Lochinvar AQUAS AP 285 User manual

100279257_2000537708_Rev B
Installation & Operation Manual
Models: AP 285
This manual must only be used by
a qualified heating installer/service
technician. Read all instructions,
including this manual and the
AQUAS/Knight Fire Tube Boiler
Service Manual, before installing.
Perform steps in the order given.
Failure to comply could result in
severe personal injury, death, or
substantial property damage.
⚠WARNING
Save this manual for future reference.

2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
⚠DANGER
⚠WARNING
⚠CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
HAZARD DEFINITIONS .................................................. 2
PLEASE READ BEFORE PROCEEDING.................. 3-4
THE AQUAS FIRE TUBE -- HOW IT WORKS........... 5-6
RATINGS .......................................................................... 7
1. DETERMINE BOILER LOCATION
Provide Clearances............................................................ 8
Provide Air Openings to Room ........................................ 10
Flooring and Foundation ................................................. 10
Residential Garage Installation ........................................ 10
Vent and Air Piping .......................................................... 10
Prevent Combustion Air Contamination........................... 10
Corrosive Contaminants and Sources ............................. 11
Using an Existing Vent System to Install a New Boiler ... 11
Removing a Boiler from Existing Common Vent.............. 12
2. PREPARE BOILER
Gas Conversions......................................................... 13-14
3. GENERAL VENTING
Direct Venting Options ..................................................... 15
Install Vent and Combustion Air Piping ........................... 16
Requirements for Installation in Canada.......................... 17
Sizing ............................................................................... 17
Materials............................................................................ 18
Optional Room Air............................................................ 19
PVC/CPVC ....................................................................... 20
Polypropylene................................................................... 21
Stainless Steel Vent ......................................................... 22
4. SIDEWALL DIRECT VENTING
Vent/Air Termination - Sidewall................................... 23-25
Determine Location................................................ 23-25
Prepare Wall Penetrations..................................... 25-26
Multiple Vent/Air Terminations ......................................... 26
Sidewall Termination - Optional Concentric Vent ....... 27-29
5. VERTICAL DIRECT VENTING
Vent/Air Termination - Vertical .................................... 30-31
Determine Location..................................................... 30
Prepare Roof Penetrations ......................................... 31
Multiple Vent/Air Terminations.................................... 31
Vertical Termination - Optional Concentric Vent ... 32-33
Alternate Vertical Concentric Venting.................... 34-35
6. HYDRONIC PIPING
AQUAS Fire Tube Installation Instructions ................. 36-37
Indirect Heat Exchanger Installation Instructions............. 38
AQUAS Fire Tube Pool Setup ......................................... 39
Standalone Operation ...................................................... 39
Auxiliary Heat Exchanger / DHW ................................ 40-42
Low Water Cutoff Device ................................................. 43
Freeze Protection............................................................. 43
General Piping Information .............................................. 43
7. GAS CONNECTIONS
Connecting Gas Supply Piping ................................... 44-45
Natural Gas ...................................................................... 45
Pipe Sizing for Natural Gas ........................................ 45
Natural Gas Supply Pressure Requirements ............. 45
Propane Gas .................................................................... 45
Pipe Sizing for Propane Gas ...................................... 45
Propane Supply Pressure Requirements ................... 45
Check Inlet Gas Supply ................................................... 46
Gas Pressure ................................................................... 47
Gas Valve Replacement .................................................. 47
8. FIELD WIRING
Line Voltage Connections ................................................ 48
Low Voltage Connections ................................................ 48
Wiring of the Cascade...................................................... 50
9. CONDENSATE DISPOSAL
Condensate Drain ............................................................ 53
10. STARTUP ............................................................. 54-60
11. OPERATING INFORMATION
General........................................................................ 61-64
Cascade ...................................................................... 65-66
Sequence of Operation ............................................... 67-68
AQUAS Fire Tube Control Module................................... 69
Display Panel Menu Access ............................................ 70
Status Display Screens ............................................... 71-73
12. MAINTENANCE
Maintenance and Annual Startup................................ 74-78
13. DIAGRAMS
Ladder Diagram ............................................................... 79
Wiring Diagram................................................................. 80
Revision Notes .................................................. Back Cover
Contents

Installation & Operation Manual
Please read before proceeding
The AQUAS Fire Tube pool package system is a high efficiency commercial condensing boiler, pre-piped package system from
the factory to an indirect heat exchanger. This pool heater is a low temperature operating system designed to take advantage of
the stainless steel heat exchanger and condensing operating temperatures to ensure the highest efficiency possible. The AQUAS
is designed around a predetermined flow set by the manufacturer between the boiler and the indirect heat exchanger. The
AQUAS operates off the pool system pump itself which will continually supply water to the indirect heat exchanger. This means
there is no need to purchase a dedicated circulator to deliver water to this package system.
DIR# 2000538219 00
SYSTEM
SENSOR
LOCATION
CUPRO-NICKEL
OR TITANIUM
HEAT EXCHANGER SKID MOUNTED
ON FRAME
FLOW
SWITCH
RELIEF
VALVE
CONDENSATE
DRAIN
AIR INLET
CONNECTION
T&P
GAUGE
Figure A AQUAS Fire Tube Package System
3
AQUAS Fire Tube Pool Package

4
Installation & Operation Manual
Please read before proceeding
Installer – Read all instructions, including
this manual and the Knight
Fire Tube
Boiler Service Manual, before installing.
Perform steps in the order given.
User – This manual is for use only
by a qualified heating installer/
service technician. Refer to the User’s
Information Manual for your reference.
Have this boiler serviced/inspected by
a qualified service technician, at least
annually.
Failure to comply with the above could
result in severe personal injury, death or
substantial property damage.
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
If the information in this manual is not
followed exactly, a fire or explosion may
result causing property damage, personal
injury or loss of life.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do
not use any phone in your building.
• Immediately call your gas supplier
from a near by phone. Follow the
gas supplier’s instructions.
• If you cannot reach your gas supplier,
call the fire department.
• Installation and service must be
performed by a qualified installer,
service agency, or the gas supplier.
⚠WARNING
NOTICE
⚠WARNING
⚠WARNING
When servicing boiler –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Boiler water –
• Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
Do not use petroleum-based cleaning or
sealing compounds in the boiler system.
Gaskets and seals in the system may be
damaged. This can result in substantial
property damage.
⚠CAUTION
⚠CAUTION Do not use “homemade cures” or “boiler
patent medicines”. Serious damage to
the boiler, personnel, and/or property
may result.
⚠WARNING DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1B on page 11).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.

The AQUAS Fire Tube boiler - How it works...
1. Stainless steel heat exchanger
Allows system water to flow around specially designed tubes
for maximum heat transfer, while providing protection against
flue gas corrosion.
2. Combustion chamber access cover
Allows access to the combustion side of the heat
exchanger.
3. Blower
The blower pulls in air and gas through the venturi (item
5). Air and gas mix inside the blower and are pushed into the
burner, where they burn inside the combustion chamber.
4. Gas valve
The gas valve senses the negative pressure created by the
blower, allowing gas to flow only if the gas valve is
powered and combustion air is flowing.
5. Venturi
The venturi controls air and gas flow into the burner.
6. Flue gas sensor (limit rated)
This sensor monitors the flue gas exit temperature. The control
module will modulate and shut down the boiler if flue gas
temperature gets too hot. This protects the flue pipe from
overheating.
7. Boiler outlet temperature sensor (housed with the
high limit sensor)
This sensor monitors boiler outlet water temperature (system
supply). If selected as the controlling sensor, the control
module adjusts boiler firing rate so the outlet temperature is
correct.
8. Boiler inlet temperature sensor
This sensor monitors return water temperature (system
return). If selected as the controlling sensor, the control
module adjusts the boiler firing rate so the inlet temperature is
correct.
9. Temperature and pressure gauge
Monitors the outlet temperature of the boiler as well as the
system water pressure.
10. Electronic LCD display
The display features a high resolution liquid crystal screen, four
(4) buttons, and a navigation dial. A serial and USB port
support additional communication with the control.
11. Flue pipe adapter
Allows for the connection of the vent system to the
boiler.
12. Burner (not shown)
Made with metal fiber and stainless steel construction,
the burner uses pre-mixed air and gas and provides a
wide range of firing rates.
13. Water inlet (system return)
Copper water connection that returns water from the system to
the heat exchanger, either 1-1/4".
14. Gas connection pipe
Threaded pipe connection. This pipe should be connected
to the incoming gas supply for the purpose of delivering
gas to the boiler.
15. SMART SYSTEM Control Module
The SMART SYSTEM Control responds to internal and
external signals to regulate the blower, gas valve, and pump
functions to meet heating demand. Optional remote
connectivity allows boiler settings to be monitored and
modified when connected to the internet.
16. Air intake adapter
Allows for the connection of the PVC air intake pipe to
the boiler.
17. High voltage junction box
The junction box contains the connection points for the line
voltage power and all pumps.
18. Low voltage connection board
The connection board is used to connect external low voltage
devices.
19. Low voltage wiring connections (knockouts)
Conduit connection points for the low voltage
connection board.
20. Condensate trap
The condensate trap has a 1/2" CPVC outlet connection pipe.
21. Access cover - front
Provides access to the gas valve, control panel, and heat exchanger.
22. Ignition electrode
Provides direct spark for igniting the burner.
23. Flame inspection window
The quartz glass window provides a view of the burner
surface and flame.
24. Relief valve
Protects the heat exchanger from an over pressure condition.
The relief valve provided with the unit is set at 30 psi.
25. Flame sensor
Used by the control module to detect the presence of burner
flame.
26. Line voltage wiring connections (knockouts)
Conduit connection points for the high voltage junction box.
27. Top panel
Removable panel allows access to the gas train and combustion
chamber.
28. Side access panels
Remove panels to gain access to temperature sensors.
29. Power switch
Turns 120 VAC ON/OFF to the boiler.
30. Leveling legs
Used to allow the heat exchanger to be leveled. This is needed
for the proper draining of the condensate from the combustion
chamber.
31. Flue and temperature access door
Provides access to the flue and temperature sensor.
32. Transformer
The transformer provides 24V power to the integrated control.
33. High limit sensor (housed with the outlet
temperature sensor)
Device that monitors the outlet water temperature. If the
temperature exceeds its setting, the integrated control will
break the control circuit, shutting the boiler down.
34. Stainless steel flue collector (not shown)
Flue gas and condensate enter the stainless flue collector through
the fire tubes. A 1" drain connection allows condensate to flow
through the collector into a condensate trap for disposal.
5
Installation & Operation Manual

6
Installation & Operation Manual
DIR #2000507762 00
21
10
27
Front View
DIR #2000507764 00
26
29
19
30
13
14
7
33
6
11
8
28
31
Left Side (inside unit) Front View (inside unit)
The AQUAS Fire Tube boiler - How it works...
Top View (inside unit)
DIR #2000507551 00
3
2
4
5
22
25 23
24
DIR #2000507559 00
20
16
9
1
17
18
15
32

7
Ratings
ASME
H
Notes:
1. As an Energy Star Partner, Lochinvar has determined that
AQUAS Fire Tube boilers meet the Energy Star guidelines
for energy efficiency.
2. The ratings are based on standard test procedures prescribed
by the United States Department of Energy.
3. Net AHRI ratings are based on net installed radiation of
sufficient quantity for the requirements of the building
and nothing need be added for normal piping and pickup.
Ratings are based on a piping and pickup allowance of 1.15.
4. AQUAS Fire Tube boilers require special gas venting.
Use only the vent materials and methods specified in
the AQUAS Fire Tube boiler Installation and Operation
Manual.
5. Standard AQUAS Fire Tube boilers are equipped to
operate from sea level to 4,500 feet only. The boiler will
de-rate by 4% for each 1,000 feet above sea level up to 4,500
feet.
6. High altitude AQUAS Fire Tube boilers are equipped to
operate from 3,000 to 9,600 feet only. e boiler will not
de-rate up to 5,000 feet and will de-rate 1.7% for each 1000
feet above 5000 feet. e operation given in this manual
remains the same as the standard boilers. A high altitude
label (as shown in FIG. B) is also axed to the unit.
De-rate values are based on proper combustion calibration
and CO2 ’s adjusted to the recommended levels.
7. Ratings have been confirmed by the Hydronics Section of
AHRI.
Maximum allowed working pressure is located on the rating plate.
NOTICE
AQUAS Fire Tube boiler
AHRI Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Input
MBH
(Note 5)
Min Max
Heating
Capacity
MBH
(Note 2,7)
Net
AHRI
Ratings
Water,
MBH
(Note 3,7)
AFUE
%
(Note 1, 7)
APN285 28.5 285 264 229 95
Other Specifications
Boiler
Water
Content
Gallons
Water
Connections
Gas
Connections
Air
Size
Vent
Size
(Note 4,8)
4.9 1-1/4" 1/2" 3" 3"
Figure B High Altitude Label Location
DIR #2000507830 00
UNIT EQUIPPED FOR
HIGH ALTITUDE
3,000 FT. TO 9,600 FT.
8. The AP285 model can be alternatively vented using a 4"
vent/air size. If the 3" vent/air size is used, the maximum
vent/air pipe lengths are limited to 50 equivalent feet each.
9. The manual reset high limit provided with the AQUAS
Fire Tube boiler is listed to UL353.
Installation & Operation Manual

8
Installation & Operation Manual
The AQUAS Fire Tube boiler gas manifold
and controls met safe lighting and other
performance criteria when the boiler
underwent tests specified in ANSI Z21.13
– latest edition.
Failure to keep boiler area clear and free
of combustible materials, gasoline, and
other flammable liquids and vapors can
result in severe personal injury, death, or
substantial property damage.
Installation must comply with:
• Local, state, provincial, and national codes, laws,
regulations, and ordinances.
• National Fuel Gas Code, ANSI Z223.1 – latest edition.
• Standard for Controls and Safety Devices for Automatically
Fired Boilers, ANSI/ASME CSD-1, when required.
• National Electrical Code.
• For Canada only: B149.1 Installation Code, CSA C22.1
Canadian Electrical Code Part 1 and any local codes.
Before locating the boiler, check:
1. Check for nearby connection to:
• System water piping
• Venting connections
• Gas supply piping
• Electrical power
2. Locate the appliance so that if water connections should
leak, water damage will not occur. When such locations
cannot be avoided, it is recommended that a suitable
drain pan, adequately drained, be installed under the
appliance. The pan must not restrict combustion air
flow. Under no circumstances is the manufacturer to be
held responsible for water damage in connection with
this appliance, or any of its components.
3. Check area around the boiler. Remove any combustible
materials, gasoline, and other flammable liquids.
4. The AQUAS Fire Tube boiler must be installed so that gas
control system components are protected from dripping
or spraying water or rain during operation or service.
5. If a new boiler will replace an existing boiler, check for
and correct system problems, such as:
• System leaks causing oxygen corrosion or heat
exchanger cracks from hard water deposits.
• Incorrectly-sized expansion tank.
• Lack of freeze protection in boiler water causing system
and boiler to freeze and leak.
6. Check around the boiler for any potential air
contaminants that could risk corrosion to the boiler or
the boiler combustion air supply (see Table 1B on page
11). Prevent combustion air contamination. Remove
any of these contaminants from the boiler area.
⚠WARNING This appliance is certified as an indoor
appliance. Do not install the appliance
outdoors or locate where the appliance
will be exposed to freezing temperatures
or to temperatures that exceed 100°F.
Do not install the appliance where the
relative humidity may exceed 93%.
Do not install the appliance where
condensation may form on the inside
or outside of the appliance, or where
condensation may fall onto the appliance.
Failure to install the appliance indoors
could result in severe personal injury,
death, or substantial property damage.
Provide clearances:
Clearances from combustible materials
1. Hot water pipes—at least 1/4" (6 mm) from combustible
materials.
2. Vent pipe – at least 1" (25 mm) from combustible
materials.
3. See FIG.’s 1-1 and 1-2 on page 9 for other clearance
minimums.
Closet and alcove installations
This appliance requires a special venting
system. If using PVC the vent connection
to the appliance must be made with the
starter CPVC pipe section provided with
the appliance. The field provided vent
fittings must be cemented to the CPVC
pipe section. Use only the vent materials,
primer and cement specified in this
manual to make the vent connections.
Failure to follow this warning could result
in fire, personal injury, or death.
For closet and alcove installations as shown
in FIG.’s 1-1 and 1-2, CPVC, polypropylene
or stainless steel vent material must be
used inside the structure. The ventilating
air openings shown in FIG.’s 1-1 and 1-2
are required for this arrangement. Failure
to follow this warning could result in fire,
personal injury, or death.
⚠WARNING
⚠WARNING
NOTICE
⚠WARNING
1 Determine boiler location
A closet is any room the boiler is installed in which the room
volume is less than the room volume listed in the table below.
An alcove is any room which meets the criteria for a closet,
but it does not have a door.
DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1B on page 11).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
⚠WARNING
Example: Room dimensions = 4 feet long, 3 feet wide, and
8 foot ceiling = 4 x 3 x 8 = 96 cubic feet. This would be
considered a closet for a APN285 model.
Model Room Volume (in cubic feet)
285 124
Table 1A Room Volume

Installation & Operation Manual
1 Determine boiler location (continued)
18"
FRONT
12"
LEFT
0"
RIGHT
0"
REAR
DIR #2000507571 00
TOP
12"
Figure 1-2 Alcove Installation - Minimum Required Clearances
12"
LEFT
6"
6"
6"
FRONT
TOP
12"
0"
REAR
0"
RIGHT
DIR #2000507564 00
VENTILATING*
AIR OPENING
VENTILATING*
AIR OPENING
*AREA OF EACH OPENING:
1 SQ. INCH PER 1000 BTU PER HOUR INPUT
WITH A MINIMUM OF 100 SQ. INCHES.
Figure 1-1 Closet Installation - Minimum Required Clearances
⚠WARNING For closet installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used in
a closet structure due to elevated
temperatures. Failure to follow
this warning could result in fire,
personal injury, or death.
⚠WARNING For alcove installations, CPVC,
polypropylene or stainless steel
vent material MUST BE used
in an alcove structure due to
elevated temperatures. Failure to
follow this warning could result
in fire, personal injury, or death.
9

10
Installation & Operation Manual
1 Determine boiler location
Provide air openings to room:
AQUAS Fire Tube boiler alone in boiler room
1. No air ventilation openings into the boiler room are
needed when clearances around the AQUAS Fire Tube
boiler are at least equal to the SERVICE clearances shown
above. For spaces that do NOT supply this clearance,
provide two openings as shown in FIG. 1-1. Each
opening must provide one square inch free area per 1,000
Btu/hr of boiler input.
AQUAS Fire Tube boiler in same space with other
gas or oil-fired appliances
1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1
(Canada) to size/verify size of the combustion/ventilation
air openings into the space.
The space must be provided with
combustion/ventilation air openings
correctly sized for all other appliances
located in the same space as the AQUAS
Fire Tube boiler.
Do not install the boiler in an attic.
Failure to comply with the above warnings
could result in severe personal injury,
death, or substantial property damage.
2. Size openings only on the basis of the other appliances in
the space. No additional air opening free area is needed
for the AQUAS Fire Tube boiler because it takes its
combustion air from outside (direct vent installation).
Do not install the boiler on carpeting even
if foundation is used. Fire can result,
causing severe personal injury, death, or
substantial property damage.
If flooding is possible, elevate the boiler sufficiently to prevent
water from reaching the boiler.
Flooring and foundation
Flooring
The AQUAS Fire Tube boiler is approved for installation
on combustible flooring, but must never be installed on
carpeting.
Residential garage installation
Precautions
Take the following precautions when installing the appliance
in a residential garage. If the appliance is located in a
residential garage, it should be installed in compliance with
the latest edition of the National Fuel Gas Code, ANSI Z223.1
and/or CAN/CGA-B149 Installation Code.
• Appliances located in residential garages and in
adjacent spaces that open to the garage and are not part
of the living space of a dwelling shall be installed so that
all burners and burner ignition devices are located not
less than 18 inches (46 cm) above the floor.
• The appliance shall be located or protected so that it is
not subject to physical damage by a moving vehicle.
Vent and air piping
The AQUAS Fire Tube boiler requires a special vent system,
designed for pressurized venting.
The boiler is to be used for either direct vent installation or
for installation using indoor combustion air. When room
air is considered, see Section 3, General Venting. Note
prevention of combustion air contamination below when
considering vent/air termination.
Vent and air must terminate near one another and may be
vented vertically through the roof or out a side wall, unless
otherwise specified. You may use any of the vent/air piping
methods covered in this manual. Do not attempt to install
the AQUAS Fire Tube boiler using any other means.
Be sure to locate the boiler such that the vent and air piping
can be routed through the building and properly terminated.
The vent/air piping lengths, routing and termination method
must all comply with the methods and limits given in this
manual.
Prevent combustion air contamination
Install air inlet piping for the AQUAS Fire Tube boiler as
described in this manual. Do not terminate vent/air in
locations that can allow contamination of combustion air.
Refer to Table 1B, page 11 for products and areas which may
cause contaminated combustion air.
You must pipe combustion air to the boiler
air intake. Ensure that the combustion air
will not contain any of the contaminants
in Table 1B, page 11. Contaminated
combustion air will damage the boiler,
resulting in possible severe personal
injury, death, or substantial property
damage. Do not pipe combustion air near
a swimming pool, for example. Also,
avoid areas subject to exhaust fumes from
laundry facilities. These areas will always
contain contaminants.
⚠WARNING
⚠WARNING
⚠WARNING
Recommended clearances for service access
- Front ............................................................................. 24"
- Left ................................................................................ 24"
- Top................................................................................ 24"
If you do not provide the recommended
service clearances shown, it may not be
possible to service the boiler without
removing it from the space.
NOTICE

11
Installation & Operation Manual
1 Determine boiler location (continued)
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
⚠WARNING
When using an existing vent system to
install a new boiler:
Check the following venting components before installing:
• Material - For materials listed for use with this appliance,
see Section 3 - General Venting. For polypropylene or
stainless steel venting, an adapter of the same
manufacturer must be used at the flue collar connection.
• Size - To ensure proper pipe size is in place, see Table 3A.
Check to see that this size is used throughout the vent
system.
• Manufacturer - For a stainless steel or polypropylene
application, you must use only the listed manufacturers
and their type product listed in Tables 3E and 3G for CAT
IV positive pressure venting with flue producing
condensate.
• Supports - Non-combustible supports must be in place
allowing a minimum 1/4" rise per foot. The supports
should adequately prevent sagging and vertical slippage,
by distributing the vent system weight. For additional
information, consult the vent manufacturer’s
instructions for installation.
• Terminations - Carefully review Sections 3 through 5 to
ensure requirements for the location of the vent and air
terminations are met and orientation of these fit the
appropriate image from the Sidewall or Vertical
options listed in the General Venting Section. For
stainless steel vent, only use terminations listed in Table
3G for the manufacturer of the installed vent.
• Seal - With prior requirements met, the system should be
tested to the procedure listed in parts (c) through (f) of
the Removal of an Existing Boiler Section on page 12.
With polypropylene and stainless steel vent, seal and connect
all pipe and components as specified by the vent manufacturer
used; with PVC/CPVC vent, see the Installing Vent and Air
Piping Section on page 16.
⚠WARNING If any of these conditions are not met,
the existing system must be updated or
replaced for that concern. Failure to
follow all instructions can result in flue gas
spillage and carbon monoxide emissions,
causing severe personal injury or death.
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other
similar products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Table 1B Corrosive Contaminants and Sources

Installation & Operation Manual
12
When removing a boiler from existing
common vent system:
Do not install the AQUAS into a common
vent with any other appliance. This
will cause flue gas spillage or appliance
malfunction, resulting in possible severe
personal injury, death, or substantial
property damage.
Failure to follow all instructions can result
in flue gas spillage and carbon monoxide
emissions, causing severe personal injury
or death.
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.
a. Seal any unused openings in the common venting
system.
b. 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.
c. Test vent system – Insofar as is practical, close all
building doors and windows and all doors between the
space in which the appliances remaining connected to
the common venting system are located and other spaces
of the building. Turn on clothes dryers and any appliance
not connected to the common venting system. Turn on
any exhaust fans, such as range hoods and bathroom
exhausts, so they will operate at maximum speed. Do not
operate a summer exhaust fan. Close fireplace dampers.
d. Place in operation the appliance being inspected. Follow
the lighting instructions. Adjust thermostat so appliance
will operate continuously.
e. Test for spillage at the draft hood relief opening after
5 minutes of main burner operation. Use the flame of a
match or candle, or smoke from a cigarette, cigar, or pipe.
f. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined herein, return
doors, windows, exhaust fans, fireplace dampers, and any
other gas-burning appliance to their previous conditions
of use.
⚠DANGER
⚠WARNING
g. Any improper operation of the common venting system
should be corrected so the installation conforms with the
National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or
CAN/CSA B149.1, Natural Gas and Propane Installation
Code. When resizing 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 of the National Fuel Gas Code,
ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas
and Propane Installation Code.
1 Determine boiler location

13
Installation & Operation Manual
For a boiler already installed, you must
turn off gas supply, turn off power, and
allow boiler to cool before proceeding.
You must also completely test the boiler
after conversion to verify performance
as described under Start-up, Section 10
of this manual. Failure to comply could
result in severe personal injury, death, or
substantial property damage.
1. If boiler is already installed, you must turn
off the gas supply, turn off the power, and allow
the boiler to cool before proceeding.
2. Remove the top panel front access cover from the
unit (no tools required for removal) and remove
the bezel.
3. Disconnect the air inlet piping from the venturi
by loosening the band clamp around the rubber
boot coupling. Slide the rubber boot off of the
venturi.
4. Disconnect gas piping from the venturi by
loosening the threaded nut on the venturi. Remove
the gasket between the gas piping and venturi.
5. Remove the bolts connecting the venturi to the
fan and proceed to remove the natural gas venturi
from the unit, making sure not to damage the
blower O-ring gasket (FIG. 2-1).
6. This unit requires an air shutter to be installed (see
Table 2A):
a. Disconnect the wiring from the fan and
remove the bolts securing the fan to the
combustion chamber access cover.
b. Remove the fan and gasket, and install
the air shutter provided in the kit. Install
the air shutter so that the hole in the corner is
oriented towards the back right corner of the
unit (opposite the front door and gas piping).
c. Replace all torn or damaged gaskets.
Reassemble the fan.
d. Reconnect the wiring harness before
operation.
7. Install the propane venturi and verify the following:
a. The UP arrow on the plastic housing is
pointing up.
b. The threaded connection for the gas piping is
facing towards the front of the unit.
8. Reassemble the gas pipe to the threaded connection
on the venturi. Replace torn or damaged gasket(s)
and ensure the venturi gasket is seated properly
before tightening the nut on the venturi.
9. Reconnect the rubber boot on the air inlet to the
venturi inlet and tighten the band clamp at this
connection.
10. After installation is complete, attach the propane
conversion label (inside the conversion kit) next to
the boiler rating plate. Attach the LP caution label
(inside the conversion kit bag) to the left side of
the boiler underneath the gas supply piping.
11. Replace the top bezel and front access cover
removed in Step 1 and resume operation.
Gas conversions
⚠WARNING
Model Kit # Venturi Ø
(mm)
Orifice Ø Air
Shutter
Bottom Top
285 100268109 30 mm 4.20 mm 4.00 mm 100150434
Table 2A LP Conversion Table
2 Prepare boiler
You must install a propane venturi to operate the AQUAS
Fire Tube boiler on propane gas. Verify when installing
that the venturi label marking matches the boiler size (see
Table 2A).
*Note: The air shutter should have the hole oriented towards the back
right corner of the unit.

14
Installation & Operation Manual
⚠WARNING After converting to LP, check combustion
per the Start-up procedure in Section 10
of this manual. Failure to check and verify
combustion could result in severe personal
injury, death, or substantial property damage.
2 Prepare boiler
BLOWER
VENTURI
SCREWS (4)
AIR
SHUTTER
GASKET
DIR #2000508264 00
Figure 2-1 Remove Natural Gas Venturi
⚠DANGER When removing the natural gas
venturi, inspect the gasket at the gas
connection and the O-ring at the
blower. These gaskets must be in
good condition and must be installed.
Failure to comply will cause a gas
leak, resulting in severe personal
injury or death.

15
Installation & Operation Manual
3 General venting
DIR #2000507755 00
DIR #2000507732 00
Figure 3-1 Two-Pipe Sidewall Termination - See
page 23 for more details Figure 3-2 PVC/CPVC Concentric Sidewall
Termination - See page 27 for more details
Direct venting options - Sidewall Vent
DIR #2000507759 00
Figure 3-3 Two-Pipe Vertical
Termination - See page 30 for
more details
Direct venting options - Vertical Vent
DIR #2000507752 00
Figure 3-4 PVC/CPVC Concentric
Vertical Termination - See page 32
for more details
DIR #2000507739 00
Figure 3-5 Vertical Vent, Sidewall
Air

Installation & Operation Manual
3 General venting
This appliance requires a special venting
system. Use only approved stainless steel,
PVC, CPVC or polypropylene pipe and
fittings listed in Tables 3D, 3E, and 3G for
vent pipe and fittings. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
Installation must comply with local
requirements and with the National
Fuel Gas Code, ANSI Z223.1 for U.S.
installations or CSA B149.1 for Canadian
installations.
Install vent and combustion air piping
⚠DANGER The AQUAS Fire Tube boiler must be
vented and supplied with combustion and
ventilation air as described in this section.
Ensure the vent and air piping and the
combustion air supply comply with these
instructions regarding vent system, air
system, and combustion air quality. See
also Section 1 of this manual.
Inspect finished vent and air piping
thoroughly to ensure all are airtight and
comply with the instructions provided and
with all requirements of applicable codes.
Failure to provide a properly installed vent
and air system will cause severe personal
injury or death.
⚠WARNING
NOTICE
⚠WARNING For closet and alcove installations, CPVC,
polypropylene, or stainless steel material
MUST BE used in a closet/alcove structure.
Failure to follow this warning could result
in fire, personal injury, or death.
Air intake/vent connections
1. Combustion Air Intake Connector (FIG. 3-6) - Used to
provide combustion air directly to the unit from outdoors.
On Model 285, a fitting is provided on the unit for
final connection. Combustion air piping must be supported
per guidelines listed in the National Mechanical Code,
Section 305, Table 305.4 or as local codes dictate.
2. Vent Connector (FIG.'s 3-7 thru 3-10) - Used to provide a
passageway for conveying combustion gases to the
outside. A transition fitting is provided on the unit for
final connection. Vent piping must be supported per the
National Building Code, Section 305, Table 305.4 or as
local codes dictate.
The AQUAS Fire Tube boiler vent and air piping can be
installed through the roof or through a sidewall. Follow the
procedures in this manual for the method chosen. Refer to the
information in this manual to determine acceptable vent and
air piping length.
You may use any of the vent/air piping methods covered in this
manual. Do not attempt to install the AQUAS Fire Tube boiler
using any other means.
You must also install air piping from outside to the boiler
air intake adapter unless following the Optional Room Air
instructions on page 19 of this manual. The resultant installation
is direct vent (sealed combustion).
⚠WARNING DO NOT mix components from different
systems. The vent system could fail,
causing leakage of flue products into the
living space. Mixing of venting materials
will void the warranty and certification of
the appliance.
⚠WARNING Do not connect any other appliance to
the vent pipe or multiple boilers to a
common vent pipe. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
Improper installation of venting systems
may result in injury or death.
⚠CAUTION
Follow the instructions in Section 1, page
12 of this manual when removing a boiler
from an existing vent system.
NOTICE
16
DIR #2000507838 00
AIR INLET
Figure 3-6 Near Boiler Air Piping

Installation & Operation Manual
3 General venting (continued)
17
Requirements for installation in
Canada
1. Installations must be made with a vent pipe system
certified to ULC-S636.
2. The first three (3) feet of plastic vent pipe from the
appliance flue outlet must be readily accessible for visual
inspection.
3. The components of the certified vent system must not be
interchanged with other vent systems or unlisted
pipe/fittings. For concentric vent installations, the inner
vent tube must be replaced with field supplied certifiedvent
material to comply with this requirement.
4. The 3" and 4" Concentric Vent Kit available from
Lochinvar (see Section 4 – Sidewall Termination – Optional
Concentric Vent) and the 3" and 4" Concentric Vent Kit
available from IPEX are both approved for use on the
AQUAS Fire Tube boiler. Both kits are listed to the ULC-
S636 standard for use in Canada.
Vent
Diameter
Vent
Supplier
Vent
Material
Part Number
Lochinvar SAP /
Legacy
3 inch Lochinvar PVC 100140480
4 inch Lochinvar PVC 100140484
3 inch IPEX PVC 196006
4 inch IPEX PVC 196021
3 inch IPEX CPVC 197009
4 inch IPEX CPVC 197021
Table 3B Approved Concentric Vent Systems
Sizing
The AQUAS Fire Tube boiler uses model specific combustion
air intake and vent piping sizes as detailed in Table 3A below.
Model Inlet
Diameter
Vent
Diameter
Maximum
Length
285 3 inches / 4 inches 3 inches / 4 inches 50 feet / 100 feet
Table 3A Air Intake/Vent Piping Sizes
Increasing or decreasing combustion air or
vent piping sizes is not authorized.
NOTICE
When determining equivalent combustion air and vent
length, add 5 feet for each 90° elbow and 3 feet for each 45°
elbow.
EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2)
45° elbows + (1) concentric vent kit (100140480) = 49
equivalent feet of piping.
For Model 285 using 3" venting, the first
seven (7) equivalent feet of vent must be
CPVC or polypropylene (field supplied).
This includes any transition piece used to
increase or decrease the vent diameter.
NOTICE
The minimum combustion air and vent
piping length is 12 equivalent feet.
NOTICE
The appliance output rating will reduce
by up to 2.3% for each 25 feet of vent
length. Consult factory to determine
de-rate values.
NOTICE

Installation & Operation Manual
18
3 General venting
Materials
Air inlet pipe materials:
The air inlet pipe(s) must be sealed. Choose acceptable
combustion air inlet pipe materials from the following list:
PVC, CPVC, Polypropylene or ABS
Dryer Vent or Sealed Flexible Duct (not recommended
for rooftop air inlet)
Galvanized steel vent pipe with joints and seams sealed as
specified in this section.
Type “B” double-wall vent with joints and seams sealed as
specified in this section.
AL29-4C, stainless steel material to be sealed to
specification of its manufacturer.
*Plastic pipe may require an adapter (not provided) to
transition between the air inlet connection on the appliance
and the plastic air inlet pipe.
⚠WARNING Using air intake materials other than
those specified can result in personal
injury, death, or property damage.
NOTICE The use of double-wall vent or insulated
material for the combustion air inlet pipe is
recommended in cold climates to prevent
the condensation of airborne moisture in
the incoming combustion air.
Sealing of Type “B” double-wall vent material or galvanized
vent pipe material used for air inlet piping on a sidewall or
vertical rooftop Combustion Air Supply System:
a. Seal all joints and seams of the air inlet pipe using either
Aluminum Foil Duct Tape meeting UL Standard 723 or
181A-P or a high quality UL Listed silicone sealant such as
those manufactured by Dow Corning or General Electric.
b. Do not install seams of vent pipe on the bottom of
horizontal runs.
c. Secure all joints with a minimum of three (3) sheet metal
screws or pop rivets. Apply Aluminum Foil Duct Tape or
silicone sealant to all screws or rivets installed in the vent
pipe.
d. Ensure that the air inlet pipes are properly supported.
The PVC, CPVC, or ABS air inlet pipe should be cleaned and
sealed with the pipe manufacturer’s recommended solvents
and standard commercial pipe cement for the material used.
The PVC, CPVC, ABS, Dryer Vent, or Flex Duct air inlet pipe
should use a silicone sealant to ensure a proper seal at the
appliance connection and the air inlet cap connection. Dryer
vent or flex duct should use a screw-type clamp to seal the
vent to the appliance air inlet and the air inlet cap. Proper
sealing of the air inlet pipe ensures that combustion air will be
free of contaminants and supplied in proper volume.
Follow the polypropylene manufacturer's instructions when
using polypropylene material as an inlet pipe.
When a sidewall or vertical rooftop combustion air supply
system is disconnected for any reason, the air inlet pipe
must be resealed to ensure that combustion air will be free of
contaminants and supplied in proper volume.
⚠DANGER Failure to properly seal all joints and seams
as required in the air inlet piping may
result in flue gas recirculation, spillage
of flue products and carbon monoxide
emissions causing severe personal injury
or death.

Installation & Operation Manual
19
3 General venting (continued)
Air contamination
Pool and laundry products and common household and hobby
products often contain fluorine or chlorine compounds. When
these chemicals pass through the boiler, they can form strong
acids. The acid can eat through the boiler wall, causing serious
damage and presenting a possible threat of flue gas spillage or
boiler water leakage into the building.
Please read the information given in Table 1B, page 11,
listing contaminants and areas likely to contain them. If
contaminating chemicals will be present near the location of the
boiler combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per this manual.
If the boiler combustion air inlet is located in
a laundry room or pool facility, for example,
these areas will always contain hazardous
contaminants.
To prevent the potential of severe personal
injury or death, check for areas and products
listed in Table 1B, page 11 before installing
the boiler or air inlet piping.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
• Relocate air inlet and vent terminations
to other areas.
⚠WARNING
⚠WARNING
Optional room air
⚠WARNING When utilizing the single pipe method,
provisions for combustion and ventilation
air must be in accordance with Air for
Combustion and Ventilation, of the latest
edition of the National Fuel Gas Code,
ANSI Z223.1, in Canada, the latest edition
of CGA Standard B149 Installation
Code for Gas Burning Appliances and
Equipment, or applicable provisions of
the local building codes.
Model Vent
Diameter
Part Number
SAP
285 2 inch 100157614
Table 3C Optional Room Air Kit
Commercial applications utilizing the AQUAS Fire Tube
boiler may be installed with a single pipe carrying the flue
products to the outside while using combustion air from
the equipment room. In order to use the room air venting
option the following conditions and considerations must be
followed.
• The unit MUST be installed with the appropriate
room air kit (Table 3C).
• The equipment room MUST be provided with
properly sized openings to assure adequate
combustion air. Please refer to instructions provided
with the room air kit.
• There will be a noticeable increase in the noise level
during normal operation from the inlet air opening.
• Using the room air kit makes the unit vulnerable to
combustion air contamination from within the
building. Please review Section 1, Prevent
Combustion Air Contamination, to ensure proper
installation.
• Vent system and terminations must comply with the
standard venting instructions set forth in this
manual.
NOTICE Optional room air is intended for
commercial applications. Combustion
air piping to the outside is recommended
for residential applications.

20
3 General venting
Installation & Operation Manual
Installing vent and air piping
Use only cleaners, primers, and solvents
that are approved for the materials which
are joined together.
NOTICE
1. Work from the boiler to vent or air termination. Do
not exceed the lengths given in this manual for the air
or vent piping.
2. Cut pipe to the required lengths and deburr the inside
and outside of the pipe ends.
3. Chamfer outside of each pipe end to ensure even
cement distribution when joining.
4. Clean all pipe ends and fittings using a clean, dry rag.
(Moisture will retard curing and dirt or grease will
prevent adhesion.)
5. Dry fit vent or air piping to ensure proper fit up before
assembling any joint. The pipe should go a third to
two-thirds into the fitting to ensure proper sealing
after cement is applied.
6. Priming and Cementing:
a. Handle fittings and pipes carefully to prevent
contamination of surfaces.
b. Apply a liberal even coat of primer to the fitting
socket and to the pipe end to approximately 1/2"
beyond the socket depth.
c. Apply a second primer coat to the fitting socket.
d. While primer is still wet, apply an even coat of
approved cement to the pipe equal to the
depthof thefittingsocket alongwithan evencoatof
approved cement to the fitting socket.
e. Apply a second coat of cement to the pipe.
f. While the cement is still wet, insert the pipe into
the fitting, if possible twist the pipe a 1/4 turn as
you insert it. NOTE: If voids are present,
sufficient cement was not applied and joint could
be defective.
g. Wipe excess cement from the joint removing ring
or beads as it will needlessly soften the pipe.
PVC/CPVC
Table 3D PVC/CPVC Vent Pipe, and Fittings
All PVC vent pipes must be glued, properly
supported, and the exhaust must be
pitched a minimum of a 1/4 inch per foot
back to the boiler (to allow drainage of
condensate).
NOTICE
⚠WARNING Insulation should not be used on PVC
or CPVC venting materials. The use of
insulation will cause increased vent wall
temperatures, which could result in vent
pipe failure.
Approved PVC/CPVC Vent Pipe and Fittings
Item Material Standard
Vent pipe
PVC Schedule 40, 80 ANSI/ASTM D1785
PVC - DWV ANSI/ASTM D2665
CPVC Schedule 40, 80 ANSI/ASTM F441
Vent fittings
PVC Schedule 40 ANSI/ASTM D2466
PVC Schedule 80 ANSI/ASTM D2467
CPVC Schedule 40 ANSI/ASTM F438
CPVC Schedule 80 ANSI/ASTM F439
PVC - DMV ANSI/ASTM D2665
Pipe Cement /
Primer
PVC ANSI/ASTM D2564
CPVC ANSI/ASTM F493
NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE
CPVC TEE SUPPLIED
WITH BOILER
DIR #2000507838 00
NOTE: CPVC VENT PIPE AND VENT FITTINGS MUST BE USED IN CLOSET
AND ALCOVE INSTALLATIONS.
Figure 3-7 Near Boiler PVC/CPVC Venting
This product has been approved for use with the PVC/CPVC
vent materials listed in Table 3D.
NOTE: In Canada, CPVC and PVC vent pipe, ttings, and cement/
primer must be ULC-S636 certied.