Kenmore K90-50, K90-100, K90-75 Installation Instructions Manual
GAS-FIRED, DIRECT VENT, CONDENSING, HOT WATER
BOILERS
INSTALLATION INSTRUCTIONS
These instructions must be aff'Lxedon or adjacent to the boiler
WARNING
Improper installation, adjustment, alteration, service, or maintenance can cause injury or
property damage. Refer to this manual. For assistance or additional information consult a qualified
installer, service agency, or the gas supplier.
Sears, Roebuck and Co.
Hoffman Estates, IL 60179 U.S.A.
First edition 10/09/00
TABLE OF CONTENTS
INTRODUCTION ...................................................................................................
BOILER RATINGS AND CAPACITIES .......................................................................
RULES FOR SAFE INSTALLATION AND OPERATION ................................................
BEFORE INSTALLING THE BOILER ........................................................................
A. codes ..............................................................................................................
B. boiler sizing ......................................................................................................
C. considerations for boiler location .............................................................................
D. locating the boiler ...............................................................................................
E. combustion air and vent pipe requirements ..................................................................
F. condensate drain requirements .................................................................................
G. foundation requirements .......................................................................................
H. removing existing boiler from common venting system ..................................................
PLACING THE BOILER ..........................................................................................
NEAR BOILER PIPING ...........................................................................................
A. supply and return lines .........................................................................................
B. pressure relief valve .............................................................................................
C. expansion tank and make-up water ...........................................................................
D. condensate drain piping ........................................................................................
E. filling condensate trap ..........................................................................................
F. chilled water piping .............................................................................................
COMBUSTION AIR AND VENT PIPE ........................................................................
A. connections and terminations .................................................................................
B. installation .......................................................................................................
GAS SUPPLY PIPING .............................................................................................
A. check gas supply ................................................................................................
B. connecting the gas piping ......................................................................................
C. checking the gas piping ........................................................................................
ELECTRICAL WIRING ..........................................................................................
A. electric power supply ...........................................................................................
B. install your thermostat ..........................................................................................
C. field wiring connections .......................................................................................
D. schematic wiring diagram .....................................................................................
E. ladder wiring diagram ..........................................................................................
CONTROLS AND ACCESSORIES ..............................................................................
A. UT 1013-10 integrated boiler control .......................................................................
B. gas control valve ................................................................................................
C. hot surface igniter ...............................................................................................
D. L4006A high limit aquastat control ..........................................................................
E. draft inducer temperature safety switch ......................................................................
F. casting temperature safety switch .............................................................................
G. differential pressure air proving switch ......................................................................
H. draft inducer .....................................................................................................
3
4
7
7
7
8
8
8
9
10
11
11
11
12
12
16
16
19
19
20
21
21
22
25
25
25
26
27
27
28
29
30
31
32
32
32
32
32
32
33
33
33
I. circulator pump.................................................................................................. 33
J. drain valve....................................................................................................... 33
K. relief valve....................................................................................................... 34
L. flamerollout safetyshutoff..................................................................................... 34
M. (optional)externalcondensatepump......................................................................... 34
START-UP............................................................................................................ 34
A. watertreatmentandfreezeprotection........................................................................ 34
B. filling boiler with waterandpurgingair with diaphragmtypeexpansiontanks....................... 35
C. filling boilerwith waterandpurgingair with conventionalclosedtypeexpansion 35
tanks ............
D. placing boiler in operation ..................................................................................... 36
I. for your safety read before operating
II. operating instructions
III. to turn off gas to appliance
CHECK-OUT PROCEDURES AND ADJUSTMENTS ..................................................... 37
A. verify proper sequence of operation .......................................................................... 37
B. inspect venting and air intake system ........................................................................ 38
C. inspect condensate drain ....................................................................................... 38
D. inspect system piping .......................................................................................... 38
E. test ignition system safety shutoff ............................................................................ 38
F. test high limit control and adjust .............................................................................. 38
G. test other safety controls ....................................................................................... 39
H. set thermostat heat anticipator ................................................................................. 39
I. measure the gas input rate ...................................................................................... 39
J. set thermostat to desired room temperature .................................................................. 41
K. review all instructions .......................................................................................... 41
L. installation and check-out certificate ......................................................................... 41
MAINTENANCE AND CLEANING ............................................................................ 43
A. beginning of each season ....................................................................................... 43
B. daily during heating season .................................................................................... 43
C. monthly during heating season ................................................................................ 44
D. periodically during heating season ........................................................................... 44
E. end of each heating season-annual shut down procedure .................................................. 44
F. annual examination and cleaning of boiler components ................................................... 44
SERVICE HINTS .................................................................................................... 47
A. flow chart/detailed sequence of operation ................................................................... 47
B. trouble shooting ................................................................................................. 50
C. differential air pressure switch check ........................................................................ 58
REPAIR PARTS ..................................................................................................... 59
A. jacket and base assembly ....................................................................................... 59
B. condensate drain trap assembly ............................................................................... 61
C. block and piping assembly ..................................................................................... 62
D. mixer and air pressure switch assembly ..................................................................... 64
E. flue adapter and exhauster assembly ......................................................................... 66
TheKenmore(K90) is a gas-fireddirectventhot waterboiler with castaluminumboiler sections.A
revolutionarycastaluminumheatexchangermeansbetterheattransferandthermalstoragethan
similarly sizedcastironboilers, which resultsin higherefficiency. Theheatingsystemwaterabsorbs
largeamountsof heatfromthe castaluminumheatexchanger,coolingthe flue gasesandcausing
condensation.Sealedcombustion,premix gasburner,andlow flametemperaturemeansdrastically
reducedCOandNOxemissions,which contributeto a cleanerandhealthierenvironment.
TheK90, unlike normalresidentialatmosphericandinduceddraft units, takesits combustionair
directly from the outdoors(sealedcombustion)anddoesnotcompetewith buildingoccupantsfor fresh
air. Sealedcombustion(alsoknownas "direct vent") isthesafestandbestway to obtainplentyof
cleancombustionair. The induceddraftfandrawsin the outsidecombustionair, thentakesthecooler
flue gasesfrom theboiler unit andprovidesapositiveremovalof theflue gasesfrom thebuilding
throughinexpensiveandreadilyavailablePVC andCPVCpipes.
I
_T_N_ _rslLE_ WaTE_ i.
Tilt'
FIGURE 1 Q90 BOILER
TABLE 1 SEA LEVEL RATINGS - NATURAL AND PROPANE GASES
+ + Heating Net I =B =R Shipping Flue
Model Input *(MBH) Capacity Rating Weight Dia.
*(MBH) *(MBH) (lbs.)
K90-50 50 45 39 220 2" CPVC & Pvc
K90-75 75 68 59 220 2" CPVC & Pvc
K90-100 100 90 78 220 2" cPVC & Pvc
"1 MBH = 1,000 Btuh Btuh = British Thermal Units Per Hour
These low pressure gas-fired hot water boilers are design certified by CSA International for use with natural
and propane gases. The boilers are constructed and hydrostatically tested for a maximum working pressure of
50 psig (pounds per square inch gage) in accordance with A.S.M.E. (American Society of Mechanical
Engineers) Boiler and Pressure Vessel Code Section IV Standards for heating boilers.
+ + AFUE (Annual Fuel Utilization Efficiency) and Heating Capacity is based on the D.O.E.
(Department of Energy) test procedure.
The K90-50, 75 and 100 Boilers are certified in accordance with ANSI (American National
Standards Institute) Z21.13 standards as gas-fired, direct vent, condensing, hot water boilers.
The Heating Capacity indicates the amount of heat available after subtracting the losses up the stack.
Most of this heat is available to heat water. A small portion is heat from the jacket and surfaces of the
boiler, and it is assumed that this heat stays in the structure. The Net I=B=R Rating represents the
portion of the remaining heat that can be applied to heat the radiation or terminal units (i.e. finned
tube baseboard, cast iron radiators, radiant floor, etc.). The difference between the Heating Capacity
and the Net I=B=R Rating, called the piping and pickup allowance, establishes a reserve for heating
the volume of water in the system and offsetting heat losses from the piping. The Net I=B=R Ratings
shown are based on a piping and pickup factor of 1.15 in accordance with the I=B=R Standard as
published by the Hydronics Institute. The Net I=B=R Rating of the boiler selected should be greater
than or equal to the calculated peak heating load (heat loss) for the building or area(s) served by the
boiler and associated hot water heating systems. The manufacturer should be consulted before
selecting a boiler for installations having unusual piping and pickup requirements.
BOILERS FOR USE AT HIGH ALTITUDE
The K90 boilers are factory equipped for operation at altitudes ranging from 0-2,000 feet above sea
level. For use of these boilers at altitudes above 2,000 feet above sea level, the gas input ratings
(MBH) must be reduced.
U.S.A. ONLY: For altitudes above 2,000 feet above sea level, input ratings should be reduced as
shown in tables 1A, C, & E for natural gas boilers or in tables 1B, D & F for propane fired boilers.
Reduced input ratings are achieved by the natural deration of the gas at higher elevations and fine
tuned by adjusting the manifold pressure.
CANADA ONLY: For altitudes in the range of 2,000-4,500 feet above sea level, boilers may be
field equipped for use at high altitude by using a certified high altitude conversion kit. The change in
main burner orifice size results in a 10% reduction of the boiler gas input rating (MBH).
Theconversionshallbecarriedout by a manufacturer's authorized representative, in accordance with
the requirements of the manufacturer, provincial or territorial authorities having jurisdiction, and in
accordance with the requirements of the CAN/CGA-B149.1 and CAN/CGA-B149.2 Installation
Codes. The certified field conversion kit includes a conversion data plate, indicating that the boiler
has been converted for high altitude use. The correct conversion information must be entered on the
conversion data plate.
TABLE 1A K90-50 NATURAL GAS HIGH ALTITUDE
RATINGS
5,000 6,000
47.5 46.0
42.8 41.4
37.1 35.9
.0615 .0615
3.2 3.1
ELEVATION (FEET) 0-2000 3,000 4,000 7,000 7,500 8,500
NOMINAL INPUT (MBH) 50.0 48.0 47.8 44.0 43.5 42.0
HEAT CAPACITY (MBH) 45.0 43.2 43.0 39.6 39.2 37.8
NET I=B=R RATING (MBH) 39.0 37.4 37.3 34.3 34.0 32.8
GAS ORIFICE DRILL SIZE .0615 .0615 .0615 .0615 .0615 .0615
MANIFOLD PRESSURE 2.5 2.7 3.0 3.0 2.8 2.7
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT 1.55 1.55 1.55 1.55 1.55 1.55 1.55 1.55
(INCHES WATER COLUMN)
TABLE 1B K90-50 PROPANE GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET) 0-2000 3,000 4,000 5,000 6,000 7,000 7,500 8,500
NOMINAL INPUT (MBH) 50.0 49.0 49.0 49.0 48.0 46.5 46.0 44.0
HEATING CAPACITY (MBH) 45.0 44.1 44.1 44.1 43.2 41.9 41.4 39.6
NET I=B =R RATING (MBH) 39.0 38.2 38.2 38.2 37.4 36.3 35.9 34.3
GAS ORIFICE DRILL SIZE .0492 .0492 .0492 .0492 .0492 .0492 .0492 .0492
MANIFOLD PRESSURE 2.5 2.8 3.1 3.4 3.4 3.5 3.5 3.5
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT 1.55 1.55 1.55 1.55 1.55 1.55 1.55 1.55
(INCHES WATER COLUMN)
TABLE 1C K90-75 NATURAL GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET)
NOMINAL INPUT (MBH)
HEATING CAPACITY (MBH)
NET I=B=R RATING (MBH)
GAS ORIFICE DRILL SIZE
MANIFOLD PRESSURE
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT
(INCHES WATER COLUMN)
0-2000 l
75.0
68.0
58.9
.0760
2.5
3,000 4,000 5,000 6,000 7,000 7,500 8,500
70.0 69.0 68.0 63.5 58.0 56.5 52.0
63.0 62.1 61.2 57.2 52.2 50.9 46.8
54.6 53.8 53.0 49.6 45.2 44.1 40.6
.0760 .0760 .0760 .0760 .0760 .0760 .0760
2.7 2.8 3.0 2.8 2.6 2.3 2.1
1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35
TABLE 1D K90-75 PROPANE GAS HIGH
ELEVATION (FEET)
NOMINAL INPUT (MBH)
HEATING CAPACITY (MBH)
NET I=B=R RATING (MBH)
GAS ORIFICE DRILL SIZE
MANIFOLD PRESSURE
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT
(INCHES WATER COLUMN)
ALTITUDE RATINGS
0-2000 3,000 4,000 5,000 6,000 7,000 7,500 8,500
75.0 70.0 69.0 67.0 66.0 64.5 64.0 62.0
68.0 63.0 62.1 60.3 59.4 58.1 57.6 55.8
58.9 54.6 53.8 52.3 51.5 50.4 49.9 48.4
.0605 .0605 .0605 .0605 .0605 .0605 .0605 .0605
2.5 2.4 2.3 2.2 2.2 2.2 2.3 2.3
1.35 1.35 1.35 1.35 1.35 1.35 1.35 1.35
TABLE 1E K90-100 NATURAL GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET)
NOMINAL INPUT (MBH)
HEATING CAPACITY (MBH)
NET I=B=R RATING (MBH)
GAS ORIFICE DRILL SIZE
MANIFOLD PRESSURE
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT
(INCHES WATER COLUMN)
0-2000 3,000 4,000 5,000 6,000 7,000 7,500 8,500
100.0 97.0 96.0 95.0 90.0 84.0 82.0 76.0
90.0 87.3 86.4 85.5 81.0 75.6 73.8 68.4
78.0 75.7 74.9 74.1 70.2 65.5 64.0 59.3
.0860 .0860 .0860 .0860 .0860 .0860 .0860 .0860
2.5 2.9 3.3 3.7 3.4 3.2 2.9 2.6
1.17 1.17 1.17 1.17 1.17 1.17 1.17 1.17
TABLE 1F K90-100 PROPANE GAS HIGH ALTITUDE RATINGS
ELEVATION (FEET)
NOMINAL INPUT (MBH)
HEATING CAPACITY (MBH)
NET I=B =R RATING (MBH)
GAS ORIFICE DRILL SIZE
MANIFOLD PRESSURE
(INCHES WATER COLUMN)
PRESSURE SWITCH SETPOINT
(INCHES WATER COLUMN)
0-2000 3,000 4,000 5,000 6,000 7,000 7,500 8,500
100.0 95.0 94.0 92.0 92.0 91.5 91.5 91.0
90.0 85.5 84.6 82.8 82.8 82.4 82.4 81.9
78.0 74.1 73.3 71.8 71.8 71.4 71.4 71.0
.0670 .0670 .0670 .0670 .0670 .0670 .0670 .0670
2.5 2.7 2.9 3.1 3.2 3.3 3.4 3.5
1.17 1.17 1.17 1.17 1.17 1.17 1.17 1.17
6
1. Read the entire installation manual before beginning the installation. Failure to follow these rules
for safe installation and operation and these instructions could cause a malfunction of the boiler
and result in death, serious bodily injury, and/or property damage.
2. Check all applicable state and local building codes and utility company requirements before
installation. The installation must conform with these requirements in their entirety. In the absence
of these codes, use NFPA Installation Codes and good industry practice.
3. Before servicing the boiler - allow the boiler to cool. Always shut off any electricity and gas
supply connected to the boiler prior to servicing.
4. Inspect gas line for leaks.
5. Be certain gas input rate is correct. Over firing may result in early failure of the boiler sections.
This may cause dangerous operation. Under firing may result in too much air for the pre-mix
burner causing poor or loss of combustion.
6. Never vent the products of combustion from this boiler to an enclosed space. Always vent to the
outdoors. Never vent to another room or to inside a building.
7. Be sure there is adequate outdoor air supply to boiler for complete combustion.
8. Follow a regular service and maintenance schedule for efficient and safe operation.
9. Keep boiler area clean of debris and free of combustible and flammable materials.
10. Proper through the wall or through the roof combustion venting shall be in accordance with the
materials and methods described in this manual. Installation must comply with local codes.
11. This boiler and related hot water heating systems are not do it yourself items. They must be
installed and serviced by qualified professionals.
WARNING
This boiler has been equipped for residential installations. If used for commercial applications, any
additional code requirements must be adhered to for installation. This may require additional controls
including but not limited to a low water cut off, a manual reset high temperature limit, and wiring
and/or piping modifications. The manufacturer is not responsible for any field installation changes
made to a boiler installation which are not described or acknowledged in this manual.
Complete all of the following prior to installing the boiler.
A. CODES
This boiler product is a gas-fired, direct vent, condensing boiler and must be installed in
accordance with all applicable federal, state and local building codes including, but not limited to
the following :
United States - Installation shall conform with National Fuel Gas Code (NFPA-54/ANSI Z223. l-
latest edition)
Canada - Installation shall be in accordance with CAN/CGA-B 149.1 and .2 installation
codes.
Whererequiredby theauthorityhavingjurisdiction, theinstallationmustconformto theAmerican
Societyof MechanicalEngineersSafetyCodefor ControlsandSafetyDevicesfor Automatically
FiredBoilers, No.CSD-1.
Theinstallation 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 - latest revision.
Installers - Follow local regulations with respect to installation of CO (Carbon Monoxide)
Detectors. Follow maintenance recommendations in this manual.
Teclmiciens - Veuillez vous conformer _tla r6glementation en vigeur concernant 1"installation
des d_tecteurs d'oxyde de carbone. Suivre les consignes d'entretien figurant clans
le manuel d'instruction ci-joint.
B. BOILER SIZING
• Check to be sure you have selected the K90 boiler with the proper capacity before starting the
installation. The I=B=R Rating of the boiler selected should be greater than or equal to the
calculated peak heating load (heat loss) for the building or area(s) served by the boiler and
associated hot water heating systems. See the table "BOILER RATINGS AND
CAPACITIES".
• Heat loss calculations should be based on approved industry methods.
C. CONSIDERATIONS FOR BOILER LOCATION
Before selecting a location for the boiler, the following should be considered. Each boiler
considered for installation must be:
• Supplied with the correct type of gas (natural gas or propane).
• Connected to a suitable combustion air intake piping system to supply the correct amounts of
fresh (outdoor) air for combustion. (maximum length 80' for K90-100 boiler, and maximum
length 100' for K90-75 and K90-50 boilers).
• Connected to a suitable venting system to remove the hazardous products of gas combustion
(maximum length 80' for K90-100 boiler, and maximum length 100' for K90-75 and K90-50
boilers).
• Connected to a suitable hot water heating system.
• Supplied with a suitable electrical supply for all boiler motors and controls.
• Connected to a properly located thermostat or operating control. (not included with boiler)
• Placed on level surface (must NOT be installed on carpeting)
• Condensate drain line must be pitched down to floor drain or external condensate pump with
reservoir at _A"per foot (wood frame or blocks may be used to raise boiler).
D. LOCATING THE BOILER
TABLE 2
L_IT
TOP
LEFT SIDE
RIGHT SIDE
BASE
FRONT
BACK
INTAKE/VENT PIPING
NEAR BOILER HOT WATER PIPING
BOILER CLEARANCES
COMBUSTIBLE
CONSTRUCTION
1"
1"
8"
1"
0
l"
o
1"
ACCESSIBILITY/
CLEANING
8"
24"
24"
SERVICING
8"
24"
24"
1. Select a location which is level, central to the piping systems served and as close to the vent
and air intake terminals as possible.
2. Accessibility clearances, if more stringent (i.e. larger clearances) than required fire protection
clearances, must be used for the boiler installation. Accessibility clearances may be achieved
with the use of removable walls or partitions.
3. The boiler is approved for installation in closets and on combustible floors. This boiler shall
NOT be installed on carpeting.
4. The clearances shown in Table 2 indicate required clearances per IAS listing. A minimum I"
clearance must be maintained between combustible construction and each of the left, top and
back surfaces of the boiler. A minimum 8"clearance is required on the right side, to allow
room for the inlet air pipe. An 18"clearance must be maintained at a side where passage is
required to access another side for cleaning or servicing, inspection or replacement of any
parts that normally may require such attention. Allow at least 24"at the front and left side and
8"at the top for servicing. No clearances are required to venting or combustion air intake
piping.
5. Equipment shall be installed in a location which facilitates the operation of venting and
combustion air intake piping systems as described in this manual.
6. Advise owner of boiler to keep venting and combustion air intake passages free of
obstructions.
both the venting and combustion air intake piping systems connected to the outdoors must
permit flow through the piping systems without restrictions for the boiler to operate.
7. The boiler shall be installed such that the automatic gas ignition system components are
protected from water (dripping, spraying, rain, etc.) during operation and service (circulator
replacement, control replacement, etc.).
E. COMBUSTION AIR AND VENT PIPE REQUIREMENTS
This boiler requires a dedicated direct vent system. In a direct vent system, all air for
combustion is taken directly from outside atmosphere, and all flue products are discharged to
outside atmosphere.
Combustion air and vent pipe connections must terminate together in the same atmospheric
pressure zone, either through the roof or sidewall (roof termination preferred). See Fig.9 & 10
for required clearances.
CAUTION
KEEP BOILER AREA CLEAN OF DEBRIS AND FREE OF FLAMMABLE AND
COMBUSTIBLE MATERIALS, VAPORS AND LIQUIDS
WARNING
When vent pipe is exposed to temperatures below freezing, such as when it passes through an
unheated space or when a chimney is used as a raceway, vent pipe must be insulated with
l/2"Armaflex or equivalent. In extreme cold climate areas, use ¾ "Armaflex or equivalent.
Combustion air must be clean outdoor air. Combustion air must not be taken from inside structure
because that air frequently is contaminated by halogens, which include fluorides, 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 Fig.9 or 10.
Vent connections serving appliances vented by natural draft shall not be connected into any portion of
mechanical draft systems operating under positive pressure.
Solvent cements are combustible. Keep away from heat, sparks, and open flame. Use only in well
ventilated areas. Avoid breathing in vapor or allowing contact with skin or eyes.
FAILURE TO FOLLOW THE AFOREMENTIONED WARNINGS COULD RESULT IN FIRE,
PROPERTY DAMAGE, PERSONAL INJURY, OR DEATH.
F. CONDENSATE DRAIN REQUIREMENTS
Condensate drain line to be pitched down to floor drain at a minimum of ¼"per foot. An external
condensate pump (not furnished) may be used if floor drain is not available. The condensate pump
must be designed for flue gas condensate application
NOTE: 1. Condensate trap is built into the boiler, an external trap is not required and should not
be used.
2. Wood frame or blocks may be used to raise the boiler to maintain drain pitch or to be
above external condensate pump reservoir.
3. There is a 115 volt AC receptacle provided on the service switch junction box which
is located at the boiler right side, to provide power for an external condensate pump
(if needed).
10
G. FOUNDATION REQUIREMENTS
Boiler must be placed on level surface. Boiler is NOT to be installed on carpeting.
NOTE: 1. If boiler is not level condensate drain lines will not function properly. Adjustable feet
are located on the boiler to make up for minor surface irregularities or tilt.
2. Wood frame or blocks may be used to raise boiler to maintain drain pitch or to be
above external condensate pump reservoir.
H. 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 restrictions, leakage, corrosion and other deficiencies which could cause an
unsafe condition.
3. Insofar as is practical, close all building doors and windows and all doors between the space
in which the appliances remaining connected to the common venting system are located and
other spaces of the building. Turn on clothes 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
fire dampers.
4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust
thermostat so appliances will operate continuously.
5. 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 the smoke from a cigarette, cigar or pipe.
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 and
any other gas-burning appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so the installation
conforms with the National Fuel Code, NFPA-54/ANSI -Z223. l-latest revision, or section 5
of CAN/CGA-B149 for Canadian standards. When resizing any portion of the common
venting system, the common venting system should be resized to approach the minimum size
as determined using the appropriate tables in part I 1 in the National Fuel Gas Code, NFPA-
54/ANSI- Z223. l-latest revision, or section 5 of CAN/CGA-B149 for Canadian standards.
PLACING THE BOILER
The boiler should be placed to provide the most direct connections to the combustion air, vent and
system piping as possible.
Place crated boiler as close to selected location as possible and uncrate boiler. The uncrated boiler
may be moved into position with an appliance dolly or 2-wheel hand truck. The dolly or hand truck
should be inserted under the left hand side of the boiler. It is possible to slide the boiler for a short
distance on a smooth floor or surface.
11
NOTE: Refer to manual section "LOCATING THE BOILER" for required clearances for servicing
and maintenance.
CAUTION
Copper supply and return piping must NOT be installed directly into aluminum boiler section castings
due to galvanic corrosion between dissimilar metals. Iron or steel bushings or pipe nipples should be
used between copper system piping and boiler to make final connection to boiler. Also, the use of
dielectric unions is acceptable. The packaged boiler is furnished with iron piping in the front boiler
section for the supply and return connections.
When the installation of the boiler is for a new heating system, first install all of the radiation units
(panels, radiators, baseboard, or tubing) and the supply and return mains. After all heating system
piping and components have been installed, make final connection of the system piping to the boiler.
A hot water boiler installed above radiation level must be equipped with a low water cut off device. A
periodic inspection is necessary, as is flushing of float type devices, per low water cut off
manufacturers specific instructions.
A. SUPPLY AND RETURN LINES
The packaged boiler unit is set up to receive 1_,_"NPT supply and return piping from top access.
The boiler unit can also be piped from the left side by turning the supply elbow, and from the rear
of the unit by removing plugs in the rear boiler section.
NOTE: The circulator pump and isolation valves are furnished within a carton inside the boiler
cabinet and can be installed at the installer preferred location.
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SERVICE -_
VALVE
SUPPLY TO
f SYSTEM
CIRCULATOR
SERVICE
VALVE
RETURN FROM
_J_'-SYSTEM
--_ PURGE (DRAIN)
VALVE
FIGURE 2 SINGLE ZONE BOILER PIPING
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VALVE
f OI_E SERVICE
VALVE
SUPPL TO
ZONES
CIRCULATOR
ZONE SERVICE
VALVE
FROM
ZONES
(DRAIN)
VALVES
ZONE SERVICE
VALVE
ZONESERVICE
VALVE
FIGURE 3 MULTI ZONE BOILER PIPING WITH ZONE VALVES
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FLOW CHECK --_
VALVE
CIRCULATORS
ZONE SERVICE
VALVE
TO
ZONES
ZONE SERVICE
VALVE
FLOW CHECK
VALVE
FROM
ZONES
PURGE (DRAIN)
VALVES
ZONE SERVICE
VALVE
SERVICE
VALVE
NOTE: When zoning with circulators, the furnished circulator pump should be used as one of the
zone pumps. Each stripped end of the electrical wires for the circulator pump inside the junction box
should be taped or wire nutted to prevent short circuits. Unplug the circulator pump wiring at the
integrated boiler control.
FIGURE 4 MULTI ZONE BOILER PIPING WITH CIRCULATORS
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RELIEF VALVE
DISCHARGE
PIPING
FIGURE 5 RELIEF VALVE DISCHARGE PIPING
B. PRESSURE RELIEF VALVE
The boiler is furnished with a factory installed relief valve in the top of the boiler. Provide ¾"
piping from the supplied relief valve to a local floor drain, but leave an air gap between piping and
drain. No shutoff of any description shall be placed between safety relief valve and the boiler, or
on the discharge pipes between such safety valve and the atmosphere. Installation of the safety
relief valve shall conform to ANSI/ASME Boiler and Pressure Vessel Code, Section IV. The
manufacturer is not responsible for any water damage.
C. EXPANSION TANK AND MAKE-UP WATER
Determine required system fill pressure, system design temperature, and system 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)
as shown in Fig.6 for diaphragm type expansion tank and Fig.7 for conventional closed type
expansion tanks. For diaphragm type expansion tanks, adjust the tank air pressure to match the
system fill 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 a pressure
reducing valve is used, adjust to match the system fill pressure. In connecting the cold make-up
water supply to the boiler, make sure that clean water supply is available. When the water supply
is from a well or pump, a sand strainer should be installed at the pump.
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MANUAL FILL
VALVE
AIR
BUSHING"
COLD WATER
-FILL
DIAPHRAGM TYPE
EXPANSION TANK
COMBINATION QUICK FILL
VALVE, STRAINER, CHECK
VALVE AND PRESSURE
REDUCING VALVE
TEE"
_" NIPPLE (FURNISHED
INSTALLED ON
PACKAGED BOILER)
3/4" STREET ELL"
• - FURNISHED IN
PARTS BAG.
FIGURE 6 DIAPHRAGM TYPE EXPANSION TANK PIPING
17
CLOSED TYPE
E_°ANSION TANK
L
MANUAL
VALVE
COLD
FILL
_CHEUK AND PRESSURE
REDUCING VALVE
FIGURE 7 CONVENTIONAL(closed type) EXPANSION TANK PIPING
]8
OPEN
DRAIN PIPE TO
BE PITCHED DOWN
TO FLOOR DRAIN
AT A MINIMUM
I/4" PER FOOT
TO
DRAIN
THREADED NIPPLE
(INSTALLED)
CONDENSATE
DRAIN
PVC TEE
I/2"SMPxl/2"SMPxl/2 "NPT
FURNISHED IN PARTSBAG
FIGURE 8 CONDENSATE - DRAIN PIPING
D. CONDENSATE DRAIN PIPING
The condensate trap is built into the boiler, an external trap is not required and should NOT be
used.
Provide '/2"PVC condensate drain and fittings. Condensate drain to be pitched down to floor drain
at a minimum of ¼"per foot.
Install furnished I/z"PVC tee to overflow fitting as shown in Fig.8.
The 1/2"diameter schedule 40 PVC or CPVC condensate drain piping and pipe fittings must
conform to ANSI standards and ASTM D1785 or D2846. Schedule 40 PVC or CPVC cement and
primer must conform to ASTM D2564 or F493. In Canada, use CSA or ULC certified schedule 40
PVC or CPVC drain pipe and cement.
A condensate pump with a reservoir (not furnished) may be used to remove condensate to a drain
line (sanitary line) above boiler if a floor drain is not available or is inaccessible.
19
E. FILLING CONDENSATE TRAP WITH WATER
ON THE INITIAL START UP THE CONDENSATE TRAP MUST BE MANUALLY FILLED WITH
WATER
The following are the steps required to initially fill the condensate trap for start up, these steps are
only required at the initial start up or if maintenance requires draining of the condensate trap:
1. Disconnect the vent condensate drain line from the bottom of the vent tee on the boiler.
2. Pour about 1 cup of cold tap water into the vent drain line with a proper funnel.
3. Excess water should go through the overflow and out through the condensate drain line.
Verify proper operation of the drain line (or external condensate pump if used).
4. Reinstall the vent drain line.
F. CHILLED WATER PIPING
The boiler, when used in connection with a refrigeration system, must be installed so the chiller
medium is piped in parallel with the boiler with appropriate valves to prevent the chilled medium
from entering the boiler.
The boiler piping system of a hot water boiler connected to heating coils is located in air handling
units where they may be exposed to refrigerated air circulation must be equipped with flow control
valves or other automatic means to prevent gravity circulation of the boiler water during cooling
cycle.
A. CONNECTIONS AND TERMINATION
For boilers connected to gas vents or chimneys, vent installations shall be in accordance with part
7, Venting of Equipment, of the National Fuel Gas Code, ANSI Z223. l-latest revision,
CAN/CGA-B149.1 and B149.2, and applicable provisions of the local building codes.
Provisions for combustion and ventilation air must be in accordance with section 5.3, Air For
Combustion and Ventilation, of the National Fuel Gas Code,ANSI Z223. l-latest revision,
CAN/CGA-B149.1 and B149.2, or applicable provisions of the local building code.
These boilers require a dedicated direct vent system. All air for combustion is taken directly from
outdoors through the combustion air intake pipe. All flue products are discharged to the outdoors
through the vent pipe.
1. See Fig.9 & 10 for combustion air and vent pipe roof and sidewall termination. (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 a maximum 24 inches, minimum 1_"thickness.
2. Combustion air and vent pipe fittings must conform to American National Standards Institute
(ANSI) standards and American Society for Testing and Materials (ASTM) standards D1784
(schedule-40 CPVC), D1785 (schedule-40 PVC), D2665 (PVC-DWV), D2241 (SDR-21 and
SDR-26 PVC), D2661 (ABS-DWV), or F628 (schedule-40 ABS). Pipe cement and primer
must conform to ASTM standards D2564 (PVC) or D2235 (ABS).
2O
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