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Boiler Model Number 20_PV_I -_ _ _ _ Boiler Serial Number 6_ _ _ _ _ _ _ Installation Date Heating Contractor Phone Number Address The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DANGER CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage. WARNING NOTICE Table of Contents I. Pre-Installation .......................................... 4 II. Unpack Boiler ............................................. 5 III. Water Piping ............................................... 6 IV. Gas Piping ................................................... 8 V. Venting ........................................................ 9 VI. Electrical .................................................... 12 VII. System Start-up ........................................ 13 VIII. Service Instructions ................................ 21 IX. Repair Parts ............................................... 24 NOTICE USA boilers built for installation at altitudes greater than 2,000 feet above sea level have been specially orificed to reduce gas input rate 4 percent per 1,000 feet above sea level per the National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 8.1.2 and Appendix F. Canadian boilers' orifice sizing is indicated on the rating label. High altitude boiler models are identifiable by the second digit in the model number suffix on the rating label: 20_PV_I-__2: Less than 2000 ft. elevation 20_PV_I-__4: 2000 ft. and higher elevation, Canada 20_PV_I-__5: 2000 ft. and higher elevation, USA Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage. Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage. Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards. 2 Figure 1: Elevation Views 3 I.Pre-Installation WARNING Carefully read all instructions before installing boiler. Failure to follow all instructions in proper order can cause personal injury or death. A. Inspect shipment carefully for any signs of damage. All equipment is carefully manufactured, inspected and packed. Our responsibility ceases upon delivery of boiler to carrier in good condition. Any claim for damage or shortage in shipment must be filed immediately against carrier by consignee. No claims for variances or shortages will be allowed by Boiler Manufacturer, unless presented within sixty (60) days after receipt of equipment. B. Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements, installation must conform to National Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/ CGA B149 Installation 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. C. Appliance is design certified for installation on combustible flooring. The boiler must not be installed on carpeting. D. Provide clearance between boiler jacket and combustible material in accordance with local fire ordinance. See Figure 2 for minimum clearance from combustible material for closet installation. For alcove installation provide top clearance of 27 inches and right side clearance of 6 inches. Recommended service clearance is 24 inches from left side, right side and front. Service clearances may be reduced to minimum clearances to combustible materials. E. Install on level floor. For basement installation provide solid base, such as concrete, if floor is not level or if water may be encountered on floor around boiler. F. Install near outside wall for through wall venting. Refer to Section V: Venting, for vent length limitations. WARNING Certified as Category III appliance. Install vent system in accordance with Section V: Venting. Do not vent using masonry chimney, Type B gas vent, or other Category I venting system. G. Protect gas ignition system components from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, condensate trap, control replacement, etc.). H. Provide combustion and ventilation air in accordance with applicable provisions of local building codes, or National Fuel Gas Code, NFPA 54/ANSI Z223.1, Section 5.3, Air for Combustion and Ventilation, or Sections 7.2, 7.3 or 7.4 of CAN/CGA B149 Installation Codes. WARNING Adequate combustion and ventilation air must be provided to assure proper combustion. The following guideline is based on the National Fuel Gas Code, NFPA 54/ANSI Z223.1. 1. Determine volume of space (boiler room). Rooms communicating directly with space (through openings not furnished with doors) are considered part of spa...