A.O. Smith 405 User Manual
COPPER BOILERS FOR
HYDRONIC HEATING AND
HOT WATER SUPPLY
WARNING: 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.
• Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance.
WHAT TO DO IF YOU SMELL GAS:
•Extinguish any open flame.
•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.
PLACE THESE INSTRUCTIONS ADJACENT TO BOILER AND NOTIFYOWNERTOKEEPFORFUTUREREFERENCE.
1000, 1300, 1500, 1850, 2100, 2500
SERIES: 400, 401, 402, 403, 404, 405
TEXT PRINTED OR OUTLINED IN RED CONTAINS INFORMATION RELATIVE TO YOUR SAFETY. PLEASE READ THOROUGHLY BEFORE INSTALLING AND USING THIS APPLIANCE.
Thankfor buying this cost efficient, high recovery unit from
A. O. Smith Water Products Co.
You should thoroughly read and understand this manual before installation and/or operation of this boiler. Please pay particular attention to the important safety and operating instructions as well as the WARNINGS and CAUTIONS.
DIMENSIONS/CAPACITIES DATA ..........................
4 - 5
5 - 7
INSTALLATION INSTRUCTIONS .......................
7 - 9
SYSTEM INSTALLATION ................................
11 - 16
HYDRONIC INSTALLATION ............................
HOT WATER SUPPLY INSTALLATION ...........
GAS CONNECTIONS ......................................
18 - 23
31 - 34
LIGHTING AND OPERATING ..........................
CONTROL SYSTEM .......................................
34 - 44
PREVENTATIVE MAINTENANCE ..................
TROUBLE SHOOTING ....................................
42 - 44
WIRING DIAGRAM/SCHEMATIC ...................
LIMITED WARRANTY .............................................
MC BEE, SC., RENTON, WA.,
NANJING, CHINA www.hotwater.com / email:email@example.com
PRINTED IN U.S.A. 0906
Refer to "Installation Clearances" section of manual (page 7) for recommended service clearances prior to boiler placement.
TABLE 1: GAS AND ELECTRICAL REQUIREMENT
Type of Gas
All Models - Maximum Supply Pressure: 14.0 In. W.C. (3.49 kPa)
Minimum Supply Pressure Natural Gas: 6.0 In. W.C. (1.22 kPa)
Minimum Supply Pressure Propane Gas: 11.0 In. W.C. (2.74 kPa)
Minimum Pressures must be maintained during operating conditions.
TABLE 2. DIMENSIONAL DATA
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
2 1/2 NPT
DIMENSIONS DATA FOR OUTDOOR CONFIGURATION
TABLE 3. DIMENSIONAL DATA
TABLE 4: RECOVERY CAPACITIES
TEMPERATURE RISE - DEGREES °F (°C)
GW - 1000
GW - 1300
GW - 1500
GW - 1850
GW - 2100
GW - 2500
TABLE 5: PUMPING PERFORMANCE GUIDE
20 Deg. F Rise
30 Deg. F Rise
40 Deg. F Rise
Maximum Flow Rate
Minimum Flow Rate
GB - 1000
GB - 1300
GB - 1500
GB - 1850
GB - 2100
GB - 2500
Note: GW models (GB optional) are equipped with pumps capable of handling 50 equivalent feet (15.2 m) of normal pipe fittings.
Detailed installation diagrams are in this manual. These diagrams will provide the installer with a reference of materials needed and a suggested method of piping. IT IS NECESSARY THAT ALL WATER AND GAS PIPING, AND THE ELECTRICAL WIRING BE INSTALLED AND CONNECTED AS SHOWN IN THE DIAGRAMS.
CHECK DIAGRAMS THOROUGHLY BEFORE STARTING INSTALLATION TO AVOID POSSIBLE ERRORS AND MINIMIZE TIME AND MATERIALS COST. SEE FIGURES 1 THROUGH 5 AND TABLES 1, 2, AND 3.
This design complies with the current edition of ANSI
MAKE SURE THE GAS ON WHICH THE BOILER WILL OPERATE IS THE SAME AS THAT SPECIFIED ON THE BOILER RATING PLATE.
The boiler installation must conform to these instructions and the local code authority having jurisdiction. In the absence of local codes, the installation must comply with the latest editions of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and the National Electrical Code, NFPA 70 or CAN/CSA B149.1, and CSA 2 C22.1. The former is available from the Canadian Standards Association, 8501 East Pleasant Valley Road, Cleveland, OH 44131, and both documents are available from the National Fire Protection Association, 1 Batterymarch Park, Quincy, MA 02269.
This boiler must be grounded in accordance with the National Electrical Code, NFPA 70 or the Canadian Electrical Code CSA 2 C22.1 and/or local codes. The boiler is polarity sensitive, correct wiring is imperative for proper operation.
This boiler must be connected to a grounded metal, permanent wiring system, or an equipment grounding conductor must be run with the circuit conductors and connected to the equipment grounding terminal or lead on the boiler.
YOUR BOILER IS NOT DESIGNED TO OPERATE WITH A BOILER INLET WATER TEMPERATURE OF LESS THAN 120°F (49°C). COLDER INLET WATER TEMPERATURE WILL RESULT IN SIGNIFICANT CONDENSATION DEVELOPING ON THE HEAT EXCHANGER. THIS SITUATION CAN CAUSE A CORROSIVE ENVIRONMENT FOR THE HEAT EXCHANGER, BURNERS AND VENTING RESULTING IN PREMATURE DAMAGE, WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
FOR SYSTEMS THAT USE LARGE VOLUMES OF COLD WATER OR SYSTEMS UTILIZING HEAVY WATER DRAWS, CONDENSATION CAN BE PREVENTED BY USING A BYPASS LOOP.
Make sure the gas on which the boiler will operate is the same as that specified on the boiler rating plate. Do not install the boiler if equipped for a different type of gas, consult your gas supplier.
IF THE UNIT IS EXPOSED TO THE FOLLOWING, DO NOT OPERATE UNTILALL CORRECTIVE STEPS HAVE BEEN MADE BY A QUALIFIED SERVICEMAN:
1.EXPOSURE TO FIRE.
3.FIRING WITHOUT WATER.
IF THE BOILER HAS BEEN EXPOSED TO FLOODING, IT MUST BE REPLACED.
LIQUID PETROLEUM MODELS
Boilers for propane or liquefied petroleum gas (LPG) are different from natural gas models. A natural gas boiler will not function safely on LP gas and no attempt should be made to convert a boiler from natural gas to LP gas.
LP gas must be used with great caution. It is highly explosive and heavier than air. It collects first in the low areas making its odor difficult to detect at nose level. If LP gas is present or even suspected, do not attempt to find the cause yourself. Leave the building, leaving doors open to ventilate, then call your gas supplier or service agent. Keep area clear until a service call has been made.
At times you may not be able to smell an LP gas leak. One cause is odor fade, which is a loss of the chemical odorant that gives LP gas its distinctive smell. Another cause can be your physical condition, such as having a cold or diminishing sense of smell with age. For these reasons, the use of a propane gas detector is recommended. IF YOU EXPERIENCE AN OUT OF GAS SITUATION, DO NOT TRY TO RELIGHT APPLIANCES YOURSELF. Call your local service agent. Only trained LP professionals should conduct the required safety checks in accordance with industry standards.
HIGH ALTITUDE INSTALLATION
INSTALLATIONS ABOVE 4,500 FEET REQUIRE REPLACEMENT OF THE BURNER ORIFICES. FAILURE TO REPLACE THE ORIFICES WILL RESULT IN IMPROPER AND INEFFICIENT OPERATION OF THE APPLIANCE, PRODUCING CARBON MONOXIDE GAS IN EXCESS OF SAFE LIMITS, WHICH COULD RESULT IN SERIOUS PERSONAL INJURY OR DEATH.
GENESIS BOILERS ARE EQUIPPED WITH
Some utility companies derate their gas for altitude. You should contact your gas supplier for any specific changes which may be required in your area. Call the local gas utility to verify BTU content of the gas supplied.
Input rating specified on the rating plate applies to elevations up to 4,500 feet (1350 m). For elevations above 4,500 feet (1350 m), ratings must be reduced, consult the factory.
ALL MODELS - The control system consists of four basic components: 1) Central Control Board 2) Flame Control Board 3) User Interface Module 4) Power Distribution Board; see Figures 17, 18, 19 and 21. The Central Control Board, Flame Control Boards and the Power Distribution Board are located in the control box and can be accessed through panels on the left side and top of the unit. The User Interface Module is attached to the front jacket panel. The control system is a
The Control Boards Figure 17 and 18, contain dipswitches which allow the user to control several system options. See Control System Section.
DIFFERENTIAL PRESSURE SWITCH
COMBUSTION AIR BLOWER
The differential pressure switch ensures that a sufficient differential exists between the air pressure in the
The differential pressure switch is normally open and closes when the combustion blower starts.
BLOCKED FLUE PRESSURE SWITCH
The blocked flue pressure switch ensures that the vent system is clear. This pressure switch is normally closed and only opens on fault conditions.
The flame sensor detects the flame presence on burner's ports. If no flame is sensed, the gas valve(s) will close automatically. If no flame is sensed on three ignition trials the boiler will lock out. In the event of a lockout, depress the SELECT button on the UIM to restart the boiler.
WATER FLOW SWITCH
The water flow switch is installed at the boiler outlet to prevent burner operation in the event of inadequate water flow through the boiler. It is a normally open switch that will close its contacts when increasing water flow rate is detected. The water flow switch is
LIMIT CONTROLS ARE SAFETY DEVICES AND ARE NOT TO BE USED AS AN OPERATING CONTROL (THERMOSTAT).
The "G(B/W)" models incorporate an outlet water probe consisting of two limit controls:
1.An adjustable automatic reset limit control, that can be set as high as either 210°F (99°C) or 235°F (113°C) depending on the application.
2.A fixed manual reset limit (ECO) factory set at 244°F (118°C). If the manual reset should open due to high temperature, the gas valves will close and the unit will go into lockout. If lockout occurs, push the SELECTION button on the UIM to restart the boiler.
The ON/OFF switch is a
Provides air for combustion process. The blower settings are adjustable through the use of the air shutter, however, blowers are set at the factory and might require slight adjustment depending on site installation.
FOR HOT WATER SUPPLY SYSTEMS (GW models), a tank probe is supplied with each hot water supply boiler.
Note: The tank probe must be designated as the controlling probe using dip switch "4" on Central Control Board (Figure 17) before it can be used for (GW) hot water supply applications.
FOR HOT WATER HEATING SYSTEMS (GB models), a tank probe is not supplied with the GB models due to the many various types of systems and operating conditions. A tank probe can be used as an option to control loop temperature and unit staging. Additionally, the inlet temperature probe can be used as the loop thermostat in some heating applications. The tank probe connects to designated wires in the junction box at the rear of the boiler. Do not operate this boiler using the internal high limits only, use a tank probe or operating thermostat to control system temperatures.
Note: The tank probe or additional 24VAC devices must be identified using Dipswitches on Central Control Board before they are recognized as a part of the heating system; see Table 5. Refer to "Control System" section for more information about dipswitch settings.
The pump flow rate should not exceed the maximum recommended flow rate; see Table 5.
FOR HOT WATER SUPPLY SYSTEMS (GW models), ordered with the circulator as an integral part of the boiler; the pump has been lubricated at the factory, and future lubrication should be in accordance with the motor manufacturer's instructions provided as supplement to this manual.
FOR HOT WATER HEATING SYSTEMS (GB models or GW models ordered without circulator), the circulator is NOT provided and must be
LOW WATER CUTOFF (Not Supplied)
If low water level protection is required by the authorities having jurisdiction, a low water cutoff switch should be installed next to the boiler in the outlet water line as shown in "HYDRONIC INSTALLATION" section; see page 16. The switch should receive periodic (every six months) inspection to assure proper operation. A low water cutoff device of the float type should
be flushed every six months.
DRAIN VALVE (Not Supplied)
Additional drain valves must be obtained and installed on each boiler and tank for draining purposes.
SAFETY RELIEF VALVES
Your local code authority may have other specific relief valve requirements not covered below.
THE PURPOSE OF A SAFETY RELIEF VALVE IS TO AVOID EXCESSIVE PRESSURE WHICH MAY CAUSE TANK EXPLOSION, SYSTEM OR BOILER DAMAGE.
TOAVOID WATER DAMAGEADRAIN LINE MUST BE CONNECTED TOASAFETY RELIEF VALVE FOR DIRECT DISCHARGE TOASAFE LOCATION. A DRAIN LINE MUST NOT BE REDUCED FROM THE SIZE OF THE VALVE OUTLET AND IT MUST NOT CONTAIN ANY VALVES BETWEEN THE BOILER AND THE RELIEF VALVE OR THE RELIEF VALVE AND THE DRAIN EXIT. IN ADDITION, THERE SHOULD NOT BE ANY RESTRICTIONS IN A DRAIN LINE NOR SHOULD IT BE ROUTED THROUGH AREAS WHERE FREEZING CONDITIONS MIGHT OCCUR. DO NOT THREAD OR CAP THE DRAIN LINE EXIT. RESTRICTING OR BLOCKING A DRAIN LINE WILL DEFEAT THE PURPOSE OF THE RELIEF VALVE AND MAY CREATE AN UNSAFE CONDITION. INSTALLA DRAIN LINE WITH A DOWNWARD SLOPE SUCH THAT IT NATURALLY DRAINS ITSELF.
If any safety relief valve is replaced, the replacement valve must comply with the latest version of the ASME Boiler and Pressure Vessel Code, Section IV (HEATING BOILERS). Select a relief valve with a discharge rating NOT less than the boiler input, and a set pressure NOT exceeding the working pressure of any component in the system.
The storage tank temperature and pressure relief valve must comply with the applicable construction provisions of the Standard for Relief Valves for Hot Water Supply Systems, ANSI
FOR HOT WATER HEATING SYSTEMS, the boilers are shipped with a 50 psi pressure relief valve. This relief valve is factory installed on the water outlet header of the boiler.
FOR HOT WATER SUPPLY SYSTEMS, the boilers are shipped with a 125 psi pressure relief valve. This relief valve is factory installed on the water outlet header of the boiler. This
In addition, a CSA
The T & P relief valve should have a temperature rating of 210°F (99°C), a pressure rating NOT exceeding the lowest rated working pressure of any system component, and a discharge capacity exceeding the total input of the water boilers supplying water to the storage tank.
Locate the T & P relief valve (a) in the top of the tank, or (b) in the
side of the tank on a center line within the upper six (6) inches (15 cm) of the top of the tank. The tapping shall be threaded in accordance with the latest edition of the Standard for Pipe Threads, General Purpose (inch), ANSI/ASME B1.20.1. The location of, or intended location for, the T & P relief valve shall be readily accessible for servicing or replacement.
INSTALLATION OR SERVICE OF THIS BOILER REQUIRES ABILITY EQUIVALENT TO THAT OFALICENSED TRADESMAN IN THE FIELD INVOLVED. PLUMBING,AIR SUPPLY, VENTING, GAS SUPPLYAND ELECTRICAL WORK ARE REQUIRED.
When installing the boiler, consideration must be given to proper location. The location selected should be as close to the stack or chimney as practical with adequate air supply and as centralized with the piping system as possible. The location should also be such that the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation and service (circulator replacement, control replacement, etc.)
•THE BOILER MUST NOT BE INSTALLED ON CARPETING.
•THE BOILER SHOULD NOT BE LOCATED IN AN AREA WHERE IT WILL BE SUBJECT TO FREEZING.
•THE BOILER SHOULD BE LOCATED NEAR A FLOOR DRAIN.
•THE BOILER SHOULD BE LOCATED IN AN AREA WHERE LEAKAGE FROM THE BOILER OR CONNECTIONS WILL NOT RESULT IN DAMAGE TO THE ADJACENTAREA OR TO LOWER FLOORS OF THE STRUCTURE.
WHEN SUCH LOCATIONS CANNOT BE AVOIDED, A SUITABLE DRAIN PAN SHOULD BE INSTALLED UNDER THE BOILER. Such pans should be fabricated with sides at least
THERE IS A RISK IN USING FUEL BURNING APPLIANCES IN ROOMS OR AREAS WHERE GASOLINE, OTHER FLAMMABLE LIQUIDS OR ENGINE DRIVEN EQUIPMENT OR VEHICLES ARE STORED, OPERATED OR REPAIRED. FLAMMABLE VAPORS ARE HEAVY AND TRAVEL ALONG THE FLOOR AND MAY BE IGNITED BY THE IGNITER OR MAIN BURNER FLAMES CAUSING FIRE OR EXPLOSION. SOME LOCAL CODES PERMIT OPERATION OF GAS APPLIANCES IF INSTALLED 18 INCHES (46.0 CM) OR MORE ABOVE THE FLOOR. THIS MAY REDUCE THE RISK IF LOCATION IN SUCH AN AREA CANNOT BE AVOIDED.
FLAMMABLE ITEMS, PRESSURIZED CONTAINERS OR ANY OTHER POTENTIAL FIRE HAZARDOUS ARTICLES MUST NEVER BE PLACED ON OR ADJACENT TO THE BOILER.
OPEN CONTAINERS OF FLAMMABLE MATERIAL SHOULD NOT BE STORED OR USED IN THE SAME ROOM WITH THE BOILER. A hot water boiler installed above radiation level or as required by
the authority having jurisdiction, must be provided with a low water cutoff device either as a part of the boiler or at the time of boiler installation.
UNDER NO CIRCUMSTANCES SHOULD THE EQUIPMENT ROOM WHERE THE BOILER IS INSTALLED EVER BE UNDER NEGATIVE PRESSURE. PARTICULAR CARE MUST BE TAKEN WHEN EXHAUST FANS, COMPRESSORS, AIR HANDLING EQUIPMENT, ETC., MAY INTERFERE WITH THE COMBUSTION AND VENTILATION AIR SUPPLIES OF THIS BOILER.
CHEMICAL VAPOR CORROSION
Heat exchanger corrosion and component failure can be caused by the heating and breakdown of airborne chemical vapors. Spray can propellants, cleaning solvents, refrigerator and air conditioning refrigerants, swimming pool chemicals, calcium and sodium chloride, waxes, and process chemicals are typical compounds which are corrosive. These materials are corrosive at very low concentration levels with little or no odor to reveal their presence.
Products of this sort should not be stored near the boiler. Also, air which is brought in contact with the boiler should not contain any of these chemicals. If necessary, uncontaminated air should be obtained from remote or outside sources. Failure to observe this requirement will void the warranty.
Sufficient area should be provided at the front and sides of the unit for proper servicing. For ease of service, minimum clearances of 24" (61.0 cm) in the front and 18" (46.0 cm) on the sides are recommended. It is important that the minimum clearances be observed to allow service to the control box and other controls. Observing proper clearances will allow service to be performed without movement or removal of the boiler from its installed location. Failure to observe minimum clearances may require removal of the boiler in order to service such items as the heat exchanger and burners. In a utility room installation, the door shall be wide enough to allow the boiler to enter or to permit the replacement of another appliance.
Two inch (5.1 cm) clearance is allowable from combustible construction to hot water pipes. Sufficient clearance should be provided at one end of the boiler to permit access to heat exchanger tubes for cleaning.
Access to control box items such as the Central Control Board, Flame Control Boards, Power Distribution Board and wiring harnesses is provided through a panel on the left side of the unit. A minimum service clearance of 18" (46.0 cm) is required.
These boilers are approved for installation on noncombustible flooring in an alcove with minimum clearance to combustibles of: 3 inches (7.6 cm) Right Side, and Back; 6 inches (15.2 cm) Top; Front, Alcove; 12 inches (30.5 cm) Left Side; and 6 inches (15.2 cm) surrounding the Vent.
For installation on combustible flooring use the Combustible Floor Kit. The combustible floor kit base adds 4" (10.1 cm) to the overall height of the boiler. See Figure 3.
COMBUSTIBLE BASE KIT NUMBER
G(B,W) - 1000
G(B,W) - 1300
G(B,W) - 1500
G(B,W) - 1850
G(B,W) - 2100
G(B,W) - 2500
Figure 3. Boiler on Combustible Floor Base and Kit Numbers.
Each unit must be checked after installation to be certain that it is level.
FOR SAFE OPERATION, AN AMPLE SUPPLY OF AIR MUST BE PROVIDED FOR PROPER COMBUSTION AND VENTILATION IN ACCORDANCE WITH THE NATIONAL FUEL GAS CODE, ANSI Z223.1 OR
In buildings of conventional frame, brick or stone construction, unconfined spaces may provide adequate air for combustion.
If the unconfined space is within a building of tight construction (buildings using the following construction: weather stripping, heavy insulation, caulking, vapor barrier, etc.), air for combustion, ventilation, must be obtained from outdoors or spaces freely communicating with the outdoors. The installation instructions for confined spaces in tightly constructed buildings must be followed to ensure adequate air supply.
(a) U. S. INSTALLATIONS
When drawing combustion and dilution air from inside a conventionally constructed building to a confined space, such a space shall be provided with two permanent openings, ONE WITHIN 12 INCHES OF THE ENCLOSURE TOP AND ONE WITHIN 12 INCHES OF THE ENCLOSURE BOTTOM. Each opening shall have a free area of at least one square inch per 1000 Btu/hr (22 cm2/k W) of the total input of all appliances in the enclosure.
If the confined space is within a building of tight construction, air for combustion, ventilation, and draft hood dilution must be obtained from outdoors. When directly communicating with the outdoors or communicating with the outdoors through vertical ducts, two permanent openings, located in the above manner, shall be provided. Each opening shall have a free area of not less than one square inch per 4000 Btuh (5.5 cm2/kW) of the total input of all appliances in the enclosure. If horizontal ducts are used, each opening shall have a free area of not less than one square inch per 2000 Btuh (11 cm2/kW) of the total input of all appliances in the enclosure.
(b) CANADIAN INSTALLATIONS
Ventilation of the space occupied by the boiler(s) shall be provided by an opening for ventilation air at the highest practical point communicating with outdoors. The total
In addition to the above, there shall be permanent air supply opening(s) having a
Where power vented equipment is used in the same room as the boiler, sufficient air openings must be supplied. UNDERSIZED OPENINGS MAY RESULT IN INSUFFICIENT AIR FOR COMBUSTION.
Where an exhaust fan is installed in the same room with a boiler, sufficient openings for air must be provided in the walls. UNDERSIZED OPENINGS WILL CAUSE AIR TO BE DRAWN INTO THE ROOM THROUGH THE CHIMNEY, CAUSING POOR COMBUSTION. SOOTING MAY RESULT WITH AN INCREASED RISK OFASPHYXIATION.
WHEN VENTING THE GENESIS BOILER THROUGH AN OVERSIZED CHIMNEY (INCLUDING MASONRY CHIMNEYS), ADDITIONAL CARE MUST BE EXERCISED TO ASSURE PROPER DRAFT. FOR PROPER OPERATION, A MINIMUM DRAFT OF
THE INSTRUCTIONS IN THIS SECTION ON VENTING THE BOILER MUST BE FOLLOWED TO AVOID CHOKED COMBUSTION OR RECIRCULATION OF FLUE GASES. SUCH CONDITIONS CAUSE SOOTING OR RISKS OF FIRE AND ASPHYXIATION.
This boiler is approved to be vented as a Category I, Category III (horizontal venting), or a Direct Vent appliance. The Horizontal and Direct Venting options require a special vent kit.
STANDARD (VERTICAL) VENTING, CATEGORY I
THIS BOILER MAY BE VENTED ACCORDING TO TABLE 10 (ALSO
SEE FIGURE 6). AT LEAST TYPE B VENTING MUST BE USED WITH THE STANDARD VENTING OPTION
VENT SIZING, VENT CONNECTORS, INSTALLATION AND TERMINATION SHALL BE IN ACCORDANCE WITH THE CURRENT EDITION OF NATIONAL FUEL GAS CODE, ANSI Z223.1 OR CAN/
Horizontal runs of vent pipe shall be securely supported by adequately placed (approximately every 4 feet [1.2 m]), noncombustible hangers suitable for the weight and design of the materials employed to prevent sagging and to maintain a minimum upward slope of 1/4" per foot (2 cm/m) from the boiler to the vent terminals. Dampers or other obstructions must not be installed in the vent. Be sure that the vent connector does not extend beyond the inside wall of the chimney.
TABLE 6: VENT CONNECTION
10" (25.4 cm)
12" (30.5 cm)
12" (30.5 cm)
14" (35.6 cm)
14" (35.6 cm)
16" (40.6 cm)
For vent arrangements other than Table 10 and for proper boiler operation, a barometric damper is required to maintain draft between
STANDARD (HORIZONTAL) VENTING, CATEGORYIII
Vent sizing, installation and termination shall be in accordance with the NATIONAL FUEL GAS CODE, ANSI Z223.1 OR
For Category III installations, it is important that the Installed vent be airtight. Please insure that all joints are sealed properly during installation. For Horizontal Vent Kit part numbers, see Table 7.
TABLE 7: HORIZONTAL VENT KITS.
HORIZONTAL VENT KIT
DIRECT VENT VERTICALAND HORIZONTAL VENTING
For direct vent applications, this boiler may be vented according to Tables 12 and 13; see Figures 8 and 9. For category III applications,
the exhaust vent pipe must be listed for use with category III gas burning heaters such as
The intake air piping can be PVC, CPVC, ABS, Galvanized steel or any suitable intake air piping that can be sealed. See Table 8 for Direct Vent Kit numbers.
TABLE 8: DIRECT VENT KITS.
HORIZONTAL DIRECT VENT KIT NO.
VERTICAL DIRECT VENT KIT NO.
AIR INTAKE TERMINAL
G(B/W) 2100, 2500
HORIZONTAL VENT INSTALLATION
This boiler can be vented through the rear of the cabinet with the use of the fluebox and vent adaptor. Any of the previous venting configurations can be installed with rear connections.
To change the unit to rear exhaust:
1.The vent collar and cover plates must be removed from the top and rear of the unit.
2.Trim the insulation from around the rear flue hole in the jacket and the fluebox. Support insulation from inside the fluebox to facilitate cutting. Use safety precautions such as gloves. Place the gasket and vent adaptor in the horizontal position. Place the gasket and flue plate in the vertical position as shown in Figure 4.
Figure 4. Switching from Vertical to Horizontal Venting.
POWER VENT (OPTIONAL)
The length of vent used in horizontally vented installations can be extended beyond the lengths shown in Tables 11 and 13 by implementing the kits listed below:
TABLE 9: POWER VENT KITS.
POWER VENT KIT NO.
110' (33.5 m)
100' (30.5 m)
100' (30.5 m)
100' (30.5 m)
100' (30.5 m)
100' (30.5 m)
CONNECTING BOILER TO A COMMON VENT
Do not connect the boiler to a common vent or chimney with solid fuel burning equipment. This practice is prohibited by most local building codes as is the practice of venting gas fired equipment to the duct work of ventilation systems.
Where a separate vent connection is not available and the vent pipe from the boiler must be connected to a common vent with an oil burning furnace, the vent pipe should enter the common vent or chimney at a point ABOVE the flue pipe from the oil furnace.
UL/ULC listed double wall type
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. Perform these steps while the other appliances remaining connected to the common venting system are not in operation.
1.Seal any unused opening 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 unsafe condition.
3.Insofar as is practical, close all building doors, windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.
4.Test fire the appliance(s) being inspected, making sure to follow the manufacturers lighting and operating instructions. Appliance(s) operating controls should be adjusted to provide continuous service.
5.Check vent pressure of the appliance 24 inches (61.0 cm) above boiler vent collar. Vent pressure should be maintained between
6.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,