Utica Boilers SSV Operation and Installation Manual

WALL MOUNTED

GAS BOILER

INSTALLATION, OPERATION &

MAINTENANCE MANUAL

Models

SSV-050

SSV-075 SSV-100

SSV-150

SSV-200

Manufactured by:

ECR International, Inc.

2201 Dwyer Avenue, Utica NY 13501

web site: www.ecrinternational.com

P/N# 240010615, Rev. D [03/2015]

VERIFY CONTENTS RECEIVED

Description

No. Illustration

Item

Fully Assembled Boiler 1

Metal Wall Bracket 2

Lag Bolt, 3/8" x 3" Hex (4 ea) 3

*Safety Relief Valve 4

SIZE

SHOWN

050/075/100

Condensate Trap Height 12.45" [316mm]

**Temperature Pressure Gauge 6

Bushing 3/4" x 1/4" 7

3/4" FNPT Adapter 8

3/4" Tee

50/75/100

3/4" Tee

50/75/100

1"x 1" x 3/4" Reducing

Tee 150/200

1"x 1" x 3/4" Reducing

Tee 150/200

3/4" FNPT Adapter 11

Drain Valve, 3/4" 12

1/2" Gas Shutoff Valve 50/75/100 3/4" Gas Shutoff Valve with Increaser

and Nipple 150/200

Bushing 7/8" OD, Heyco (2 ea) 14

050/75/100 150/200

(shown in open position)

Used for electrical wire knockouts.

Stopper, Rubber 5/16" (2 ea) 15 Used for packaging holes on back of boiler.

Plastic Plug (2 ea) 16 Used for packaging holes on back of boiler.

Outdoor Sensor 17 Used for measuring outside temperature.

Critical Installation Instruction 18

11" x 17" Page for critical installation issues.

Document Package 19 Includes essential documents.

* Boiler provided with 30 psig (206 kpa) safety relief valve. Field source safety relief valve if system pressure greater than 25 psig.

Boiler provided with 75 psig temperature pressure gauge. Field source temperature pressure gauge if system pressure greater than 60 psig.

OVERALL DIMENSIONS

(D)

Wall Hanging

Bracket

(D)

BACK OF BOILER

LEFT SIDE

OF BOILER

(B)

Vent Connector

Gas Connection(K)

Safety Relief Valve

(L)

Connection (¾ NPT)

Combustion Air

TOP OF BOILER

(A)

FRONT OF BOILER

(M)

(E)

RIGHT SIDE

OF BOILER

Table 1 : Physical Data

Models

Width (A) 20" (508mm)

Height - Unit only (B) 27.75" (705mm)

Depth (C) 14.75" (375mm)

Bracket (D)

Height unit w/ Piping (E) 30.75" (781mm)

Height unit w/vent (L) 31" (787mm)

Height unit from vent w/piping

supply & return (M)

Water

Connections

Bottom of Boiler

Condensate

Drain

Connection

Gas Connection

Top of Boiler - Size (K)

Weight

Vent Connector/Combustion Air 2" (51mm) 3" (76mm)

Size (F) 3/4" Type L Copper 1" Type L Copper

Location (G) 2.22" (56.4mm)

Location (H) 2.33" (59mm)

Location (I) 9.32" (237mm)

Location (J) 1.4" (35.6mm)

Size 3/4" NPT

Shipping 135 lb (61 kg) ~200 lb (91kg)

Unit 75 lb (34kg) ~127 lb (58kg)

050/075/100 150/200

23" (584mm)

37.75" (959mm)

16.3" (414mm)

24.41" (620mm)

33.94" (862mm}

1/2" NPT

35.6" (904mm)

40.75" (104cm)

41.8" (106cm)

44.75" (114cm)

2" (51mm)

3" (76mm)

11" (282mm)

4.6" (116.8)

3/4" NPT

Wire

Knockouts

Supply Water

to Heating

System (F)

(G)

BOTTOM OF BOILER

(I)

(H)

BOTTOM OF BOILER

Condensate

Drain (K)

(C)

(J)

Return Water from Heating

System (F)

TABLE OF CONTENTS

1 - Introduction ............................................................................................................................... 5

2 - Important Safety Information .................................................................................................... 6

3 - Component Listing .....................................................................................................................7

4 - Locating Boiler ......................................................................................................................... 11

5 - Hydronic Piping ........................................................................................................................ 13

5.2 Special Conditions ................................................................................................................. 13

5.3 Safety Relief Valve and Air Vent .............................................................................................. 13

5.4 Trim Piping ........................................................................................................................... 14

5.5 System Piping....................................................................................................................... 14

6 - Combustion Air And Vent Piping ...............................................................................................22

6.2 Removal of Existing Boiler From Common Vent System................................................................22

6.3 Venting Materials ................................................................................................................. 22

6.4 Vent Pipe Installation ............................................................................................................. 23

6.5 Vent Termination .................................................................................................................. 23

6.7 Venting Congurations ........................................................................................................... 24

6.8 Side Venting Terminal Requirements of : .................................................................................. 29

6.9 Multiple Boiler Venting Installation ........................................................................................... 31

6.10 Condensate Piping ............................................................................................................... 31

7 - Gas Supply Piping ....................................................................................................................32

8 - Electrical Connections ..............................................................................................................34

8.3 Line Voltage Connections.........................................................................................................34

8.4 External Connections ............................................................................................................. 34

9 - Start Up Procedure ...................................................................................................................36

9.6 Perform CSD-1 Compliance Test ..................................................................................................... 40

9.7 Complete Start Up Procedure ......................................................................................................... 41

10 - Operating Instructions ........................................................................................................... 42

11 - General Maintenance And Cleaning ........................................................................................43

12 - Ratings And Capacities ........................................................................................................... 45

13 - Trouble Shooting .................................................................................................................... 46

13 - Trouble Shooting (Temperature Resistance Chart).................................................................63

14 - Wiring Diagram ...................................................................................................................... 64

15 - Glossary ................................................................................................................................. 68

APPENDIX A - CONTROL MODULE....................................................................................................70

1.1 Introduction ........................................................................................................................ 70

1.2 Operation ........................................................................................................................... 70

1.3 Status Indication ................................................................................................................. 70

1.4 Sequence of Operation ......................................................................................................... 71

1.5 User Menu .......................................................................................................................... 73

OPTIONAL USER INTERFACE RELOCATION......................................................................................83

PRIMARY LOOP EQUIVALENT LENGTH CALCULATIONS & PUMP SELECTION...............................84-87

1 - INTRODUCTION

1.1 Designated Use

• Hot water heating boiler.

• Indoor installation.

• Closet or alcove installation.

• Direct vent or single vent pipe boiler.

• For use with natural gas or liqueed petroleum gases (LP/propane).

1.2 The unit MUST NOT:

• Directly heat potable water. Indirect heating is acceptable.

• Heat water with non-hydronic heating system chemicals present (example, swimming pool water).

• Exceed 150 psig (1.03 MPa) maximum allowable working pressure.

• Exceed 195°F (90.5°C) system design temperature.

1.3 Operational Features

• Modulating: 20-100%.

• Integral Dual Limit.

• Connection provided for required eld sourced low water cutoff (LWCO).

• Outdoor Temperature Reset.

• Integral Multiple Boiler Control.

• Heat exchanger over heat protection.

• Alternate mounting of User Interface

Check our website frequently for updates: www.ecrinternational.com

Information and specications outlined in this manual in effect at the

time of printing of this manual. ECR International reserves the right to

discontinue, change specications or system design at any time without

notice and without incurring any obligation, whatsoever.

2 - IMPORTANT SAFETY INFORMATION

2.1 General

Boiler installation shall be completed by qualied agency.

See glossary for additional information.

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.

2.2 Become familiar with symbols identifying potential hazards.

This is the safety alert symbol. Symbol alerts you to potential personal injury hazards. Obey all safety messages following this symbol to avoid possible injury or death.

DANGER

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

2.3 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements:

•

United States

• National Fuel Gas Code, ANSI Z223.1/NFPA 54

• National Electrical Code, NFPA 70.

• Canada

• Natural Gas and Propane Installation Code, CAN/CSA B149.1.

• Canadian Electrical Code, Part I, Safety Standard for Electrical Installations, CSA C22.1

2.4 Where required by authority having jurisdiction,

installation shall conform to Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD-1.

Additional manual reset low water cutoff may be required.

2.5 Requirements for Commonwealth of Massachusetts:

Boiler installation must conform to Commonwealth of Massachusetts code 248 CMR which includes but is not limited to:

• Installation by licensed plumber or gas tter.

WARNING

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

CAUTION

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

NOTICE

Used to address practices not related to personal injury.

3 - COMPONENT LISTING

3.1 Component Listing - Refer to diagrams on

following pages.

Gas Shutoff Valve (Field Installed) Fuel supply isolation during servicing. Factory supplied, Field installed. See section 7.

Vent Connector See section 6.

Combustion Air Inlet (2"/3") See section 6.

Igniter

Flame Sensor

Sight Glass Permits observation of burner ame.

Flue Air Mixture Pressure Test Port - Not available on all models.

User Interface Displays information regarding boiler condition. Allows adjustment of boiler operating parameters. NOTE: Does not replace thermostat used to control central heating space.

18.

Supply Water Outlet to Heating System (Out)

Connections supplied for connecting from bottom of boiler. See section 5.

19.

Temperature Pressure Gauge (Field Installed)

20.

High Voltage Junction Box For connection of 120V components. See section 8.

21.

Flue Collector

22.

Vent Temperature Sensor

23.

Combustion Analysis Test Port

24.

Gas (Control) Valve Delivers proper quantity of fuel to Combustion Air Blower. See section 7.

25.

Combustion Air Blower Delivers proper quantity of combustion air, receives fuel from gas valve, mixes air and fuel sending mixture to burner for combustion.

26.

Heat Exchanger Surface Temperature Switch

Boiler Control Module

10.

Heat Exchanger

11.

ASME Plate

12.

Low Voltage Terminal Strip Connection of all low voltage wiring, including thermostat.

13.

Return Water Temperature Sensor

14.

Return Water From Heating System (In) and Drain Valve Connection supplied at bottom of boiler.

See section 5.

15.

Condensate Drain Boiler produces a liquid (condensate) as a by-product of combustion. (See page

14)

16.

Condensate Trap (Field Installed) Condensate must be piped to appropriate drain. See section 6.

27.

Supply Water Temperature Sensor and High Limit Switch

28.

Safety Relief Valve Factory supplied, Field installed. See section 5.

29.

Pump Relay

30.

Burner not shown (see page 39)

31.

Wall Hanging Support Bracket not shown (see page

12) Integral to boiler. Allows wall mounting when used with supplied wall mounting bracket. See section 4.

32.

Gas Connection (See section 7)

17.

Jacket Panel Latch

3 - COMPONENT LISTING

FIGURE 3-1 Boiler Components (Viewed from Back of Boiler)

050/075/100/150/200

SIZE SHOWN

(2) VENT CONNECTOR

(3) COMBUSTION

AIR INLET

(31) WALL MOUNT SUPPORT BRACKET

See Section 5-3

For Safety Relief

(32) GAS CONNECTION

(28) SAFETY RELIEF VALVE

NOTE:

Valve Piping Instructions

FIGURE 3-2 Jacket Removal (Viewed from Bottom of Boiler

FIGURE 3-3 Jacket Removal (Viewed from Left Side of Boiler

Bottom of Boiler

Jacket Latch - Lift

latch to dis-engage

Jacket Support (Lip)

Jacket Latch

Disengage latch and lift jacket up and off

jacket support

3 - COMPONENT LISTING

FIGURE 3-4 Boiler Components 50/75/100 MBH (View from Front of Boiler) As seen on front cover

(28) SAFETY RELIEF

VALVE

(27) SUPPLY WATER

TEMPERATURE SENSOR

& HIGH LIMIT SWITCH

(26) HEAT

EXCHANGER SURFACE

TEMPERATURE SWITCH

BRACKET

(25) COMBUSTION

AIR

BLOWER

(24) GAS (CONTROL)

VALVE

(23) COMBUSTION

ANALYSIS TEST

PORT

(22) VENT

TEMPERATURE

SENSOR

(1) GAS (CONNECTION)

SHUT OFF VALVE

(2) VENT CONNECTOR

(3) COMBUSTION

AIR INLET

NOTE:

See Section 5

For Piping

Instructions

(4) IGNITER

(5) FLAME

SENSOR

(6) SIGHT GLASS

(7)AIR FLUE

MIXTURE

PRESSURE

TEST PORT

(8) USER

INTERFACE

(9) BOILER

CONTROL

MODULE

Fuse and

Holder

(10) HEAT

EXCHANGER

(21) FLUE

COLLECTOR

(20) HIGH VOLTAGE

JUNCTION BOX

(19) TEMPERATURE/PRESSURE

GAUGE

(18) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(17) Jacket Latch

(16) CONDENSATE

TRAP

(11) ASME

PLATE

(29) Pump Relay

(12) LOW VOLTAGE

TERMINAL STRIP

(13) RETURN WATER

TEMPERATURE

SENSOR

(14) RETURN WATER

FROM HEATING

SYSTEM (IN)

(15) CONDENSATE

DRAIN

3 - COMPONENT LISTING

FIGURE 3-5 Boiler Components 150-200 MBH (View from Front of Boiler)

(1) ) GAS (CONNECTION)

(28) SAFETY RELIEF VALVE

SHUT OFF VALVE

(2) VENT CONNECTOR

NOTE:

See Section 5

For Piping

Instructions

(27) SUPPLY

WATER

TEMPERATURE

SENSOR & HIGH

LIMIT SWITCH

(25)

COMBUSTION

AIR

BLOWER

(24) GAS (CONTROL)

VALVE

(26) HEAT

EXCHANGER SURFACE

TEMPERATURE

SWITCH

(29) PUMP RELAY

(9) BOILER CONTROL

MODULE

Fuse and Holder

(3) COMBUSTION

AIR INLET

(4) IGNITER

(5) FLAME SENSOR

(6) SIGHT GLASS

(8) USER INTERFACE

(10) HEAT

EXCHANGER

(23) COMBUSTION

ANALYSIS TEST

PORT

(22) VENT TEMPERATURE

SENSOR

(21) FLUE

COLLECTOR

(20) HIGH VOLTAGE

JUNCTION BOX

(19) TEMPERATURE/

PRESSURE GAUGE

(18) SUPPLY WATER TO

HEATING SYSTEM (OUT)

(17) Jacket

Latch

(16) CONDENSATE

TRAP

(11) ASME

PLATE

(12) LOW VOLTAGE

TERMINAL STRIP

(13) RETURN

TEMPERATURE

SENSOR

(14) RETURN WATER

FROM HEATING

SYSTEM (IN)

(15) CONDENSATE

DRAIN

4 - LOCATING BOILER

4.1 Boiler Location Considerations

• Ambient room temperature always above 32°F (0°C) to prevent freezing of liquid condensate.

• Approved for installation in closets.

• Protect gas ignition system components from water (dripping, spraying, rain, etc.) during operation and service (circulator replacement, condensate trap, control replacement, etc.).

• Wall mount, optional oor stand available.

• Determine alternate User Interface mounting location if desired. See page 83 - Optional User Interface Relocation.

• Access to outdoors to meet minimum and maximum pipe lengths for combustion air and vent piping. See section 6.

• Disposal of condensate. See section 6.

• Drainage of water (or water - antifreeze solution) during boiler service or from safety relief valve discharge. See section 5.

• Access to system water piping, gas supply, and electrical service. See sections 5, 7 and 8.

FIGURE 4-1 Clearance to Combustible Materials

FRONT OF BOILER

FLOOR

• Clearances to combustible materials and service

clearances. See Table 2 and gure 4-1.

• Multiple Boilers can be wall mounted, placed side by side, or back to back.

TABLE 2: BOILER CLEARANCES

Dimension

Model

Top (A)

Left Side (B)

Right Side (C)

Front (D)

Back (E)

Bottom (F)

Combustion Air/Vent piping

Hot Water Piping

(1)

Required distances measured from boiler jacket.

(2)

Service, proper operation clearance recommendation.

Combustible

Materials

050/075/100/

See local code 6" (16 cm)

LEFT SIDE OF BOILER

FLOOR

(1)

150/200

0" (0 cm) 14" (36 cm)

0" (0 cm) 0" (0 cm)

0" (0 cm) 6" (16 cm)

0" (0 cm) 0" (0 cm)

0" (0 cm) 12" (32 cm)

0" (0 cm) 6" (16 cm)

Service

050/075/100/

150/200

(1)(2)

4 - LOCATING BOILER

FIGURE 4-2 Wall Mount Bracket Engaged with Bracket on Boiler (50-100 size shown)

Center brackets. Avoid

overhang on sides of

wall mount bracket.

4 Slots for attaching

Wall Mount Bracket

to Studs

4.2 Pre-pipe supply and return water connections

with factory ttings before wall mounting.

4.3 Wall Mounting

Mount boiler on wall using wall mounting bracket included with unit.

• Structure must be capable of supporting boiler weight plus 60 lbs (28 kg). See Table 1, page 2.

• Wall mount bracket has 4 slots allowing mounting on two (2) wall studs spaced at 11½" to 16½" on center.

See gure 4-2.

• Boiler includes (4) 3/8" x 3" lag screws and (4) washers for attaching wall mount bracket to wood studs. Field source appropriate fasteners for other wall constructions (masonry, concrete).

• Attach wall mount bracket level on wall.

• Boiler must engage with wall mount bracket.

• Avoid overhang on sides of wall mount bracket. Verify

boiler bracket is centered on wall bracket. See gure

4-2.

WARNING

Fire, explosion hazard. Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff. Failure to follow these instructions could result in death or serious injury.

• When mounting boiler onto wall insert two plastic stoppers and two plastic plugs to packaging holes on back of boiler. See parts listed on page 2, number 15 and 16.

CAUTION

Boiler weight exceeds 75 pounds (34 kg). Do not lift boiler onto wall without assistance.

NOTICE

Lift boiler using chassis. Using front jacket, vent

piping, water or gas ttings to lift boiler may cause

damage to the boiler.

5 - HYDRONIC PIPING

5.1 General

• Install piping in accordance with authority having jurisdiction.

NOTICE

Use two (2) wrenches when tightening boiler's

tting and pipes. Boiler's internal piping can be

damaged if subjected to excessive torque.

• Support system piping and safety relief valve discharge piping. Boiler's internal piping and wall mount bracket can be damaged if subjected to excessive weight.

• Size central heating pump (and domestic hot water pump, if used) for system requirements only.

• Thoroughly clean and ush system before connecting to boiler.

• If oil is present in system water, use approved detergent to wash system.

• Flush system to remove any solid objects such as metal

chips, bers, or Teon tape, etc.

5.2 Special Conditions

• System piping exposed to freezing conditions: Use

inhibited propylene glycol solutions certied by uid

manufacturer for use with closed water heating system. Do not use automotive or ethylene glycol.

• Boiler used in connection with refrigeration system. Install piping in parallel with boiler, with appropriate valves to prevent chilled medium from entering boiler.

• System piping connected to heating coils located in air handling unit exposed to refrigerated air circulation. Install

ow control valves or other automatic means to prevent

gravity circulation of boiler water during cooling cycle.

WARNING

• Poison hazard. Ethylene glycol is toxic. Do not use ethylene glycol.

• Never use automotive or standard glycol antifreeze, even ethylene glycol made for hydronic systems.

• Ethylene glycol can attack gaskets and seals used in hydronic systems.

• Use only inhibited propylene glycol solutions

certied by uid manufacturer as acceptable for

use with closed water heating system.

• Thoroughly clean and ush any system that used glycol before installing new Boiler.

• Provide user with Safety Data Sheet (SDS) on uid used.

NOTICE

Do not expose boiler and condensate piping to freezing temperatures.

FIGURE 5-1 Safety Relief Valve (Viewed from rear of boiler)

Shown 50/75/100 Model

Safety Relief

Valve

5.3 Safety Relief Valve

NOTICE

Boiler rated at 150 psig (1.03 MPa) maximum allowable working pressure. Boiler provided with 30 psig (206 kPa) safety relief valve. Field source safety relief valve for system pressures greater than 25 psig. Temperature Pressure Gauge satisfactory for 60 psig operation. Field source temperature pressure gauge for system pressures greater than 60 psig.

• Install safety relief valve. See gure 5-1

• 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. See

gure 5-2.

• Use ¾" or larger pipe.

• Use pipe suitable for temperatures of 375°F (191°C) or greater.

Position Safety Relief Valve to provide

space for discharge piping.

5 - HYDRONIC PIPING

WARNING

Burn and scald hazard. Safety relief valve could discharge steam or hot water during operation. Install discharge piping per these instructions.

FIGURE 5-2 Safety Relief Valve Discharge Piping

Safety Relief Valve

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

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

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

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

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

• Terminate pipe with plain end (not threaded).

• Arrange piping to prevent water dripping onto boiler.

5.4 Trim Piping

• Temperature - Pressure Gauge. Install temperature pressure gauge using adapter, tee and bushing provided

with boiler. See gure 5-3.

• Protect chassis grommets from heat damage while soldering.

• Drain Valve. Install drain valve using, tee and adapter

provided with boiler. See gure 5-3.

5.5 System Piping

• See Table 3 for basic system piping congurations.

Check Local Codes

For Maximum

Distance To Floor

FIGURE 5-3 Temperature Pressure Gauge and Drain Valve Installations

Temperature Pressure

Gauge shown at

System Supply

Connection

Drain Valve shown

at System Return

Connection to Boiler

• Systems with automatic ll valves require back ow prevention device.

• Single boiler system. See gures for general guidance. Additional considerations:

• Boiler control is designed for single central heating pump. Installer responsible for integration of multiple central heating pumps.

• Boiler control allows domestic hot water pri o riti zation. Function could be lost if central heating pump not directly connected to control system.

• Multiple boiler system. general guidance. Additional considerations:

• Control system requires equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature.

• Install multi boiler sensor kit. See "Parts, Kits & Optional Accessories" manual for part number.

• Low Water Cutoff (LWCO) probe location. See gures 5-4A for minimum probe height. Do not install shutoff valve between boiler and LWCO probe.

• If boiler is below radiation level, use gure 5-4A.

Boilers above radiation level use gures 5.4B thru

5.4D.

• If using separate stand pipe, install air vent using tee to avoid nuissance shutdowns.

• See gures 5-4B, 5-4C and 5-4D for suggested probe location alternatives.

• Arrange piping to prevent water dripping onto boiler.

See gures 5-8A, B & C

5-4A,

5-5, 5-6, 5-7A & B

for

5 - HYDRONIC PIPING

FIGURE 5-4A System Piping - LWCO Probe Location

Safety Relief Valve

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

WALL

MOUNTED

ONLY

FIGURE 5-4C LWCO Suggested Probe Location

Shown 50/75/100 Model

Air Vent

Safety Relief Valve

LWCO

MINIMUM

ACCEPTABLE

HEIGHT FOR

LWCO PROBE

Pipe to

condensate

drain

System

Supply

Pipe to

condensate

drain

FIGURE 5-4B LWCO Suggested Probe Location

Shown 50/75/100 Model

LWCO

Safety Relief Valve

Air Vent

System

Return

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

Stand

Pipe

Valves

System

Supply

FIGURE 5-4D LWCO Suggested Probe Location

Shown 50/75/100 Model

LWCO

MINIMUM ACCEPTABLE HEIGHT FOR

LWCO PROBE

Air Vent

Safety Relief Valve

System Return

Valves

System

Supply

12"

Max.

System Return

System

Supply

12"

Max.

System Return

5 - HYDRONIC PIPING

NOTICE

Illustrations are meant to show system piping concept only. Installer is responsible for all equipment and detailing required by authority having jurisdiction.

NOTICE

Arrange piping to prevent water dripping onto boiler.

Primary Loop Equivalent Length Calculation & Pump Selections may be found on pages 84 thru 87 of this

manual.

Piping Legend

Single Boiler

Multiple Boilers

Table 3 - System Piping Congurations

Primary/Secondary

Two Pipe Zoned System

Primary/Secondary Pumping

Primary/Secondary

Two Pipe Zoned System

Primary/Secondary Pumping

With Zone Valves gure 5-5

With Zone Pumps gure 5-6

Without DHW Tank

With DHW Tank gure 5-7B

With Zone Valves gure 5-8A

With Zone Pumps Not Shown

Without DHW Tank

With DHW Tank

gure 5-7A

gure 5-8B

gure 5-8C

5 - HYDRONIC PIPING

FIGURE 5-5 Single Boiler Primary/Secondary Two-Pipe Zoned System With Zone Valves

DHW Pump

CH/System

Pump

FIGURE 5-6 Single Boiler Primary/Secondary Two-Pipe Zoned System With Zone Pumps

DHW Pump

Zone

Pump

Primary Loop Equivalent Length

Calculation & Pump Selections may

be found on pages 84 thru 87 of this

manual.

5 - HYDRONIC PIPING

FIGURE 5-7A Single Boiler Using Primary/Secondary Pumping

12"(305mm)

Maximum

separation

closely spaced tees

in primary system loop

CH/System

Pump

Limit length

5' (1.6m)

FIGURE 5-7B Single Boiler Using Primary/Secondary Pumping With DHW Tank

Heating Load Heating Load

12"(305mm) Maximum separation

Closely spaced

tees

in primary

system loop

Heating Load

CH/System

Pump

Limit length

5' (1.6m)

Primary Loop Equivalent Length

Calculation & Pump Selections may

be found on pages 84 thru 87 of this

manual.

5 - HYDRONIC PIPING

FIGURE 5-8A Multiple Boiler Primary/Secondary Two Pipe Zoned System With Zone Valves - (See Multiple Boiler

Guide)

DHW Pump

CH/System

Pump

12"/305mm Maximum Separation

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit length to 5' (1.6m)

Up to 16

boilers

(See Multiple Boiler Guide)

5 - HYDRONIC PIPING

FIGURE 5-8B Multiple Boilers Using Primary/Secondary Pumping

12"/305mm Maximum Separation

Closely spaced tees

in primary system loop

CH/System

Pump

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

5 - HYDRONIC PIPING

5-8C Multiple Boilers Using Primary/Secondary Pumping with DHW Tank

12"/305mm Maximum Separation

Closely

spaced tees

in primary

system loop

CH/System

Pump

System

Temperature

Sensor

Size common piping

per maximum heat

capacity of entire

system

Limit

length to

5' (1.6m)

Up to 16

boilers

6 - COMBUSTION AIR AND VENT PIPING

6.1 General

This boiler requires a dedicated vent system. Install combustion air and vent piping in accordance with these

instructions, authority having jurisdiction, and:

• USA - National Fuel Gas Code, ANSI 223.1/NFPA 54.

• Canada - Natural Gas and Propane Installation Code, CAN/CSA B149.1

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

Install vent system in accordance with these instructions.

6.2 Removal of Existing Boiler From Common Vent System

When existing boiler is removed from common venting system, common venting system is likely to be too large for proper venting of appliances remaining connected to it.

After removal of existing boiler, following steps shall be followed with each appliance remaining connected to common venting system placed in operation, while other appliances remaining connected to common venting system are not in operation:

• Seal any unused openings in common venting system.

• Visually inspect venting system for proper size and horizontal pitch. Determine there is no blockage or

restrictions, leakage, corrosion and other deciencies

which could cause an unsafe condition.

• When practical, close all building doors, windows, and all doors between space in which appliances remaining connected to common venting system are located and other spaces of building. Turn on clothes dryer and any appliance not connected to common venting system. Turn on exhaust fans, such as range hoods and bathroom exhaust so they will operate at maximum speed. Do not operate summer exhaust fan. Close

replace dampers.

• Turn on appliance being inspected. Follow lighting instructions. Adjust thermostat so appliances will operate continuously.

• Test for spillage at draft hood relief opening after 5

minutes of main burner operation. Use ame of match or

candle, smoke from cigarette, cigar or pipe.

• Determine each appliance remaining connected to common venting system properly vents when tested as outlined above. Then return doors, windows, exhaust fans and any other gas-burning appliance to their previous condition of use.

• Any improper operation of common venting system should be corrected so installation conforms with National Fuel Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1. When re-sizing any portion of common venting system, common venting system should be re-sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

6.3 Venting Materials

• See Table 4

Table 4 - Combustion air and vent pipe ttings

must conform with the following:

Item Material Standards

PVC schedule 40 ANSI/ASTM D1785

PVC - DWV ANSI/ASTM D2665

CPVC schedule 40

Vent Pipe

and Fittings

Pipe

Cement/

Primer

• 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.

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

ABS-DWV ANSI/ASTM D2661

Schedule 40ABS ANSI/ASTM F628

PP (Polypropylene)

Pipe and Components

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Schedule 40 ABS ANSI/ASTM D2235

WARNING

ANSI/ASTM D1784/

F441

UL 1738

ULC S636-08

Use of cellular core PVC for venting ue gas could

result in death, or serious injury.

WARNING

Covering non-metallic vent pipe and ttings with

thermal insulation shall be prohibited.

6 - COMBUSTION AIR AND VENT PIPING

6.4 Vent Pipe Installation

• Minimum and maximum combustion air and vent pipe lengths listed in Table 5. Pipe length counted from combustion air connector to termination.

• Install eld-sourced 2" to 3" transition, if used, in vertical section at combustion air inlet and vent connector.

• 90° elbows equivalent to 5.0 ft (1.6 m). 45° elbows equivalent to 3.5 ft (1.1 m). 2" to 3" transition has no equivalent length. See Table 6.

• Use exible Polypropylene piping (PP) in a vertical position only. Check PP pipe manufacturer for details. Each foot of PP exible pipe is equivalent to 2⅝ feet of smooth pipe of same diameter.

• Slope vent pipes minimum 1/4" per foot (21 mm/m) back toward boiler. Support horizontal sections to prevent sags capable of accumulating condensate.

• Support piping in accordance with pipe manufacturer's instruction and authority having jurisdiction. In absence of manufacturer's instruction use pipe hooks, pipe straps, brackets, or hangers of adequate and strength located at intervals of 4 ft (1.2m) or less. Allow for expansion/contraction of pipe.

• Combustion air and vent piping must be air tight and water tight.

• Certied vent system components must NOT be interchanged with other vent systems or unlisted pipe/

ttings.

• Canadian installations only. All venting material, primer and glue must be listed to ULC S636.

• Canadian installations only. First 3 ft (0.9 m) of plastic vent pipe from vent connector must be readily accessible for visual inspection.

6.5 Vent Termination

• Terminate combustion air and vent pipes with ttings or concentric vent kit.

A. See "Parts, Kits and Optional Accessories" manual

for concentric vent kit part numbers.

B. Use horizontal pipe for vent and 90° elbow for

combustion air termination when using ttings.

• Follow gures 6-1 thru 6-11 for termination of combustion air and vent pipes.

• Locate combustion air termination as far as possible from swimming pool, swimming pool pump house, and other sources of airborne chlorine.

• Locate combustion air and vent terminals as required by authority having jurisdiction.

WARNING

Vent extending through exterior wall shall not terminate adjacent to wall or below building extensions such as eaves, balconies, parapets or decks. Failure to comply could result in death or serious injury.

Table 5 - Combustion Air and Vent Piping Length

Minimum/Maximum Vent Lengths

2” Pipe 3” Pipe

Model 050 075/100 075/100 150/200

Min.

Max.

For Example: Boiler can be installed on outside wall and vented with one 90° elbow and 1 ft (0.30 m) of vent pipe.

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

50 ft.

(15.2 m)

Table 6 -Equivalent Length of Venting Components

Equivalent Length of Venting Components

Component Feet Meters

90° Elbow 5 1.6

45° Elbow 3½ 1.1

2" x 4" Adapter 0 0

3" x 4" Adapter 0 0

Concentric Vent Kit 5 1.6

Polypropylene Flexible Pipe per Foot 2⅝ 0.8

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 ft.

(1.8 m)

100 ft.

(30.5 m)

6 - COMBUSTION AIR AND VENT PIPING

6.6 Venting Congurations

Various venting congurations can be applied to this boiler. For guidance see Venting Conguration Table 7 and

corresponding gures.

Table 7 - Venting Congurations

Flue Gas Location

Roof

Combustion Air

Location

Roof

Side Wall Single Pipe gure 6-8

NOTICE

Use of vent covers may cause freezing. If using vent covers overall vent length must be considered. Failure to heed this information may compromise operation of this boiler.

Flue Gas Terminals

Two Pipe gure 6-1

Concentric gure 6-7

Corresponding Figures

Side Wall

Inside Air Single Pipe gure 6-9

Roof Single Pipe gure 6-10

Two Pipe gures 6-2, 6-3

Side Wall

Concentric gures 6-4, 6-5, 6-6

Inside Air Single Pipe gure 6-11

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-1 Two Pipe Roof Vent

3" (76mm)

Minimum

12" (305mm)

Minimum

8" (203mm)

Minimum

Vent Combustion

Air

12" (305mm) US,

18" (457mm) Canada

Minimum Above

Anticipated Snow Line

15" (381mm)

Maximum

Roof Line

Roof

Terminations

 3" (76mm) Minimum horizontal

separation between combustion air intake and vent of same appliance.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent of different appliances.

 15" (381mm) Maximum horizontal

length of vent.

 Minimum vent/intake between

different appliances 12" (305mm).

 Maximum allowable total vertical

vent length with outside exposure is 10 ft.(3.05m).

 Abandoned unused masonry

chimney may be used as chaseway for combustion air and vent. Both combustion air and vent pipe must exit above top of chimney with

clearances as shown in gure 6-1.

FIGURE 6-2 Two Pipe Side Wall Vent

12" (305mm)

Minimum From

3" (76mm)

Minimum

Separation

See Snow & Ice

Page 29

FIGURE 6-3 Two Pipe Side Wall Vent (Multiple Appliances.

12" (305mm)

Overhang

12" (305mm) Minimum

Separation Between

Bottom Of Combustion Air

Intake And Bottom Of Vent

Vent

Combustion Air

Minimum

Separation

Side Wall

Terminations

 3" (80mm) Minimum horizontal

separation between combustion air intake and vent terminations.

 8" (203mm) Minimum vertical

separation between combustion air intake and vent terminations.

 12" (305mm) Minimum separation

between bottom of combustion air intake and bottom of vent.

 Multiple terminations as shown in

6-1, and 6-3 must be a minimum of 12” (305mm) horizontally between vent of one termination and air intake of next appliance.

 Maximum allowable total outside

exposure vent length equals 10 ft. (3.05m).

 Maintain a pitch of 1/2" per ft.

(13mm/m) outside exposure back to boiler to ensure proper condensate drainage for horizontal runs.

See Snow & Ice

Page 29

Combustion Air

Vent

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-4 Side Wall Concentric Terminal FIGURE 6-5 Side Wall Concentric Terminal Multiple

Appliances

1"(2.54cm)

1" (25.4mm)

Maximum

Vent

Combustion

Air

FIGURE 6-6 Concentric Terminal Connection

*2 or 3" (51 or 77 mm) Diameter

PVC intake/combustion air

Roof

1" (25mm)

Maximum

* See Note

Below

Combustion

Air

Overhang

12" (305mm) Minimum

36"(0.9m(914mm)

Vent

Maintain 12"(30cm) US

(18"(46cm) Canada)

highest anticipated

Minimum Clearance Above

snow level or grade

Highest Anticipated Snow

(28m)) Minimum

Maintain 12"

clearance above

Level Or Grade

*Must be less than 4" (102mm) or greater than 24" (610mm) Horizontal distance between end bells of each air

intake to prevent ue gas recirculation.

Note: Securing strap must

be eld installed to prevent

movement of termination kit in side wall

Combustion Air

OD 3½" (

89mm)

- *2" (

51mm)

kit

OD 4½" (114mm) - 3" (77mm) kit

** Note Overall length may be modied by cutting or extending

both combustion air and vent pipes. 12" (305mm) is minimum allowable length and 60" (1.2m) is maximum allowable length for this dimension.

SDR-26 PVC (D2241) only may be used for extending pipes. Do not use Schedule 40 PVC or use couplings to extend pipes. Dimension will change if intake/vent pipes are lengthened or shortened.

**See

Note

*2" (

51mm)

Diameter = 41" Length (1.1m)

3" (77mm) Diameter = 47" Length (1.2m)

1"(25.4mm) Maximum

Vent

Combustion Air

* Note: 2" (51mm) For use with models 050/075/100. 3" (77mm) For use with models 075/100/150/200

6 - COMBUSTION AIR AND VENT PIPING

FIGURE 6-7 Concentric Roof Terminal

Vent

Combustion Air

Roof boot/ashing (eld supplied)

Note: Support must

be eld installed to

secure termination kit to structure

Vent

FIGURE 6-8 Flue on Roof, Air Intake on Side Wall

Vent

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow

level 24" (610mm) above

roof

Support

(eld supplied)

Combustion Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow

level 24" (610mm) above

roof

Combustion Air

Concentric

Vent Roof

Terminations

Grade, Snow

& Ice

 Glue inner vent pipe to prevent

recirculation.

 Maintain 12" (305mm) US

(18"(457mm) Canada) minimum clearance above highest anticipated snow level. Maximum of 24"(610mm) above roof.

 Support must be eld installed to

secure termination kit to structure.

 Elbow, roof boot/ashing eld supplied.  Allowed Wall/Roof thickness 1/2"-30"

(12.7mm - 762mm).

 Vertical concentric vent system can be

installed in unused masonry chimney.

 Contact Technical Support 800-

325-5479 for questions regarding installation or use.

Terminate vent system bottom, minimum 12" (305mm) above highest anticipated snow level.

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.

12" (305mm) Minimum anticipated snow line

Ground Level

FIGURE 6-9 Flue on Roof, Combustion Air

Vent

Combustion

Air

Maintain 12"(305mm) US

(18"(457mm) Canada)

minimum clearance above

highest anticipated snow level

maximum 24" (610mm) above

roof

24" (610mm) * Minimum Length

Doors &

Windows

* See Tables

4 & 5

Combustion air and vent termination must be 12" (305mm) from or below doors, windows or gravity inlet.

Combustion air and Vent Piping Length Page 23 .

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