Lochinvar SOLUTION 260000 Supplement

Installation & Service Manual
Models: 45,000 - 260,000 Btu/hr
This manual supplies information for the installation,
operation, and servicing of the appliance. It is strongly
recommended that this manual be reviewed completely
before proceeding with an installation. 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.
SBR-I-S Rev B

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.
Contents
HAZARD DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
PLEASE READ BEFORE PROCEEDING . . . . . . . . . . . . 3-4
RATINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
THE SOLUTION --HOW IT WORKS . . . . . . . . . . . . . . . . . . . 6-8
1. DETERMINE BOILER LOCATION
Location of Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Combustion and Ventilation Air . . . . . . . . . . . . . . . . . . . 10-12
2. VENTING
A Conventional Negative Draft Venting System . . . . . . . 13-14
Vertical Vent Termination Clearances . . . . . . . . . . . . . . . 15
Masonry Chimney Installation . . . . . . . . . . . . . . . . . . . . . 16
Inspection of a Masonry Chimney . . . . . . . . . . . . . . . 16
Automatic Vent Damper . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3. GAS CONNECTIONS
Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Pressure Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Gas Manifold Pressure Adjustment Procedure . . . . . . . . 20
Checking Gas Supply Pressure . . . . . . . . . . . . . . . . . . . 21
Combination Gas Valves . . . . . . . . . . . . . . . . . . . . . . . . . 22
4. WATER CONNECTIONS
Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Water Flow Switch (if equipped) . . . . . . . . . . . . . . . . . . . 23
Low Water Cutoff (if equipped) . . . . . . . . . . . . . . . . . . . . 24
Typical Heating Boiler Installations . . . . . . . . . . . . . . . . . 24-25
Piping of the Boiler System . . . . . . . . . . . . . . . . . . . . . . . 25
Performance Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Primary/Secondary Boiler Piping . . . . . . . . . . . . . . . . . . . 27-28
Low Temperature Bypass Requirements . . . . . . . . . . . . . 28
Boiler Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Primary / Secondary Piping . . . . . . . . . . . . . . . . . . . . 29-31
Full System Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32-33
5. ELECTRICAL CONNECTIONS
Boiler Operating Temperature Control . . . . . . . . . . . . . . . 34
Room Thermostat or Remote Thermostat Connection . . 34
Auxiliary Device Connection to Terminal Strip . . . . . . . . . 34
Pump Wiring for a Heating Boiler . . . . . . . . . . . . . . . . . . 35
Temperature Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 35
Temperature Control Settings . . . . . . . . . . . . . . . . . . . . . 35
Maximum Set Point Determination . . . . . . . . . . . . . . . . . 36
Outdoor Air Reset Option . . . . . . . . . . . . . . . . . . . . . . . . 38
Additional Temperature Controls . . . . . . . . . . . . . . . . . . . 38
Blocked Vent and Flame Roll-Out / Flame Interlock Switch . 39
6. STARTUP
Initial Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Lighting Instructions for Spark Ignition Pilot Models (M9) . . . . 40
Safety Shutoff Test for Spark Ignition Pilot System . . . . . . 41
Intermittent Pilot Spark Ignition System (M9) . . . . . . . . . . . . 42
Freeze Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7. MAINTENANCE
Maintenance and Annual Startup . . . . . . . . . . . . . . . . . . 43-48
8. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . 49
9. DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

3
Installation & Service Manual
Please read before proceeding
NOTICE This is a gas appliance and should be
installed by a licensed electrician and/or
certified gas supplier. Service must be
performed by a qualified service installer,
service agency or the gas supplier.
WARNING If the information in these instructions is
not followed exactly, a fire or explosion may
result causing property damage, personal
injury, or death.
This appliance MUST NOT be installed in
any location where gasoline or flammable
vapors are likely to be present, unless the
installation is such to eliminate the probable
ignition of gasoline or flammable vapors.
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.
Warranty –
Installation and service must be performed by a qualified
service installer, service agency or the gas supplier.
Factory warranty (shipped with unit) does not apply to units
improperly installed or improperly operated.
Experience has shown that improper installation or system
design, rather than faulty equipment, is the cause of most
operating problems.
1. Excessive water hardness causing a lime/scale build-up in
the copper tube is not the fault of the equipment and is
not covered under the manufacturer’s warranty (see
Water Treatment and Water Chemistry).
2. Excessive pitting and erosion on the inside of the copper
tube may be caused by too much water velocity through
the tubes and is not covered by the manufacturer’s
warranty (see Boiler Flow Rates and Temperature Rise for
flow requirements).
Checking equipment –
Upon receiving equipment, check for signs of shipping damage.
Pay particular attention to parts accompanying the appliances
which may show signs of being hit or otherwise being
mishandled. Verify total number of pieces shown on the
packing slip with those actually received. In case there is damage
or a shortage, immediately notify the carrier.
Do not use this appliance 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.
WARNING Improper installation, adjustment,
alteration, service or maintenance can result
in severe personal injury, death, or
substantial property damage. Refer to this
manual for assistance or additional
information, consult a qualified installer,
service agency or the gas supplier.
Owner warning –
NOTE: Retain this manual for future reference.
The information contained in this manual is intended for use by
qualified professional installers, service technicians, or gas
suppliers. Consult your local expert for proper installation or
service procedures.
IMPORTANT Consult and follow all local Building and
Fire Regulations and other Safety Codes
that apply to this installation. Consult your
local gas utility company to authorize and
inspect all gas and flue connections.
Your conventionally vented gas appliance must have a supply of
fresh air circulating around it during burner operation for
proper gas combustion and proper venting.
WARNING Should overheating occur or the gas supply
fail to shut off, do not turn off or disconnect
the electrical supply to the pump. Instead,
shut off the gas supply at a location external
to the appliance.

4
Installation & Service Manual
Please read before proceeding
WARNING To minimize the possibility of serious
personal injury, fire, or damage to your
appliance, never violate the following safety
rules:
1. Boilers are heat producing appliances. To
avoid damage or injury, do not store
materials against the appliance or the
vent-air intake system. Use proper care
to avoid unnecessary contact (especially
children) with the appliance and vent-air
intake components.
2. Never cover your appliance, lean
anything against it, store trash or debris
near it, stand on it or in any way block
the flow of fresh air to your appliance.
3. UNDER NO CIRCUMSTANCES must
flammable materials such as gasoline or
paint thinner be used or stored in the
vicinity of this appliance, vent-air intake
system or any location from which fumes
could reach the appliance or vent-air
intake system.
Codes –
The equipment shall be installed in accordance with those
installation regulations in force in the local area where the
installation is to be made. These regulations shall be carefully
followed in all cases. Authorities having jurisdiction shall be
consulted before installations are made. In the absence of such
requirements, the installation shall conform to the latest edition
of the National Fuel Gas Code, ANSI Z223.1. Where required by
the authority having jurisdiction, the installation must conform
to American Society of Mechanical Engineers Safety Code for
Controls and Safety Devices for Automatically Fired Boilers,
ASME CSD-1. All boilers conform to the latest edition of the
ASME Boiler and Pressure Vessel Code, Section IV. Where
required by the authority having jurisdiction, the installation
must comply with the Canadian Association Code, CAN/CGA-
B149.1 and/or B149.2 and/or local codes.
This appliance meets the safe lighting performance criteria with
the gas manifold and control assembly provided as specified in
the ANSI standards for gas-fired appliances, ANSI Z21.13 and
ANSI Z21.10.3.

5
Ratings
Notes:
1. The ratings are based on standard test procedures
prescribed by the United States Department of Energy.
2. Net I=B=R 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.
3. Use only the vent materials and methods specified in the
Installation and Service Manual.
4. The Solution is orificed for operation up to 2000 feet
altitude. The appliance will be derated 4% per 1000 feet
above 2000 feet elevation. Consult the factory for
installations above 2000 feet elevation.
5. Ratings have been confirmed by the Hydronics Institute,
Section of AHRI.
Maximum allowed working pressure is located on the rating plate.
NOTICE
Installation & Service Manual
Solution Boiler
I=B=R Rating
Model Number
Note: Change “N” to
“L” for L.P. gas models.
Input
MBH
(Note 4)
Min Max
Gross
Output
MBH
(Note 1,5)
Net
I=B=R
Ratings
Water,
MBH
(Note 1,5)
CBN045 23 45 37 32
CBN075 38 75 62 54
CBN090 45 90 75 65
CBN135 68 135 112 97
CBN180 90 180 149 130
CBN215 108 215 178 155
CBN260 130 260 216 188
Other Specifications
Boiler Water
Content
Gallons
Water
Connections
Gas
Connections
Vent
Size
(Note 3)
0.87 1 1/2" 1/2" 4"
0.91 1 1/2" 1/2" 5"
0.91 1 1/2" 1/2" 5"
0.95 1 1/2" 1/2" 6"
0.99 1 1/2" 3/4" 7"
1.02 1 1/2" 3/4" 7"
1.06 2" 3/4" 8"
Figure A High Altitude Label Location
UNIT EQUIPPED FOR
HIGH ALTITUDE
UP TO 2000 FT.

The Solution - How it works...
1. Control panel cover
The control panel cover provides access to the thermostat, ignition
module, and transformer.
2. Burner (not shown)
The burner is a cylindrical stainless steel tube used to regulate
burner flame.
3. Drain port
Location from which the heat exchanger can be drained.
4. Flue outlet
The flue outlet allows the connection of the vent pipe to the unit.
5. Gas connection
The gas pipe connection on this appliance is 1/2", or 3/4" NPT. To
deliver the correct amount of gas volume to the appliance it may
be necessary to have a larger gas line reduced at the appliance.
Please reference the National Fuel Gas Code charts for more
details.
6. Gas valve
The gas valve allows the proper amount of gas to pass into the
burner for combustion.
7. Heat exchanger
The heat exchanger allows system water to flow through specially
designed tubes for maximum heat transfer. The glass lined
headers and copper finned tubing are encased in a jacket that
contains the combustion process.
8. High limit sensor
Device that monitors the outlet water temperature to ensure
safe operation. If the temperature exceeds its setting, it will break
the control circuit, shutting the appliance down.
9. Ignition module
The ignition module responds to a call for heat signal to provide
burner operation.
10. Junction box
The junction box contains the connection points for the line
voltage power and all pumps.
11. Performance loop
A pumped bypass provides constant flow through the heat
exchanger when the building system flow is reduced.
12. Performance Loop Pump
The pump ensures adequate flow to operate the unit.
13. Pilot (not shown)
The pilot is a spark ignition device used to light a pilot flame which
in turn is used to light the main burners.
14. Pump relay
The pump relay energizes the pump on a call for heat.
15. Relief valve
The relief valve is a safety device that ensures the maximum
pressure of the appliance is not exceeded.
16. Sight Glass
The sight glass provides a view of the burner surface, burner flame,
and the pilot flame.
17. Temperature and pressure gauge
The temperature and pressure gauge monitors the outlet
temperature of the appliance as well as the system water
pressure.
18. Temperature sensor
This sensor monitors inlet water temperature. If selected as the
controlling sensor, the appliance will maintain the setpoint at this
sensor.
19. Terminal strip
The boiler is equipped with a terminal strip on the left side of the
unit to allow easy connection to contact points.
20. Top panel
Removable panel to gain access to the internal components.
21. Thermostat
The thermostat monitors the water temperature via a temperature
sensor and will initiate a call for heat when the water temperature
drops below the setpoint plus the differential on the thermostat.
22. Transformer
The transformer reduces 120 VAC supply voltage to 24 VAC for the
control circuit.
23. Water inlet (system return)
The water inlet is a 1 1/2" pipe connection that receives water
from the system and delivers it to the heat exchanger.
24. Water outlet (system supply)
The water outlet is a 1 1/2" pipe connection that supplies
water to the system with connections for a flow switch, a relief
valve, and a temperature and pressure gauge.
25. Gas manifold pipe
Delivers gas from the gas valve to the main burners through a
number of orifices.
Installation & Service Manual
6

Models 45,000 - 90,000 Btu/hr Front View
Models 45,000 - 90,000 Left Side (inside unit)
Models 45,000 - 90,000 Right Side (inside unit)
Models 45,000 - 90,000 Rear View
The Solution - How it works... (continued)
11
22
14
23
21
25
9
16
7
18
12
6
24
1
10
19
8
3
17
15
5
4
20
Installation & Service Manual
7

8
Installation & Service Manual
The Solution - How it works...
Models 135,000 - 260,000 Btu/hr Left Side (inside unit)
Models 135,000 - 260,000 Btu/hr Right Side (inside unit)
Models 135,000 - 260,000 Btu/hr Rear View
Models 135,000 - 260,000 Btu/hr Front View
10
1
19
3
8
15
17
5
4
20
22
21
9
14
25
23
11
3
3
7
18
12
24
6

Installation & Service Manual
1 Determine boiler location
NOTICE Clearances from combustible construction
are noted on the appliance rating plate.
Location of unit
1. 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.
2. The appliance must be installed indoors where it is
protected from exposure to wind, rain and weather.
3. The appliance must be installed so that the ignition system
components are protected from water (dripping, spraying,
rain, etc.,) during appliance operation and service
(circulator replacement, control replacement, etc.,).
4. Appliances located in a residential garage and in adjacent
spaces that open to the garage and are not part of the
living space of a dwelling unit must be installed so that all
burners and burner ignition devices have a minimum
clearance of not less than 18" (46cm) above the floor. The
appliance must be located or protected so that it is not
subject to physical damage by a moving vehicle.
5. DO NOT install this appliance in any location where
gasoline or flammable vapors are likely to be present.
6. All units have been approved for alcove installation (an
ALCOVE is a closet enclosure without a front door).
7. The appliance must not be installed on carpet.
8. All units have been approved for use on combustible
surfaces.
9. Allow sufficient space for servicing pipe connections,
pump and other auxiliary equipment, as well as the
appliance.
Figure 1-1_Alcove Installation - Models 45,000 -
180,000 Btu/hr
18 "
FRONT
18 "
LEFT
6 " RIGHT
14"
TOP
6 " REAR
Recommended Service Clearances:
Left - 24”
Front - 24”
18 "
FRONT
18 "
LEFT
6 " RIGHT
29"
TOP
6 " REAR
Recommended Service Clearances:
Left - 24”
Front - 24”
Figure 1-2_Alcove Installation - Models 215,000 -
260,000 Btu/hr
9

Installation & Service Manual
10
Figure 1-3_Combustion Air Direct from Outside
Combustion and ventilation air
requirements for conventionally vented
appliances
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.
The room where the appliance is installed MUST be provided
with properly sized openings to assure adequate combustion
air and proper ventilation when the appliance is installed with
conventional venting.
1. If air is taken directly from outside the building
with no duct, provide two permanent openings (see
FIG. 1-3):
(a) Combustion air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5 cm2per kW). This opening must be
located within 12" (30 cm) of the floor.
(b) Ventilation air opening, with a minimum free
area of one square inch per 4000 Btu/hr input
(5.5 cm2 per kW). This opening must be
located within 12" (30 cm) of the ceiling.
Figure 1-4_Combustion Air Through Ducts
2. If combustion and ventilation air is taken from the
outdoors using a duct to deliver the air to the room where
the appliance is installed, each of the two openings should
be sized based on a minimum free area of one square inch
per 2000 Btu/hr (11cm2per kW) (see FIG. 1-4).
Figure 1-5_Combustion Air from Interior Space
3. If air is taken from another interior space that is adequately
ventilated, each of the two openings specified above should
have a net free area of one square inch for each 1000 Btu/hr
(22cm2per kW) of input, but not less than 100 square
inches (645cm2) (see FIG. 1-5).
1 Determine boiler location

4. If a single combustion air opening is provided to bring
combustion air in directly from the outdoors, the
opening must be sized based on a minimum free area of
one square inch per 3000 Btu/hr (7 cm2per kW). This
opening must be located within 12" (30 cm) of the top of
the enclosure (see FIG. 1-6).
Figure 1-6_Combustion Air from Outside Single Opening
Combustion air requirements are based on the latest edition
of the National Fuel Gas Code, ANSI Z223.1, in Canada refer
to National Standard CAN B149.1. Check all local code
requirements for combustion air.
All dimensions are based on net free area in square inches.
Metal louvers or screens reduce the free area of a combustion
air opening a minimum of approximately 25%. Check with
louver manufacturers for exact net free area of louvers. Where
two openings are provided, one must be within 12" (30 cm) of
the ceiling and one must be within 12" (30 cm) of the floor of
the room where the appliance is installed. Each opening must
have a net free area as specified in Table 1B (on page 12).
Single openings shall be located within 12" (30 cm) of the
ceiling.
CAUTION Under no circumstances should the room
where the appliance is installed ever be
under a negative pressure. Particular care
should be taken where exhaust fans, attic
fans, clothes dryers, compressors, air
handling units, etc., may take away air from
the appliance.
The combustion air supply must be completely free of any
flammable vapors that may ignite or chemical fumes which may
be corrosive to the appliance. Common corrosive chemical
fumes which must be avoided are fluorocarbons and other
halogenated compounds, most commonly present as
refrigerants or solvents, such as freon, tricholorethylene,
perchlorethylene, chlorine, etc. These chemicals, when burned,
form acids which quickly attack the heat exchanger finned tubes,
headers, flue collectors, and the vent system. The result is
improper combustion and a non-warrantable, premature
appliance failure.
The result is improper combustion and a non-warrantable,
premature appliance failure.
EXHAUST FANS: Any fan or equipment which exhausts air
from the equipment room may deplete the combustion air
supply and/or cause a downdraft in the venting system. Spillage
of flue products from the venting system into an occupied living
space can cause a very hazardous condition that must be
immediately corrected. If a fan is used to supply combustion air
to the equipment room, the installer must make sure that it does
not cause drafts which could lead to nuisance operational
problems with the appliance.
Installation & Service Manual
11
1 Determine boiler location (continued)

Installation & Service Manual
12
TABLE - 1B
MINIMUM RECOMMENDED COMBUSTION
AIR SUPPLY TO EQUIPMENT ROOM
Input
Btu/hr
*Outside Air from
2 Openings Directly from
Outdoors
*Outside Air from
1 Opening Directly
from Outdoors, in2
*Outside Air from
2 Ducts Delivered from
Outdoors
**Inside Air from
2 Ducts Delivered from
Interior Space
Top
Opening, in2
Bottom
Opening, in2
Top
Opening, in2
Bottom
Opening, in2
Top
Opening, in2
Bottom
Opening, in2
45,000 12
(78 cm2)
12
(78 cm2)
15
(97 cm2)
23
(149 cm2)
23
(149 cm2)
100
(646 cm2)
100
(646 cm2)
75,000 19
(123 cm2)
19
(123 cm2)
25
(162 cm2)
38
(246 cm2)
38
(246 cm2)
100
(646 cm2)
100
(646 cm2)
90,000 23
(148 cm2)
23
(148 cm2)
30
(194 cm2)
45
(291 cm2)
45
(291 cm2)
100
(646 cm2)
100
(646 cm2)
135,000 34
(220 cm2)
34
(220 cm2)
45
(291 cm2)
68
(439 cm2)
68
(439 cm2)
135
(871 cm2)
135
(871 cm2)
180,000 45
(291 cm2)
45
(291 cm2)
60
(388 cm2)
90
(581 cm2)
90
(581 cm2)
180
(1,162 cm2)
180
(1,162 cm2)
215,000 54
(349 cm2)
54
(349 cm2)
72
(465 cm2)
108
(697 cm2)
108
(697 cm2)
215
(1,388 cm2)
215
(1,388 cm2)
260,000 65
(420 cm2)
65
(420 cm2)
87
(562 cm2)
130
(839 cm2)
130
(839 cm2)
260
(1,678 cm2)
260
(1,678 cm2)
*Outside air openings shall directly communicate with the outdoors. When combustion air is drawn from the outside through a
duct, the net free area of each of the two openings must have twice (2 times) the free area required for Outside Air/2 Openings.
The above requirements are for the boiler only; additional gas fired appliances in the equipment room will require an increase in
the net free area to supply adequate combustion air for all appliances.
**Combined interior space must be 50 cubic feet per 1,000 Btu/hr input. Buildings MUST NOT be of *“Tight Construction”.
For buildings of *“Tight Construction”, provide air openings into the building from outside.
*No combustion air openings are needed when the water heater is installed in a space with a volume NO LESS than 50 cubic feet
per 1,000 Btu/hr of all installed gas fired appliances. Buildings MUST NOT be of *“Tight Construction”.
*”Tight Construction” is defined as a building with less than 0.40 ACH (air changes per hour).
The distance of the vent terminal from adjacent
buildings, windows that open and building openings MUST
comply with 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 Equip-
ment.
Vent connection is made directly to the top of the
appliance. This appliance is designed with a built-in draft
diverter. No additional external draft hood is required. The
connection from the appliance vent to the common vent or
chimney must be made as direct as possible.
Vent installations for connection to gas vents or
chimneys must be in accordance with “Venting of
Equipment,” 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.
Adequate combustion and ventilation air must be
supplied to the room where the appliance is installed in
accordance with 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.
1 Determine boiler location

Installation & Service Manual
13
2 Venting
A Conventional Negative Draft
Venting System
The negative draft in a conventional vent installation must be
within the range of a negative 0.02 to 0.05 inches water
column to ensure proper operation. All draft readings are
made while the appliance is in stable operation
(approximately 2 to 5 minutes).
Multiple appliance installations with combined venting or
common venting with other negative draft appliances require
that each appliance must have draft within the proper range.
If the draft measured above the appliance’s built-in draft
diverter exceeds the specified range in a dedicated chimney
for a single appliance installation or in combined venting with
other negative draft appliances, a barometric damper must be
installed to control draft.
Figure 2-1_Conventional Negative Draft Vertical Venting
TABLE - 2A
VENT PIPE SIZES
Input Btu/hr Flue Size
45,000 4"
75,000 5"
90,000 5"
135,000 6"
180,000 7"
215,000 7"
260,000 8"
On a conventionally vented, negative draft appliance, the
connection from the vent to the chimney or vent termination
on the outside of the building MUST be made with listed Type
“B” double wall (or equivalent) vent connectors and must be
direct as possible with no reduction in diameter. Use the
National Fuel Gas Code venting tables for double wall vent to
properly size all vent connectors and stacks. The Type “B” vent
and accessories, such as firestop spacers, thimbles, caps, etc.,
MUST be installed in accordance with the manufacturer’s
listing. The vent connector and firestop must provide correct
spacing to combustible surfaces and seal to the vent connector
on the upper and lower sides of each floor or ceiling through
which the vent connector passes.
Any vent materials used must be listed by a nationally
recognized test agency for use as vent material.

Locate appliance as close as possible to a chimney or gas vent.
Avoid long horizontal runs of the vent pipe, 90° elbows,
reductions and restrictions. Horizontal portions of the
venting system shall be supported to prevent sagging.
Horizontal runs must slope upwards not less than 1/4 inch
per foot (21 mm/m) from the appliance to the vent terminal.
Follow manufacturer’s instructions.
Do not use an existing chimney as a raceway for a flue pipe if
another appliance or fireplace is vented through the chimney.
The weight of the venting system must not rest on the
appliance. Adequate support of the venting system must be
provided in compliance with local codes and other applicable
codes. All connections should be secured with rustproof
sheet metal screws.
Vent connectors serving appliances vented by natural draft
shall not be connected to any portion of a
mechanical draft system operating under positive
pressure. Connection to a positive pressure chimney may
cause flue products to be discharged into the living space
causing serious health injury.
Common venting systems may be too large when an existing
appliance is removed. At the time of removal of an existing
appliance, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while other appliances remaining
connected to the common venting system are not in
operation.
(a) Seal any unused opening 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 and other
deficiencies which could cause an unsafe condition.
(c) Insofar as is practical, close all building doors and
windows and all doors between the space in which
the appliances remaining connected to the common
venting system are located and other spaces of the
building. Turn on clothes dryers and any other
appliances 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 above, return
doors, windows, exhaust fans, fireplace dampers and
other gas burning appliances to their previous
conditions of use.
(g) Any improper operation of the common venting
system should be corrected so that the installation
conforms to 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.
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 in 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.
Installation & Service Manual
2 Venting
14

Vertical Vent Termination Clearances
Figure 2-2_Vent Termination from Peaked Roof 10' or
Less from Ridge
Figure 2-4_Vent Termination from Flat Roof 10' or Less
from Parapet Wall
Figure 2-3_Vent Termination from Peaked Roof More
than 10' from Ridge
Figure 2-5_Vent Termination from Flat Roof More Than
10' from Parapet Wall
The vent terminal should be vertical and exhaust outside the
building at least 2 feet (0.61m) above the highest point of the
roof within a 10 foot (3.05m) radius of the termination. The
vertical termination must be a minimum of 3 feet (0.91m)
above the point of exit.
A vertical terminal less than 10 feet (3.05m) from a parapet
wall must be a minimum of 2 feet (0.61m) higher than the
parapet wall.
The vent cap should have a minimum clearance of 4 feet
(1.22m) horizontally from and in no case above or below,
unless a 4 foot (1.22m) horizontal distance is maintained
from electric meters, gas meters, regulators and relief
equipment.
The venting system shall terminate at least 3 feet (0.9m) above
any forced air inlet within 10 feet (3.05m).
The venting system shall terminate at least 4 feet (1.2m)
below, 4 feet (1.2m) horizontally from, or 1 foot (30cm) above
any door, window or gravity air inlet into any building.
Do not terminate the vent in a window well, stairwell, alcove,
courtyard or other recessed area. The vent can not terminate
below grade. The bottom of the vent terminal shall be located
at least 12 inches (30cm) above grade.
To avoid a blocked vent condition, keep the vent cap clear of
snow, ice, leaves, debris, etc.
Flue gases will form a white plume in winter. Plume could
obstruct window view.
Flue gas condensate can freeze on exterior surfaces or on the
vent cap. Frozen condensate on the vent cap can result in a
blocked vent condition. Flue gas condensate can cause
discoloration of exterior building surfaces. Adjacent brick or
masonry surfaces should be protected with a rust resistant sheet
metal plate.
NOTICE Examine the venting system at least once a
year. Check all joints and vent pipe
connections for tightness. Also check for
corrosion or deterioration. Immediately
correct any problems observed in the
venting system.
2' MIN
10' OR LESS
3' MIN
CHIMNEY
RIDGE
MORE THAN 10'
10'
2' MIN
3' MIN
CHIMNEY
RIDGE
2' MIN
10' OR LESS 10' OR LESS
2' MIN
3' MIN
CHIMMEY WALL OR
PARAPET
CHIMMEY
10' OR MORE
3'
NOTE:
NO HEIGHT ABOVE
PARAPET REQUIRED
WHEN DISTANCE
FROM WALLS OR
PARAPETS IS MORE
THAN 10'.
WALL OR
PARAPET CHIMNEY
Installation & Service Manual
15
2 Venting (continued)

Installation & Service Manual
16
Masonry Chimney Installation
A masonry chimney must be properly sized for the
installation of a gas fired appliance. Venting of an appliance
into a cold or oversized masonry chimney can result in
operational and safety problems. Exterior masonry
chimneys, with one or more sides exposed to cold outdoor
temperatures, are more likely to have venting problems. The
temperature of the flue gases from an appliance may not be
able to sufficiently heat the masonry structure of the chimney
to generate proper draft. This will result in condensing of flue
gases, damage the masonry flue/tile, insufficient draft and
possible spillage of flue gases into an occupied living space.
Carefully inspect all chimney systems before installation. If
there is any doubt about the sizing or condition of a masonry
chimney, it must be relined with a properly sized and
approved chimney liner system.
Inspection of a Masonry Chimney
A masonry chimney must be carefully inspected to determine
its suitability for the venting of flue gases. A clay tile lined
chimney must be structurally sound, straight and free of
misaligned tile, gaps between liner sections, missing sections
of liner or any signs of condensate drainage at the breaching
or clean out. If there is any doubt about the condition of a
masonry chimney, it must be relined. An unlined masonry
chimney must not be used to vent flue gases from this appliance.
An unlined chimney must be relined with an approved
chimney liner system when a new appliance is being attached to
it. Metallic liner systems (Type “B” double wall or flexible or
rigid metallic liners) are recommended. Consult with local
code officials to determine code requirements or the
advisability of using or relining a masonry chimney.
Sidewall Venting - Negative Draft
Figure 2-6_Unit with Fan Assisted Venting
The induced draft fan MUST also be equipped with a proving
switch, properly interlocked into the appliance’s control circuit
to prove fan operation before the main burners are allowed to
fire. A vertical or sidewall vent termination for an induced draft
fan MUST be installed per the recommendations of the fan
manufacturer and provide proper clearances from any
combustion or ventilation openings, windows, doors or other
openings into the building. All induced draft fan installations
must comply with local code requirements.
Fan Assisted Venting
A Power Venter Kit is available on Models 45,000 - 135,000
Btu/hr only (see Table 2B).
TABLE - 2B
VENT MATERIALS
Kit
Number
Input
Btu/hr Material
KIT3103 45,000 PVC Rated (CPVC Optional)
75,000 PVC Rated (CPVC Optional)
KIT3104 90,000 CPVC Rated
135,000 CPVC Rated
Minimum Vent Length = 12 Equivalent Feet*
(ALL UNITS)
Maximum Vent Length = 25 Equivalent Feet*
(ALL UNITS)
* Equivalent Feet: 90° Elbow = 5 Feet
45° Elbow = 3 Feet
2 Venting
This appliance is NOT approved for sidewall venting with
the negative draft venting system as shipped from the
factory. An induced draft fan MUST be used if the
installation requires that the flue gases be vented out a
sidewall unless a power venter is used, see Fan Assisted
Venting. A properly sized and installed induced draft fan
may also be used to vent the flue gases vertically if required
by jobsite restrictions. The induced draft fan must be listed
by a nationally recognized test agency, be properly sized and
installed per the recommendations of the induced draft fan
manufacturer and meet local code requirements. Use care to
ensure that the mechanically supplied draft does not exceed
the range of a negative 0.02 to 0.05 inches water column to
ensure proper operation. If draft exceeds the specified range,
the fan must be adjusted or the installation of a barometric
damper in the flue may be required to properly control draft.
An induced draft fan MUST be interlocked into the
appliance’s control circuit to start when the appliance calls
for heat.

Installation & Service Manual
17
The vent damper is a useful tool for saving energy when
installed inside the living space where air can circulate freely
around the appliance. The vent damper will not save as much,
if any, energy if it is installed in locations such as:
- Unheated garage
- Attic
- Crawlspace
- Mechanical room that is vented outdoors
For installation and maintenance on the vent damper, refer to
the instructions supplied with the vent damper.
Residential heating boilers with inputs of less than
300,000 Btu/hr must have the vent damper properly installed
and the vent damper wire harness plugged into the terminal
block on the side of the control panel to allow the boiler to
function. Larger input heating boilers will have a jumper plug
installed in the terminal block to allow operation without a
damper. Remove the jumper plug from the terminal block to
connect an optional vent damper wire harness. The jumper
plug MUST be in place if an optional vent damper is not used
on larger input heating boilers.
CAUTION Do not install the vent damper within 6"
(152 mm) of combustible materials.
Install the vent damper to service only the single appliance for
which it is intended. If improperly installed, a hazardous
condition such as an explosion or carbon monoxide poisoning
could result.
The damper position indicator must be in a visible location
with access for service following installation. The damper
must be in an open position when appliance main burners are
operating.
The part number for the automatic vent damper required on
this heating boiler is printed on the rating plate. Vent damper
regulations are design certified per the latest edition of ANSI
Z21.66.
VENT DAMPER
Figure 2-7_Vent Damper and Vent Damper Terminal
Block
WARNING The vent damper must be installed directly
on the flue outlet located on the top of the
draft hood (see FIG. 2-7). Do not alter the
wire harness supplied with the vent damper.
Follow the instructions supplied with the
vent damper.
CAUTION An appliance which is shut down or will not
operate may experience freezing due to
convective air flow down the flue pipe
connected to the unit. Proper freeze
protection must be provided, see Freeze
Protection.
Automatic Vent Damper
This heating boiler is design certified for use with the
automatic vent damper (FIG. 15) part number printed on the
boiler’s rating plate. A vent damper must be installed on all
residential heating boilers with inputs of less than 300,000
Btu/hr to comply with minimum efficiency requirements. A
vent damper is factory supplied with residential heating
boilers with inputs of 45,000 thru 260,000 Btu/hr.
2 Venting (continued)

18
3 Gas connections
Installation & Service Manual
Gas Supply
Verify that the appliance is supplied with the type gas
specified on the rating plate. This appliance is orificed for
operation up to 2000 feet altitude. The appliance will be
derated 4% per 1000 feet above 2000 feet elevation. Consult
the factory for installations above 2000 feet elevation. Field
conversions for operation at high altitude must be performed
by certified personnel only. The appliance will be marked to
indicate suitability for high altitude operation.
GAS SUPPLY PRESSURE: Measured at the inlet pressure tap
located upstream of the combination gas valve(s) see
FIG. 3-5, page 22.
TABLE - 3A
GAS SUPPLY PRESSURE
Max. (Inches Water Column)
Natural Gas LP Gas
14 14
Min. (Inches Water Column) 4.5 11
Maximum inlet gas pressure must not exceed the value
specified. Minimum value listed is for the purposes of input
adjustment.
MANIFOLD PRESSURE: Measured at the pressure tap on
the downstream side of the combination gas valve(s) (see
FIG. 3-5, page 22). The gas regulator settings for single stage
and two stage operation are factory set to supply proper
manifold pressure for normal operation. To check manifold
pressure, see Manifold Adjustment Procedure. Do not increase
manifold pressure beyond specified pressure settings shown
below in Table 3B.
TABLE - 3B
MANIFOLD PRESSURE
Input Gas
Btu/hr
Single and
Two-Stage Two Stage
Full or High Fire
Settings Low Fire Settings
Natural
Gas LP Gas Natural Gas LP Gas
45,000 3.5" 10" 0.9" 2.5"
75,000 2.4" 7" 0.9" 2.5"
90,000 - 180,000 3.5" 10" 0.9" 2.5"
215,000 - 260,000 3.5" 10" 0.9" 2.5"
Gas Pressure Test
1. The appliance must be disconnected from the gas supply
piping system during any pressure testing of that system at
a test pressure in excess of 1/2 PSIG (3.5kPa).
2. The appliance must be isolated from the gas supply piping
system by closing a manual shutoff valve during any
pressure testing of the gas supply piping system at test
pressures equal to or less than 1/2 PSIG (3.5kPa).
3. The appliance and its gas connection must be leak-tested
before placing it in operation.
Gas Connection
1. Safe operation of the appliance requires properly sized gas
supply piping. See data in Table 3C.
2. Gas pipe size may be larger than appliance gas connection.
3. Installation of a union is suggested for ease of service, see
FIG. 3-1 on page 19.
4. Install a manual main gas shutoff valve, outside of the
appliance gas connection and before the gas valve or
manifold connection, when local codes require.
5. A trap (drip leg) MUST be provided by the installer in
the inlet of the gas connection to the appliance, see
FIG. 3-1 on page 19.
6. The combination gas valve has an integral vent limiting
device and does not require venting to atmosphere,
outside the building.
7. Optional gas controls may require routing of bleeds and
vents to the atmosphere, outside the building when
required by local codes.
TABLE - 3C
FITTINGS TO EQUIVALENT STRAIGHT PIPE
Diameter Pipe (inches)
3/4 11 1/4 1 1/2 2 3 4 5
Equivalent Length of Straight Pipe (feet)
2 2 3 4 5 10 14 20
TABLE - 3D
GAS CONNECTIONS
Btu/hr
INPUT Pipe Size
45,000 - 135,000 1/2"
180,000 - 260,000 3/4"

3 Gas connections (continued)
19
Installation & Service Manual
TABLE - 3E
GAS PIPING SIZE CHART
Nominal
Iron Pipe
Size
Inches
Length of Pipe in Straight Feet Maximum
Capacity of Pipe
in Thousands of
Btu/hr per hour
for gas pressures
of 13.5 Inches
Water Column
(0.5 PSIG) or less
and a pressure
drop of 0.5 Inch
Water Column
(Based on NAT
GAS, 1025
Btu/hr per Cubic
Foot of Gas and
0.60 Specific
Gravity)
10 20 30 40 50 60 70 80 90 100 125 150 175 200
3/4 369 256 205 174 155 141 128 121 113 106 95 86 79 74
1 697 477 384 328 292 267 246 226 210 200 179 164 149 138
1 1/4 1,400 974 789 677 595 543 502 472 441 410 369 333 308 287
1 1/2 2,150 1,500 1,210 1,020 923 830 769 707 666 636 564 513 472 441
2 4,100 2,820 2,260 1,950 1,720 1,560 1,440 1,330 1,250 1,180 1,100 974 871 820
2 1/2 6,460 4,460 3,610 3,100 2,720 2,460 2,310 2,100 2,000 1,900 1,700 1,540 1,400 1,300
3 11,200 7,900 6,400 5,400 4,870 4,410 4,000 3,800 3,540 3,300 3,000 2,720 2,500 2,340
4 23,500 16,100 13,100 11,100 10,000 9,000 8,300 7,690 7,380 6,870 6,150 5,640 5,130 4,720
Gas Piping
GAS SHUTOFF VALVE
GAS VALVE
TRAP
(DRIP LEG)
Figure 3-1_Gas Line Connection
All gas connections must be made with pipe joint
compound resistant to the action of liquefied petroleum and
natural gas. All piping must comply with local codes. Tubing
installations must comply with approved standards and
practices. Reference FIG. 3-1 for a typical installation.
Install Piping to Control
1. The gas line should be a separate line direct
from the meter unless the existing gas line is of sufficient
capacity. Verify pipe size with your gas supplier.
2. Use new, properly threaded black iron pipe free from chips.
If tubing is used, make sure the ends are cut squared,
deburred and clean. All tubing bends must be smooth and
without deformation. Avoid flexible gas connections.
Internal diameter of flexible lines may not provide proper
volume of gas.
3. Run pipe or tubing to the gas valve or manifold inlet. If
tubing is used, obtain a tube to pipe coupling to connect
the tubing to the gas valve or manifold inlet.
4. DO NOT OVER TIGHTEN. Over tightening may result in
damage to the gas valves. Valve distortion or malfunction
may result if the pipe is inserted too deeply into the gas
valve.
5. Apply a moderate amount of good quality pipe compound
(DO NOT use Teflon tape) to pipe only, leaving two end
threads bare.
6. Remove seal over gas valve or manifold inlet.
7. Connect pipe to gas valve or manifold inlet. Use wrench to
square ends of the gas valve (FIG. 3-2).

Installation & Service Manual
20
APPLY WRENCH FROM TOP OR BOTTOM
OF GAS CONTROL TO EITHER SHADED AREA
APPLY WRENCH
TO FLANGE ONLY
WHEN FLANGE IS
NOT USED
WHEN FLANGE
IS USED
Figure 3-2_Wrench
8. For L.P. gas, consult your L.P. gas supplier for expert
installation.
IMPORTANT Upon completion of any piping
connections to the gas system, leak test all
gas connections with a soap solution
while system is under pressure.
Immediately repair any leaks found in the
gas train or related components. Do Not
operate an appliance with a leak in the gas
train, valves or related piping.
Gas Manifold Pressure Adjustment
Procedure
3.5"
MANOMETER
GAS VALVE
PRESSURE REGULATOR ADJUSTMENT
(UNDER CAP SCREW)
OUTLET
PRESSURE TAP
PILOT OUTLET
GAS CONTROL KNOB
RED RESET BUTTON
INLET
PRESSURE TAP
Figure 3-3_Manifold Pressure Adjustment
1. Turn the power “OFF” at the main disconnect switch.
2. Turn gas valve control knob to “OFF” position.
3. Remove the 1/8" hex plug located on the outlet side of the
gas valve and install a fitting suitable to connect to a
manometer or magnahelic gauge. See FIG. 3-3. Minimum
range of scale should be up to 5" w.c. for Natural gas
models and 10" w.c. for L.P. gas models.
4. Remove the pressure regulator adjustment cap screw on
the gas valve. See FIG. 3-3 for location.
5. Turn the power “ON” at the main disconnect switch.
6. Turn gas valve control knob to “ON” position.
7. Set the thermostat(s) to call for heat.
8. Observe gas regulator pressure when all burners are firing.
See Table 3B, Manifold Pressure (page 18) for proper
regulator pressure settings.
9. If adjustment is necessary, turn regulator adjustment screw
clockwise to raise regulator gas pressure, counterclockwise
to lower gas pressure, to proper setting. NOTE:Adjustment
fitting is plastic and may require slightly greater turning
force than a metal fitting.
10. Turn the power “OFF” at the main disconnect switch.
NOTICE Do not increase regulator pressure beyond
specified pressure setting.
11. Turn gas valve control knob to “OFF” position.
12. Remove fitting from the gas valve and replace the 1/8" hex
plug that was previously removed and tighten.
13. Turn the gas valve control knob to “ON” position.
14. Turn the power “ON” at the main disconnect switch. The
appliance is now ready to operate.
If manifold pressure can not be properly adjusted, use the
procedure on page 21 to check gas supply pressure with a
manometer connected to the inlet pressure tap on the gas
control.
3 Gas connections