Weil-McLain EVG 70, EVG 155, EVG 110 User Manual

CONDENSING GAS BOILER

70/110/155

Boiler Manual

• Installation

• Startup

• Maintenance

• Parts

This manual must only be used by a qualiﬁ ed heating installer/service technician. Read all instructions, including this manual and all other information shipped with the boiler, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death or substantial property damage.

Part number 550-100-191/0917

Contents

gas-fired water boiler — 70/110/155 Boiler Manual

The Evergreen® Gas-ﬁ red water boilers . . . . . . . . . . . . 2

Please read before proceeding . . . . . . . . . . . . . . . . 7

Boiler location . . . . . . . . . . . . . . . . . . . . . . . . . 8

Prepare boiler location . . . . . . . . . . . . . . . . . . . . 10

Wall-mounting the boiler. . . . . . . . . . . . . . . . . . . 10

Boiler hydrostatic test . . . . . . . . . . . . . . . . . . . . 13

Converting boiler to propane — EVG 70 . . . . . . . . . . . 15

Converting boiler to propane — EVG 110 . . . . . . . . . . 17

Converting boiler to propane — EVG 155 . . . . . . . . . . 19

Gas piping — sizing gas lines . . . . . . . . . . . . . . . . 21

Venting/air piping — general . . . . . . . . . . . . . . . . 22

Commonwealth of Massachusetts installations . . . . . . 25

Vent termination requirements . . . . . . . . . . . . . . . 26

Boiler room air openings . . . . . . . . . . . . . . . . . . . 27

DIRECT VENT — Sidewall with separate pipes . . . . . . . 28

DIRECT VENT — Sidewall concentric . . . . . . . . . . . . 30

DIRECT VENT — Sidewall with W-M vent/air plate . . . . . 32

DIRECT VENT — Vertical with separate pipes. . . . . . . . 34

DIRECT VENT — Vertical concentric. . . . . . . . . . . . . 36

Concentric termination, typical (sidewall or vertical). . . . 38

Vent and air piping and boiler connections . . . . . . . . . 39

Install water piping . . . . . . . . . . . . . . . . . . . . . 40

Direct Connect System Piping - Single Boiler System . . . 41

Verify the application will work. . . . . . . . . . . . . . . . . . 41

Expansion tank location. . . . . . . . . . . . . . . . . . . . . . 41

Diaphragm- or bladder-type tank. . . . . . . . . . . . . . . . . 41

Closed-type expansion tank . . . . . . . . . . . . . . . . . . . 42

System water piping methods . . . . . . . . . . . . . . . . . . 43

Install relief valve . . . . . . . . . . . . . . . . . . . . . . . . . 43

ZONE VALVE zoning – direct connection . . . . . . . . . . . . . 44

Primary/Secondary System Piping - Single Boiler System See

Advanced Manual for Multiple Boiler Systems . . . . . . . 45

Expansion tank location. . . . . . . . . . . . . . . . . . . . . . 45

Diaphragm- or bladder-type tank. . . . . . . . . . . . . . . . . 45

Closed-type expansion tank . . . . . . . . . . . . . . . . . . . 46

System water piping methods . . . . . . . . . . . . . . . . . . 47

Install relief valve . . . . . . . . . . . . . . . . . . . . . . . . . 48

ZONE VALVE zoning – primary/secondary . . . . . . . . . . . . . . . 49

CIRCULATOR zoning – primary/secondary . . . . . . . . . . . . . . 50

CIRCULATOR zoning – primary/secondary multi. temp. zone . . . . 51

Install condensate line. . . . . . . . . . . . . . . . . . . . . . . . 52

Gas piping . . . . . . . . . . . . . . . . . . . . . . . . . . 53

DO NOT SERVICE THE BOILER

WITHOUT AN Evergreen® MAINTENANCE KIT AVAILABLE

The maintenance kit includes components that may have to be replaced when accessing or disassembling parts of the boiler. Failure to replace damaged components and to use only the parts speciﬁ cally intended for the boiler can result in severe personal injury, death or substantial property damage. See Figure 110, page 127 for part number.

Field wiring . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Wiring diagram — schematic . . . . . . . . . . . . . . . . 62

Wiring diagram — ladder . . . . . . . . . . . . . . . . . . 63

Zoning with the EVG Control . . . . . . . . . . . . . . . . . 64

Evergreen control operation . . . . . . . . . . . . . . . . . 66

EVG control settings menus . . . . . . . . . . . . . . . . . 70

EXPRESS SETUP — Example A . . . . . . . . . . . . . . . 72

EXPRESS SETUP — Example B . . . . . . . . . . . . . . . 74

EXPRESS SETUP — Example C . . . . . . . . . . . . . . . 76

Available control settings and system presets . . . . . . . 78

CONTRACTOR menus . . . . . . . . . . . . . . . . . . . . . 79

BOILER SETTINGS menu, BASIC mode . . . . . . . . . . . . 80

PRIORITY 1, 2, 3 menus, BASIC mode . . . . . . . . . . . . 81

ASSIGN INPUTS menu, BASIC mode . . . . . . . . . . . . . 82

DIAGNOSTIC menu . . . . . . . . . . . . . . . . . . . . . . 84

MAINTENANCE, DATE AND TIME menus . . . . . . . . . . . 89

Startup — ﬁ ll the system . . . . . . . . . . . . . . . . . . 91

Startup — ﬁ nal checks . . . . . . . . . . . . . . . . . . . 93

Check-out/startup veriﬁ cation. . . . . . . . . . . . . . . . 99

Annual startup and general maintenance . . . . . . . . . . 100

Annual startup . . . . . . . . . . . . . . . . . . . . . . . . 101

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . 107

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 115

Cleaning heat exchanger ﬂ ue side, 70. . . . . . . . . . . . 117

Cleaning heat exchanger ﬂ ue side, 110 . . . . . . . . . . . 120

Cleaning heat exchanger ﬂ ue side, 155 . . . . . . . . . . . 123

Replacement parts . . . . . . . . . . . . . . . . . . . . . . 126

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Ratings — Evergreen® boilers . . . . . . . . . . . . . . . 139

Installation and Service Certiﬁ cate . . . . . . . . . . . . . 141

Evergreen® Gas Boiler Data Collection Sheet . . . . . . . 144

Hazard deﬁ nitions

The following deﬁ ned terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or to important information concerning the life of the product.

Indicates presence of hazards that will cause severe

personal injury, death or substantial property damage.

Indicates presence of hazards that can cause severe

personal injury, death or substantial property damage.

Indicates presence of hazards that will or can

cause minor personal injury or property damage.

Indicates special instructions on installation,

operation or maintenance that are important but not related to personal injury or property damage.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

The Evergreen® Gas-ﬁ red water boilers

1. Stainless steel ﬁ retube heat exchanger

2. Heat exchanger access cover/burner mounting plate

3. Blower

The advanced blower design and air inlet silencer on Evergreen® boilers result in very quiet operation. Air enters the boiler enclosure through the air intake adapter (Item 19),

ﬂ ows through the enclosure, enters the air inlet silencer (Item 5), then enters the venturi (Item 6) where it mixes with gas before entering the blower. The blower pulls air through these components and then pushes it through the cover plate to the burner (Item 12).

4. Gas valve

The automatic gas valve references the pressure in the cabinet and allows gas to ﬂ ow when the control (Item 16) applies power. A manual gas shut off valve is shipped loose with the boiler. It allows shutting off the gas supply for servicing or shut down. See instructions in this manual for manual gas valve installation.

5. Air inlet silencer

The horn-shaped air inlet silencer signiﬁ cantly reduces fan noise, providing exceptionally quiet operation.

6. Venturi

When air ﬂ ows through the venturi, a negative pressure is created. This causes gas to ﬂ ow from the gas valve into the venturi, where it is mixed with the air. The gas/air mixture then continues into the blower.

7. Supply water temperature dual sensor

This dual sensor monitors boiler outlet water temperature. The control adjusts boiler ﬁ ring rate so the outlet water temperature is correct, based on the calculated (if outdoor reset used — see page 139 ) or ﬁ xed target temperature.

8. Return water temperature sensor

This sensor monitors return water temperature to the boiler. The control reduces or increases boiler input, depending on how close the return water temperature is to the outlet water temperature.

9. Electronic display & buttons

The electronic display is used to conﬁ gure boiler settings and monitor boiler operation. The buttons allow changing display mode, selecting and adjusting control settings, and resetting the control after lockout.

10. Flue adapter (ﬁ ts 3" PVC)

11. Flue pipe

12. Burner (not shown)

Made with high-grade stainless steel construction, the burner uses premixed air and gas. The burner and control provide modulating ﬁ ring.

13. Water outlet pipe (system supply)

14. Water inlet pipe (system return)

15. Gas line

This stainless steel ﬂ exible gas line connects the incoming gas line to the gas valve.

The gas line has a ½” NPT connection for installation.

16. Control module (see discussion upper right)

17. Communication Board

The communication board provides boiler-to-boiler communication and Building Management System (BMS) interface.

18. Boiler circulator terminal block

19. Air intake adapter (ﬁ ts 3" PVC) 20a. Electrical entrances (line voltage)

The top left side knockouts are designated for line voltage wiring only. Ensure all wiring entrances are sealed.

20b. Electrical entrances (low voltage)

The bottom left side knockouts are designated for low voltage wiring only. Ensure all wiring entrances are sealed.

20c. Electrical entrance (multiple boiler communication)

The top right knockout (1) is designated for multiple boiler communication and BMS wiring. Ensure all wiring entrances are sealed.

21. Boiler drain valve (not shown)

Shipped loose for ﬁ eld piping. Pipe drain valve on reducing tee at the lowest point of return piping to boiler. See instructions, page 14 in this manual.

22. Condensate trap nozzle

The outlet at the bottom of the condensate collection dish. This is where condensate is discharged from the boiler. The condensate trap assembly attaches here.

Part number 550-100-191/0917

Evergreen® control overview

• The Evergreen® control can operate a single boiler or coordinate with other Evergreen® boilers in a multiple boiler system.

• Control inputs and outputs allow operation of multiple heating circuits (space heating and DHW, for example).

• Up to three priority levels can be set, providing automatic switchover on demand.

• This manual provides quick set-up information for single boiler installations.

• The Advanced Manual, also supplied with the boiler, provides instructions for setting up multiple-boiler systems and for using

advanced options for single boilers.

Evergreen® control operation

• The control responds to signals from the room thermostats, DHW aquastats (if used), boiler sensors (boiler return, boiler supply, ﬂ ue temperature), outdoor temperature and system sensors, if used.

• The control automatically adjusts blower speed (and gas ﬂ ow rate) to match boiler output to space heating and/or DHW heating demand.

• The default control settings provide for three space heating zones. The control can be easily set up for operation with a DHW zone,

with or without domestic priority.

Evergreen® control WIZARD

• The control setup Wizard is available from the BOILER SETTINGS menu that appears during initial startup.

• The Wizard leads through a step-by-step setup procedure designed for the application chosen.

• Context-sensitive help is available to explain the purpose of key setup items.

23. Flue gas condensate drain trap assembly and bracket

The condensate trap assembly and bracket are ﬁ eld-installed, condensate drain trap is connected to the condensate trap nozzle as shown in this manual.

24. Jacket door

The jacket door is sealed to the boiler assembly around its entire perimeter.

25. Front door latches

Two (2) latches secure the door in place.

26. Door retention screw

27. Ignition electrode/ﬂ ame sensor

The burner ﬂ ame is ignited by applying a high voltage to the ignition electrode. This causes a spark (from electrode to ground). After ignition, the electrode measures ﬂ ame signal.

28. Flame inspection window

The quartz glass window provides a view of the burner surface, the ﬂ ame, and the ignition electrode.

29. Flue gas dual sensor

This dual sensor monitors the ﬂ ue gas exit temperature. The Evergre en® control will shut down the boiler if ﬂ ue gas temperature gets too hot. This protects the ﬂ ue pipe and the heat exchanger from overheating.

30. Gas valve reference hose (EVG-70 only)

This rubber line connects the gas valve diaphragm reference chamber to the venturi intake to insure the valve senses the correct reference pressure.

31. Transformer

The 120V/24V transformer provides 24V to low voltage control circuitry. Do NOT splice wiring into transformer.

32. Air bafﬂ e

The air baffle protects internal boiler components by diverting any incoming moisture or debris away from critical components. It must be temporarily removed while servicing the heat exchanger.

33. Floor stand assembly

The provided stand allows for the Evergreen® boiler to be either wall hung or ﬂ oor standing.

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Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Please read before proceeding

Installer— Read all instructions, including this

manual and all other information shipped with the boiler, before installing. Perform steps in the order given.

User — This manual is for use only by a qualiﬁ ed

User — Have this boiler serviced/inspected by a

Failure to comply with the above could result in severe

heating installer/service technician. Refer to User’s Information Manual for your reference.

qualiﬁ ed service technician, at least annually.

personal injury, death or substantial property damage.

If any part of a boiler, burner or its controls has

been sprayed with or submerged under water, either partially or fully, DO NOT attempt to operate the boiler until the boiler has been either replaced or completely repaired, inspected, and you are sure that the boiler and all components are in good condition and fully reliable.

Otherwise, by operating this boiler, you will

cause a ﬁ re or explosion hazard, and an electrical shock hazard, leading to serious injury, death, or substantial property damage. See the instructions at right.

Failure to adhere to the guidelines below can result in severe personal injury, death or substantial property damage.

EXPANSION TANK

• Relieve pressure from the system before isolating the expansion tank.

When servicing boiler —

• To avoid electric shock, disconnect all electrical supplies to the boiler before performing maintenance.

• To avoid severe burns, allow boiler to cool before performing maintenance.

• This boiler contains ceramic fiber and fiberglass materials. Refer to the WARNING and instructions on page 101 .

Boiler operation —

• Do not block ﬂ ow of combustion or ventilation air to boiler.

• Should overheating occur or gas supply fail to shut off, do not turn off or disconnect electrical supply to circulator. Instead, shut off the gas supply at a location external to the appliance.

Combustion air —

• DO NOT install combustion air intake where there is a risk of combustion air contamination.

Carbon monoxide detector —

• A carbon monoxide detector that is wired on the same electrical circuit as the boiler is strongly recommended.

SURGE PROTECTOR —

• Provide surge protection in the boiler power supply. This will reduce the possibility of damage to the boiler control.

Boiler water —

• The Evergreen® heat exchanger is made of stainless steel, and requires that system water chemistry be within the limits in this manual. Use the Sentinel X100 inhibitor supplied with boiler.

ADDITIONAL CHEMICAL TREATMENT MAY BE NECESSARY

details.

• Thoroughly ﬂ ush the system (BEFORE connecting boiler) to remove sediment. The high-efﬁ ciency heat exchanger can be damaged by build-up or corrosion due to sediment.

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in eat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by make-up water can cause internal corrosion. Leaks in

Write in the CP number in the space provided on the

Installation certiﬁ cate on page 141 if not already shown.

When calling or writing about the boiler— Please

Consider piping and installation when determining

have the boiler model number from the boiler rating label and the CP number from the boiler jacket.

boiler location.

Any claims for damage or shortage in shipment

must be ﬁ led immediately against the transportation company by the consignee.

Saltwater Damage — The exposure of boiler components to

saltwater can have both immediate and long-term effects. While the immediate effects of saltwater damage are similar to those of freshwater (shorting out of electrical components, washing out of critical lubricants, etc.), the salt and other contaminants left behind can lead to longer term issues after the water is gone due to the conductive and corrosive nature of the salt residue. Therefore, Weil-McLain equipment contaminated with saltwater or polluted water will no longer be covered under warranty and should be replaced.

Electrical Damage — If any electrical component or wiring

came into contact with water, or was suspected to have come into contact with water, replace the boiler with a new Weil-McLain boiler.

boiler or piping must be repaired at once to prevent make-up water. Use this boiler ONLY in a closed-loop system.

• Do not add cold water to a hot boiler. Thermal shock can cause the heat exchanger to crack.

Freeze protection ﬂ uids —

• NEVER use automotive or standard glycol antifreeze. Use only freezeprotection fluids made for hydronic systems. Follow all guidelines given by

. See page 91 for

the antifreeze manufacturer. Thoroughly clean and ﬂ ush any replacement boiler system that has used glycol before installing the new boiler. Use only the products listed by Weil-McLain for use with this boiler. See page 92 for details.

Frozen Water Damage

Hazard

Residences or buildings that are unattended in severely cold weather, boiler system components failures, power outages, or other electrical system failures could result in frozen plumbing and water damage in a matter of hours. For your protection, take preventative actions such as having a security system installed that operates during power outages, senses low temperature, and initiates an effective action. Consult with your boiler contractor or a home security agency.

Commonwealth of

Massachusetts

When the boiler is installed within the Commonwealth of Massachusetts:

• This product must be installed by a licensed plumber or gas ﬁ tter.

• If antifreeze is used, a reduced pressure back-ﬂ ow preventer device shall be used.

• Sidewall vent air installations — see instruction on page 25 .

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Boiler location

Installations must comply with:

• Local, state, provincial, and national codes, laws, regulations and ordinances.

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

• National Electrical Code ANSI/NFPA 70 – latest edition. Electrical installation and grounding must be in accordance with CSA C22.1, Part 1, Canadian Electrical Code, and/or local codes.

• For Canada only: CAN/CSA B149.1, Natural Gas and Propane Installation Code, and any local codes.

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

The Evergreen® boiler gas manifold

and controls met safe lighting and other performance criteria when boiler underwent tests speciﬁ ed in ANSI Z21.13 — latest edition.

Before locating the boiler, check:

1. The Evergreen

mounted.

2. Wall construction — If the boiler is wall-mounted,

make sure the wall construction is suitable to carry the weight of the boiler and components. See page 10 for instructions.

3. The boiler is suitable for INDOOR installation

4. Check for nearby connection to:

• System water piping • Venting connections

• Gas supply piping • Electrical power

• Condensate drain

5. Check area around boiler. Remove any combustible materials, gasoline and other ﬂ ammable liquids.

Failure to keep boiler area clear and free of

6. The Evergreen control system components are protected from dripping or spraying water or rain during operation or service.

7. If new boiler will replace existing boiler, check for and correct system problems, such as:

• Sediment or corrosion in system piping — clean and

ﬂ ush piping BEFORE connecting the new boiler. See page 91 .

• System leaks causing oxygen corrosion or heat ex-

changer cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing

system and boiler to freeze and leak.

boiler

can be ﬂ oor-standing or wall

only.

combustible materials, gasoline and other ﬂ ammable liquids and vapors can result in severe personal injury, death or substantial property damage.

boiler must be installed so that gas

Residential garage installation

Precautions

1. Take the following special precautions when installing the boiler in a residential garage. If the boiler is located in a residential garage:

• Mount the boiler with its burner and igniter are at least

18 inches above the ﬂ oor. Follow the National Fuel Gas Code, ANSI Z223.1 for U. S. installations, or Natural Gas and Propane Installation Code, CSA B149.1 and B149.2 for Canadian installations.

• Locate or protect the boiler so it cannot be damaged by a

moving vehicle.

• Ensure that the installation complies with all applicable codes.

• Prevent boiler water and condensate from freezing.

Provide air openings to room

Evergreen® boiler alone in boiler room

1. No air ventilation openings into boiler room are needed if clearances around boiler are at least equal to the SERVICE clearances shown in Figure 1, page 9 .

2. For spaces that DO NOT supply the minimum service clearances, provide two openings as shown in Figure 1, page 9 . Each opening must provide 1 square inch free area per 1,000 Btuh of boiler input.

The space must be provided with combustion/

ventilation air openings correctly sized for all appliances located in the same space as the Evergreen® boiler.

Reinstall boiler jacket door after servicing. The boiler

Failure to comply with the above warnings could

jacket door must be securely fastened to the boiler to prevent boiler from drawing air from inside the boiler room. This is particularly important if the boiler is located in the same room as other appliances.

result in severe personal injury, death or substantial property damage.

Evergreen® boiler in same space with other gas or oil-ﬁ red appliances

1. Follow the sizing requirements shown in Figure 25, page 27 .

Vent and air piping

1. The EVG boiler requires a special vent system, designed for pressurized venting. The boilers are rated ANSI Z21.13 Category IV (pressurized vent, likely to condense in the vent). See instructions beginning on page 22 .

2. You must also install air piping from outside to the boiler air intake adapter. The resultant installation is categorized as direct vent (sealed combustion). Note prevention of combustion air contamination on

3. Vent and air must terminate near one another unless otherwise speciﬁ ed in this manual. Vent and air piping may be routed vertically through the roof or out a side wall, following the options given in this manual. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the EVG boiler using any other means.

4. Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits in instructions beginning on

page 22 when considering vent/air termination.

page 22 .

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Boiler location (continued)

Provide clearances for service access — RECOMMENDED

1. See Figure 1 for recommended service clearances.

2. If you do not provide minimum service clearances shown, it might not be possible to service the boiler without removing it from the space.

3. Clearance D, Figure 1 allows for the installation of piping as shown in Figure 8, page 12 plus a close nipple and elbow.

Closet or small-enclosure installations

which do not provide at least these recommended clearances require the specially-sized and placed air openings

shown in Figure 2

Figure 1 RECOMMENDED service clearances

(

all dimensions are in inches)

Provide clearances from combustible materials — REQUIRED

1. See Figure 2 for REQUIRED minimum clearances. ALL installation must provide at least these minimums.

2. Hot water pipes — at least ½ inches from combustible materials.

3. Vent pipe — at least

4. Clearance D, Figure 2 allows for the installation of a reducer bushing (155 only) and elbow. Other piping may require additional clearance.

5. See Figure 1 for service clearance minimums.

Closet or small-enclosure installations which do

not provide at least the recommended service clearances shown in sized and placed air openings shown in Figure 2

Figure 2 REQUIRED minimum clearances

(

all dimensions are in inches)

3/16 inches from combustible materials.

Figure 1 require the specially-

A Provide combustion air/ventilation openings per

Figure 25, page 27 or as otherwise directed in this manual or by applicable codes. NOTE: If the installation does not provide the minimum clearances in this illustration, then the enclosure

must have air openings located and sized per Figure 2 . B Left side service clearance = 3.5 inches minimum. C Service clearance above top of boiler = 12 inches minimum. D Right side service clearance = 8.5 inches minimum. E Service clearance below the boiler = 12 inches minimum for

wall hung installation, 0 inches minimum for ﬂ oor standing

installation. F Service clearance in front of the boiler = 24 inches minimum.

ADDITIONAL service clearance may be

needed, depending on how piping is routed to the boiler.

Part number 550-100-191/0917

A Provide combustion air/ventilation openings per Figure 25, page 27 or as

otherwise directed in this manual or by applicable codes. installation does not provide the minimum clearances in Figure 1 , then the enclosure MUST HAVE air openings located per Figure 2 , above. Each of these air openings must have free area of at least 1 square inch per 1,000 MBH of boiler

input. B Left side clearance to combustibles =2.5 inches minimum. C Top of boiler clearance to combustibles = 10.5 inches minimum. D Right side clearance to combustibles = 2.5 inches minimum. E Bottom of boiler clearance to combustibles = 7 inches minimum (must be

18 inches above ﬂ oor for garage installations) for wall hung installation, 0 inches

minimum for ﬂ oor standing installation. F Clearance in front of the boiler = 0.5 inches, but 24 inches minimum required

for service.

G Air openings must be located in the FRONT of the enclosure, as shown. They must

be no more than 12 inches from the ﬂ oor or ceiling, as shown. H Vent pipe must be minimum 3/16 inch from combustibles. Opening in

combustible wall, ﬂ oor, ceiling or roof must be 3/8 inches larger than ﬂ ue pipe

diameter, ﬁ tted with corrosion resistant steel thimble, or larger if required by

codes or as speciﬁ ed by vent pipe manufacturer.

If the

gas-fired water boiler — 70/110/155 Boiler Manual

Prepare boiler location

Flooring and foundation

Flooring

1. The boiler is approved for installation on combustible ﬂ ooring, but must never be installed on carpeting.

Do not install boiler on carpeting even if foundation is

used. Fire can result, causing severe personal injury, death or substantial property damage.

Foundation

1. Provide a solid foundation pad, at least 2 inches above the ﬂ oor, if any of the following is true:

• ﬂ oor can become ﬂ ooded.

• the ﬂ oor is dirt, sand, gravel or other loose material.

• the boiler mounting area is severely uneven or sloped.

2. The minimum foundation size is:

• Evergreen

3. Foundation may be of wood, brick or concrete (minimum 2 inches thick) construction.

If ﬂ ooding is possible, elevate boiler sufﬁ ciently to prevent water from reaching boiler.

Remove boiler from crate

Do not drop boiler or bump jacket on ﬂ oor or pallet.

1. The Evergreen after removing the shipping container.

2. Remove items 1, 2, 3 and 6 in Figure 3 . Remove trim kit and parts from item 2.

Leave the boiler resting on the styrofoam protective base

(item 6) and bottom cardboard cap (item 7), until ready to place on the wall. If removing the boiler from the shipping base, rest the boiler on its back, NOT on its bottom.

: 18 inches wide x 18 inches deep

The boiler is heavy. Use caution not to drop the boiler

or cause bodily injury while lifting and handling. Verify that the boiler is securely attached to prevent possibility of boiler falling after installation.

After the boiler is removed from the shipping carton,

DO NOT allow the boiler to sit on its bottom. This would

cause pressure on protruding plastic, resulting in interior damage. Either lay the boiler on its back or leave on the styrofoam protective shipping base.

Damage to boiler can result.

Cold weather handling — If boiler has been stored in a

very cold location (below 0°F) before installation, handle with care until the plastic components come to room temperature.

boiler is generally easier to handle and maneuver

Wall-mounting the boiler

(continued)

The operating weights for Evergreen® boilers are:

EVG 70 112 125 EVG 110 107 120

1. Stud spacing: Bracket holes are spaced for studs on 16-inch centers. For other stud spacing, provide secure, solid mounting surface on which to attach the boiler wall-mounting bracket. The mounting surface must not extend above the top of the boiler jacket.

2. Wood stud wall: Install bracket with lag screws (3/8" x 3") included in kit, only into the studs.

3. Metal stud wall: Secure bracket and spacer board to studs with 3/16-inch toggle bolts and 3/16-inch ﬂ at washers (not included with kit).

Figure 3 Boiler shipping container

EVG 155 129 143

Failure to comply with above and the procedure

given below could result in severe personal injury, death or substantial property damage.

Without

Stand

lbs.

With

Stand

lbs.

Wall-mounting the boiler

Wall-mounting requirements

DO NOT attempt to attach the wall mount bracket using anchors or any means other than directly securing to the wall studs (or equivalent wood structure if studs are not on 16-inch centers).

The wall must be vertically plumbed and capable of carrying the weight of the boiler and any attached piping components.

1 Cardboard cap, top 2 Floor stand assembly 3 Trim box (

4 Styrofoam protective cap

nestled inside Floor

stand assembly)

5 Boiler 6 Cardboard sleeve 7 Styrofoam protective base 8 Cardboard cap, bottom

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Wall-mounting the boiler (continued)

Verify that the studs are suitable for carrying a wall-

mounted load. Some metal studs are not designed for this purpose.

4. If the mounting wall has exposed studs, installer must provide a backer board to mount boiler. Boiler cannot be leveled without a backing surface.

5. Mount the boiler on the wall following these instructions. The boiler mounting studs must engage with the wall-mount bracket. Make sure the bracket is not just resting on the edge of the mounting

stud or washer. Perform all procedures given in the Boiler Manual on previous pages before mounting the boiler.

Install the wall-mount bracket (by installer)

1. See Figure 4 .

2. Locate the studs — must be on 16-inch centers. See previous page instructions if studs are not on 16-inch centers.

3. Place the wall-mount bracket (Figure 4, item 2) on the wall, using a level to align correctly.

4. Place the wall-mount bracket so the mounting slots are centered over the studs.

5. Level the bracket and trace the outline of the screw slots with a pencil.

6. Remove the mounting bracket and drill holes 1/4" diameter by 3 inches deep, centered on the screw slot outlines. (For metal stud walls, using 3/16" toggle bolts, drill required clearance holes.)

7. Position the wall-mount bracket on the wall. Insert and loosely tighten the two lag screws (or toggle bolts for metal studs).

8. Level the wall-mounting bracket. Then tighten lag screws securely. For drywall or plaster lathe installations, avoid tightening so much that the bracket digs into the wall surface.

The boiler is heavy, and requires two

people to lift and place. Wear non-slip leather gloves to prevent possibility of cuts from sheet metal edges.

The jacket door can be left in place when

handling the boiler, but the boiler must ONLY be lifted by the bottom and rear of the sheet metal housing — NOT by any pipe or plastic part.

3. Obtain assistance to lift the boiler into position.

4. Lift the boiler high enough that its mounting studs ( Figure 6, page 12 , item 3) will be above the wallmount bracket (item 2).

5. Let the rear of the boiler slide against the lag screw heads as you lower the boiler into place. The V-groove will help guide the studs into the slot.

Figure 5 Place boiler on wall-mount bracket

Place boiler on bracket

1. See Figure 5 . The wall-mount bracket must be installed before mounting the boiler.

2. Measure 22 1/2 inches below the bottom edge of the wall-mount bracket (item 2). Strike a line or place a piece of masking tape with its top edge even with the 22 1/2-inch mark. (This line, or tape, will indicate whether the boiler has been properly seated onto the wall-mount bracket.)

Figure 4 Wall-mount bracket and studs

1 Studs — Pre-drill through the wall into the studs ¼ inch diameter x 3 inches deep for

3/8-inch lag screws— Studs must be on 16-inch centers. If studs are any other spacing, provide a secure, solid mounting surface on which to attach the boiler wall-mounting bracket.

2 Wall-mount bracket

1 Studs — Pre-drill through the wall into the studs ¼ inch diameter x 3

inches deep — Studs must be on 16-inch centers. If studs are any other spacing, provide a secure, solid mounting surface on which to attach the boiler wall-mounting bracket.

2 Wall-mount bracket — secure wall mount bracket to wall as instructed

on previous page.

3 Boiler mounting studs (Figure 6 back of boiler) — The V-groove on the

wall-mount bracket will help guide the studs into the slots. The studs are attached to the back of the boiler.

4 Floor surface

Part number 550-100-191/0917

(continued)

gas-fired water boiler — 70/110/155 Boiler Manual

Floor Stand AssemblyWall-mounting the boiler

Floor Standing

Figure 6 Boiler mounting studs

6. When the brackets are engaged correctly, the bottom of the boiler enclosure will be at or near the pencil line, or tape, you applied in step 2.

7. Adjust the studs properly until engaged with the bracket and the boiler slips into the correct position.

When mounting the boiler, use the method

described on step 2, page 11 to ensure the mounting studs are properly engaged. If not, the boiler could fall. Failure to comply could result in severe personal injury, death or substantial property damage.

8. Ensure boiler is level front-to-back.

Ensure boiler is NOT pitched upward

with the front of the boiler higher than the back of the boiler. This can prevent condensate from draining properly. Failure to comply could result in severe personal

injury, death or substantial property damage.

The boiler is heavy, and requires two people to

lift and place upright. Use caution not to drop the boiler or cause bodily injury while lifting and handling. Wear non-slip gloves to prevent possibility of cuts from sheet metal edges. After the boiler is removed from the shipping carton, DO NOT allow the boiler to sit on its bottom, before stand is installed. Doing so may result in damage to the condensate dish.

1. Carefully remove boiler from styrofoam protective base and set on back. Remove door from front of boiler by loosening screw on top of boiler and unfastening latches on side of cabinet.

2. Remove four (4) 5/16” studs from ﬂ oor stand hardware trim bag. Install studs by hand in rivet nuts on bottom of Evergreen boiler. See Figure 7 .

3. Remove front access panel from stand assembly using 5/16” driver.

4. Align holes in top of stand with studs on bottom of boiler. Slide stand over studs. Remove 5/16” nuts from trim bag. Install nuts on studs using ½” socket or wrench. Make sure to align sides of stand with cabinet before tightening down nuts. Do not overtighten.

5. Install the condensate trap assembly following instructions on page 52

6. After conﬁ rming nuts are tightened, obtain assistance and lift the boiler into upright position.

7. Set boiler in place and level by adjusting leveling legs with ﬂ at head screwdriver.

Figure 7 Floor stand assembly (front access panel

removed)

(9*

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Boiler hydrostatic test

DO NOT install a relief valve with a pressure

higher than 30 PSIG

allowable relief valve setting for the boiler. Failure to comply could prevent the relief valve from operating as needed, resulting in possibility of severe personal injury, death or substantial property damage.

Use two wrenches when tightening any pipe

connection to the boiler

boiler pipes from turning could damage pipes or heat exchanger, resulting in possible severe personal injury, death or substantial property damage.

. This is the maximum

. Failure to prevent the

Hydrostatic pressure test

Pressure test the boiler before permanently attaching water or gas piping or electrical supply.

Install pipe ﬁ ttings for relief valve and P/T gauge

1. Install the reducer bushings (155 only), reducing tees, and close nipples, shipped loose with the boiler, located and oriented as shown in Figure 8, page 14 .

Boilers installed in locations with less than the

RECOMMENDED service clearances will need to adjust piping layout to meet space requirements.

2. Apply pipe dope to all ﬁ ttings sparingly.

DO NOT install the relief valve until after

the hydrostatic test. Temporarily install a ¾" pipe plug in the relief valve location as directed in these instructions. The plug must be removed after the test.

TEMPORARILY insert a ¾" NPT pipe plug in the relief valve

2. tapping. After the hydrostatic test, this plug must be removed and the relief valve must be installed.

Fill and pressure test

1. See Figure 9, page 14 for use with the following instructions.

2. CLOSE the boiler drain valve (item 11). Connect a hose to fresh water supply and to the drain valve.

3. Place a bucket under the ends of the isolation valves (item 9 and 10) to catch water drippings.

4. CLOSE isolation valve item 10, then crack open the valve slightly. Leave isolation valve item 9 open.

5. Slowly open the boiler drain valve (item 11) and fresh water supply to ﬁ ll boiler with water. The boiler and piping will ﬁ ll quickly because of the low water content.

6. When water begins to ﬂ ow from bottom isolation valve (item

10), close the valve.

7. Continue ﬁ lling until water ﬂ ows from top isolation valve (item

9), then close the valve.

8. When pressure on the pressure/temperature gauge (item 4) reaches at least 45 PSIG, but no higher than 55 PSIG, CLOSE the boiler drain valve (item 11).

9. Hold at test pressure for 10 minutes.

Do not leave boiler unattended. A cold water ﬁ ll

could expand and cause excessive pressure, resulting in severe personal injury, death or substantial property damage.

10. Make sure constant gauge pressure has been maintained

throughout test. Check for leaks. Repair if found.

Leaks must be repaired at once. Failure to

do so can damage boiler, resulting in substantial property damage.

Connect the relief valve ONLY on the

BOILER SUPPLY OUTLET, NOT the boiler return. Connect the relief valve only as shown in this manual. Ensure relief valve is located above heat exchanger.

Failure to comply with the above could prevent

the relief valve from operating as needed, resulting in possibility of severe personal injury, death or substantial property damage.

3. Install the pressure/temperature gauge to the reducing tee as shown in Figure 8, page 14 .

Install ﬁ ttings and valves required for hydrostatic testing

1. The following piping components (supplied by installer) are required for the test conﬁ guration:

a. Two shut-off valves (1" NPT on 70/110,

1¼" NPT on 155).

b. Two close nipples (1" NPT on 70/110,

1¼" NPT on 155).

c. ¾" NPT pipe plug.

Part number 550-100-191/0917

Do not use petroleum-based cleaning or sealing

compounds in boiler system. Gaskets and seals in the system may be damaged. This can result in substantial property damage.

Drain and remove ﬁ ttings

1. Disconnect ﬁ ll water hose from water source.

2. Drain boiler through drain valve

Use caution when releasing pressure from the boiler.

Rapid water ﬂ ow could cause injury.

3. Remove hose after draining.

4. Remove nipples and valves unless they will remain for use in the system piping.

5. Remove plug and install relief valve as speciﬁ ed in the following WARNING.

Remove plug from relief valve tee. Install the

relief valve in the ¾" tee. See page 43 or page 48 to install relief valve discharge piping. Failure to install the boiler relief valve could result in severe personal injury, death or substantial property damage.

(item 11).

gas-fired water boiler — 70/110/155 Boiler Manual

Boiler hydrostatic test (continued)

Figure 8 Install pipe ﬁ ttings for relief valve and

pressure/temperature gauge —

NOT mount relief valve until AFTER hydrostatic testing

(see legend below)

Piping to system

Piping from system

Figure 9 Install piping components required for

(155 only)

Recommended but

not included

hydrostatic test (





B



see legend below)

B

C



C



(9*

(155 only)

1 Boiler supply (outlet) connection, (male, 1" NPT )

2 Boiler return (inlet) connection, (male, 1" NPT )

3 Boiler relief valve, shipped loose with boiler — DO NOT mount relief valve until AFTER hydrostatic testing.

3a TEMPORARILY ONLY — Insert a ¾" NPT plug in the relief valve tapping of the reducing tee. This MUST BE REMOVED after

the test and the relief valve mounted here.

4 Pressure/temperature gauge, shipped loose with boiler

5a Reducing tee, NPT, 1 " x 1 " x ¼" on 70/110, & 1 ¼" x 1 ¼" x ¼" on 155, shipped loose with boiler

5b Reducing tee, NPT, 1 " x 1 " x ¾" on 70/110, & 1 ¼" x 1 ¼" x ¾" on 155, shipped loose with boiler

6 Nipple, NPT 1" x close on 70/110, & 1 ¼" x close on 155, shipped loose with boiler

7 Bushing, NPT, 1 ¼" x 1", shipped loose with boiler (155 only)

8 Nipple, NPT 1" x close on 70/110, & 1 ¼" x close on 155, by installer

9 Isolation valve on supply connection, by installer (1" NPT on 70/110, 1¼" NPT on 155)









(9*D

10 Isolation valve on return connection, by installer (1" NPT on 70/110, 1¼" NPT on 155)

11 ¾" NPT boiler drain valve, shipped loose with boiler — after hydrostatic testing, move drain valve to lowest point on the return piping if not

already there.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 70

Prepa re boiler for propane — EVG 70 only (if required)

Propane operation

ALL Evergreen

for propane operation

Converting an existing natural gas-ﬁ red

boiler for propane

installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance and start up the boiler following instructions beginning on page 91 of this manual.

Failure to comply could result in severe personal

Verify 70 propane gas orifice size —

See Figure 10 . Verify when installing that the oriﬁ ce size marking is correct. Oriﬁ ces will be stamped as in illustration or with “3.75” for model 70.

injury, death or substantial property damage.

boilers must be converted

— For a boiler already

Figure 10 Propane gas oriﬁ ce identiﬁ cation

EVG 70 (may be stamped 3.75)

Figure 11 Gas valve and venturi

Installing propane oriﬁ ce — EVG 70 only

If boiler is already installed — You must turn off

electrical supply to the boiler and close the external manual gas shut-off valve to isolate the boiler during conversion. Allow the boiler to cool if it has been operating.

Following conversion of an installed boiler, follow

all instructions in this manual to start up the boiler and verify operation of the boiler and all system components.

1. Locate the propane oriﬁ ce from the propane conversion kit bag.

2. Verify that the stamping on the oriﬁ ce is correct for the model size (see Figure 10 ).

3. If the jacket door is not already removed, remove it.

4. Locate the gas valve and venturi (see Figure 11 ).

5. Pull the gas valve retention ring (item 3, Figure 11 ) off of the gas valve/venturi joint.

6. Carefully pull the gas valve to the right until it is free of the venturi. Leave the pressure reference hose (item 4, Figure 11 ) connected at both ends.

1 Gas valve

2 Venturi

3 Gas valve retention ring

4 Pressure reference hose — LEAVE CONNECTED AT BOTH

ENDS

Support the gas valve after disconnecting

it. DO NOT allow it to hang from the gas valve ﬂ ex line. When re-attaching the gas

valve, ensure the gas valve-to-venturi O-ring (item 5, Figure 12, page 16 ) is in place and in good condition. Inspect the gas valve ﬂ ex line to ensure it is undamaged and in good condition.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 70

Figure 12 Installing the propane gas oriﬁ ce (some details omitted for clarity)

(continued)

7. See Figure 12 . Insert the propane gas oriﬁ ce (item 4) into the gas valve outlet as shown.

8. Press the oriﬁ ce into the gas valve outlet until the bushing ﬂ ange butts against the gas valve outlet.

Inspect the O-rings on the propane gas oriﬁ ce an on the

gas valve outlet (item 5, Figure 12 ). The O-rings must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

9. Reposition gas valve into the venturi and reinstall the gas valve retention ring (item 3, Figure 12 ).

DO NOT ATTEMPT TO MEASURE VALVE OUTLET

PRESSURE.

ﬂ uid contamination. Failure to comply could result in severe personal injury, death or substantial property damage.

10. After installation is complete, attach the propane conversion label (in conversion kit bag) next to the boiler rating plate.

11. Perform complete start-up sequence (beginning on page 91 ), including check for gas leaks and checking for proper operation.

12. Reinstall jacket door.

The valve could be damaged by manometer

LEGEND for Figure 12

1 Gas valve

2 Venturi

3 Gas valve retention ring

4 Propane oriﬁ ce with o-ring

5 Gas valve o-ring

6 Pressure reference hose — LEAVE CONNECTED AT BOTH

ENDS

The jacket door must be in place

during operation.

the boiler with the jacket door removed except for inspection and testing as directed in this manual.

DO NOT operate

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 110

Prepa re boiler for propane — EVG 110 only (if required)

Propane operation

ALL Evergreen

for propane operation

Converting an existing natural gas-ﬁ red boiler for propane

Verify 110 propane gas orifice size —

See Figure 13 . Verify when installing that the oriﬁ ce size marking is correct. Oriﬁ ces will be stamped as in illustration or “3.7” for model

110.

boilers must be converted

— For a boiler already

Figure 13 Propane gas oriﬁ ce identiﬁ cation

EVG 110 (may be stamped 3.7

Figure 14 EVG 110 Gas valve and venturi

only

)

Failure to comply could result in severe personal

injury, death or substantial property damage.

Installing propane oriﬁ ce — EVG 110 only

If the boiler is already installed — You must turn

off electrical supply to the boiler and close the external manual gas shut-off valve to isolate the boiler during conversion. Allow the boiler to cool if it has been operating.

Following conversion of an installed boiler, follow

all instructions in this manual to start up the boiler and verify operation of the boiler and all system components.

1. Locate the propane oriﬁ ce from the propane conversion kit bag.

2. Verify that the stamping on the oriﬁ ce is correct for the model size (see Figure 13 ).

3. If the jacket door is not already removed, remove it.

4. Locate the gas valve and venturi (see Figure 14 ).

5. Release the gas line from the silencer bracket clip (item 5, page

18) and rotate it out of the way.

6. Use a T25-mm torx bit to remove the two (2) bolts (item 3) that secure the gas valve to the venturi.

1 Gas valve 2 Venturi 3 Gas valve screws to venturi

Support the gas valve after disconnecting

it. DO NOT allow it to hang from the gas valve ﬂ ex line. When re-attaching the gas

valve, ensure the gas valve propane oriﬁ ce is properly seated in rubber boot (item 6, Figure 15, page 18 ) and is in place and in good condition. Inspect the gas valve ﬂ ex line to ensure it is undamaged and in good condition.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 110

Figure 15 EVG-110 -Installing the propane gas oriﬁ ce (some details omitted for clarity)

(continued)

7. See Figure 15 , Carefully pull the gas valve down until it is free of the venturi. Securely support the gas valve — DO NOT leave it dangling.

8. Remove the rubber boot from the gas valve or venturi.

9. Insert the propane gas oriﬁ ce into the rubber boot. Oriﬁ ce must be seated into the inner groove inside the center of the rubber boot.

10. Install the rubber boot (item 6) guaranteeing that it is ﬁ rmly seated on the gas valve opening.

When re-attaching the gas valve, ensure the gas

valve rubber boot (item 6, Figure 15 ) is in place and in good condition. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

11. Reposition gas valve onto the venturi and reinstall the gas valve retention bolts (item 3). Make sure the rubber boot is fully seated on both the gas valve and venturi.

12. Swing the silencer bracket clip (item 5) back into position and snap on to the gas line.

DO NOT ATTEMPT TO MEASURE VALVE

OUTLET PRESSURE.

damaged by manometer fluid contamination. Failure to comply could result in severe personal injury, death or substantial property damage.

The valve could be

LEGEND for Figure 15

1 Gas valve 2 Venturi 3 Bolts (2) for attaching gas valve to venturi 4 Blower 5 Air silencer bracket clip 6 Propane oriﬁ ce with boot

13. After installation is complete, attach the propane conversion label (in conversion kit bag) next to the boiler rating plate.

14. Perform complete start-up sequence (beginning on page 91 ), including check for gas leaks and checking for proper operation.

15. Reinstall jacket door.

The jacket door must be in place during

operation.

with the jacket door removed except for inspection and testing as directed in this manual.

DO NOT operate the boiler

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 155

Prepa re boiler for propane — EVG 155 only (if required) Propane operation

ALL Evergreen

for propane operation

Failure to comply could result in severe personal

Converting an existing natural gas-fired boiler for propane

Verify propane gas orifice size — See

Figure 16 . Verify when installing that the oriﬁ ce size marking is correct. Oriﬁ ce will be stamped as in illustration.

injury, death or substantial property damage.

boilers must be converted

— For a boiler already

Installing propane oriﬁ ce — EVG 155 only

If boiler is already installed — You must turn off

electrical supply to the boiler and close the external manual gas shut-off valve to isolate the boiler during conversion. Allow the boiler to cool if it has been operating.

Following conversion of an installed boiler, follow

all instructions in this manual to start up the boiler and verify operation of the boiler and all system components.

1. Locate the propane oriﬁ ce from the propane conversion kit bag.

2. Verify that the stamping on the oriﬁ ce is correct for the model size (see Figure 16 ).

3. If the jacket door is not already removed, remove it.

4. See Figure 17, page 20 and Figure 18, page 20 for the following.

5. Locate the gas valve and venturi (items 1 and 3).

6. Release the gas line to silencer bracket (item 6) from the gas line and rotate it forward out of the way.

7. Use a 5mm hex wrench to remove the three (3) Allen screws (item 2) that secure the gas valve to the venturi.

8. See Figure 18, page 20 . Carefully pull the gas valve to the right until it is free of the venturi. Securely support the gas valve — DO NOT leave it dangling.

Figure 16 Propane gas oriﬁ ce identiﬁ cation

EVG 155

Support the gas valve after

disconnecting from the venturi. DO NOT allow it to hang from the gas valve ﬂ ex line.

valve, ensure the gas valve grommet (item 8, Figure 18, page 20 ) is in place and in good condition. Inspect the gas valve ﬂ ex line to ensure it is undamaged and in good condition.

9. Insert the propane gas oriﬁ ce (item 7) into the gas valve opening as shown in Figure 18, page 20 .

10. Make sure that the rubber grommet (item 8) is ﬁ rmly seated in the gas valve opening.

When re-attaching the gas valve, ensure the

gas valve grommet (item 8, Figure 18, page 20 ) is in place and in good condition. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

11. Reposition gas valve onto the venturi and reinstall the gas valve retention screws (item 2).

12. Swing the gas line to silencer bracket (item 6) back into position and snap onto the gas line.

DO NOT ATTEMPT TO MEASURE VALVE

OUTLET PRESSURE.

damaged by manometer ﬂ uid contamination. Failure to comply could result in severe personal injury, death or substantial property damage.

13. After installation is complete, attach the propane conversion label (in conversion kit bag) next to the boiler rating plate.

14. Perform complete start-up sequence (beginning on page 91 ), including check for gas leaks and checking for proper operation.

15. Reinstall jacket door.

When re-attaching the gas

The valve could be

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Converting boiler to propane — EVG 155 (continued)

Figure 17 Installing the propane gas oriﬁ ce (some details omitted for clarity)

LEGEND for Figure 17 and Figure 18

1 Venturi (leave venturi attached to blower)

2 (3) hex-head screws, 5 mm hex (remove and retain)

3 Gas valve

4 Air silencer (leave connected to venturi)

5 Flexible gas line

6 Gas line to silencer bracket (rotate forward before disconnecting gas valve

from venturi

7 Propane oriﬁ ce (in propane conversion kit envelope)

8 Rubber grommet (must be installed in valve for all applications) — make

sure grommet is properly seated in valve before inserting the propane oriﬁ ce

The jacket door must be in place during

operation.

DO NOT operate the boiler with the jacket door removed except for inspection and testing as directed in this manual.

Figure 18 Gas valve and venturi

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Gas piping — sizing gas lines

Boiler gas connection is ½" NPT. Size gas lines large

enough to provide gas to all connected appliances.

Natural Gas:

Pipe sizing for natural gas

1. Size gas piping from meter outlet to entrance of boiler in accordance with Figure 19 and Figure 20 .

2. Use total input of all connected appliances. Divide total input in Btuh by 1,000 to obtain cubic feet per hour of natural gas.

a. Pipe lengths in Figure 19 are equivalent length of straight

pipe. Convert pipe ﬁ ttings to equivalent lengths using data from Figure 20 .

b. Figure 19 is only for natural gas with speciﬁ c gravity 0.60,

with a pressure drop through the gas piping as listed in the table.

c. For additional gas pipe sizing information, refer to ANSI

Z223.1 NFPA 54 - latest edition (or Natural Gas and Propane Installation CAN/CSA B149.1 or B149.2 for Canadian installations).

Natural gas s upply pressure

1. Pressure required at gas valve inlet pressure port: a. Maximum: 13" (330 mm) w.c. with no ﬂ ow (lockup). b. Minimum gas pressure, with gas ﬂ owing (verify during

boiler startup, while boiler is at high ﬁ re):

EVG 70: 3½" (89 mm) w.c. EVG 110: 3½" (89 mm) w.c. EVG 155: 3½" (89 mm) w.c.

c. Nominal gas pressure: 7.0" (178 mm) w.c.

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 13" w.c. at any time. Adjust lockup regulator for 13" w.c. maximum.

Propane Gas:

You must follow the instructions, beginning on

page 15 , to operate the boiler on propane. Failure to comply could result in severe personal injury, death or substantial property damage.

Figure 19 Pipe capacity for 0.60 speciﬁ c gravity

natural gas; pipe length is in equivalent feet.

Gas

Cubic feet per hour, natural gas, 0.60 speciﬁ c gravity

pipe total

length,

feet

10 132 278 520 1050 1600 3050 4800

20 92 190 350 730 1100 2100 3300

30 73 152 285 590 890 1650 2700

40 NA 130 245 500 760 1450 2300

50 NA 115 215 440 670 1270 2000

75 NA 105 175 360 545 1020 1650

100 NA 96 150 305 460 870 1400

150 NA 90 120 250 380 710 1130

Gas pressure 13" (330 mm) w.c. or less Pressure drop 0.3 inches (7.6 mm) w.c

½" ¾" 1" 1¼" 1½" 2" 2½"

Capacity

Figure 20 Equivalent lengths of straight pipe for

typical gas line ﬁ ttings.

Equivalent length, feet

Pipe size

inches

90° Elbow Tee

short

radius

3.6 2.2 1.7 4.2

4.4 2.3 2.4 5.3

5.2 2.7 3.2 6.6

long

radius

line

ﬂ ow

branch

ﬂ ow

Pipe sizing for propane gas

1. Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

Propane supply pressure

1. Adjust propane supply regulator provided by gas supplier for 13" (330 mm) w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port: a. Maximum: 13" (330 mm) w.c. with no ﬂ ow (lockup). b. Minimum gas pressure, with gas ﬂ owing (verify during

boiler startup, while boiler is at high ﬁ re):

EVG 70: 3½" (89 mm) w.c. EVG 110: 3½" (89 mm) w.c. EVG 155: 3½" (89 mm) w.c.

c. Nominal gas pressure: 11.0" (279 mm) w.c.

Part number 550-100-191/0917

1¼

1½

2½

6.6 3.2 4.6 8.7

7.4 3.4 5.6 9.9

8.5 3.6 7.7 12.0

9.3 4.0 9.3 13.0

gas-fired water boiler — 70/110/155 Boiler Manual

Venting/air piping — general

Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54- latest edition, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. 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 Chapter 13 of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 - latest edition, and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1.

Do not install the Evergreen® boiler into a common vent

with any other appliance. This will cause ﬂ ue gas spillage or appliance malfunction, resulting in possible severe personal injury, death or substantial property damage.

Existing common vent systems may be too large for the

appliances remaining connected after the existing boiler is removed.

Failure to follow all instructions can result in ﬂ ue gas spillage

and carbon monoxide emissions, causing severe personal injury or death.

When removing a boiler from an existing common vent system

The Evergreen® boiler cannot be common vented with any other appliance

. When an existing boiler is replaced with an Evergreen® boiler,

the Evergreen® boiler CANNOT use the existing common vent. The boiler requires its own vent and air piping, as speciﬁ ed in this manual. This may cause a problem for the appliances that remain on the old common vent, because the vent may be too large. The following test is intended to check for proper operation of the appliances remaining on the old common vent system.

Vent system veriﬁ cation

Perform the test sequence below for each appliance remaining on the original common vent system. Operate each appliance individually, with other appliances turned off. This procedure will test whether the common vent system can properly vent each appliance.

Existing vent test procedure

(The following is intended to test whether the appliances remaining on an existing vent system will operate satisfactorily.)

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

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

3. Test vent system — 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 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 ﬁ replace dampers.

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

5. Test for spillage at draft hood relief opening after 5 minutes of main burner operation. Use the ﬂ ame of a match or candle, or 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 herein, return doors, windows, exhaust fans, ﬁ replace dampers, and any other gas-burning appliance to their previous conditions of use.

You must pipe combustion air to the

boiler air intake

Install air inlet piping for the Evergreen

boiler as described in this manual.

The air termination fitting must

be installed with the clearances and geometry relative to the vent outlet depicted in this manual to ensure that ﬂ ue products do not enter the air intake.

Ensure that the combustion air will

not contain any of the contaminants in Figure 16. Do not pipe combustion air near a swimming pool, for example. Avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

Contaminated combustion air will

damage the boiler, resulting in possible severe personal injury, death or substantial property damage.

Figure 21 Corrosive contaminants and sources

Products to avoid

Spray cans containing chloro/ﬂ uorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms

Adhesives used to fasten building products and other similar products

Excessive dust and dirt

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture reﬁ nishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Venting & air — general (continued)

Figure 22 Evergreen

The table below lists the acceptable vent/air pipe terminations described in this manual. Follow all instructions provided to install the vent/air system. For these applications, use ONLY the manufacturers’ parts listed and follow all instructions provided by the pipe manufacturer.

Maximum vent and air pipe length = 100 feet for all applications

(All applications include allowance for the termination ﬁ ttings plus one elbow in air piping and one elbow in vent piping).

See Figure23,page24 for material speci cations | See Figure110,page127 for part/kit numbers

If using 2" pipe, provide 3"x 2" tapered reducers at boiler connections and at Weil-McLain vent/air cap or at concentric terminations.

Boilers will derate as vent/air pipe length increases — see rating data on Figure123,page139 for derate amounts.

Model

Separate pipes

[Note 1]

Evergreen

venting and air piping — DIRECT VENT ONLY — OPTIONS and PIPING LIMITS

NOT SHOWN below, but also approved, are the polypropylene piping and terminations listed in Figure 23, page 24 .

USE SWEEP

(Minimum length for all applications is 2 feet)

ELBOWS

ONLY

Vent and air pipe sizes:

Maximum vent lengths apply for either 2" or 3" vent and air pipe.

SIDEWALL termination VERTICAL termination

PVC or PP Concentric

[Note 1]

3” Weil-McLain PVC

vent/air cap [Note 1]

Separate pipes

[Note 1]

PVC or PP Concentric

[Note 1]

See page 28 See page 30 See page 32 See page 32 See page 36

Size,

inches

110

155

Equivalent feet for elbows (USE SWEEP ELBOWS ONLY) —

• 7 feet per for each additional 90° sweep elbow or 45° elbow —

Note 1:

** Model 155 may be concentric sidewall vented using Centrotherm polypropylene pipe (Eco Systems InnoFlue® Single-wall) ONLY

if using Centrotherm stainless steel concentric termination kit, part number ICWS3513.

Material abbreviations: PP = polypropylene, SS = AL29-4C stainless steel If using polypropylene or stainless pipe, provide adapters to for 3” boiler connections and for terminations, if required

IPEX 3” PVC concentric vent kits can be used with standard PVC pipe, ﬁ ttings and cement (ANSI/ASTM D1785) except if ULC S636 compliance is required. For ULC S636 compliance, all pipe, ﬁ ttings and cement must be IPEX System 636. If using IPEX kits, use only IPEX product code 196006 for 3” venting. Contact Weil-McLain for ordering information and availability of Weil-McLain venting kits.

Materials

Fig. 23, page 24

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

All elbows in vent and air piping must be sweep elbows ONLY. DO NOT use short-radius elbows. When

transitioning to 3" to 2", use tapered reducer with 3" PVC nipple (L  6"). Do not use 3" to 2" bushing. Bushings will not seal in boiler adapters.

Size,

inches

Materials

Fig. 23, page 24

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC Concentric

only

PVC/PVC-DWV

CPVC, SS, PP**

Size,

inches

––3

deduct from max. equivalent length of piping (does not apply to termination ﬁ ttings).

If piping contains more than 1 elbow in air or vent piping, other than termination ﬁ ttings.

Materials

Fig. 23, page 24

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

Size,

inches

Materials

Fig. 23, page 24

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

Size,

inches

Materials

Fig. 23, page 24

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, PP, SS

PVC/PVC-DWV

CPVC, SS,

Note 2: Use only Weil-McLain approved termination kits listed in Figure 110, page 127

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Venting & air — general (continued)

Figure 23 Vent and air piping materials — Use only the materials listed below, ensuring that all materials meet

local codes (see Figure 110, page 127 for part/kit numbers)

Item Material

Plastic piping materials Vent or air piping

Vent or air pipe

ﬁ ttings

PVC & ABS pipe cement & primer

Polypropylene

vent pipe, ﬁ ttings,

terminations and

cement

Simpson-Duravent — Obtain all materials from M&G

Simpson-Duravent

Centrotherm Eco Systems InnoFlue

Obtain all materials from Centrotherm Note: See page 127 for correct appliance adapters to be used.

PVC-DWV schedule 40 (Note 1) ANSI/ASTM D2665 NA

CPVC schedule 40 (Note 1) ANSI/ASTM F441 ULC S636

PVC schedule 40 ANSI/ASTM D1785 ULC S636

PVC ANSI/ASTM D2564/F656 ULC S636

CPVC (Note 1) ANSI/ASTM F493 ULC S636

See manufacturer’s literature for

Single-wall —

detailed information

MUST USE LOCKING

COLLAR ON EVERY JOINT

Standards for installations in:

United States Canada

Vent

piping

ULC S636

(Note 2)

Air

piping

PVC, PVC-DWV,

CPVC or

polypropylene

Use only cement and primer suitable for piping material used

PVC, PVC-DWV,

CPVC or

polypropylene

AL29-4C stainless steel piping materials

Certiﬁ ed for Category IV and direct vent appliance venting

Vent pipe

AL29-4C

stainless

steel

Heat Fab, Inc. — Saf-T-Vent

Z-Flex, Inc. — Z-Vent II

Dura-Vent — FasNSeal™

Metal-Fab, Inc. — CORR/GUARD

Centrotherm Eco Systems — InnoFlue

Weil-McLain stainless steel bird screens, 2" or 3" (purchase separately) — see Figure 110, page 127 for part numbers

Note 1: Weil-McLain concentric vent kits are made from PVC pipe

and  ttings.

Note 2: System 636 PVC concentric terminations utilize PVC

pipe/ ttings certi ed to ULC S636. If ULC S636 compliance is required, use only System 636 pipe,  ttings and cement.

DO NOT mix piping from di erent pipe manufacturers

unless using adapters speci cally designed for the purpose by the manufacturer.

Every joint on polypropylene vent piping must include

ADAPTERS — Polypropylene piping — Provide adapters

ADAPTERS — AL29-4C piping — Install a PVC-to-stainless

adapter supplied by the AL29-4C stainless pipe manufacturer at the 3" PVC boiler vent connection and at the termination (if using Weil-McLain plate or concentric PVC termination).

from polypropylene pipe to the 3" PVC connections at the boiler and at terminations, if required (Weil-McLain sidewall plate, for example).

a locking collar.

DO NOT use cellular core PVC (ASTM F891), cellular core

CPVC, or Radel® (polyphenolsulfone) in venting systems.

DO NOT cover non-metallic vent pipe and  ttings with

thermal insulation.

ADAPTERS — If using 2" piping, where approved for

the application, provide adapters for the 3" PVC boiler connections and at the terminations, if required (WeilMcLain sidewall plate, for example)

USE SWEEP ELBOWS FOR ALL VENT AND AIR PIPING — DO NOT use short

radius elbows for vent or air piping. Boiler performance could be a ected.

ALL vent and air pipes require a BIRD SCREEN at each termination. Most kits do not include

the bird screens. Purchase bird screens separately from Weil-McLain or vent kit supplier if not included. [Note — bird screening is integral to the 3" PVC Weil-McLain sidewall vent cap,

available for purchase from Weil-McLain

. No additional screening is required.]

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Commonwealth of Massachusetts installations

Commonwealth of Massachusetts — When the boiler is installed within the Commonwealth of Massachusetts,

the boiler must be installed by a licensed plumber or gas ﬁ tter. Read and comply with the instructions below.

(a) For all sidewall horizontally-vented gas-fueled equipment

installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above ﬁ nished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisﬁ ed:

INSTALLATION OF CARBON MONOXIDE DETECTORS.

At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂ oor level where the gas equipment is to be installed. In addition, the installing plumber or gas ﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equipment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas

fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent ﬂ oor level.

b. In the event that the requirements of this subdivision

can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

APPROVED CARBON MONOXIDE DETECTORS. Each

carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certiﬁ ed.

SIGNAGE. A metal or plastic identiﬁ cation plate shall

be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS.”

INSPECTION. The state or local gas inspector of the

side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

(b)

EXEMPTIONS: The following equipment is exempt from

248 CMR 5.08(2)(a)1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c)

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT VENTING SYSTEM PROVIDED

of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for the installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d)

MANUFACTURER REQUIREMENTS — GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED

of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the ﬂ ue gases, but identiﬁ es “special venting systems”, the following requirements shall be satisﬁ ed by the manufacturer:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved

side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

. When the manufacturer

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Vent termination requirements

Figure 24 The vent termination must be located to meet all requirements below (also applies to vertical vent terminations). The minimum distance from

adjacent public walkways, adjacent buildings, openable windows and building in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. The vent termination clearances below are for U.S.A., for Canadian vent termination clearances please refer to the requirements of CAN/CSA B149.1 Natural Gas and Propane Installation Code. Consideration should be given to avoid possible damage caused by vent plumes and condensate when choosing a venting conﬁ guration and location. Maintain a minimum clearance of 4 ft. (1.22m) horizontally from, and in no case above or below, unless a 4 ft. (1.22m) horizontal distance is maintained, from electrical meters, gas meters, regulators, and relief equipment.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

Boiler room air openings

Figure 25 Combustion and ventilation air openings for Direct Vent installations, also follow the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 - latest edition, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or applicable provisions of the local building codes.

The Evergreen® boiler CANNOT be in the same space with other appliances if clearances around the Evergreen®

are less than the recommended service clearances shown in Figure 1, page 9 .

Air openings

The required air opening sizes below are FREE AREA, after reduction for louver obstruction. Note the exception below for large spaces.

Evergreen

boiler

WITH other

appliances in room

TWO openings, each at least:

1 square inch per 1,000 Btuh

of all other appliances in the room

(Unless speciﬁ ed otherwise by

appliance manufacturer)

TWO openings, each at least:

1 square inch per 4,000 Btuh

of all other appliances in the room

ONE opening **, each at least:

1 square inch per 3,000 Btuh

of all other appliances in the room

(Unless speciﬁ ed otherwise by

appliance manufacturer)

TWO openings, each at least:

1 square inch per 4,000 Btuh

of all other appliances in the room

ONE opening **, each at least:

1 square inch per 3,000 Btuh

of all other appliances in the room

(Unless speciﬁ ed otherwise by

appliance manufacturer)

— OR —

Evergreen® boiler

WITHOUT other

appliances in room

NO openings are required if the boiler installation provides at least the recommended service clearances shown in

If the space is smaller than

Figure 1, page 9 , provide openings

ONLY as shown in

Each opening must have a free area no less than 1 square inch per 1,000 Btuh input of the boiler.

Figure 1, page 9 .

Figure 2, page 9 .

** NOTICE: Requirements for using the SINGLE air opening option.

SPECIAL EXCEPTION FOR LARGE SPACES (

EVG WITH other appliances in room only):

Part number 550-100-191/0917

TWO openings, each at least:

1 square inch per 2,000 Btuh

of all other appliances in the room

ONE opening **, each at least:

1 square inch per 3,000 Btuh

of all other appliances in the room

(Unless speciﬁ ed otherwise by

appliance manufacturer)

A single combustion air opening can be used for cases b, c or d above (EVG with other appliances in room only), sized as listed, provided that:

• The single opening must communicate directly to the outdoors or to a space that

communicates directly with outdoors (NOT to an interior space).

• The top of the opening must be within 12 inches of the ceiling.

• The free area of the opening must be at least equal to the sum of the areas of all

equipment vent connectors in the space.

NO combustion air openings are needed if the boiler (and other appliances) are installed in a space with a volume NO LESS than 50 cubic feet per 1,000 Btuh of all appliances in the space. That is, total the input of all appliances in MBH (1,000’s of Btuh), then multiply this total times 50. The building MUST NOT be of tight construction.

Example: For a total input of 500 MBH (500,000 Btuh), the minimum volume would be 50 x 500 = 25,000 cubic feet.

— OR —

gas-fired water boiler — 70/110/155 Boiler Manual

DIRECT VENT — Sidewall with separate pipes

Allowable vent/air pipe materials & lengths

Use only the vent materials and kits

listed in Figure 23, page 24 . Provide pipe adapters if speciﬁ ed.

1. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 22, page 23 .

For polypropylene applications,

comply with any additional requirements in the vent system manufacturer’s instructions. Provide 3" PVC transition pieces at the boiler vent and air connections. Install a locking collar at every joint.

For AL29-4C vent pipe applications,

comply with any additional requirements in the vent system manufacturer’s instructions. Provide a 3" PVC transition piece at the boiler vent connection. The air piping must be PVC or CPVC. Provide a 3" PVC transition piece at the boiler air connection if using 2" air piping.

Determine termination location

1. The air and vent terminations must be installed as shown in Figure 26 and Figure 28, page 29 .

2. The terminations must comply with clearances and limitations shown in Figure 24, page 26 .

3. Locate the terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Do not exceed the maximum

lengths of the outside vent piping shown in Figure 26 . Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown. In extremely cold climates, install an insulated chase around the vent piping, particularly if using longer lengths. The chase must allow for inspection of the vent pipe, and insulation must be protected from water.

Multiple vent/air terminations

1. When terminating multiple boilers, terminate each vent/air connection as described in this manual.

All vent pipes and air inlets must

terminate at the same height to avoid possibility of severe personal injury, death or substantial property damage.

Figure 26 INSTALLATION SEQUENCE — Separate pipes sidewall

Step 1 Read and follow all instructions in this manual. DO NOT proceed with

Step 2 Install the boiler in a location that allows proper routing of all vent and air

Step 3 Make sure the selected sidewall termination location complies with

vent/air installation until you have read page 22 through page 27 .

See notices at left.

piping to the selected sidewall location.

Figure 24, page 26 . (Multiple boiler sidewall plates must also comply with

Figure 27, page 29 .)

Step 4 Use only the vent materials listed in Figure 23, page 24 . Provide pipe adapters

Step 5 Prepare the sidewall penetrations and secure the sidewall plates as instructed

Step 6 The air piping must terminate in a down-turned elbow as shown above.

Step 7 Install vent and air piping between the boiler and the sidewall openings.

Step 8 Install pipe supports every 5 feet on both the horizontal and vertical runs.

Step 9 Attach the vent termination exterior piping: Use either of the conﬁ gurations

Step 10 The vent and air pipes may run up as high as 4 feet with no enclosure.

Step 11 External venting greater than 4 feet requires an insulated enclosure around

where required. Vent piping and air piping lengths must not exceed the values shown in

in this section. See “Prepare wall penetrations” on page 29 . See notices at left.

The vent piping must terminate in an elbow pointed outward or away from the air inlet as shown above. See illustration above.

Slope horizontal piping downward toward the boiler at least 1/4 inch per foot. See

Install a hanger support within 6 inches of any upturn in the piping, or per vent pipe manufacturer’s instructions.

shown above, as needed to ensure clearance above grade or snow line.

The vent and air pipes must be secured with braces, and all clearances and lengths must be maintained. Space braces no further than 24 inches apart.

the vent and air pipes. The vent and air terminations must exit through the enclosure as shown in the illustration above, maintaining all required clearances.

Figure 22, page 23 .

page 39 for general guidelines. See notices at left.

See notices at left.

USE SWEEP ELBOWS FOR ALL VENT AND AIR PIPING

— DO NOT use short radius elbows for vent or air piping. Boiler performance could be affected.

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

DIRECT VENT — Sidewall with separate pipes (continued)

See notices on previous page.

2. Place wall penetrations to obtain minimum clearances shown in Figure 27 for U. S. installations. For Canadian installations, provide clearances required by CSA B149.1 or B149.2 Installation Code and a ULC S636 compliant vent kit.

3. The air inlet of a boiler is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Prepare wall pe netrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as

desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or

noncombustible construction, size the vent pipe hole at least

0.4" larger than the vent pipe diameter.

b. Insert a corrosion resistant metal thimble in the vent pipe hole

as shown in Figure 28 .

3. Use the provided paper template for correct location of hole centers.

4. Use of a sidewall termination plate is REQUIRED. a. Kits for several vent sizes are available from Weil-McLain.

See “VENT/AIR PARTS AND KITS” on page 127 .

b. Plate may be ﬁ eld fabricated from corrosion resistant material

of sufﬁ cient strength. Plate must allow venting to maintain minimum clearance to combustibles.

Ensure that the plate material is strong enough to prevent

the termination from being pushed inward if struck or pushed from the outside.

5. Follow all local codes for isolation of vent pipe when passing through ﬂ oors or walls.

6. Seal exterior openings thoroughly with exterior caulk.

Figure 27

Multiple separate pipes sidewall terminations — maintain vertical spacing between vent and air ﬁ ttings shown in Figure 26, page 28

Termination and ﬁ ttings

1. Prepare the vent termination elbow and the air termination elbow by inserting bird screens. (See Figure 26, page 28 .) Bird screens must be purchased separately. See the parts list at the end of this manual for part numbers.

2. Secure the elbows so they will butt against the sidewall termination plate.

3. When completed, the air termination coupling must be oriented at least 12 inches below the vent termination and at least 12 inches above grade or snow line as shown in Figure 26, page 28 .

4. You can orient the vent termination elbow either directly outward or 90 degrees away from the air inlet elbow as shown in Figure 26, page 28 .

5. Maintain the required dimensions of the ﬁ nished termination piping as shown in Figure 26, page 28 .

6. For multiple boiler terminations, see Figure 27 .

7. Do not extend exposed vent pipe outside of building more than shown in this document. Condensate could freeze and block vent pipe.

If extending the vent and air pipes out from the wall,

install a coupling on each pipe. Mount the piping with the coupling ﬂ ush with the outer plate.

Figure 28 Sidewall termination assembly — using

separate pipes

1 Vent piping

2 Air piping

3 Sidewall termination plates: for 3" PVC,

use plates supplied with boiler in W-M vent/air plate kit; for 3" AL29-4C or 2" PVC, purchase optional sidewall separate pipes plate kit

4 Corrosion resistant thimbles,

by installer 5 Bird screen, by installer 6 Air inlet elbow 7 Elbow 8 Nipple 9 Elbow (vent termination)

Part number 550-100-191/0917

gas-fired water boiler — 70/110/155 Boiler Manual

DIRECT VENT — Sidewall concentric

Allowable vent/air pipe materials & lengths

1. The concentric termination kit must be purchased separately.

Use only the vent materials and kits

listed in Figure 23, page 24 . Provide pipe adapters if speciﬁ ed.

2. Locate the termination such that the total air piping and vent piping from the boiler to the termination will not exceed the maximum length given in Figure 22, page 23

3. This termination requires a 45-degree elbow that is not supplied with the termination kit. The maximum vent/air pipe lengths include allowance for this elbow.

For polypropylene applications, comply

with any additional requirements in the vent system manufacturer’s instructions. Provide 3" PVC transition pieces at the boiler vent and air connections and at the termination if using a 3" PVC concentric vent kit. Install a locking collar at every joint.

For AL29-4C vent pipe applications,

comply with any additional requirements in the vent system manufacturer’s instructions. Provide a 3" PVC transition at the boiler vent connection. Air pipe must be PVC or CPVC. Provide a 3" PVC transition at the boiler air connection if using 2" air pipe. Provide transition pieces to PVC at the vent and air pipe termination connections.

Determine termination location

1. The concentric termination kit must be installed as shown in Figure 31, page 31 .

2. The termination must comply with clearances and limitations shown in

Figure 24, page 26

3. Locate the termination so it is not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Multiple vent/air terminations

1. When terminating multiple boilers, install each concentric termination as described in this manual.

All vent pipes and air inlets must

terminate at the same height to avoid possibility of severe personal injury, death or substantial property damage.

2. Place wall penetrations to obtain minimum clearance as shown in Figure 30, page 31 for U. S. installations. For Canadian installations, provide clearances required by CSA B149.1 or B149.2 Installation Code and a ULC S636 compliant vent kit.

3. The air inlet of a boiler is part of a direct vent connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Figure 29 INSTALLATION SEQUENCE — Concentric horizontal

Step 1 Read and follow all instructions in this manual. DO NOT proceed

Step 2 Install the boiler in a location that allows proper routing of all vent

Step 3 Make sure the selected sidewall termination location complies with

with vent/air installation until you have read page 22 through page 27 .

and air piping to the selected sidewall location.

See notices at left.

Figure 24, page 26 . (Multiple boiler concentric terminations must also

comply with Figure 30, page 31 .)

Step 4 Use only the vent materials listed in Figure 23, page 24 . Provide pipe

Step 5 Vent piping and air piping lengths must not exceed the values shown

Step 6 The concentric termination must be assembled and installed before

Step 7 Prepare the sidewall penetration — assemble the concentric

Step 8 Install vent and air piping between the boiler and the concentric vent/

Step 9 Install pipe supports every 5 feet on both the horizontal and vertical

Step 10 Install a hanger support within 6 inches of any upturn in the piping.

adapters where required.

Figure 22, page 23 .

piping from the boiler to the termination.

termination kit and secure the cover plates as instructed in this section. Provide the supports indicated and mount the termination assembly. See “Install termination — concentric pipes” on page 31 .

air termination. Slope horizontal piping downward toward the boiler at least 1/4 inch per foot. See page 39 for general guidelines.

runs.

See notices at left.

USE SWEEP ELBOWS FOR ALL VENT AND AIR

PIPING — DO NOT use short radius elbows for vent or

air piping. Boiler performance could be affected.

Part number 550-100-191/0917

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