2
90 125-200 cast alUMiNUM Boiler
InstallatIon Manual and opERatIng InstRuctIons
taBle oF coNteNts
I. Introduction ............................................................. 2
II. Safety Symbols...................................................... 2
III. Rules For Safe Installation and Operation .............. 3
IV. Boiler Ratings and Capacities .............................. 4
V. Before Installing The Boiler ................................... 5
VI. Placing The Boiler ................................................ 9
VII. Near Boiler Piping ............................................. 10
VIII. Combustion Air and Vent Pipe ......................... 13
IX. Gas Supply Piping.............................................. 15
X. Electrical Wiring .................................................. 16
XI. Controls and Accessories................................... 20
XII. Startup............................................................... 22
XIII. Checkout Procedures and Adjustments ............. 26
XIV. Maintenance and Cleaning .............................. 29
XV. Detailed Sequence of Operation ....................... 31
XVI. Troubleshooting ............................................... 34
XVII. Installation and Checkout Certificate
.............. 43
KeeP tHis MaNUal Near Boiler aND
retaiN For FUtUre reFereNce.
i. iNtroDUctioN
This appliance is a gas-fired direct vent cast aluminum
hot water boiler. A revolutionary cast aluminum heat
exchanger means better heat transfer and thermal
storage than similarly sized cast iron boilers, which
results in higher efficiency. The heating system water
absorbs large amounts of heat from the cast aluminum
heat exchanger, cooling the flue gases and causing
condensation. Sealed combustion, premix gas burner,
and low flame temperature means drastically reduced
CO and NOx emissions, which contribute to a cleaner
and healthier environment.
This appliance, unlike normal residential atmospheric
and induced draft units, takes its combustion air directly
from the outdoors (sealed combustion) and does not
compete with building occupants for fresh air. Sealed
combustion (also known as “direct vent”) is the safest
and best way to obtain plenty of clean combustion air.
The forced draft fan draws in the outside combustion
air to mix with gas, which flows into the pre-mix
burner and combusts. The fan then forces the
resulting flue gases from the boiler unit and provides
a positive removal of the flue gases from the building
through inexpensive and readily available PVC and
CPVC vent pipes.
ii. saFetY sYMBols
The following defined symbols are used throughout
this manual to notify the reader of potential hazards of
varying risk levels.
iMPortaNt:
Read the following instructions
COMPLETELY before installing!
indicates a potentially hazardous situation
which, if not avoided, could result in death,
serious injury or substantial property damage
.
WARNING
!
Indicates a potentially hazardous situa-
tion which, if not avoided, could result in mi-
nor or moderate injury or property damage.
CAUTION
!
indicates an
imminently
hazardous situation
which, if not avoided,
will
result in death, se-
rious injury or substantial property damage.
DANGER
!
