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SAFE INSTALLATION, USE AND SERVICE.......................................................................................................................................................................... 2
GENERAL SAFETY................................................................................................................................................................................................................ 3
TABLE OF CONTENTS .......................................................................................................................................................................................................... 4
DIMENSIONS AND CAPACITY DATA .................................................................................................................................................................................... 5
INTRODUCTION .................................................................................................................................................................................................................... 7
Grounding Instructions ................................................................................................................................................................................................... 7
Correct Gas .................................................................................................................................................................................................................... 7
Precautions ....................................................................................................................................................................................................................7
Liquid Petroleum Gas Models ........................................................................................................................................................................................ 7
High Altitude Installations ............................................................................................................................................................................................... 7
CONTROLS AND FUNCTION ................................................................................................................................................................................................ 8
High Limit .......................................................................................................................................................................................................................8
Intermittent Ignition Control Module ............................................................................................................................................................................... 8
Thermal Balancer ........................................................................................................................................................................................................... 9
Auto Reset High Limit Control ........................................................................................................................................................................................ 9
Safety Flow Switch ......................................................................................................................................................................................................... 9
Safety Relief Valves...................................................................................................................................................................................................... 10
Tank Temperature Control .............................................................................................................................................................................................11
Thermometers (not installed) ....................................................................................................................................................................................... 12
DRAIN VALVE ......................................................................................................................................................................................................................12
GENERAL ............................................................................................................................................................................................................................ 12
Required Ability ............................................................................................................................................................................................................ 12
Location ........................................................................................................................................................................................................................12
Air Requirements .......................................................................................................................................................................................................... 13
Chemical Vapor Corrosion............................................................................................................................................................................................ 13
Installation Clearances ................................................................................................................................................................................................. 14
Leveling ........................................................................................................................................................................................................................ 14
System Connections .................................................................................................................................................................................................... 14
VENTING ............................................................................................................................................................................................................................. 14
Venting the Boiler ......................................................................................................................................................................................................... 14
Venting Maintenance ....................................................................................................................................................................................................16
Venting Sidewall ........................................................................................................................................................................................................... 16
Venting System ............................................................................................................................................................................................................ 16
Venting Tables ..............................................................................................................................................................................................................17
SYSTEM INSTALLATIONS .................................................................................................................................................................................................. 18
Installations ..................................................................................................................................................................................................................18
Conventional ........................................................................................................................................................................................................ 18
Linear Temp .......................................................................................................................................................................................................... 18
Water Supply Line ................................................................................................................................................................................................19
Expansion Tank .................................................................................................................................................................................................... 19
Vent Valves ........................................................................................................................................................................................................... 20
Manifold Headers .................................................................................................................................................................................................20
Cooling Piping ......................................................................................................................................................................................................20
Circulating Pump .................................................................................................................................................................................................. 20
Gas Connections ..........................................................................................................................................................................................................20
Gas Supply Line Purging and Sizing ............................................................................................................................................................................21
Gas Pressure Regulators ............................................................................................................................................................................................. 22
WIRING ................................................................................................................................................................................................................................23
WIRING DIAGRAMS .......................................................................................................................................................................................................24-33
PIPING ............................................................................................................................................................................................................................34-39
OPERATION AND START-UP INSTRUCTIONS .................................................................................................................................................................. 39
Important ...................................................................................................................................................................................................................... 39
Filling the System ......................................................................................................................................................................................................... 39
Pilot Alignment and Main Burner ..........................................................................................................................................................................................39
Lighting Instructions ................................................................................................................................................................................................43-44
Checking and Adjusting Input .......................................................................................................................................................................................41
Operating Sequence ....................................................................................................................................................................................................42
REMOVAL OF EXISTING BOILER FROM A COMMON VENTING SYSTEM ..................................................................................................................... 45
GENERAL MAINTENANCE ................................................................................................................................................................................................. 45
Cleaning and Flushing Instructions ...................................................................................................................................................................................... 46
PRE TROUBLESHOOTING ................................................................................................................................................................................................. 46
TROUBLESHOOTING ....................................................................................................................................................................................................47-54
LIMITED WARRANTY .......................................................................................................................................................................................................... 55
TABLE OF CONTENTS