMBUSTION AIR AND VENT PIPING
3 INCH INTAKE ANO
EXHAUST TERMINATqONS
2- By 3-TR ANS rllON tN
THE VERTICAL pOS ITION
EXHAUST TEE
(FURNISHEO}
2# (50.SMM) CPVC COUPLING
_-- (FURNISHED)
)_ 2" (50"BMM} CPVC vE NT PIPING
I __ (FUR NISHEO &REQUIR ED)
NOT IN
HORIZONAL
SECTION
Reduce the maximum vent length 5 feet per
each additional elbow.
4. Combustion air and vent piping to be pitched
back to boiler at minimum 1/,,,per foot from intake
and vent terminals so that all moisture in com-
bustion air and vent piping drains to boiler. Pipes
must be pitched continuously with no sags or low
spots where moisture can accumulate and block
the flow of air or flue gas. Combustion air and
vent pipes must be airtight and watertight.
5. Consideration for the following should be used
when determining an appropriate location for ter-
mination of combustion air and vent piping:
• Comply with all clearances required as
stated in paragraph 6 (below)
• Termination should be positioned where
vent vapors will not damage plants/shrubs,
air conditioning equipment, or siding on the
house.
• Termination should be positioned so that
it will not be effected by wind eddy, air born
leaves, snow, or recirculated flue gases.
• Termination should be positioned where it
will not be subjected to potential damage by
foreign objects, such as stones, balls, etc.
• Termination should be positioned where
vent vapors are not objectionable.
• Put vent on a wall away from the prevailing
winter wind. Locate or guard the vent to pre-
vent accidental contact with people or pets.
• 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.
NOTE: The exhaust transition from 2" pipe to 3" pipe must_'_
e made in a vertical run. (Transition pieces not included.)_
6 ft. in length plus 60 ft. in length and up
four (4) 90°elbows to four (4) 90 ° elbows
The length of pipe is counted from the boiler jack-
et (air intake pipe) or from vent tee (vent pipe).
The first five feet of "Total Equivalent Length" of
vent pipe must be CPVC.
• Under certain conditions, flue gas will con-
dense, forming moisture, and may be corro-
sive. In such cases, steps should be taken
to prevent building materials at the vent from
being damaged by exhaust of flue gas.
6. The venting system shall terminate at least 3
feet above any forced air inlet (except the boiler's
combustion air inlet) within 10 feet. The venting
system shall terminate at least 12 inches from
any air opening into any building. The bottom
of the vent shall be located at least 12 inches

abovegrade.Terminationof the vent shall be
notless than 7 feet above an adjacentpublic
walkway.Theventterminalshallnotbeinstalled
closerthan3 feetfromtheinsidecornerofan L
shapedstructure.Terminationoftheventshould
be kept at least 3 feet away fromvegetation.
Theventingsystemshall terminateat least 4
feethorizontallyfrom, andin no caseabove or
belowelectricmeters,gas meters,regulators,
andreliefequipment.
Ifmultipleterminationsareused,theremustbe
a minimumof 12 inchesbetweenthe exhaust
ofoneterminationandtheairintakeof thenext
termination.SeeFigures1-3in SectionE5foril-
lustrations.
(_NOTE: All field installed vent pipe must be 3".
1. Attach combustion air intake piping to sup-
plied Fernco 2" coupling on CVI gas valve. At-
tach vent piping to furnished 2" CPVC vent tee
on draft inducer outlet.
(_NOTE:AII pipe joints are to be water tight.
2. Working from the boiler to the outside, cut
pipe to required length(s).
3. Deburr inside and outside of pipe. Remove all
chips and shavings.
4. Chamfer outside edge of pipe for better distri-
bution of primer and cement.
5. Clean and dry all surfaces to be joined.
6. Check dry fit of pipe and mark insertion depth
on pipe.
(_OTE: It is recommended that all pipes be cut, prepared, and_
re-assembled before permanently cementing any joint. ,J
7. After pipes have been cut and pre-assem-
bled, apply cement primer to pipe fitting socket
and end of pipe to insertion mark. Quickly apply
approved cement to end of pipe and fitting sock-
et (over primer). Apply cement in light, uniform
coat on the inside of socket to prevent buildup of
excess cement. Apply second coat.
8. While cement is still wet, insert pipe into sock-
et with a 1/, turn twist. Be sure pipe is fully in-
serted into fitting socket.
9. Wipe excess cement from joint. A continuous
bead of cement will be visible around perimeter
of a properly made joint.
10. Handle pipe joint carefully until cement sets.
11. Support combustion air and vent piping a mini-
mum of every 5feet using pre-formed metal hang-
ing straps. Do not rigidly support pipes. Allow for
movement due to expansion and contraction.
_.NOTE: Rigid supports will cause excess noise in vent piping._
I2. Slope combustion air and vent pipes toward
boiler a minimum of 1¼,,per linear foot with no
sags between hangers.
13. Use appropriate methods to seal open-
ings where vent and combustion air pipes pass
through roof or side wall.
Minimum 4" w.c. 10" w.c.
Maximum 10" w.c. 14" w.c.
Please check fine pressure while unit is running.
The gas pipe to your boiler must be the correct size
for the length of run and for the total BTU per hour
input of all gas utilization equipment connected to
it. See Table 6 for proper size. Be sure your gas
line complies with local codes and gas company
requirements.
The boiler and its individual shutoff valve must be
disconnected from the gas supply piping system
during any pressure testing of that system at test
pressures in excess of ½ psig (3.5kPa).
The boiler must be isolated from the gas supply pip-
ing system by closing its individual manual shutoff
valve during any pressure testing of the gas supply
piping system at test pressures equal to or greater
than ½ psig (3.5kPa).

92,000 190,000 350,000 625,000
63,000 130,000 245,000 445,000
50,000 105,000 195,000 365,000
requirements, by the National Fuel Gas Code,
ANSI Z223.1- latest revision. In Canada, follow
the CAN/CGA B149.1 and .2 Installation Codes
for Gas Buming Appliances and Equipment.
2. Use pipe joint compound suitable for liquefied
petroleum gas on male threads only.
131,000 216,000
90,000 145,000
72,000 121,000 103,000 217,000
mlncludes Fittings (2_OutsideDiameter
flMPORTANT: The length of pipe or tubing should"_
be measured from the gas meter or propane sec-
_.ond stage regulator, j
Refer to Figure 12 for the general layout at the boil-
er. The gas line enters the boiler through the left
side panel.
GAS PIPING
CONNECTION
The boiler is equipped with a ½" NPT connection on
the gas valve for supply piping and 1/£ NPT ball cock
for manual shut off. The following rules apply:
3. Use ground joint unions.
4. Install a sediment trap upstream of gas con-
trols.
5. Use two pipe wrenches when making the con-
nection to the gas valve to keep it from turning.
6. Install a manual shutoff valve in the vertical
pipe about 5 feet above floor outside the boiler
jacket.
7. Tighten all joints securely.
8. Propane gas connections should only be
made by a licensed propane installer.
9. Two stage regulation should be used by the
propane installer.
10. Propane gas piping should be checked out
by the propane installer.
11. It is recomended to use a ½" union suitable
for natural and propane gas after the ball cock to
facilitate service on the unit.
After all connection have been made, check imme-
diately for leaks. Open the manual shutoff valve.
Test for leaks by applying soap suds (or a liquid
detergent) to each joint. Bubbles forming indicate
leak. CORRECT EVEN THE SMALLEST LEAK
AT ONCE.
WARNING
1. Use only those piping materials and joining
methods listed as acceptable by the authority
having jurisdiction, or in the absence of such

WARNING
All electrical work must conform to local codes as
well as the National Electrical Code, ANSI/NFPA-
70, latest revision, in Canada, electrical wiring shall
comply with the Canadian Electrical Codes, CSA-
C22.1 and .2.
The boiler, when installed, must be electrically
grounded in accordance with the requirements of
the authority having jurisdiction or, in the absence
of such requirements, with the National Electrical
Code, ANSI/NFPA-70, latest revision. In Canada,
electrical wiring shall comply with the Canadian
Electrical Codes, CSA-C22.1 and .2.
Run a 14 gauge or heavier copper wire from the
boiler to a grounded connection in the service pan-
el or a properly driven and electrically grounded
ground rod.
Prior to making any line voltage connections, ser-
vice switch at boiler should be in the off position
and the power turned off at the fuse box.
Run a 120 volt circuit from a separate over current
protection device in the electrical service entrance
panel.
(_NOTE: Use copper conductors only.
This should be a 15 ampere circuit. A service switch
has been pre-wired and located on the exterior
boiler jacket. See Figure 13 for diagram showing
location of service switch junction box and power
supply connection points. Connect black (hot) lead
from the power supply to either of the unused brass
screws on the service switch. Connect the white
(neutral) lead from the power supply to the white
screw on the service switch. Connect the green
(ground) lead from the power supply to the ground
(green) screw on the service switch. The recepta-
cle on the service switch is always powered regard-
less of whether the switch is on or off, and could be
used as a power supply for an external condensate
pump if one is used.
The thermostat location has an important effect on
the operation of your boiler system. BE SURE TO
FOLLOW THE INSTRUCTIONS INCLUDED WITH
YOUR THERMOSTAT.
Locate the thermostat about five feet above the
floor on an inside wall. It may be mounted directly
on the wall or on a vertical mounted outlet box. It
should be sensing average room temperature.
AVOID THE FOLLOWING:
• Dead Spots -corners; alcoves; behind
doors
•Cold Spots - concealed pipes or ducts;
stairwells - drafts; unheated rooms on the
other side of the wall
• Hot Spots - concealed pipes; fireplaces; TVs
or radios; lamps; direct sunlight; kitchens
Set heat anticipator at 0.7 amps. Connect 24 volt
thermostat leads to the two (2) yellow wires located
in service switch junction box, located on outer jack-
et of boiler. See Figure 12 for service switch junction
box and thermostat field wiring connections.
See Figure 14 for service switch junction box and
circulator pump field wiring connections. If the two
120 volt circulator wire terminals inside the junction
box are not used, please leave the two wire nuts to
prevent the short circuit.
fL.___ CAUTION _1 "_
abel atl wires prior to disconnection when ser- I
icing controls. Wiring errors can cause improp- I
r and dangerous operation. VERIFY PROPER I
PERATION AFTER SERVICING. J

SCHEMATIC WIRING CONNECTIONS
NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent.
.%
24 VA¢
SR PC_3l_Ct _SFORM_R
SECONE_RY
W BK P_
TO I_N_ORM_R
G F_J_RY p6
p_
{_ pURCta
(NOTE: USE COP_ER COttOU_ORS ONLYI
LADDER WIRING DIAGRAM
120 VOLT POWER SUPPLy
(NOTE: USE COPPER COI_DUCTORS ONLy]
H%TI
C_N/OF F8LK
SWITCH
LWCO
_-1 CASTING TEMpERATLJR E
/SAFE_" SWITCH
(MANtJAL RESE_ tl
4K1 3K1
fl
DIFFERENTIAL
AIR PRESSLJRE O_
NWITCH (NO)
S_T AT
TNERMOSTAT
2)
CIRCULATOR FIELD WIRED
HOT SURFACE IGNITE R P12. 2p6-2
P7-2
_7-3
p4-3
p10-2 P5-3
J;
P10-3
5K2
"I
120 VAC
SFORM_R
GAS VALVE
II ]_ I I {(
P3"5 I I P3-2
AIR LC_IC & riMERS
:P3.3 O Pt/RGE
HIGH LIN_T OFLAME
AQU_STAT
CONTROL 1013 10 CONTROL
:P34

This section provides a brief description of the key
controls and accessories found in this boiler.
See Section XVII, "Troubleshooting," in this instal-
lation manual for detailed sequences of operation
and troubleshooting procedures. See the separate-
ly provided "Repair Parts Manual"for locations of all
control components and accessories described.
The integrated Boiler Control (IBC) is a micro-
processor based controller for high efficiency gas
boilers that monitors all safety controls and which
controls the operation of the combustion air blow-
er, circulator pump, burner, and a combination hot
surface igniter/flame sensor. This controller is not
intended for use with a vent damper. This controller
is mounted on the control panel inside the boiler
and contains five diagnostic indicator lights.
The electronic 24 volt gas control valve contains a
1:1 gas/air pressure regulator to control gas flow to
the main burner of the appliance, is suited for both
natural and LP gas, and is rated in accordance with
ANSI Z21.21 - latest revision and and CGA-6.5-M95.
GAS VALVE
THROTTLE
VALVE
INLET
PRESSURE_
TAP"-
INLET
PRESSURE
CONNECTION
--OUTLET
HOLEX NOT RENOVE
THIS CAP
HEABER
the failure mode as a lack of flame signal. The IBC is
manually reset from lockout by either removing and
reestablishing the thermostat's call for heat, or by
turning the service switch off, then back on.
INDICATOR LIGHTS
The High LimitAquastat Control determines the maxi-
mum boiler water temperature and also provides a
means for protecting the boiler and heating system
from unsafe operating conditions which could dam-
age the boiler. The aquastat is mounted in the ½" NPT
control well and ¾" x ½" bushing on the top of the front
boiler section at the hot water outlet. The aquastat is
tied in with the IBC and is factory set at 180°F water
temperature. The high limit setpoint is field adjustable
and may be set anywhere between 100°F and 200°F.
The field setpoint adjustment for each installation de-
pends on heating system requirements. The aquastat
automatically resets when the boiler water tempera-
ture drops 20°F below the setpoint value. This reset
value can be field adjusted within a range of 5-30°E
NOTE: The maximum setpoint of the aquastat must not_
xceed 200°F. .)
The 120 volt Hot Surface Igniter heats up to 1800°F
to initiate combustion of the gas in the burner. The
igniter is mounted next to the burner through the
gas/air mixer. The igniter also serves as a means
for proving the main burner flame by flame rectifica-
tion. In the event of a lack of flame signal on three
consecutive trials for ignition, the IBC will lockout.
The "Valve" and "Flame" diagnostic indicator lamps
(lamps "D" and "E" in Figure 16) will blink indicating
In the event of lack of or loss of water in the boiler,
the Casting Temperature Safety Switch (230°F set-
point) installed on the top of the aluminum boiler
section behind the supply piping shuts offthe boiler
by shutting off power to the Integrated Boiler Con-
trol (IBC) and causes the Power Indicator Light to
go out. This fault requires manual reset of the cast-
ing temperature safety switch to restart the boiler.
Verify that the boiler is properly filled with water be-
fore resetting this switch.

,_ WARNING
The diaphragm type differential pressure switches
are connected by vinyl tubing to the gas valve and
the air inlet connection on the negative side and
the sight glass adapter on the positive side. The
pressure switches monitor air flow by sensing the
differential pressure measured in inches of water
(" w.c.). The factory settings on these switches are
0.5" w.c. on the normally open switch and 3.5" w.c.
for the normally closed switch. See Section XVI,
"Detailed Sequence of Operation," for details on
the operation of the diferential pressure switches.
The blower provides a means for pushing combus-
tion air into and through the mixer, the bumer, the flue
ways of the cast aluminum boiler section before being
discharged through the vent piping to the outdoors.
Every forced hot water system requires at least one
circulating pump. The circulating pump imparts the
necessary energy to move the water through the
closed loop supply and return piping systems, termi-
nal heating equipment (i.e., finned tube radiators, etc.)
and back through the boiler for reheating. To provide
the required hot water flow rates, the circulator pump
must be properly sized to overcome frictional losses
(usually measured in feet of water, also referred to
as "pump head loss") of the supply and retum piping
systems and boiler. The circulator pump is fumished
in a carton within the boiler cabinet. The circulator(s)
should always be located on the downstream (i.e.,
"pumping away") side of the expansion tank.
The manual drain valve provides a means of draining
the water in the heating system, including the boiler and
hot water supply and return piping systems installed
above the drain valve. This drain valve is installed in
the ¾" tapping at the bottom of the boiler. Any piping in-
stalled below the elevation of this drain valve will require
additional drain valves to be installed at low points in the
piping systems in order to drain the entire system.
Each boiler must have a properly sized and installed
American Society of Mechanical Engineers rated pres-
sure relief valve. Water expands as it is heated by the
burner/boiler sections. If there is no place for the water
to expand its volume, (i.e., a properly sized and prop-
erly functioning expansion tank) pressure on the inside
of the boiler and heating system will increase. The fur-
nished relief valve will automatically open at 30 psig
pressure te relieve the strain on the boiler and heating
system from the increasing pressure. The pressure re-
lief valve discharge must be piped with the same size
as the valve discharge opening to an open drain, tub
or sink, or other suitable drainage point not subject to
freezing, in accordance with A.S.M.E. specifications.
Failure to provide the pressure relief valve with piping
as herein described may cause water damage and/or
serious bodily injury. The boiler manufacturer is net re-
sponsible for any water damage or personal injury.
This boiler is equipped with a blocked vent safety shutoff
means, which shuts off the main bumer gas in the event
that the flow of combustion products through the flue-
ways is reduced. The Integrated Boiler Control will have
to be manually reset in the event of three consecutive
attempts for ignition that are halted by a blocked vent.
In the event of blocked vent, enough air will not be avail-
able to support combustion, and the boiler control will
lockout due to loss of adequate air flow (arcer 3 trials
for ignition). The "Purge" diagnostic indicator lamp (lamp
"B" in Figure 16) will blink indicating the failure mode as
a lack of adequate air flow. The IBC is manually reset
from lockout by either removing and reestablishing the
thermostat's caUfor heat, or by tuming the service switch
off, then back on. If the boiler cannot be restored to nor-
mal operating condition by resetting the control, contact
a qualified service agency to check heat exchanger
flueways for blockage.
This unit is equipped with a Low Water Cut Off con-
trol that protects against dry firing. This control pro-
vides burner cut off if there is an unsafe water loss,
which can result from a broken or leaking radiator,
pipe, or boiler. A water/glycol mixture up to 50% con-
centration may be used with the Low Water Cut Off.
For installations where there is no floor drain or other
appropriate drainage available to receive condensate
from the boiler, an extemal float activated condensate
pump with integral sump (supplied by others)is required.
The condensate pump can be piped to a remote tie in
point to a sanitary sewer system. For this application,
the boiler must be installed so that proper pitch of piping
to the extemal condensate reservoir (sump) can be ac-
complished. Use wood frame or blocks (not factory sup-
plied) to raise boiler as required for proper installation.

1. Consultlocalwater treatmentspecialistfor wa-
ter treatmentrecomendationsif yourwaterpH lev-
elsarebelowof 7.0orhardnessisabove7grains
hardness.
a.This boileris designedfor use ina closed
hydronicheatingsystemONLY!
b.Excessivefeedingoffreshmake-upwater
to the boiler may lead to premature failure of
the boiler sections.
2. Use clean fresh tap water for initial fill and peri-
odic make-up of boiler.
a. A sand filter must be used if fill and make-
up water from a well is to be used.
b. Consideration should be given to cleaning
the heating system, particularly in retrofit sit-
uations, where a new boiler is being installed
in an older piping system.
c. In older systems, obviously discolored,
murky, or dirty water, or a pH reading below
7, are indications that the system should be
cleaned.
d. A pH reading between 7 and 8 is preferred.
3. Antifreeze, if needed, must be of a type specifically
designed for use in closed hydronic heating systems
and be compatible with type 356 T6 aluminum at op-
erating temperatures between 20°F and 250°F.
a. Use of antifreeze must be in accordance
with local plumbing codes.
b. Pure glycol solutions are very corrosive,
therefore hydronic system antifreeze typi-
cally contains corrosion inhibitors. Different
brands of hydronic system antifreeze contain
different types of corrosion inhibitors. Some
brands have corrosion inhibitors that break
down more rapidly or become ineffective at
higher temperatures when used with alumi-
num. This could lead to premature failure of
the aluminum boiler. Consult the antifreeze
manufacturer on the compatibility of their
product with aluminum.
c. Follow the antifreeze manufacturer's in-
structions on determining proper ratio of an-
tifreeze to water for the expected low tem-
perature conditions, and for maintaining the
quality of the antifreeze solution from year to
year. Improperly maintained antifreeze solu-
tions will gradually lose their ability to protect
the aluminum boiler from corrosion.
d. The recommended premixed antifreeze
solution is INTERCOOL NFP-50. This
product is sold direct to distributors by the
antifreeze manufacturer. Please contact In-
terstate Chemical Company, New York Cus-
tomer Service at 1-800-422-2436 or your dis-
tributor for more information.
Use of an alternate manufacturer's premix
antifreeze is acceptable if the product speci-
fications are comparable with those of the
recommended premix antifreeze and the an-
tifreeze is compatible with type 356 T6 alu-
minum. Use of incompatible antifreeze could
damage the heat exchanger and will void the
product warranty.
The antifreeze must be maintained per the
specifications of the manufacturer. Failure to
do so will result in the warranty being voided.
Follow the antifreeze manufacturer's instruc-
tions on determining the proper ratio of an-
tifreeze to water for the expected low tem-
perature conditions and for maintaining the
antifreeze solution from year to year.
e. DO NOT USE AUTOMOTIVE ANTIFREEZE,
as the type of corrosion inhibitors used will coat
the boiler's heat transfer surfaces and greatly re-
duce capacity and efficiency.
f. Use of antifreeze in any boiler will reduce
heating capacity by as much as 10-20%,
due to differing heat transfer and pumping
characteristics. This must be taken into con-
sideration when sizing the heating system,
pump(s) and expansion tank. Consult anti-
freeze manufacturer's literature for specific
information on reduced capacity.
g. Water content of the boiler is 2,6 gallons
(10 liters).

Refer to the appropriate diagrams in Section VII,
"Near Boiler Piping," for more information.
1. Close all zone service valves on the supply
and return piping. Open the feed valve and fill
boiler with water. Make sure air vent is open.
Hold relief valve open until water runs air free for
five seconds to rapidly bleed air from boiler, then
let the relief valve snap shut.
2. Open the zone service valve on the
pipe for the first zone. Open the purge valve
on the first zone. Feed water will fill the zone,
pushing air out the purge valve. Close the purge
valve when the water runs air free. Close the
zone service valve.
3. Repeat step 2 for all remaining zones.
4. Open all service valves. Any air remaining
trapped in the return lines between the service
valves and the boiler will be pushed towards the
air vent when the boiler is placed in operation.
5. Inspect piping system. Repair any leaks im-
mediately.
4. Open the expansion tank service valve and
the tank vent. Fill the tank to the proper level
and close the tank vent. Remove the handle
from the expansion tank service valve so the
homeowner doesn't accidentally close it.
5. Open all service valves. Any air remaining
trapped in the return lines between the service
valves and the boiler will be pushed towards the
expansion tank when the boiler is placed in op-
eration.
6. Inspect piping system. Repair any leaks im-
mediately.
OTE: DO NOT use stop leak compounds. Leaks in"_
readed connections in the aluminum boiler sections mus._t I
e repaired immediately. Aluminum threads will not seal I
emselves. J
(_ READ BEFORE OPERATING APPLIANCE ,,_
1. This appliance does not have a pilot. It is
equipped with an ignition device which automat-
ically lights the burner. Do NOT try to light this
burner by hand.
2. Before operating smell all around the appli-
ance area for gas. Be sure to smell next to the
floor because some gas is heavier than air and
will settle to the floor.
Refer to the appropriate diagrams in Section VII,
"Near Boiler Piping," for more information.
1. Close all zone service valves on the supply
and return piping and close the expansion tank
service valve. Drain expansion tank. Open the
feed valve and fill boiler with water. Hold relief
valve open until water runs air free for five sec-
onds to rapidly bleed air from boiler, then let the
relief valve snap shut.
2. Open the zone service valve on the
pipe for the first zone. Open the purge valve
on the first zone. Feed water will fill the zone,
pushing air out the purge valve. Close the purge
valve when the water runs air free. Close the
zone service valve.
3. Repeat step 2 for all remaining zones.
3. Use only your hand to turn the gas shut off
valve. Never use tools. If the valve will not turn
by hand, do not try to repair it, call a qualified
service technician. Force or attempted repair
may cause fire or explosion.
4. Do not use this appliance if any part has been
under water. Immediately call a qualified ser-
vice technician to inspect the appliance and to