Attachment 5 Product Specs.pdf

Innovative. Efficient. Dependable. Dunkirk.

Q90-200 Series II 90% AFUE Gas Fired Condensing Hot Water Boiler

Q90-200 Series II

• High Efficiency Cast Aluminum Monoblock Heat Exchanger with low pressure drop.

• Fuel Smart Hydrostat Control: 3 functions in 1 Control.

- Temperature Limit Control with easy dial settings and function indicator lights.

- Low Water Cut-Off (LWCO), protects the boiler from damaging low water conditions.

- Boiler Reset, lowers the boiler temperature to save fuel without sacrificing comfort. Set-up is quick with no need to install an outdoor sensor, just dial in the number of heating zones.

• Integrated Microprocessor Control.

• Sealed Combustion, Direct Vent Forced Draft System.

• Utilizes economical CPVC, PVC and Polypropylene venting.

• Integral Combustible Floor Plate.

• Casting Temperature Safety Switch & Air Flow Pressure Switches.

• Limited 15 Year Warranty.

MADE IN THE USA

All ratings and specifications subject to change. PN 240005047 Rev. 10/13

Dunkirk Q90-200 Series II Natural or Propane Gas-Fired Condensing Hot Water Boiler

Dimensions/Weights Model Boiler Input Rate

(MBH) (1)

Heating Capacity

(MBH) (1)(2)

Net AHRI Rating, Water

(MBH) (1) (3)

AFUE % (2)

Model Ship Wgt.

Q90-125 284 lbs.

(128.8 kg.)

Q90-150 284 lbs.

(128.8 kg.)

Q90-175 284 lbs.

(128.8 kg.)

Q90-200 284 lbs.

(128.8 kg.)

Q90-125 125 113 98 90.0 Q90-150 150 134 117 90.0 Q90-175 175 158 137 90.0 Q90-200 200 180 157 90.0

(1) 1000 Btu/hr (British Thermal Units Per Hour)

(2) Heating Capacity and AFUE (Annual Fuel Utilization Efficiency) are based on DOE (Department of Energy) test procedures.

(3) Net AHRI Ratings based on piping and pickup allowance of 1.15. Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

General Information (See Installation, Operation and Maintenance Manual for complete instructions)

Clearances

(4) Required distances measured from boiler.

(5) Service, proper operation clearance recommendation.

Note: May be installed on combustible flooring (No Carpets).

Top

Combustible Materials (Required) (4) Service (5)

1” (25 mm) 8” (203 mm) Left Side 8” (203 mm) 24” (610 mm) Right Side 1” (25 mm) N/A Base 1” (25 mm) N/A Front 0” (0 mm) 24” (610 mm) Back 1” (25 mm) N/A Combustion Air/Vent Piping 0” (0 mm) N/A

Combustion Air & Vent Pipe Equivalent Length

Min. & Max. Vent Lengths - refer to the Installation Manual based on Natural or Propane Gas and Altitude.

Vent Pipe - First 5’ (1.6 m) is Schedule 80 2” CPVC (provided), then Schedule 40 2” or 3” PVC.

Air Intake - Schedule 40 3” PVC

Notes: 1 - 90° Elbow = 5 Ft. (1.6 m), 1 - 45° Elbow = 3.5 Ft. (1.1 m), 1 - 2” x 3” Adapter = 0 Ft. (0 m), Concentric Vent Kit = 5 Ft. (1.6 m) equivalent length.

Connections Return/Supply Water Gas In Condensate Drain

125/150/175/200 1-1/4” NPT 1/2” NPT 1/2” PVC

Electrical 120 Volts AC, 60 hertz, 1 phase, Less than 12 amps (15 amp circuit recommended) Water Content 125/150/175/200 - 2.6 Gallons Standard Equipment

Boiler Control Module: Integrated Microprocessor Control, Hi-Limit Control, Boiler Reset Control, Automatic Reset LWCO, Diagnostic Indicator Lights.

Heat Exchanger: Cast Aluminum Monoblock.

Combustion: Completely installed and wired safety control system with Stainless Steel Pre-Mix Gas Burner, Automatic Gas Valve, Hot Surface Igniter, Forced Draft Blower, Air Vent.

Electrical: Transformer, Service Switch & Outlet.

Other: Assembled boiler with pre-painted steel jacket, Combination Temperature/Pressure Gauge, 30 psi ASME Relief Valve, Casting Temperature Safety Switch, Air Flow Pressure Switches, Boiler Drain.

Options Taco or Grundfos Circulator Certifications

Right

Leveling Feet

40 1/4

32 5/16

Left

Gas Supply Opening

(1/2” NPT)

6 1/4

25 1/4

Top

Opening for Relief Valve Discharge Pipe

Opening for Air Vent and Expansion Tank Connection

Standard Supply & Return Openings 1 1/4 NPT Connections Provided Inside Boiler Cabinet

4 7/16

Front

Junction Box for 120 VPower & 24 V Thermostat Leads

Vent Tee

(2” CPVC)

Combustion Air Intake Fitting (2” PVC)

Condensate Drain Fitting (1/2” PVC)

Contractor Assistance: 800.325.5479 ®

P.O. Box 4729 Utica, New York 13504 tel: 315.797.1310 • fax: 315.797.3762 www.dunkirk.com

50 psi MAWP

Q90 125-200 SERIES II

GAS-FIRED DIRECT VENT

CONDENSING HOT WATER BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

An ISO 9001-2008 Certified Company P/N 240009431, Rev. B [12/2012]

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13504-4729 web site: www.ecrinternational.com

Models Q90-125 Q90-150 Q90-175 Q90-200

1 - Boiler Ratings & Capacities 2 - Safe Installation And Operation 3 - Locating The Boiler 5 - Combustion Air/ Vent Requirements 6 - Combustion Air And Vent Pipe 7 - Gas Supply Piping 8 - Electrical Wiring 9 - Controls And Accessories 10 - Startup 11 - Detailed Sequence Of Operation 12 - Sequence Of Operation Diagnostics 13 - Checkout Procedure & Adjustments 14 - High Limit Control And LWCO 15 - Troubleshooting 16 - Maintenance And Cleaning Appendix A - Dielectric Isolation &Antifreeze Protection ...44 Parts, Kits and Accessories Warranty Check Out Certifi cate

TABLE OF CONTENTS

Safety Symbols & Warnings The following defi ned symbols are used throughout this manual to notify the reader of potential hazards of varying risk levels.

NOTICE

Used to address practices not related to personal injury.

CAUTION

Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

WARNING

Indicates a hazardous situation which, if not avoided, could result in death or serious injury.

DANGER

Indicates a hazardous situation which, if not avoided, WILL result in death or serious injury

IMPORTANT: Read following instructions COMPLETELY before installing!!

KEEP THIS MANUAL NEAR BOILER

RETAIN FOR FUTURE REFERENCE

WARNING

Keep boiler area clear and free from combustible materials, gasoline and other fl ammable vapors and liquids.

DO NOT obstruct air openings to the boiler room.

Modifi cation, substitution or elimination of factory equipped, supplied or specifi ed components may result in personal injury or loss of life.

TO THE OWNER - Installation and service of this boiler must be performed by a qualifi ed installer.

TO THE INSTALLER - Leave all instructions with boiler for future reference.

When this product is installed in the Commonwealth of Massachusetts the installation must be performed by a Licensed Plumber or Licensed Gas Fitter.

WARNING

Fire, explosion, asphyxiation and electrical shock hazard. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

1 -BOILER RATINGS & CAPACITIES

Table 1 - SEA LEVEL RATINGS (NATURAL AND PROPANE GASES)

Model Input

(MBH)(1)

Heating Capacity

(MBH)(1)(2)

Net AHRI Rating

(MBH)(1)

Shipping Weight (lbs.)

AFUE

(2) Flue Diameter

125 125 113 98 284 90.0 2” CPVC & 3” PVC

150 150 134 117 284 90.0 2” CPVC & 3” PVC

175 175 158 137 284 90.0 2” CPVC & 3” PVC

200 200 180 157 284 90.0 2” CPVC & 3” PVC

(1) 1 MBH = 1,000 Btuh (British Thermal Units Per Hour)

(2) AFUE (Annual Fuel Utilization Effi ciency) and Heating Capacity is based on Department of Energy test procedure.

Figure 1 - Boiler Jackets

These low pressure gas-fi red hot water boilers are design certifi ed by CSA International, for use with natural and propane gases. Boilers are constructed and hydrostatically tested for maximum working pressure of 50 psi (pounds per square inch) in accordance with A.S.M.E. (American Society of Mechanical Engineers) Boiler and Pressure Vessel Code, Section IV Standards for heating boilers.

Boilers are certifi ed in accordance with ANSI (American National Standards Institute) Z21.13 standards as gas-fi red, direct vent, condensing, hot water boilers.

Heating Capacity indicates amount of heat available after subtracting losses up the stack. Most of this heat is available to heat water. Small portion is heat loss from jacket and surfaces of boiler, it is assumed this heat stays in the structure.

Net AHRI Rating represents portion of remaining heat applied to heat radiation or terminal units (i.e. Finned tube baseboard, cast iron radiators, radiant fl oor, etc.). Difference between Heating Capacity and Net AHRI Rating, called piping and pickup allowance, establishes reserve for heating volume of water in the system and offsetting heat losses from piping. Net AHRI Ratings shown are based on piping and pickup factor of 1.15. Net AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. Manufacturer should be consulted before selecting boiler for installations having unusual piping and pickup requirements.

1 - BOILER RATINGS & CAPACITIES

This is gas-fi red direct vent cast aluminum hot water boiler. Cast aluminum heat exchanger means better heat transfer and thermal storage than similarly sized cast iron boilers, which results in higher effi ciency. Heating system water absorbs large amounts of heat from cast aluminum heat exchanger, cooling fl ue gases and causing condensation. Sealed combustion, premix gas burner, and low fl ame temperature means drastically reduced CO and NOx emissions, which contribute to cleaner and healthier environment.

Appliance, unlike normal residential atmospheric and induced draft units, takes its combustion air directly from outdoors (sealed combustion) and does not compete with building occupants for fresh air. Sealed combustion (also known as “direct vent”) is safest and best way to obtain plenty of clean combustion air. Forced draft fan draws in outside combustion air to mix with gas, which fl ows into pre-mix burner and combusts. Fan forces resulting fl ue gases from boiler unit and provides positive removal of fl ue gases from building through PVC and CPVC vent pipes.

Table 3 - LP GAS

Nominal Input

200,000 175,000 150,000 125,000 Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min. Max Min. Max Min. Max Min. Max 0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 195,900 195,750 171,900 171,200 146,900 146,700 123,050 122,250

2,000 191,800 191,500 168,800 167,400 143,800 143,400 121,100 119,500

3,000 187,700 187,250 165,700 163,600 140,700 140,100 119,150 116,750

4,000 183,600 183,000 162,600 159,800 137,600 136,800 117,200 114,000

5,000 179,500 178,750 159,500 156,000 134,500 133,500 115,250 111,250

6,000 175,400 174,500 156,400 152,200 131,400 130,200 113,300 108,500

7,000 171,300 170,250 153,300 148,400 128,300 126,900 111,350 105,750

8,000 167,200 166,000 150,200 144,600 125,200 123,600 109,400 103,000

9,000 163,100 161,750 147,100 140,800 122,100 120,300 107,450 100,250

10,000 159,000 157,500 144,000 137,000 119,000 117,000 105,500 97,500

Table 2 - NATURAL GAS

Nominal Input

200,000 175,000 150,000 125,000 Vent Lengths Vent Lengths Vent Lengths Vent Lengths

Altitude Min Max Min. Max Min. Max Min. Max 0 200,000 200,000 175,000 175,000 150,000 150,000 125,000 125,000

1,000 197,000 196,500 172,400 172,200 147,800 147,400 123,500 123,000

2,000 194,000 193,000 169,800 169,400 145,600 144,800 122,000 121,000

3,000 191,000 189,500 167,200 166,600 143,400 142,200 120,500 119,000

4,000 188,000 186,000 164,600 163,800 141,200 139,600 119,000 117,000

5,000 185,000 182,500 162,000 161,000 139,000 137,000 117,500 115,000

6,000 182,000 179,000 159,400 158,200 136,800 134,400 116,000 113,000

7,000 179,000 175,500 156,800 155,400 134,600 131,800 114,500 111,000

8,000 176,000 172,000 154,200 152,600 132,400 129,200 113,000 109,000

9,000 173,000 168,500 151,600 149,800 130,200 126,600 111,500 107,000

10,000 170,000 165,000 149,000 147,000 128,000 124,000 110,000 105,000

Ratings shown are for sea level applications. Boiler automatically derates input as altitude increases. No alterations to boiler are required for altitudes above sea level.

Boiler is equipped for residential installations. If used for commercial applications; additional code requirements must be adhered to. This may require additional controls, including but not limited to manual reset low water cut off, manual reset high temperature limit, and wiring and/or piping modifi cations.

1. Installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the National Fuel Gas Code, ANSI

Z223.1/NFPA 54.

2. Where required by authority having jurisdiction, installation must conform to the Standard for Controls and Safety Devices for Automatically fi red Boilers, ANSI/ASME CSD-1.

3. Be certain gas input rate is correct. Over-fi ring may result in early failure of boiler components; this may cause dangerous operation. Under-fi ring may result in too much air for pre-mix burner causing poor or loss of combustion.

4. Never vent products of combustion from this boiler to enclosed space. Always vent to outdoors. Never vent to another room or to inside building.

5. Verify adequate outdoor air supply to boiler for complete combustion.

6. Follow regular service and maintenance schedule for effi cient and safe operation.

7. Keep boiler area clean of debris and free from combustible materials, gasoline and other fl ammable vapors and liquids.

8. Proper through-the-wall or through-the-roof combustion venting shall be in accordance with materials and methods described in this manual.

Installation must comply with local codes.

9. Boiler and related hot water heating systems are not do-it-yourself items. Installation and service by qualifi ed professionals are required.

2 - SAFE INSTALLATION AND OPERATION

Installers - Follow local regulations with respect to installation of CO (Carbon Monoxide) Detectors. Follow maintenance recommendations in this manual. See “Maintenance And Cleaning” on page 42.

Boiler Sizing

• Verify you have selected the boiler with proper capacity before continuing installation. AHRI Rating of boiler selected should be greater than or equal to calculated peak heating load (heat loss) for building or area(s) served by boiler and associated hot water heating systems. See “Boiler Ratings & Capacities” on page 3.

• Heat loss calculations should be based on approved industry methods.

Considerations For Boiler Location Before selecting boiler location, consider following.

• Supplied with correct type of gas (natural gas or propane).

• Connected to suitable combustion air intake piping system to supply correct amount of fresh (outdoor) air for combustion. See “Combustion Air And Vent Pipe” on page 13.

• Connected to suitable venting system to remove hazardous products of gas combustion. See “Combustion Air And Vent Pipe” on page 13.

• Connected to suitable hot water heating system.

• Supplied with suitable electrical supply for all boiler motors and controls.

• Connected to properly located thermostat or operating control. (Not included with boiler)

WARNING

Fire hazard. Do not install boiler on carpeting.

Failure to follow these instructions could result in death or serious injury.

• Placed on level surface (DO NOT install on carpeting)

• Condensate drain line must be pitched down to fl oor drain or external condensate pump with reservoir at ¼” per foot (21 mm/m) (wood frame or blocks may be used to raise boiler).

WARNING

Improper installation, adjustment, alteration, service or maintenance could result in death or serious injury.

Locating The Boiler

1. Select level location, central to piping systems served and close to vent and air intake terminals as possible.

2. Accessibility clearances, if more stringent (i.e. larger clearances) than required fi re protection clearances, must be used for boiler installation. Accessibility clearances may be achieved with use of removable walls or partitions.

3. Clearances shown in Table 4 indicate required clearances per CSA listing. Minimum 1” (25 mm) clearance must be maintained between combustible construction and each of the right, top and back surfaces of boiler. Minimum 8” (203 mm) clearance is required on left side, to allow room for inlet air pipe.

18” (457 mm) clearance must be maintained at front where passage is required for cleaning or servicing, inspection or replacement of any parts that normally require such attention. Allow 24” (610 mm) at front and left side and 8” (203 mm) at top for servicing.

No combustible clearances are required to venting or combustion air intake piping.

Table 4 - BOILER CLEARANCES

Unit Combustible Clearance

Accessibility, Cleaning, and Servicing

Top 1” (25 mm) 8” (203 mm)

Left Side 8” (203 mm) 24” (610 mm)

Right Side 1” (25 mm) -

Base 1” (25 mm) -

Front 0” (0 mm) 24” (610 mm)

Back 1” (25 mm) -

Intake/Vent Piping 0” (0 mm) -

Near Boiler Hot Water Piping 1” (25 mm) -

All distances measured from boiler cabinet.

4. Keep boiler area clean of debris and free of fl ammable and combustible materials, liquids and vapors.

5. Install equipment in location which facilitates operation of venting and combustion air intake piping systems as described in this manual.

6. Advise owner to keep venting and combustion air intake passages free of obstructions. Both venting and combustion air intake piping systems connected to outdoors must permit fl ow through piping systems without restrictions for boiler to operate.

7. Boiler shall be installed such that automatic gas ignition system components are protected from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

8. Boiler must be located where ambient temperatures (minimum possible room temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no heat to space) are always at or above 32°F (0°C) to prevent freezing of liquid condensate.

9. If boiler is not level condensate drain lines will not function properly. Adjustable feet are located on boiler to make up for minor surface irregularities or tilt.

10. Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir.

3 - LOCATING THE BOILER

Removal Of Existing Boiler From Common Vent System When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

1. Seal any unused openings in the common venting system.

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion or other defi ciencies which could cause an unsafe condition.

3. In so far 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 dryer and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhaust, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fi re dampers.

4. Place in operation appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances operate continuously.

5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use fl ame of match or candle, or smoke from cigarette, cigar or pipe.

6. After it has been determined each appliance remaining connected to common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition.

7. Any improper operation of common venting system should be corrected so installation conforms with the National Fuel Code, ANSI Z223.1/NFPA 54. When resizing any portion of common venting system, common venting system should be resized to approach minimum size as determined using appropriate tables in chapter 13 of the National Fuel Code, ANSI Z223.1/

NFPA 54.

Placing The Boiler

• Place boiler to provide most direct connections to combustion air, vent, and system piping as possible.

• Place crated boiler as close to selected location as possible and uncrate boiler.

• Move uncrated boiler into position with appliance dolly or 2-wheel hand truck.

• Insert dolly or hand truck under right hand side of boiler. It is possible to slide boiler for short distance on smooth fl oor or surface.

3 - LOCATING THE BOILER

1. Do not install copper supply and return piping directly into aluminum boiler section castings due to galvanic corrosion between dissimilar metals.

2. Use iron, steel bushings or pipe connectors between copper system piping and boiler to make fi nal connection to boiler.

3. Use of dielectric unions is acceptable, installer supplied.

4. Packaged boiler is furnished with iron piping in front boiler section for supply and return connections.

5. Install all of radiation units (panels, radiators, baseboard, or tubing) and supply and return mains fi rst, when installation of boiler is for new heating system.

6. After installation of all heating system piping and components; make fi nal connection of system piping to boiler.

7. Hot water boiler installed above radiation level or as required by authority having jurisdiction must be equipped with low water cut off device (included with boiler).

8. Periodic inspection is necessary, as is fl ushing of fl oat type devices, per low water cut off manufacturers specifi c instructions.

Expansion Tank And Make-Up Water

• Determine required system fi ll pressure, design temperature, and water content.

• Boiler contains 2.6 gallons (U.S.). Size expansion tank accordingly. Consult expansion tank manufacturer for proper sizing information.

• Connect properly sized expansion tank (not furnished) See Figure 2, for diaphragm type expansion tank.

For diaphragm type expansion tanks, adjust tank air pressure to match system fi ll pressure.

• Install air vent (furnished) as shown for diaphragm type expansion tank system only.

• Install make-up water connections as shown and per local codes.

• If pressure reducing valve is used, adjust to match system fi ll pressure. Verify clean water supply is available when connecting cold make-up water supply to boiler. When water supply is from well or pump, install sand strainer at pump.

4 - NEAR BOILER PIPING

Figure 2 - Diaphragm Type Expansion Tank Piping

Figure 3 - Relief Valve Discharge Piping

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Install discharge piping per these instructions.

Check local codes for maximum distance from fl oor or other allowable safe point of discharge

RELIEF VALVE

DISCHARGE

PIPING

Safety Relief Valve / Temperature Pressure Gauge Boiler is furnished with safety relief valve and temperature pressure gauge.

• Install safety relief valve using pipe fi ttings provided with boiler. Figure 3, Page 8.

• Install safety relief valve with spindle in vertical position.

• Do not install shutoff valve between boiler and safety relief valve.

• Install discharge piping from safety relief valve.

A. Use ¾” or larger pipe.

B. Use pipe suitable for temperatures of 375°F

(191°C) or greater.

C. Individual boiler discharge piping shall be independent of other discharge piping.

D. Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate.

E. Run pipe as short and straight as possible to location protecting user from scalding and properly drain piping.

F. Install union, if used, close to safety relief valve outlet.

G. Install elbow(s), if used, close to safety relief valve outlet and downstream of union (if used).

H. Terminate pipe with plain end (not threaded).

NOTE: When zoning with circulators, use furnished circulator pump as one of zone pumps. Tape or wire nut each stripped end of electrical wire for circulator pump inside junction box to prevent short circuits.

Unplug circulator pump wiring at integrated boiler control.

Supply And Return Lines Packaged boiler receives 1¼” NPT supply and return piping from top access.

4 - NEAR BOILER PIPING

Figure 4 - Single Zone Boiler Piping

Figure 5 - Multi Zone Boiler Piping With Zone Valves

Figure 6 - Multi-zone Boiler Piping with Circulators

Condensate Drain Requirements Pitch condensate drain line down to fl oor drain at minimum of ¼” per foot (21mm/m). External condensate pump (not furnished) may be used if fl oor drain is not available. Condensate pump must be designed for fl ue gas condensate application.

Condensate trap is proved with boiler.

1. Build condensate trap in the fi eld. See Figure 7.

2. Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be above external condensate pump reservoir.

3. 115 volt AC receptacle provided on service switch junction box which is located at boiler right side, to provide power for external condensate pump (if needed).

Condensate Drain Piping

• Condensate trap is to be fi eld installed as shown in

Figure 7.

• Provided are ½” PVC fi ttings for condensate drain trap (assembled in fi eld).

• The ½” diameter schedule 40 PVC condensate drain piping and pipe fi ttings must conform to ANSI standards and ASTM D1785 or D2846.

• Schedule 40 PVC cement and primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certifi ed schedule 40 PVC drain pipe and cement.

• Condensate pump with reservoir (not furnished) may be used to remove condensate to drain line (sanitary line) above boiler if fl oor drain is not available or is inaccessible

Filling Condensate Trap With Water Manually fi ll condensate trap at initial start up with water.

Following steps are required to fi ll condensate trap for start up. Steps are only required at initial start up or if maintenance requires draining of condensate trap:

1. Pour about 1 cup of cold tap water into condensate trap vent.

2. Excess water will go through condensate drain line.

Verify proper operation of drain line (and external condensate pump if used).

Chilled Water Piping Install boiler used in connection with refrigeration system, so chiller medium is piped in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler.

Boiler piping system of hot water boiler connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with fl ow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle.

4 - NEAR BOILER PIPING

Figure 7 - Condensate Trap and Vent

To Exhaust Vent

(2” CPVC)

½” Adapter Male NPT x Socket Weld PVC Piping

1 3/8” Long

To Boiler Flue Outlet (2” CPVC)

2” Unthreaded Male x 2” NPT Male PVC Bushing

1/2” Unthreaded PVC Elbow

1/2” Unthreaded PVC Piping 3 3/4” Long

1/2” Unthreaded PVC Elbow1/2” Unthreaded PVC Piping 2” Long

1/2” Unthreaded PVC Piping 3 3/4” Long

1/2” Unthreaded PVC Tee

To Condensate Drain (Field Supplied)

2” NPT Male PVC Bushing

1/2” Unthreaded PVC Piping 12” Long

If concentric vent termination is being used, refer to Figure 10 for proper setup.

5 - COMBUSTION AIR/ VENT REQUIREMENTS

Figure 8 - Roof Vent / Intake Terminations

Figure 9 - Sidewall Vent/Intake TerminationsCombustion Air/Vent Pipe Requirements Boiler requires dedicated direct vent system. Direct vent system, all air for combustion is taken directly from outside atmosphere, and all fl ue products are discharged to outside atmosphere.

Combustion air and vent pipe connections must terminate together in same atmospheric pressure zone, either through roof or sidewall (roof termination preferred). See Figures 8 and 9 for required clearances.

12" (305mm) Minimum

8" (203mm) Minimum

15" (381mm) Maximum

3" (76mm) Maximum

Vent Combustion Air

12" (305mm) Minimum Above

Anticipated Snow Line

Vent

3" (76mm) Minimum

Separation

12" (305mm) Minimum From

Overhang

12" (305mm) Separation Between Bottom Of

Combustion Air Intake And Bottom Of Vent

See Snow & Ice Page 23

Combustion Air

Vent

12" (305mm) Minimum

Separation

Combustion Air

Figure 10 - Concentric Vent Terminations

Combustion Air Vent

1" (26mm) Maximum

Maintain 12" clearance above highest anticipated snow level or grade

* See Note Below 36"(0.9m) Minimum

Maintain 12"(305mm) Clearance Above Highest Anticipated Snow Level

Or Grade

12" (305mm) Minimum

*Must be less than 4" or greater than 24" Horizontal distance between end bells of each air intake to prevent fl ue gas recirculation.

1" (26mm) Maximum

Overhang

• Avoid locations where snow may drift and block vent and combustion air.

• Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed.

Vent Combustion Air

5 - COMBUSTION AIR/ VENT REQUIREMENTS

Figure 11 - Concentric Vent

3” Diameter PVC Vent/Exhaust

1½” 4½” Dia.

31⅞”

A

A

B

B

C

C

D

E

F

G

G3” Diameter PVC Intake/Combustion Air

46¾”

Dimension 1³⁄ ”D

E F

Dimension

VENT

VENT

A

A B

B

C

C

D

D

COMBUSTION

AIR

COMBUSTION AIR

ROOF BOOT/FLASHING

(FIELD SUPPLIED)

ELBOW

(FIELD SUPPLIED)

SUPPORT

(FIELD SUPPLIED)

MAINTANIN 12 IN.

(18IN. FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24 IN. ABOVE ROOF

NOTE:

SUPPORT MUST BE

FIELD INSTALLED TO

SECURE TERMINATION

KIT TO STRUCTURE.

Figure 12 - Concentric Vent Roof Installation

• Covering non-metallic vent pipe and fi ttings with thermal insulation shall be prohibited.

• Combustion air must be clean outdoor air. Do not take combustion air from inside structure because that air is frequently contaminated by halogens, which includes fl uorides, chlorides, phosphates, bromides and iodides.

These elements are found in aerosols, detergents, bleaches, cleaning solvents, salts, air fresheners, paints, adhesives, and other household products.

• Locate combustion air inlet as far away as possible from swimming pool and swimming pool pump house.

• All combustion air and vent pipes must be airtight and watertight.

• Combustion air and vent piping must also terminate exactly as shown in Figures 8 and 9.

• Use of concentric vent termination refer to Figures 10, 11 and 12 for proper setup.

• Vent connections serving appliances vented by natural draft shall not be connected into any portion of mechanical draft systems operating under positive pressure.

WARNING

Fire, explosion, asphyxiation hazard. Solvent cements are combustible. Keep away from heat, sparks, or open fl ame. Use only in well ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes. Improper installation could result in death or serious injury. Read this manual and understand all requirements before beginning installation.

A Roof Boot/Flashing (Field Supplied)

B Elbow (Field Supplied) C Support (Field Supplied)

D

Maintain 12” (305mm), 18” (457mm) Minimum Clearance Above Highest Anticipated Snow Level.

Maximum of (610mm) Above Roof.

Connections And Termination To prevent damage to gas burner and ensure proper operation of unit, installer must clean and remove all shavings from interior of all PVC pipe used on air intake.

Boilers require dedicated direct vent system. All air for combustion is taken directly from outdoors through combustion air intake pipe. All fl ue products are discharged to outdoors through vent pipe. Install vent system in accordance with these instructions.

1. Figures 8 and 9 “Combustion Air and Vent Pipe Requirements, for standard two-pipe roof and sidewall terminations and Figures 10, 11, and 12 for concentric vent terminations (roof termination is preferred).

Combustion air and vent pipes must terminate together in same atmospheric pressure zone as shown.

Construction through which vent and air intake pipes may be installed is minimum ¼” and maximum 24” thickness.

2. Combustion air and vent pipe fi ttings must conform to one of the following American National Standards Institute (ANSI) and American Society for Testing and Materials (ASTM) standards:

Table 3 - Combustion air and vent pipe fi ttings must conform with the following:

Item Material Standards

Vent Pipe and Fittings

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40 ANSI/ASTM D1784/ F441

SDR-21 & SDR-26 PVC ANSI/ASTM D2241

ABS-DWV ANSI/ASTM D2661

Schedule 40 ANSI/ASTM F628

Pipe Cement/ Primer

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

• IPEX is approved vent manufacturer in Canada listed to ULC-S636.

• IPEX System 636 Cements and Primers are approved in Canada listed to ULC-S636.

Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (Polyphenolsulfone) in venting systems shall be prohibited.

WARNING

Use of cellular core PVC for venting fl ue gas could result in death, serious injury.

3. Combustion air and vent piping connections on boiler are 2”, but must increase to 3”. Due to potential for fl ue gas temperatures over 155°F, fi rst 5 feet of vent pipe must be CPVC (furnished), remaining vent pipe can be PVC. If any elbows are employed within fi rst 2 ½’ of vent, they must be CPVC. Two 30” pieces of 2” CPVC pipe and one 2” CPVC coupling are furnished with boiler. See Figure 13.

Length of pipe is counted from boiler jacket (air intake pipe) or from vent tee (vent pipe). First fi ve feet of “Total Equivalent Length” of vent pipe must be CPVC.

Reduce maximum vent length 5 feet per each additional elbow.

4. Combustion air and vent piping to be pitched back to boiler at minimum ¼” per foot (21mm/m) from intake and vent terminals so that all moisture in combustion air and vent piping drains to boiler. Pipes must be pitched continuously with no sags or low spots where moisture can accumulate and block the fl ow of air or fl ue gas. Combustion air and vent pipes must be airtight and watertight.

Figure 13 - Combustion Air & Vent Piping

Combustion Air and Vent Pipe Equivalent Length 3 in. Pipe

Minimum Venting 3 in. Pipe

Maximum Venting

6 ft. (1.8 m) in length 60 ft. (18.3 m) in length and up to four (4) 90° elbows

1 - 90° elbow = 5 ft (1.6 m) 1 - 45° elbow = 3.5 ft (1.1 m) 1- 2” x 3” adapter = 0 ft (0 m)

6 - COMBUSTION AIR AND VENT PIPE

Installation

1. Recommend all pipes be cut, prepared, and pre-assembled before permanently cementing any joint.

2. Rigid supports cause excess noise in vent piping.

3. Attach combustion air intake piping to supplied 2” coupling on CVI gas valve. Attach vent piping to furnished 2” CPVC vent tee on draft inducer outlet.

4. All pipe joints are to be water tight.

5. Working from boiler to outside, cut pipe to required length(s).

6. Deburr inside and outside of pipe. Remove all chips and shavings.

7. Chamfer outside edge of pipe for better distribution of primer and cement.

8. Clean and dry all surfaces to be joined.

9. Check dry fi t of pipe and mark insertion depth on pipe.

10. After pipes have been cut and pre-assembled, apply cement primer to pipe fi tting socket and end of pipe to insertion mark. Quickly apply approved cement to end of pipe and fi tting socket (over primer). Apply cement in light, uniform coat on inside of socket to prevent buildup of excess cement. Apply second coat.

11. While cement is still wet, insert pipe into socket with ¼ turn twist. Be sure pipe is fully inserted into fi tting socket.

12. Wipe excess cement from joint. Continuous bead of cement will be visible around perimeter of properly made joint.

13. Handle pipe joint carefully until cement sets.

14. Support combustion air and vent piping minimum of every 5 feet using pre-formed metal hanging straps. Do not rigidly support pipes. Allow for movement due to expansion and contraction.

15. Slope combustion air and vent pipes toward boiler minimum of ¼” per linear foot with no sags between hangers.

16. Use appropriate methods to seal openings where vent and combustion air pipes pass through roof or side wall.

6 - COMBUSTION AIR AND VENT PIPE

NOTICE

Exhaust transition from 2” pipe to 3” pipe must be made in vertical run. (Transition pieces not included.)

5. Consider following when determining appropriate location for termination of combustion air and vent piping:

A. Position termination where vent vapors will not damage plants/shrubs, air conditioning equipment, or siding on the house.

B. Position termination so it will not be effected by wind eddy, air born leaves, snow, or recirculated fl ue gases.

C. Position termination where it will not be subjected to potential damage by foreign objects, such as stones, balls, etc.

D. Position termination where vent vapors are not objectionable.

E. Put vent on wall away from prevailing winter wind.

Locate or guard vent to prevent accidental contact with people or pets.

F. Terminate vent above normal snow-line. Avoid locations where snow may drift and block vent.

Ice or snow may cause boiler to shut down if vent becomes obstructed.

G. Under certain conditions, fl ue gas will condense, forming moisture, and may be corrosive. In such cases, take steps to prevent building materials at vent from being damaged by exhaust of fl ue gas.

о Terminate venting system at least 3 feet (0.3m) above any forced air inlet (except boiler’s combustion air inlet) within 10 feet (3m).

о Terminate venting system at least 12 inches (300mm) from any air opening into any building.

о Locate bottom of vent at least 12 inches (300mm) above grade.

о Terminate vent not less than 7 feet (2.1m) above adjacent public walkway.

о Vent terminal shall not be installed closer than 3 feet (0.9m) from inside corner of L shaped structure.

о Termination of vent should be kept at least 3 feet (0.9m) away from vegetation.

о If multiple terminations are used, minimum of 12 inches (300 mm) between exhaust of one termination and air intake of next termination.

See Figure 8, 9, and 10.

о All fi eld installed vent pipe must be 3”.

Terminate vent system at least 4 feet (1.22 m) horizontally from, and in no case above or below, unless a 4 feet (1.22

m) horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment.

Check Gas Supply

• Gas pipe to boiler must be correct size for length of run and total Btuh input of all gas utilization equipment connected to it.

• See Tables 6 and 7 for proper size.

• Verify your gas line complies with local codes and gas company requirements.

Connecting Gas Piping

Table 5 - Gas Supply Pressure

Pressure Natural Gas Propane Gas Minimum 4” w.c. 10” w.c.

Maximum 10” w.c. 14” w.c.

Please check line pressure while unit is running.

Table 6 - Natural Gas Piping Sizes

Pipe Length Pipe Capacity - BTU/Hr. Input (1)

½” ¾” 1” 1¼” 20’ 92,000 190,000 350,000 625,000

40’ 63,000 130,000 245,000 445,000

60’ 50,000 105,000 195,000 365,000

Table 7 - Propane Gas Piping Sizes

Pipe Length

Pipe Capacity - BTU/Hr. Input (1)

Copper Tubing (2) Iron Pipe

⅝” ¾” ½” ¾” 20’ 131,000 216,000 189,000 393,000

40’ 90,000 145,000 129,000 267,000

60’ 72,000 121,000 103,000 217,000 (1)Includes Fittings (2)Outside Diameter

Refer to Figure 14 for general layout at boiler. Gas line enters boiler through left side panel.

Boiler is equipped with ½” NPT connection on gas valve for supply piping and ½” NPT ball valve for manual shut off.

Following rules apply:

1. Use only those piping materials and joining methods listed as acceptable by the authority having jurisdiction, or in the absence of such requirements, National Fuel Gas Code, ANSI Z223.1/NFPA 54.

2. Use pipe joint compound suitable for liquefi ed petroleum gas on male threads only.

3. Use ground joint unions.

4. Install sediment trap upstream of gas controls.

5. Use two pipe wrenches when making connection to gas valve to keep it from turning.

6. Install manual main shutoff valve in vertical pipe about 5 feet (1.5m) above fl oor outside boiler jacket.

7. Tighten all joints securely.

8. Propane gas connections made by licensed propane installer.

9. Two stage regulation used by licensed propane installer.

10. Propane installer to verify Propane gas piping.

11. Recommend use ½” union suitable for natural and propane gas after ball valve to facilitate service on unit.

Leak Check Gas Piping

Pressure test boiler and gas connection before placing boiler in operation.

• Pressure test over 1/2 psig (3.5 kPa). Disconnect boiler and its individual gas shutoff valve from gas supply system.

• Pressure test at 1/2 psig (3.5 kPa) or less. Isolate boiler from gas supply system by closing manual gas shutoff valve.

• Locate leakage using gas detector, noncorrosive detection fl uid, or other leak detection method acceptable to authority having jurisdiction. Do not use matches, candles, open fl ames, or other methods providing ignition source.

• Correct leaks immediately and retest.

7 - GAS SUPPLY PIPING

Figure 14 - Gas Piping

Length of pipe or tubing should be measured from gas meter or propane second stage regulator.

WARNING

Electrical shock hazard. Turn OFF electrical power supply at service panel before making electrical connections. Failure to do so could result in death or serious injury.

NOTICE

Use copper conductors only.

Electrically bond boiler to ground in accordance with requirements of authority having jurisdiction. Refer to National Electrical Code, ANSI/NFPA 70.

Electric Power Supply Turn OFF electrical power supply at service panel and boiler before making electrical connections.

• Run 120 volt circuit from separate over current protection device in electrical service entrance panel, 15 ampere circuit.

• Service switch is pre-wired and located on exterior boiler jacket. See Figure 15 for location of service switch, junction box, and power supply connection points.

• Connect black (hot) lead from power supply to either of unused brass screws on service switch.

• Connect white (neutral) lead from power supply to white screw on service switch.

• Connect green (ground) lead from power supply to ground (green) screw on service switch.

• Receptacle on service switch is powered regardless of whether switch is on or off, and could be used as power supply for external condensate pump if one is used.

• Run 14 gauge or heavier copper wire from boiler to grounded connection in service panel or properly driven and electrically grounded ground rod.

8 - ELECTRICAL WIRING

Figure 15 - Field Wiring Connection

Service Switch Junction Box

AVOID THE FOLLOWING

Dead Spots Corners Alcoves Behind doors

Cold Spots

Concealed pipes or ducts Stairwells - drafts Unheated rooms on the other side of the wall

Hot Spots

Concealed pipes Fireplaces TVs or radios Lamps Direct sunlight Kitchens

Thermostat Installation

• Follow instructions included with your thermostat.

• Locate thermostat fi ve feet above fl oor on inside wall.

• Mount directly on wall or vertically mount on outlet box.

Thermostat should sense average room temperature.

• Set heat anticipator at 0.7 amps.

• Connect 24 volt thermostat leads to the two (2) yellow wires located in service switch junction box, located on outer jacket of boiler. See Figure 15, Page 16 for service switch junction box and thermostat fi eld wiring connections.

Connect Circulator Pump Wiring

NOTICE

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

See Figure 16, Page 18 and Figure 17, Page 19 for service switch junction box and circulator pump fi eld wiring connections. If the two 120 volt circulator wire terminals inside junction box are not used, leave two wire nuts to prevent short circuit.

8 - ELECTRICAL WIRING

NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent.

Figure 16 - Schematic Wiring Connections

NOTE: If any of the original wire as supplied with this appliance must be replaced, it must be replaced with type 150°C Thermoplastic wire or its equivalent.

Figure 17 - Ladder Wiring Diagram

See “Troubleshooting” on page 34 for detailed sequences of operation and troubleshooting procedures. See separately provided “Repair Parts Manual” for locations of control components and accessories described.

Integrated Boiler Control (IBC)

• Integrated Boiler Control (IBC) is a microprocessor based controller for high effi ciency gas boilers.

• Controller monitors all safety controls which control operation of combustion air blower, circulator pump, burner, and combination hot surface igniter/fl ame sensor.

• Controller is not intended for use with vent damper.

Controller is mounted on control panel inside boiler.

Contains fi ve diagnostic indicator lights.

Gas Control Valve Electronic 24 volt gas control valve contains 1:1 gas/air pressure regulator, controls gas fl ow to main burner of appliance. Suited for both natural and LP gas, and rated in accordance with ANSI Z21.21 - latest revision and CGA- 6.5-M95.

Hot Surface Igniter

• 120 volt hot surface igniter heats up 1800°F initiates combustion of gas in burner.

• Igniter is mounted next to burner through gas/air mixer.

• Igniter also serves as means for proving main burner fl ame by fl ame rectifi cation.

A. In event of lack of fl ame signal on three consecutive trials for ignition, IBC will lock out.

B. “Valve” and “Flame” diagnostic indicator lamps blink indicating failure mode as lack of fl ame signal.

C. Manually reset IBC from lockout by removing and re-establishing thermostat’s call for heat, or turn service switch off, then back on. See Figure 19.

High Limit Control

NOTICE

Maximum set-point of limit control must not exceed 190°F.

• High limit control determines maximum boiler water temperature and provides means for protecting boiler and heating system from unsafe operating conditions which could damage boiler.

• Control is mounted in ½” NPT control well and ¾” x ½” bushing on top of front boiler section at hot water outlet.

• Control is tied in with IBC and factory set at 190°F water temperature.

• High limit set-point is fi eld adjustable and may be set between 100°F and 190°F.

• Field set-point adjustment for each installation depends on heating system requirements.

• Differentials are automatic, vary based on control settings and boiler temperature.

• Refer to limit manufacturer instructions provided with limit control.

Casting Temperature Safety Switch

NOTICE

Never run cold water into hot, empty boiler.

Casting temperature safety switch (230°F set-point) shuts off boiler by shutting off power to IBC, result of lack or loss of boiler water. Power indicator light goes out.

Switch is installed on top of aluminum boiler section behind supply piping.

Fault requires manual reset of casting temperature safety switch, restarting boiler. Verify boiler is fi lled with water before resetting switch.

9 - CONTROLS AND ACCESSORIES

Figure 18 - Gas Valve

Figure 19 - Indicator Lights

Differential Pressure Switches

• Diaphragm type differential pressure switches are connected by vinyl tubing to gas valve, air inlet connection on negative side, and sight glass adapter on positive side. Pressure switches monitor air fl ow by sensing differential pressure measured in inches of water (” w.c.).

• Switch factory settings are 0.5” w.c. on normally open switch and 3.5” w.c. for normally closed switch.

• See pages 25-27, “Detailed Sequence of Operation,” for details.

Blower Blower provides means for pushing combustion air into and through mixer, burner, and fl ue ways of cast aluminum boiler section before being discharged through vent piping to outdoors.

Circulator Pump

• Forced hot water system requires at least one circulating pump.

• Circulating pump provides energy to move water through closed loop supply, return piping systems, terminal heating equipment (fi nned tube radiators, etc.)

and back through boiler for reheating.

• To provide required hot water fl ow rates, circulator pump must be properly sized to overcome frictional losses (usually measured in feet of water, also referred to as “pump head loss”) of supply and return piping systems and boiler.

• Circulator pump is furnished in a carton within boiler cabinet. Locate circulator(s) on downstream (i.e., “pumping away”) side of expansion tank.

Drain Valve Manual drain valve is means of draining water in heating system, including boiler, hot water supply and return piping systems installed above drain valve.

Install drain valve in ¾” tapping at bottom of boiler.

Piping installed below drain valve elevation requires additional drain valves installed at low points in piping systems to drain entire system.

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation.

Install discharge piping per these instructions.

A.S.M.E. Rated Pressure Relief Valve

• Each boiler must have properly sized and installed

A.S.M.E. rated pressure relief valve.

• Water expands as it is heated by the burner/boiler sections. If no place for water to expand its volume, (i.e., properly sized functioning expansion tank) pressure inside of boiler and heating system increases.

9 - CONTROLS AND ACCESSORIES

• Pipe pressure relief valve discharge with same size as valve discharge opening to open drain, tub or sink, or other suitable drainage point. Do not subject to freezing, in accordance with A.S.M.E.

• Failure to provide pressure relief valve with piping as described may cause water damage and/or serious bodily injury.

Blocked Vent Safety Shutoff

• Boiler equipped with blocked vent safety shutoff, shuts off main burner gas in event airfl ow of combustion products through fl ue-way is reduced.

• Air will not be available to support combustion if fl ueway is blocked. IBC locks out due to loss of adequate air fl ow.

• Pressure switches monitor air fl ow by sensing differential pressure. Contacts normally open and close when draft inducer is running causing differential pressure at switch to exceed settings. Closed switch proves adequate air fl ow for combustion.

• Pressure switch shuts off main burner if differential pressure is inadequate due to blocked vent pipe, blocked air intake, blocked boiler section, or blocked air inducer.

After 5 minutes of inadequate differential pressure, IBC will lock out.

• “Purge” indicator lamp blinks, see Figure 19, Page 20, indicating failure to prove adequate combustion air fl ow or fl ue gas fl ow. IBC automatically resets after 15 minutes or manually reset as noted “Hot Surface Igniter” on page 20.