PEERLESS Stainless Steel Gas Boilers Instruction manual

Pinnacle®
Gas Boilers
Peerless®
Stainless Steel
Installation,
Operation &
Maintenance
Manual
– Do not store or use gasoline or other
flammable vapors and liquids in the vicinity
of this or any other appliance.
– WHAT TO DO IFYOU SMELL GAS
•Do not try to light any appliance.
•Do not touch any electrical switch;
do not use any phone in your building.
•Immediately call your gas supplier from
a neighbor’s phone. Follow 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.
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.
WARNING
As an ENERGY STAR®Partner, PB Heat, LLC has
determined that this product meets the ENERGY STAR®
guidelines for energy efficiency.

USING THIS MANUAL 1
A. INSTALLATION SEQUENCE . . . . . . . . . . . . .1
B. SPECIAL ATTENTION BOXES . . . . . . . . . . . .1
1. PREINSTALLATION 2
A. ACCESSIBILITY CLEARANCES . . . . . . . . . . .2
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . .2
C. INSTALLATION SURVEY . . . . . . . . . . . . . . . .2
D. PLANNING THE LAYOUT . . . . . . . . . . . . . . . .2
2. BOILER SET-UP 3
3. WATER PIPING AND CONTROLS 4
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
B. SPECIAL APPLICATIONS . . . . . . . . . . . . . . . .4
C. OPERATING PARAMETERS . . . . . . . . . . . . . .4
D. PRIMARY/SECONDARY PIPING . . . . . . . . . .4
E. SYSTEM COMPONENTS . . . . . . . . . . . . . . . .5
F. SYSTEM PIPING . . . . . . . . . . . . . . . . . . . . . . .5
G. FREEZE PROTECTION . . . . . . . . . . . . . . . . . .6
4. GAS PIPING 12
5. VENTING 14
A. GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . .14
B. EXHAUST VENT/AIR INLET VENT
LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . .14
C. EXHAUST VENT INSTALLATION . . . . . . . .14
D. AIR INLET VENT INSTALLATION . . . . . . . .15
E. EXTENDED VENT LENGTHS WITH
4” PIPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
F. CONDENSATE . . . . . . . . . . . . . . . . . . . . . . .18
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM . . . . . . . . . . . . . . . . . . .18
6. ELECTRICAL 19
A. WIRING . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
B. ZONED SYSTEM WIRING . . . . . . . . . . . . . .19
C. SEQUENCE OF OPERATION . . . . . . . . . . . .21
7. START-UP PROCEDURES 22
A. COMPLETING THE INSTALLATION . . . . . . .22
B. LIGHTING/OPERATING INSTRUCTIONS . . .23
C. CONTROL DESCRIPTIONS . . . . . . . . . . . . .24
D. CHECK-OUT PROCEDURE . . . . . . . . . . . . . .24
8. TROUBLESHOOTING 25
A. SHUT-DOWN . . . . . . . . . . . . . . . . . . . . . . . .25
B. BOILER FAULT CODES . . . . . . . . . . . . . . . .26
C. BOILER FAULT CONDITIONS . . . . . . . . . . .26
9. MAINTENANCE 28
A. GENERAL (WITH BOILER IN USE) . . . . . . .28
B. WEEKLY (WITH BOILER IN USE) . . . . . . . . .28
C. ANNUALLY (BEFORE START OF
HEATING SEASON) . . . . . . . . . . . . . . . . . . .28
10. BOILER DIMENSIONS & RATINGS 29
11. REPAIR PARTS 31
TABLE OF CONTENTS
TABLE OF CONTENTS

1
A. INSTALLATION SEQUENCE
Follow the installation instructions provided in this
manual in the order shown. The order of these
instructions has been set in order to provide the installer
with a logical sequence of steps that will minimize
potential interferences and maximize safety during
boiler installation.
B. SPECIAL ATTENTION BOXES
Throughout this manual you will see special attention
boxes intended to supplement the instructions and make
special notice of potential hazards. These categories
mean, in the judgment of Peerless Boilers:
Indicates special attention is needed, but not directly
related to potential personal injury or property
damage.
NOTICE
Indicates a condition or hazard which will or can
cause minor personal injury or property damage.
CAUTION
DANGER
Indicates a condition or hazard which will cause
severe personal injury, death or major property
damage.
USING THIS MANUAL
USING THIS MANUAL
Indicates a condition or hazard which may cause
severe personal injury, death or major property
damage.
WARNING

2
A. ACCESSIBILITY CLEARANCES
The following are the recommended minimum
accessibility clearances between boiler and adjacent wall
or other appliances.
1. 16″from right side or left side of boiler.
2. 15″from top of boiler.
3. 4″from front of boiler.
4. Provide clearance for annual inspection of vent pipe
and condensate connections.
B. CLEARANCE FROM COMBUSTIBLE
CONSTRUCTION
The design of this boiler is certified for closet installation
with the following clearances:
1. 0″from left side, right side, rear, top, bottom, front
and combustible construction.
2. 0″from vent pipe and combustible construction.
3. This boiler is design certified for use on combustible
floors.
C. INSTALLATION SURVEY
For new and existing installations, a Water Installation
Survey is available from Peerless Boilers. The survey will
provide information on how a hot water boiler works
with your specific system and will provide an overview
of hot water system operation in general.
You can also use this survey to locate system problems
which will have to be corrected. To obtain copies of the
Water Installation Survey, contact your Peerless
representative.
D. PLANNING THE LAYOUT
Prepare sketches and notes of the layout to minimize the
possibility of interferences with new or existing
equipment, piping, venting and wiring. Review
limitations on vent pipe, vent terminal, and air inlet pipe
locations in Section 5, Venting.
PREINSTALLATION
1. PREINSTALLATION
Read carefully, study these instructions before beginning work.
This boiler must be installed by a qualified contractor.
The boiler warranty can be voided if the boiler is not installed, maintained and serviced correctly.
Boiler can be installed at high altitude with no burner adjustments. LP equipped boilers must not be installed at
elevations above 7,000 feet.
The equipment must be installed in accordance with those installation requirements of the authority having
jurisdiction or, in the absence of such requirements, to the current edition of the
National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CGA B149 Installation Codes.
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, ANSI/ASME CSD-1
.
NOTICE
Do not install this boiler on carpeting. Boiler
installation on carpeting is a fire hazard.
DANGER
Liquefied Petroleum (LP) is heavier than air and may
collect or “pool” in a low area in the event of a leak
from defective equipment.This gas may then ignite,
resulting in a fire or explosion.
WARNING
Boiler is certified as an indoor appliance. Do not
install boiler outdoors or locate where it will be
exposed to freezing temperatures.
WARNING

3
BOILER SET-UP
1. Place boiler on a level surface. (Note: An optional
boiler stand is available. Contact your Peerless
Distributor.)
2. Locate boiler to allow for ease of vent pipe
installation and heating system piping.
3. Install boiler in an area with a floor drain or install in
a suitable drain pan.
2. BOILER SET-UP
Boiler must be set on a level surface so condensate
does not back up inside the boiler.
WARNING

4
A. GENERAL
1. The Pinnacle boiler is a coil type boiler that requires
adequate flow through the boiler for acceptable
operation. For this reason, Peerless recommends
piping the boiler into a secondary loop of a
primary/secondary system. This is recommended for
all but the simplest single zone, single boiler
application.
2. The boiler supply and return piping is to be sized in
accordance with system requirements. Do not use
piping smaller than the boiler connections.
3. In any hydronic system where sediment may exist,
install a basket type strainer in the boiler return
piping to prevent dirt particles and pipe scale from
entering the boiler heat exchanger coil.
4. Install this boiler so that the gas ignition system
components are protected from water (dripping,
spraying, etc.) during appliance operation and
service (circulator replacement, condensate trap
cleaning, control replacement, etc.).
B. SPECIAL APPLICATIONS
1. If the boiler is used in conjunction with a chilled
medium system, pipe the chiller in parallel with the
boiler system. Install flow control valves to prevent
the chilled medium from entering the boiler. See
Figure 3.1.
2. For boilers connected to heating coils in a forced air
system where they may be exposed to chilled air
circulation, install flow control valves or other
automatic means to prevent gravity circulation of the
boiler water during cooling cycles.
3. In accordance with Z21.13, if the boiler is installed
above the level of the connected radiation, the
contractor must install a low water cut-off device in
the boiler piping.
C. OPERATING PARAMETERSfgh
1. The Pinnacle Boiler is designed to operate in a
closed loop hydronic system above 15 psig. A
pressure limit in the boiler header will prevent the
unit from operating if the pressure drops below 10
psig. This is intended to protect the stainless steel
heat exchanger in the event of a system leak.
2. The following chart shows the water volume and
minimum flow rate for Pinnacle boilers.
D. PRIMARY/SECONDARY PIPING
1. Figures 3.4 through 3.8 show recommended piping
configurations for some typical Pinnacle boiler
applications. Since the Pinnacle is a fully condensing
boiler, it is not necessary to provide a system bypass
to temper the system return water.
2. When piping a boiler into a secondary loop, always
install the circulator on the boiler return so it is
pumping away from the common piping (the point
of no pressure change).
3. The pipes attaching to the system loop should be as
close together as possible and should not exceed
four pipe diameters between them.
3. WATER PIPING AND CONTROLS
WATER PIPING AND CONTROLS
All piping must be properly supported. Do not allow
the boiler piping to be supported by the boiler.
NOTICE
Figure 3.1:Parallel Hook-up with Water Chiller
Table 3.1
Boiler
Model
Total Water
Volume-Gallon
Minimum Flow
Rate-GPM
PI-80 0.50 (1.89) 4
PI-140 0.93 (3.50) 6
PI-199 1.13 (4.26) 8

E. SYSTEM COMPONENTS
1. Pressure/Temperature Gauge: A combination
pressure/temperature gauge is provided with the unit
to be mounted in the piping from the boiler supply to
the system. Installation of this gauge is required by
most local codes.
2. Air Elimination: Each hydronic system in which the
Pinnacle boiler is used must have an air elimination
device. As the system water is heated, dissolved
oxygen and carbon dioxide will separate from the
liquid. An air elimination device (such as a TACO
430 Series Air Scoop with an automatic air vent) is
required to remove the dissolved gasses from the
system preventing corrosion in the piping system and
eliminating system noise.
3. Expansion Tank: As the Pinnacle boiler heats the
system media, the water or glycol solution will
expand. An expansion tank is required to provide
room for this expansion.
a. Consult expansion tank manufacturer's
instructions for specific information regarding
installation.
b. Size the expansion tank for the required system
volume and capacity. Be sure the expansion tank
is sized based on the proper heating medium.
4. Circulator Sizing: The following shows how to size
the boiler circulator based on the boiler net output.
The boiler "Net I=B=R Output" for each Pinnacle
Model is listed in the chart below. This value includes
a piping pickup factor of 1.15.
a. The Pinnacle Boiler imposes a small pressure
drop on the heating medium that must be
accounted for in circulator sizing. This pressure
drop for each model, based on a 20°F water
temperature rise, is as follows:
b. We can determine the required flow based on the
design temperature difference and the "Net
I=B=R Output." For this example we will use a
20° temperature rise. The calculation is as
follows:
c. So, for a PI-80 with a 20°F design temperature
differential a circulator sized for 6.40 GPM should
be used. The pressure drop can be determined
using Figure 3.2, Pinnacle Circulator Sizing
Graph.
F. SYSTEM PIPING
1. Zone Circulators: The following illustrations show
systems in which each zone is equipped with a
dedicated circulator. This assures the proper flow
through the zone with minimal effect on the
operation of adjacent zones. Notice the air
separation is upstream of all zone circulators and is
tied into the expansion tank and system fill valve.
a. Figure 3.3: This illustration shows a single
Pinnacle Boiler, a Partner Indirect Water Heater,
and a single heating zone. This illustration is
applicable to systems where the supply
temperature of the heating zone is similar to that
of the indirect water heater.
b. Figure 3.4: This diagram shows an additional
zone in which baseboard radiation is the heat
load. Baseboard radiation typically requires
temperatures similar to that of the indirect water
heater.
c. Figure 3.5: This figure shows diverter tees used in
combination with conventional hydronic
radiators on an additional zone. Also, a second
boiler is shown piped in parallel with the first. It is
important that the common headers are sized to
match the system piping. Smaller headers may
result in flow fluctuations through the boilers.
d. Figure 3.6: This illustration shows a system in
which different types of loads and multiple boilers
are employed. This system illustrates how
different temperature loops can be combined by
mixing down the supply temperature through a
bypass. Radiant flooring typically requires much
lower temperatures than baseboard radiation and
indirect water heating, therefore a three way
mixing valve is used to temper the supply.
WATER PIPING AND CONTROLS
5
Table 3.2
Table 3.3
Boiler
Model
Boiler Input
(Btu/hr)
Net I=B=R
Output
PI-80 80,000 64,000
PI-140 140,000 112,000
PI-199 199,000 159,000
Output 64,000
GPM = = = 6.40 GPM
∆T x 500 20 x 500
Boiler
Model
Flow Rate
(GPM)
Pressure Drop
(Feet)
PI-80 6.4 5.0
PI-140 11.2 8.0
PI-199 15.9 13.2

6
Figure 3.2
WATER PIPING AND CONTROLS
Pinnacle Circulator Sizing Graph
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
345678910111213141516171819202122
Flow Rate (GPM)
Pressure Drop (Feet of Head)
PI-80
PI-140
PI-199
2. Zone Valves: Figure 3.7 shows a system in which
zone valves are used in place of zone circulators.
Notice that this system utilizes reverse return piping
(where the first zone supplied is the last zone on the
return), which makes it easier to balance the system.
If the heating loops are very different in length, then
the balancing valves, shown on the return side of
each loop, are required.
G. FREEZE PROTECTION
For new or existing systems that must be freeze-
protected:
1. Glycol in hydronic applications is specially
formulated for this purpose. It includes inhibitors
which prevent the glycol from attacking metallic
system components. Make certain that the system
fluid is checked for the correct glycol concentration
and inhibitor level.
2. The antifreeze solution should be tested at least once
a year and as recommended by the antifreeze
manufacturer.
3. Antifreeze solutions expand more than water. For
example, a 50% by volume solution expands 4.8%
in volume for a temperature increase from 32° F to
180° F, while water expands 3% with the same
temperature rise. Allowance must be made for this
expansion in system design.
Use only inhibited propylene glycol solutions of up to
50% by volume water. Ethylene glycol is toxic and can
attack gaskets and seals use in hydronic Systems.
WARNING

WATER PIPING AND CONTROLS
7
Figure 3.3

8
Figure 3.4
WATER PIPING AND CONTROLS

9
Figure 3.5
WATER PIPING AND CONTROLS

10
Figure 3.6
WATER PIPING AND CONTROLS

11
Figure 3.7
WATER PIPING AND CONTROLS

12
1. Size and install the gas supply piping properly in
order to provide a supply of gas sufficient to meet
the maximum demand without exceeding a pressure
drop greater than .5″W.C. between the meter and
the boiler.
2. Determine the volume of gas to be provided to the
boiler in cubic feet per hour. To obtain this value,
divide the Btu per hour rating (on the boiler rating
label) by the heating value of the gas in Btu per
cubic feet. Obtain the heating value of the gas from
the gas supplier. As an alternative, use Table 4.1 or
4.2 on the next page to obtain the volume of gas to
be provided to the boiler.
3. Use the value obtained above as the basis for piping
sizing. Size the gas piping in accordance with Table 3
for natural gas. Consult the National Fuel Gas Code
ANSI Z223.5/NFPA 54 and/or CAN/CGA B149 for
other sizing options and LP gas pipe sizes.
4. Locate the drop pipe adjacent to, but not in front of
the boiler.
5. Install a sediment trap. See Figure 4.1. Locate a tee
in the drop pipe at same elevation as the gas inlet
connection to the boiler. Extend the drop pipe to a
pipe cap.
6. Install a ground joint union ahead of the gas control
assembly to permit servicing of the control. Install a
service valve as shown in Figure 4.1.
7. Check piping for leaks prior to placing the boiler in
operation.
Use an approved gas detector, a non-corrosive leak
detection fluid or other leak detection method. If
leaks are found, turn off all gas flow and repair as
necessary.
8. The gas piping connection to the boiler must be a
minimum of 3/4 pipe size. Boiler is provided with a
3/4 x 1/2 pipe reducer. Do not remove the reducer.
9. Disconnect the boiler and its individual shut-off valve
from the gas supply piping system during any
pressure testing of that system at test pressure in
excess of 1/2 psig (3.5 kPa). Remove the mounting
screws of the flanged gas connection on the gas
valve, and disconnect flange from valve.
Isolate the boiler from the gas supply piping system
by closing its individual service valve during any
pressure testing of the gas supply piping system at
test pressure equal to or less than 1/2 psig (3.5 kPa).
10. Check for proper supply pressures to boiler at
sediment trap location. Remove pipe cap and
provide fittings as required. Minimum permissible
supply pressure (Inches Water Column):
Natural Gas 3.7″
LP Gas 3.7″
Maximum permissible supply pressure to the boiler
(Inches Water Column):
Natural Gas 13.5″
LP Gas 13.5″
11. Maintain a minimum distance of 10 feet between a
gas pressure regulator and boiler.
12. Gas line must be properly purged of air to allow for
normal main burner ignition.
4. GAS PIPING
Figure 4.1:Gas Connection to Boiler
When checking for leaks, do not use matches,
candles, open flames or other methods that provide a
source of ignition.This can ignite a gas leak,
resulting in fire or explosion.
WARNING
Use a pipe joint sealing compound that is resistant to
the action of liquefied petroleum gas. A non-resistant
compound may lose sealing ability in the presence of
this gas, resulting in a gas leak and fire or explosion
potential.
WARNING
Do not subject the gas valve to more than 1/2 psi
pressure. Doing so may damage the valve.
CAUTION
GAS PIPING

13
Table 4.3: Pipe Capacity
10
20
30
40
50
60
Pipe
Length
Feet
278
190
152
130
115
105
³⁄₄″″
Pipe
520
350
285
245
215
195
1″″
Pipe
1,050
730
590
500
440
400
1¹⁄₄″″
Pipe
1,600
1,100
890
760
670
610
1¹⁄₂″″
Pipe
Multipliers to be used with the above table when the
specific gravity of the gas is other than 0.60:
Specific Gravity . . . .0.5 0.55 0.60 0.65 0.70
Multiplier . . . . . . . . .1.10 1.04 1.00 0.962 0.926
Capacity of pipe of different diameters and lengths in cu. ft. per
hour with pressure drop of 0.3 in. and specific gravity of 0.60.
No allowance for an ordinary number of fittings is required.
Table 4.1: Natural Gas
PI-80
PI-140
PI-199
Model Input
(Cubic Ft/Hr)
80
140
199
Based on 1000 Btu/Cubic Ft.
Table 4.2: LP Gas
PI-80
PI-140
PI-199
Model Input
(Cubic Ft/Hr)
32
56
79
Based on 2500 Btu/Cubic Ft.
GAS PIPING

14
A. GENERAL
1 Install vent system in accordance with these
instructions and with Part 7, Venting of Equipment,
National Fuel Gas Code, ANSI Z223.1/NFPA 54,
CAN/CGA B149, or applicable provisions of the local
building codes.
2. Boiler is a direct vent appliance. The boiler vent is
listed as Category IV.
B. EXHAUST VENT/AIR INLET VENT
LOCATION
1. Determine exhaust vent location.
a. Vent is approved for 0″clearance to combustible
construction.
b. Provide 3 feet clearance above any forced air
inlet within 10 feet.
c. Provide 1 foot clearance below, 1 foot beside, or
1 foot above any door, window, or gravity air
inlet into any building.
d. Provide 1 foot clearance between bottom of vent
terminal and ground level and normal snow lines.
e. Provide 4 feet horizontal clearance from, and in
no case above or below, unless a 4 foot
horizontal distance is maintained, from electric
meters, gas meters, regulators and relief
equipment.
f. Do not locate vent terminal over public walkways
where condensate could create a nuisance or
hazard.
g. When adjacent to a public walkway, locate vent
terminal at least 7 feet above grade.
h. Do not locate directly under roof overhangs to
prevent icicles from forming.
i. Provide 3 foot clearance from inside corner of
adjacent walls.
2. Determine air inlet vent location.
a. Provide 1 foot clearance between bottom of vent
and ground level and normal snow lines.
3. Refer to venting diagrams (Figures 5.1 through 5.6)
for typical sidewall and vertical vent/air inlet piping.
a. Maintain distances between air inlet, vent, and
exhaust vent as indicated in Figures 5.1, 5.2, and
5.5. Do not space the air inlet vent and exhaust
vent greater than 6 feet apart.
b. When sidewall venting multiple 3″concentric vent
kits, the vent kits must remain in a horizontal
plane and placed no closer than 8″center to
center. Also refer to instructions provided with
vent kit.
c. When sidewall venting multiple V1000 vent kits
refer to instructions provided with vent kit.
C. EXHAUST VENT INSTALLATION
1. For minimum and maximum vent pipe lengths refer
to Table 5.1.
2. Use only 3″PVC, CPVC, or ABS solid schedule 40
or 80 material for exhaust vent. 4″PVC, CPVC, or
ABS solid schedule 40 or 80 pipe is also approved
under special conditions; see Section E, Extended
Vent Lengths with 4″Pipe, in this section for details.
FOAM CORE PIPING IS NOT APPROVED.
3. Vent connection is located on rear of boiler and is
marked “exhaust outlet”.
4. All joints must be properly cleaned, primed, and
cemented. Use only approved cement and primer for
PVC, CPVC and ABS materials. Cement must
conform to ASTM D-2564 (PVC) or D2235 (ABS).
5. Remove all burrs and debris from joints and fittings.
6. Horizontal lengths must slope back to boiler
connection not less than 1/4″per foot to allow
condensate to flow back to boiler.
7. A screened 3″straight coupling is provided with
boiler for use as a vent termination. Optional vent
terminations approved for use with the Pinnacle
boiler are 3″concentric KGAVT0601CVT Vent Kit
and V1000 Vent Kit. Both are available from a
Peerless Distributor.
8. Vent piping must be supported at 4 ft. intervals to
prevent sagging. The boiler is not intended as a
support means for vent.
5. VENTING
VENTING
This vent system will operate with a positive
pressure in the vent pipe. Do not connect vent
connectors serving appliances vented by natural
draft into any portion of mechanical draft systems
operating under positive pressure.
Flue gases will condense as they exit the vent
termination.This condensate can freeze on exterior
building surfaces which may cause discoloration of
these surfaces.
NOTICE
WARNING

VENTING
15
D . AIR INLET VENT INSTALLATION
1. For minimum and maximum pipe length refer to
Table 5.1.
2. Use same material as noted in Section C for exhaust
vent.
3. Air inlet pipe connections is located in the rear of
boiler and is marked “air inlet”. Connection is a slip
fit. No sealant is required.
4. All joints and fittings are to be assembled as per
instructions for vent pipe in Section C.
5 A screened inlet air tee is provided with boiler, to be
used as an outside termination.
6. Provide same support means as noted for exhaust
vent in Section C.
85 feetAll
Boiler
Model
16 feet
Table 5.1: Minimum/Maximum Vent Length
Total Combined **Equivalent Length of 3″″
Exhaust Vent Plus 3″″Air Inlet Vent
*Minimum Length *Maximum Length
*Lengths are the combined added lengths of the exhaust
*vent and air inlet vent.
**Include equivalent length of fittings as follows:
3″90 degree elbow = 5 equivalent feet
3″45 degree elbow = 3 equivalent feet
3″concentric vent kit = 3 equivalent feet
3″air inlet tee = 0 feet
3″V1000 vent kit = 0 feet
Refer to Venting Diagram Figures 5.1 through 5.6 for
Sidewall and Vertical Venting arrangements.

16
VENTING
DIAGRAMS FOR SIDEWALL VENTING
TEE (VERTICAL) TEE (VERTICAL)
STRAIGHT
COUPLING
FRONT ELEVATION
(MULTIPLE VENTS)
8
88
EXTERIOR
WALL
3"
3"EXHAUST
3"
EXHAUST OUTLET
RIGHT SIDE VIEW
INTAKE
GROUND LEVEL
SIDE ELEVATION
REFER TO MANUAL
FOR PROPER CLEARANCES
STRAIGHT
COUPLING
EXHAUST
TEE
1" MIN.
BOILER
INTAKE
12"
MINIMUM
T & P
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.1:3″″Sidewall Vent with Tee (Intake) &
Coupling (Exhaust)
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.2:3″″Sidewall Vent with Tee (Intake) &
Coupling (Exhaust)
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.3:3″″Sidewall Vent with V1000 Kit
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.4:3″″Sidewall Vent with 3″″Concentric
Vent Kit (KGAVT0601CVT)

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VENTING
DIAGRAMS FOR VERTICAL VENTING
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.5:3″″Roof Vent with Tee (Intake) &
Coupling (Exhaust)
**IMPORTANT NOTE: All vent pipes must be glued, properly
supported, and the exhaust must be pitched minimum of a
1/4″per foot back to the boiler (to allow drainage of
condensate).
Figure 5.6:3″″Roof Vent with 3″″Concentric
Vent Kit (KGAVT0601CVT)

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E. EXTENDED VENT LENGTHS WITH 4″″PIPE
1. The connection of air inlet vent and exhaust vent at
boiler must remain 3″and each vent must extend
from boiler a minimum of 15 equivalent feet before
transitioning to 4″vent.
2. The maximum length shown in Table 5.1 can be
increased by using 4″PVC, CPVC, or ABS solid
schedule 40 or 80 pipe.
3. Use a 4″x 3″reducing coupling to transition to
4″vent.
4. The maximum combined ∗equivalent length of 4″
air inlet vent plus 4″exhaust vent must not exceed
125 feet.
∗Equivalent Length of 4″Piping:
4″90 degree elbow = 3 feet
4″45 degree elbow = 1 foot
4″air inlet tee = 0 feet
5. Use the same pipe sizes for air inlet vent and
exhaust vent.
6. To use the V1000 Vent Kit or 3″Concentric Vent Kit
transition 4″pipe to 3″pipe at exit point of building.
F. CONDENSATE
1. This boiler is a high efficiency unit that produces
condensate.
2. The rear of the boiler has a plastic hose for
connection of a 5/8″size plastic tubing.
3. Slope condensate tubing down and away from boiler
into a drain pan or condensate neutralizing filter.
Condensate has a low PH level; check with local
codes or ordinances before connecting to drain.
4. Do not expose condensate line to freezing
temperature.
5. Use only plastic tubing as a condensate drain line.
6. To allow for proper drainage on large horizontal
runs, a second line vent may be required and tubing
size may need to increase to 1″.
7. A condensate removal pump is required if boiler is
below drain.
G. BOILER REMOVAL FROM COMMON
VENTING SYSTEM
At the time of removal of an existing boiler, follow these
steps 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 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 any clothes dryers and any
appliance not connected to 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
any other gas-burning appliance to their previous
conditions of use.
g. Any improper operation of the common venting
system should be corrected so that the installation
conforms with the National Fuel Gas Code, ANSI
Z223.1/NFPA 54 and/or CAN/CGA B149. When
resizing any portion of the common venting system,
the common venting system should be resized to
approach minimum size as determined using the
appropriate tables located in the Chapter “Sizing of
Category I Venting Systems” of the National Fuel
Gas Code, ANSI Z223.1/NFPA 54.
VENTING