Burnham Apex Installation And Operation Manual

2015-06-08

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INSTALLATION, OPERATING AND
SERVICE INSTRUCTIONS FOR

APEX™

CONDENSING HIGH EFFICIENCY
DIRECT VENT
GAS - FIRED HOT WATER BOILER

9700609

Warning: Improper installation, adjustment, alteration, service or maintenance can cause property damage,

injury, or loss of life. For assistance or additional information, consult a qualified installer, service agency or the
gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

103022-04 - 8/13

Price - $5.00

IMPORTANT INFORMATION - READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the

installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction

shall be consulted before installations are made.
All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.
All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.
The City of New York requires a Licensed Master Plumber supervise the installation of this product.
The Massachusetts Board of Plumbers and Gas Fitters has approved the Apex™ Series boiler. See the Massachusetts Board of
Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval
Code or ask your local Sales Representative.
The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

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 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, may result in moderate or minor
injury or property damage.

WARNING

NOTICE

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.

DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other
appliance.
If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use
any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas
supplier’s instructions or if the supplier is unavailable, contact the fire department.

Special Installation Requirements for Massachusetts
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 and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the
following requirements shall be satisfied:
1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of
NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally
vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.
2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm
and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the
detector on the floor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall
comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event
that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment,
the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during
said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance
with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the
sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector
may be installed on the next adjacent habitable floor level. Such detector may be a battery operated carbon monoxide
detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the
Massachusetts State Building Code.
3. A metal or plastic identification 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”.
4. A final inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed
until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of
carbon monoxide detectors and alarms as required above.
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 sidewall 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. When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design
or venting system components with the equipment, the instructions for installation of the equipment and the venting system
shall include:
1. A complete parts list for the venting system design or venting system; and
2. Detailed instructions for the installation of the venting system design or the venting system components.
D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts
for venting flue gases, but identifies “special venting systems”, the following shall be satisfied:
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 sidewall 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.

WARNING
This boiler requires regular maintenance and service to operate safely. Follow the instructions contained
in this manual.
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal
injury or loss of life. Read and understand the entire manual before attempting installation, start-up
operation, or service. Installation and service must be performed only by an experienced, skilled, and
knowledgeable installer or service agency
This boiler must be properly vented.
This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate
combustion and ventilation air.
The interior of the venting system must be inspected and cleaned before the start of the heating season
and should be inspected periodically throughout the heating season for any obstructions. A clean and
unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life
to vent safely and will contribute toward maintaining the boiler’s efficiency.
Installation is not complete unless a pressure relief valve is installed into the tapping located on left side
of appliance. - See the Water Piping and Trim Section of this manual for details.
This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start
without service. If damage due to frozen pipes is a possibility, the heating system should not be left
unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating
system to prevent damage if the boiler is inoperative.
This boiler contains very hot water under high pressure. Do not unscrew any pipe fittings nor attempt
to disconnect any components of this boiler without positively assuring the water is cool and has no
pressure. Always wear protective clothing and equipment when installing, starting up or servicing this
boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the
temperature and pressure of the boiler. This boiler contains components which become very hot when
the boiler is operating. Do not touch any components unless they are cool.
Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals,
carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause
death or serious injury and which are known to the state of California to cause cancer, birth defects and
other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing
or working nearby the appliance.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the
boiler before installing, starting up, operating, maintaining or servicing.
All cover plates, enclosures and guards must be in place at all times.

NOTICE
This boiler has a limited warranty, a copy of which is printed on the back of this manual. It is the responsibility
of the installing contractor to see that all controls are correctly installed and are operating properly when the
installation is complete.

TABLE OF CONTENTS
I.

Product Description, Specifications and Dimensional Data......................

II.

Unpacking Boiler........................................................................................ 10

III.

Pre-Installation and Boiler Mounting..........................................................

IV.

Venting......................................................................................................

A. General Guidelines............................................................................... 15
B. CPVC/PVC Venting.............................................................................. 18
C. Polypropylene Venting......................................................................... 26
D. Stainless Steel Venting........................................................................

E. Concentric Polypropylene Venting....................................................... 32
F. Removing the Existing Boiler...............................................................

G. Multiple Boiler Installation Venting....................................................... 40
V.

Condensate Disposal................................................................................. 43

VI.

Water Piping and Trim............................................................................... 45

VII.

Gas Piping ...............................................................................................

VIII. Electrical ................................................................................................... 63
IX.

System Start-Up ....................................................................................... 75

Operation......................................................................................................

A. Overview..............................................................................................

B. Supply Water Temperature Regulation................................................

C. Boiler Protection Features.................................................................... 83
D. Multiple Boiler Control Sequencer........................................................ 84
E. Boiler Sequence of Operation.............................................................. 85
1. Normal Operation...........................................................................

2. Using the Display............................................................................

F. Viewing Boiler Status..........................................................................

1. Status Screens............................................................................... 87
2. Detail Screens................................................................................

3. Multiple Boiler Sequencer Screens................................................

G. Changing Adjustable Parameters........................................................

1. Entering Adjust Mode....................................................................

2. Adjusting Parameters....................................................................

XI.

Service and Maintenance ........................................................................ 101

XII.

Troubleshooting........................................................................................ 105

XIII. Repair Parts ............................................................................................. 109
Appendix A - Figures................................................................................

124

Appendix B - Tables.................................................................................. 127
Warranty...........................................................................................Back Page

I. Product Description, Specifications and Dimensional Data
Apex™ Series boilers are condensing high efficiency
gas-fired direct vent hot water boilers designed for use
in forced hot water space or space heating with indirect
domestic hot water heating systems, where supply water
temperature does not exceed 210°F. These boilers have
special coil type stainless steel heat exchangers, constructed,
tested and stamped per Section IV ‘Heating Boilers’ of

ASME Boiler and Pressure Vessel Code, which provide a
maximum heat transfer and simultaneous protection against
flue gas product corrosion. These boilers are not designed
for use in gravity hot water space heating systems or
systems containing significant amount of dissolved oxygen
(swimming pool water heating, direct domestic hot water
heating, etc.).

Table 1: Dimensional Data (See Figures 1A, 1B and 1C)
Dimension
A - Inch
(mm)
B - Inch
(mm)
C - Inch
(mm)
D - Inch
(mm)
E - Inch
(mm)
Gas Inlet F
(FPT)

Boiler Model
APX399

APX500

APX800

28-7/8
(734)
6-3/16
(157)
13-1/16
(332)
23-3/4
(602)
15-13/16
(402)

44-7/8
(1140)
22-1/8
(562)
29
(737)
39-11/16
(1008)
29-3/8
(752)

54-9/16
(1384)
28-3/8
(724)
34-1/4
(876)
48-1/16
(1226)
33-13/16
(864)

3/4”

Return G

1-1/2” (FPT)

2” (MPT)

Supply H

1-1/2” (FPT)

2” (MPT)

Condensate Drain J

Factory Provided Socket End Compression Pipe Joining Clamp for 3/4” Schedule 40 PVC Pipe

Boiler Two-Pipe
CPVC/PVC Vent Connector
(Figures 1A, 1B and 1C) - Inch
Approx. Shipping Weight (LBS)

4x4
304

6x6
350

430

Figure 1A: Apex™ - Model APX399

I. Product Description, Specifications and Dimensional Data (continued)

8
Figure 1B: Apex™ - Model APX500

I. Product Description, Specifications and Dimensional Data (continued)

Figure 1C: Apex™ - Model APX800

I. Product Description, Specifications and Dimensional Data (continued)

I. Product Description, Specifications and Dimensional Data (continued)
Table 2A: Rating Data - Models APX399, APX500 and APX800 (0 to 5000 Feet Elevation Above Sea Level)
Apex Series Gas-Fired Boilers
Model
Number

Input (MBH)
Min.

Max.

* Output
(MBH)

Net AHRI
Ratings Water
(MBH)

Thermal
Efficiency
(%)

Combustion
Efficiency (%)

Heat Transfer
Area
(Sq. Ft.)

Boiler Water
Volume (Gal.)

APX399

399

375

326

94.1

94.5

3.4

41.8

APX500

100

500

475

413

95.0

4.2

50.8

APX800

160

800

760

661

95.0

93.0

5.0

65.3

Notes: * Gross Output
Maximum Allowable Working Pressure, Water - 160 PSI
Safety Relief Valve Pressure, Water - 50 PSI Shipped from Factory (std.) (APX399 and APX500); 60 PSI Shipped from
Factory (std.) (APX800); 80 PSI and 100 PSI - optional (APX399, APX500 and APX800)
Maximum Allowable Temperature, Water - 210°F
APX399 and APX500 Boiler models are factory shipped as Natural Gas builds and have to be field adjusted for LP
gas application. Refer to ‘System Start- Up Section of this manual for detailed procedure.
APX800 Boiler Model is factory shipped as either Natural Gas build or LP gas build.
Ratings shown are for installations at sea level and elevations up to 2000 Feet. For elevations above 2000 Feet,
ratings should be reduced at the rate of two and half percent (2.5%) for each 1000 Feet above sea level.

Table 2B: Rating Data - Models APX399, APX500 and APX800 (5001 to 10000 Feet Elevation Above Sea Level)
Apex Series Gas-Fired Boilers

Model
Number

Input (MBH)

* Output
(MBH)

Net AHRI
Thermal
Ratings
Efficiency
Water (MBH)
(%)

Combustion
Efficiency (%)

Boiler Water
Volume
(Gal.)

Heat Transfer
Area
(Sq. Ft.)

Min.

Max.

APX399

399

375

328

94.1

94.5

3.4

41.8

APX500

167

500

475

413

95.0

4.2

50.8

APX800

267

800

760

661

95.0

93.0

5.0

65.3

II. Unpacking Boiler
CAUTION
Do not drop boiler.

A. Move boiler to approximate installed position.
B. Remove all crate fasteners.
C. Lift and remove outside container.
10

D. Remove boiler from cardboard positioning sleeve on
shipping skid.

WARNING
Installation of this boiler should be undertaken
only by trained and skilled personnel from a
qualified service agency.

E. Move boiler to its permanent location.

III. Pre-Installation and Boiler Mounting
WARNING
If you do not follow these instructions exactly,
a fire or explosion may result causing property
damage or personal injury.

NOTICE
Due to the low water content of the boiler, missizing of the boiler with regard to the heating
system load will result in excessive boiler cycling
and accelerated component failure. Burnham
Commercial DOES NOT warrant failures caused
by mis-sized boiler applications.
DO NOT
oversize the boiler to the system. Multiple boiler
installations greatly reduce the likelihood of
boiler oversizing.

A. Installation must conform to the requirements of the

authority having jurisdiction. In the absence of such
requirements, installation must conform to the National
Fuel Gas Code, NFPA 54/ANSI Z223.1, and/or CAN/
CSA B149.1 Installation Codes.

B. Boiler is certified for installation on combustible
flooring. Do not install boiler on carpeting.

C. Provide clearance between boiler jacket and

Adequate combustion and ventilation air must
be provided to assure proper combustion.

F. The boiler should be located so as to minimize the

length of the vent system. The PVC combustion
air piping, or the optional concentric vent piping,
containing integral combustion air inlet piping, must
terminate where outdoor air is available for combustion
and away from areas that may contaminate combustion
air. In particular, avoid areas near chemical products
containing chlorines, chlorofluorocarbons, paint
removers, cleaning solvents and detergents. Avoid
areas containing saw dust, loose insulation fibers, dry
wall dust etc.

CAUTION
Avoid operating this boiler in an environment
where sawdust, loose insulation fibers, dry wall
dust, etc. are present. If boiler is operated under
these conditions, the burner interior and ports
must be cleaned and inspected daily to insure
proper operation.

G. General.

combustible material in accordance with local fire
ordinance. Refer to Figure 2 for minimum listed
clearances from combustible material. Recommended
service clearance is 24 inches from left side, front, top
and rear of the boiler. Recommended front clearance
may be reduced to the combustible material clearance
providing:

1. Apex boilers are intended for installations in an
area with a floor drain, or, in a suitable drain pan to
prevent any leaks or relief valve discharge to cause
property damage

1. Access to boiler front is provided through a door or
removable front access panel.
2. Access is provided to the condensate trap located
underneath the heat exchanger.

3. Apex boilers must be installed level to prevent
condensate from backing up inside the boiler.

D. Protect gas ignition system components from water

(dripping, spraying, rain, etc.) during boiler operation
and service (circulator replacement, condensate trap,
control replacement, etc.).

E. Provide combustion and ventilation air in accordance

WARNING

with applicable provisions of local building codes,
or: USA - National Fuel Gas Code, NFPA 54/ANSI
Z223.1, Air for Combustion and Ventilation;
Canada - Natural Gas and Propane Installation Code,
CAN/CSA-B149.1, Venting Systems and Air Supply for
Appliances.

2. Apex boilers are not intended to support external
piping and venting. All external piping and venting
must be supported independently of the boiler.

4. Boiler Installation:
a. For basement installation provide a solid level
base such as concrete, where floor is not level,
or, water may be encountered on the floor
around boiler. Floor must be able to support
weight of boiler, water and all additional system
components.
b. Boiler must be level to prevent condensate from
backing up inside the boiler.
c. Provide adequate space for condensate piping or
a condensate pump if required.

III. Pre-Installation and Boiler Mounting G. General (continued)
Boiler Clearances to Combustible (and NonCombustible) Material:

Boiler Service Clearances – Applicable to all Boiler
Models:

Top = 24”, Front = 24”, Left Side = 24”, Right Side =
24”, Rear = 24”

The above Clearances are recommended for Service
Access but may be reduced to the Combustible Material
Clearances provided:

APX399 and APX500 Boiler Models:
These boilers are approved for closet installation with
the following clearances – Top = 1”, Front = 1”, Left
Side = 10”, Right Side = 2”, Rear = *6”

APX800 Boiler Model:
This boiler is approved for alcove installation with the
following clearances – Top = 1”, Front = Open, Left
Side = 10”, Right Side = 2”, Rear = *6”
* Note:
When boiler is vented vertically, the minimum
clearance from the rear of the jacket is increased
to 18” with a short radius 90° elbow provided in
order to provide adequate space at boiler rear for
installation of vent and air intake piping and service
access

1. The boiler front is accessible thru a door
2. Access is provided to the condensate trap located on
the left side of boiler
3. Access is provided to thermal link located at the
boiler rear

Approved Direct
Vent System

Vent Pipe
Material

Vent
Pipe
Direction

Enclosure

Vent Pipe
Nominal
Diameter

Minimum
Clearance to
Combustible
Material

4” or 6”

1”

Factory Standard
Two-Pipe CPVC/PVC Vent and PVC
Air Intake
Available Optional
Two-Pipe Rigid Polypropylene Vent
(or, Flexible Polypropylene Liner
for Vertical Venting only) and Rigid
Polypropylene or PVC Combustion
Air Intake

* CPVC/PVC
Pipe Rigid
Polypropylene
Vent (or,
Flexible
Polypropylene
Liner for
Vertical
Venting only)

Available Optional

Vertical or
Horizontal

Unenclosed at
all Sides

4” or 6”

1”

Polypropylene

100/150 mm
(110/160 mm)

0”

* Do not enclose PVC venting - use CPVC vent pipe in enclosed spaces, or to penetrate through
combustible or non-combustible walls

1”

150 mm
(160 mm)

Stainless
Steel

Two-Pipe Stainless Steel Vent and
Galvanized Steel or Air Intake
Available Optional
Concentric Inner Polypropylene Vent
and Outer Steel Air Intake

80 mm
10 mm
(110 mm)

Figure 2: Clearances To Combustible and Non-combustible Material

III. Pre-Installation and Boiler Mounting G. General (continued)
H. Boiler Stacking

•

1. For installations with unusually high space heating
and/or domestic hot water heating loads, where
employing two (2) Apex (APX) boilers will offer the
benefits of greater operational efficiency, floor space
savings and boiler redundancy, the Apex (APX)
boilers may be installed stacked one on the top of
the other. Refer to Table 3 “Apex (APX) Boiler
Model Stacking Combinations” for details.
Table 3: Apex (APX) Boiler Model Stacking
Combinations
Bottom
Boiler Model
APX399
APX500
APX800

Top Boiler Model
APX399
APX399 or APX500
APX399, APX500 or APX800

2. To field assemble individual Apex (APX) boilers
into a stackable configuration, use the steps below:
a. Position the bottom boiler first. Refer to Sections
II “Unpacking Boiler” and III “Pre-Installation
& Boiler Mounting” of the manual for details.
Always position higher input boiler model as
bottom boiler.
b. Each Apex (APX) boiler is factory packaged
with two (2) Stacking Boiler Attachment
Brackets (P/N 101679-01) and the bracket
mounting hardware [six (6) self-drilling hex
washer head plated #8 x ½” long screws, P/N
80860743]. Locate and remove the brackets and
the hardware. The Stacking Boiler Attachments
Bracket has three 7/32” diameter holes punched
in a triangular pattern. See Figure 3 “Stacking
Boiler Attachment Bracket Placement”.
c. Apex (APX) boiler left and right side panels
have a series of dimples at panel top and bottom.
These dimples are positioning dimples for
Stacking Boiler Attachment Bracket mounting
screws. Side panel bottom positioning dimples
are evenly spaced from boiler front and back,
while side panel top positioning dimples follow
specific pattern to compensate for Apex (APX)
boiler model variable depth.
d. Position the upper boiler on the top of the bottom
boiler and align boiler front doors and sides flush
with each other.
• Place first Stacking Boiler Attachment
Bracket onto the upper boiler left side panel,
at the panel lower left corner and align
bracket two upper holes with corresponding
side panel lower dimples.
• The remaining lower bracket hole must align
with a matching bottom boiler left side panel
top positioning dimple.

Once bracket holes and side panel dimple
alignment is verified, attach the bracket to
top and bottom boiler left side panels with
the mounting screws.
e. Repeat above procedure to install second
Stacking Boiler Attachment Bracket and secure
the stacked boiler right side panels together at
the front right corner.
f. Install the third Stacking Boiler Attachment
Bracket to secure top and bottom boiler left side
panels at the rear left corner. Align the bracket
holes with corresponding positioning dimples in
the top boiler and bottom boiler left side panels,
then secure bracket with the screws.
g. Repeat above procedure to install the forth
Stacking Boiler Attachment Bracket to secure
stacked boiler right side panels at the rear right
corner.
3. When installing stackable boiler combinations
observe the following guidelines:
a. Venting - Top and bottom boilers must have their
individual vent piping and vent terminals.

WARNING
No common manifolded venting is permitted.

For side-wall venting individual model vent
terminals must terminate not closer than 12
inches horizontally and three (3) feet vertically
from each other in order to prevent combustion
air contamination. For vertical through the roof
venting, individual vertical vent terminals, if
level with each other, must be spaced no closer
than 12 inches horizontally. If vertical terminals
cannot end in one plane, they must be spaced no
closer than three (3) feet horizontally.
Chimney chase concentric venting is permitted
for modules, when stackable, providing
concentric vertical (roof) vent terminals, if level
with each other, are spaced no closer then 12
inches horizontally.
If vertical vent terminals cannot end in one
plane, they must be spaced no closer then three
(3) feet horizontally.
Follow instructions in Section IV “Venting”
of the manual for specifics of individual boiler
vent termination. Follow instructions in Section
V “Condensate Disposal” for each individual
boiler flue gas condensate line construction and
condensate disposal. Terminating individual
boiler condensate lines into common pipe prior
to drain disposal is permissible, providing
common pipe has sufficient flow capacity
to handle combined condensate volume of
stackable combination.

III. Pre-Installation and Boiler Mounting G. General (continued)
b. Gas Piping - Follow instructions in Section
VII “Gas Piping” of the manual for sizing
and installation of an individual boiler. When
common gas piping is sized, insure it will have
adequate capacity for combined input (CFH
gas flow) of the selected stackable boiler
combination.
c. Water Piping and Trim - Follow instructions
in Section VI “Water Piping and Trim” of the
manual for system piping and boiler secondary

piping selection/sizing based on combined
heating capacity and/or gross output of
the selected stackable boiler combination.
Follow instructions of Section VI “Water
Piping and Trim” for each individual boiler trim
installation.
d. Electrical - Follow instructions in Section VIII
“Electrical” of the manual to wire individual
boilers.

Figure 3: Stacking Boiler Attachment Bracket Placement

IV. Venting
WARNING
Failure to vent this boiler in accordance with these instructions could cause products of combustion to
enter the building resulting in severe property damage, personal injury or death.
Do not interchange vent systems or materials unless otherwise specified.
The use of thermal insulation covering vent pipe and fittings is prohibited.
Do not use a barometric damper, draft hood or vent damper with this boiler.
When using the CPVC/PVC vent option, the use of CPVC is required when venting in vertical or horizontal
chase ways, closets and through wall penetrations.
The CPVC vent materials supplied with this boiler do not comply with B149.1.S1-07 and are not approved for use in Canadian jurisdictions that require vent systems be listed to ULC S636-2008. In
these jurisdictions, vent this boiler using either stainless steel Special Gas vent or a listed ULC S636
Class IIB venting system.
Do not locate vent termination where exposed to prevailing winds. Moisture and ice may form on
surface around vent termination. To prevent deterioration, surface must be in good repair (sealed,
painted, etc.).
Do not locate air intake vent termination where chlorines, chlorofluorocarbons (CFC’s), petroleum
distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and
failure will result.
The use of cellular core PVC (ASTM F891), cellular core CPVC or Radel (polyphenolsulfone) is prohibited.
Do not locate vent termination under a deck.
Do not reduce specified diameters of vent and combustion air piping.
When installing vent pipe through chimney, as a chase, no other appliance can be vented into the
chimney.
Do not allow low spots in the vent where condensate may pool.

A. General Guidelines
1. Vent system installation must be in accordance
with National Fuel Gas Code, NFPA 54/ANSI
Z221.3 or CAN/CSA B149.1 Installation Code for
Canada, or, applicable provisions of local building
codes. Contact local building or fire officials about
restrictions and installation inspection in your area.
2. The Apex™ is designed to be installed as a
Direct Vent (sealed combustion) boiler. The air
for combustion is supplied directly to the burner
enclosure from outdoors and flue gases are vented
directly outdoors (through wall or roof).
3. The following combustion air/vent system options
are approved for use with the Apex™ boilers (refer
to Table 4):
a. Two-Pipe CPVC/PVC Vent/Combustion Air
System - separate CPVC/PVC pipe serves to
expel products of combustion and separate PVC
pipe delivers fresh outdoor combustion air.
Refer to Part B for specific details.
b. Two-Pipe Polypropylene Vent/Combustion Air
System - separate rigid or flexible polypropylene
pipe serves to expel products of combustion and
separate rigid polypropylene pipe or PVC pipe
delivers fresh outdoor combustion air. Refer to
part C for specific details.

c. Two-Pipe Stainless Steel Vent/Combustion Air
System - separate stainless steel pipe serves to
expel products of combustion. Separate PVC or
galvanized pipe delivers fresh outdoor air. Refer
to Part D for specific details.
d. Concentric Inner Polypropylene Vent
and Outer Steel Combustion Air System
- the assembly consists of inner fire resistant
polypropylene vent pipe and outer steel pipe
casing. The inner pipe serves as conduit to
expel products of combustion, while outdoor
fresh combustion air is drawn through the space
between the inner and outer pipes. Refer to Part
E for specific details.
4. Horizontal vent pipe must maintain a 1/4" per foot
slope down towards the boiler.
5. Horizontal combustion air pipe must maintain a
minimum ¼" per foot slope down towards terminal,
when possible. If not, slope toward boiler.
6. Do not install venting system components on
the exterior of the building except as specifically
required by these instructions (refer to Figure 4):
a. Vent terminals must be at least 1 foot from door,
window, or gravity inlet into the building.
b. Maintain the correct clearance and orientation
between the vent and air intake terminals.

IV. Venting A. General Guidelines (continued)
Table 4: Vent/Combustion Air System Options
Approved Direct
Vent System

Vent
Material

Orientation

Termination
Standard
(thru sidewall)

Horizontal

Factory Standard
Two-Pipe,
CPVC/PVC Vent and
PVC Air Intake

Optional
Snorkel
(thru sidewall)

CPVC/PVC

Optional
Vertical

Standard
(thru sidewall)

Available Optional
Two-Pipe, Rigid
Polypropylene
Vent (or Flexible
Polypropylene Liner
for Vertical venting
only) and Rigid
Polypropylene or PVC
Pipe Air Intake

Horizontal
Rigid
Polypropylene
(or Flexible
Polypropylene
Liner for vertical
Venting only)
Optional
Vertical

Available Optional
Two-Pipe,
Stainless Steel Vent
and PVC/Galvanized
Steel Air Intake

4 thru 7,
10, 11

The system includes separate CPVC
vent pipe and PVC air intake pipe
terminating thru roof with individual
penetrations for the vent and air intake
piping and separate vertical terminals.

4 thru 6, 10,
12, 13

The system includes separate Rigid
Polypropylene vent pipe and Rigid
Polypropylene or PVC air intake pipe
terminating thru sidewall with individual
penetrations for the vent and air intake
piping and separate terminals (tees).

4 thru 9A,
9B, 10

9, 10

4 thru 7,
10, 11

9, 10

Same as above but separate snorkel
type terminals.

Vertical
(thru roof or
chimney/chase)

The system includes separate Flexible
Polypropylene vent liner and Rigid
Polypropylene vent pipe combination
for venting and Rigid Polypropylene or
PVC air intake pipe terminating thru roof
with individual penetrations for the vent
and air intake and individual vent /air
terminals.

12 thru 16

Standard
(thru sidewall)

The system includes separate stainless
steel vent pipe and PVC/galvanized steel
air intake pipe terminating thru sidewall
with individual penetrations for the
vent and air intake piping and separate
terminals

9A, 9B,
16, 17

Vertical

Vertical (thru roof)

Horizontal

Horizontal
(Wall) Terminal

Same as above but separate snorkel
type terminals.

11, 16, 17

The system includes separate stainless
steel vent pipe and PVC/galvanized steel
air intake pipe terminating thru roof with
individual penetrations for the vent and
air intake piping and separate terminals.

12, 13, 17

Concentric vent/air pipe terminates thru
sidewall.

18 thru 25

Concentric vent/air pipe terminates thru
roof.

18 thru 21,
26 thru 31

Polypropylene
Vertical

Vertical (Roof)
Terminal

The centerlines between the vent and air
intake terminals must be spaced a minimum
of 12” apart. More than 12” spacing is
recommended.
ii. If possible, locate air intake and vent
terminations on the same wall to prevent
nuisance shutdowns. However, boiler
may be installed with vertical venting and
sidewall combustion air inlet or vice versa
where installation conditions do not allow
for alternate arrangement.
iii. The vent and air intake terminations may
be at varying heights when installed on
the same wall, but the height of the vent
termination should always be higher than
the air intake termination and within the
specified limit as shown in Figure 9B.

Component
Part
Table

4 thru 9A,
9B, 10

Same as above but separate snorkel
type terminals.

Optional Snorkel
(thru sidewall)

Stainless Steel

The system includes separate CPVC
vent pipe and PVC air intake pipe
terminating thru sidewall with individual
penetrations for the vent and air intake
piping and separate terminals (tees).

Figures

Optional Snorkel
(thru sidewall)

Horizontal

Available Optional
Concentric, Inner
Polypropylene Vent and
Outer Steel Air Intake

Vertical
(thru roof)

Description

11A, 11B

12, 13

c. The bottom of the vent and air intake terminal
must be at least 12" (18" in Canada) above the
normal snow line. In no case should they be less
than 12" above grade level.
d. The bottom of the vent terminal must be at least
7 feet above a public walkway.
e. Do not install the vent terminal directly over
windows or doors.
f. The bottom of the vent terminal must be at least
3 feet above any forced air inlet located within
10 feet.
g. A clearance of at least 4 feet horizontally must
be maintained between the vent terminal and
gas meters, electric meters, regulators, and relief
equipment. Do not install vent terminal over this
equipment.

IV. Venting A. General Guidelines (continued)

Figure 4: Location of Vent Terminal Relative to Windows, Doors, Grades,
Overhangs, Meters and Forced Air Inlets
(Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location Two-Pipe System Air Intake Terminal Not Shown)
h. Do not locate the vent terminal under decks or
similar structures.
i. Minimum twelve (12) inches vertically from any
roof overhang twelve (12) inches or less wide.
If a roof overhang width exceeds twelve (12)
inches the terminal vertical clearance must be
increased to avoid flue vapor condensation.
j. Top of vent terminal must be at least 5 feet
below eaves, soffits, or overhangs. Maximum
depth of overhang is 3 ft.
k. If window and/or air inlet is within four (4) feet
of an inside corner, then terminal must be at least
six (6) feet from adjoining wall of inside corner.
l. Concentric - Minimum twelve (12) inches
horizontally from a building corner.
m. Under certain conditions, water in the flue gas
may condense, and possibly freeze, on objects
around the terminal including on the structure
itself. If these objects are subject to damage by
flue gas condensate, they should be moved or
protected.
n. If possible, install the vent and air intake
terminals on a wall away from the prevailing

wind. Reliable operation of this boiler cannot be
guaranteed if the terminal is subjected to winds
in excess of 40 mph.
o. Air intake terminal must not terminate in areas
that might contain combustion air contaminates,
such as near swimming pools.
p. For sidewall venting the minimum horizontal
distance between any adjacent individual module
(boiler) vent terminations is twelve (12) inches.
Increasing this distance is recommended to avoid
frost damage to building surfaces where vent
terminations are placed.

CAUTION
Installing multiple individual module (boiler) vent
terminations too close together may result in cross
contamination and combustion product water
vapor condensation on building surfaces, where
vent termination are placed, and subsequent
frost damage. To avoid/minimize frost damage,
extend the distance from building surfaces to
vent termination end and increase the horizontal
distance between adjacent vent terminations.

IV. Venting A. General Guidelines (continued)
q. The minimum horizontal distance between any
adjacent individual module (boiler) roof vent
terminations is one (1) foot.
7. Use noncombustible ¾" pipe strap to support
horizontal runs and maintain vent location and
slope while preventing sags in pipe. Do not restrict
thermal expansion or movement of vent system.
Maximum support spacing four (4) feet. Avoid low
spots where condensate may pool. Do not penetrate
any part of the vent system with fasteners.
8. Maintain minimum clearance to combustible
materials. See Figure 2 for details.
9. Enclose vent passing through occupied or
unoccupied spaces above boiler with the material
having a fire resistance rating of at least equal to the
rating of adjoining floor or ceiling.

Note: For one or two family dwellings, fire
resistance rating requirement may not need to be
met, but is recommended.

10. Multiple individual module vertical vent pipes may
be piped through a common conduit or chase so that
one roof penetration may be made.

B. CPVC/PVC Venting

WARNING
All CPVC vent components (supplied with boiler)
must be used for near-boiler vent piping before
transitioning to Schedule 40 PVC pipe (ASTM
2665) components for remainder of vent system.

WARNING
CPVC vent components must be used within
any interior space where air cannot circulate
freely, such as air inside a stud wall, and in
any boiler closet or chase way.
When using the CPVC/PVC vent options, the
use of CPVC is required when venting in vertical
or horizontal chase ways.
All condensate that forms in the vent must
be able to drain back to the boiler.
1. Components and Length Restrictions
a. See Table 5A for CPVC/PVC Vent & Air Intake
Components included with boiler, Table 5B for
CPVC/PVC Vent and Air Intake Components
(Installer Provided) required for Optional

Table 5A: CPVC/PVC Vent & Air Intake Components Included With Boiler
Quantity
Vent & Air Intake Components

Part
Number

APX399 and APX500
Standard Termination
Vent Kit
(P/N 102189-03)
includes

APX800
Standard Termination
Vent Kit
(P/N 103253-01)
includes

4” Schedule 40 PVC Tee (Vent or Air Intake Terminals)
6” Schedule 40 PVC 90° Elbow (Vent or Air Intake
Terminal)
4” Stainless Steel Rodent Screen

102190-02

N/A

103313-01

N/A

102191-02

N/A

6” Stainless Steel Rodent Screen

102191-03

N/A

4” x 30” Schedule 40 CPVC Pipe

102193-02

N/A

6” x 30” Schedule 40 CPVC Pipe

103267-01

N/A

4” Schedule 80 CPVC 90° Elbow

102192-02

N/A

6” Schedule 80 CPVC 90° Elbow

103268-01

N/A

4 oz. Bottle of Transition Cement

102195-01

4 oz. Bottle of Primer

102194-01

4" Vent/4" Combustion Air CPVC/PVC Connector

102183-03

N/A

6" Vent/6" Combustion Air CPVC/PVC Connector
4" Vent/4" Combustion Air CPVC/PVC Connector
Gasket
6" Vent/6" Combustion Air CPVC/PVC Connector
Gasket

103270-01

N/A

102185-02

N/A

103248-01

N/A

IV. Venting B. CPVC/PVC Venting (continued)
Table 5B: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal
(Snorkel) Termination
Quantity
APX399 and APX500
APX800
Horizontal (Snorkel)
Horizontal (Snorkel)
Termination
Termination
2
N/A

Part
Number

Vent Components
4" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run
6" Schedule 40 PVC Pipe x up to 7 ft. max. vertical run

N/A

4" Schedule 40 PVC Pipe x ½ ft. min. horizontal run

N/A

6" Schedule 40 PVC Pipe x ¾ ft. min. horizontal run

N/A

4" Schedule 40 PVC 90° Elbow
6" Schedule 40 PVC 90° Elbow

N/A
Supplied by Others

Table 5C: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical
(Roof) Termination
Quantity
APX399 and APX500
APX800
Vertical (Roof)
Vertical (Roof)
Termination
Termination
1
N/A

Part
Number

Vent Components
4" Schedule 40 PVC Coupler
6" Schedule 40 PVC Coupler

N/A

4" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run

N/A

6" Schedule 40 CPVC Pipe x ¾ ft. min. horizontal run

N/A

4" Schedule 40 PVC 90° Elbow
6" Schedule 40 PVC 90° Elbow

N/A
Supplied by Others

Horizontal (Snorkel) Termination and Table 5C
for CPVC/PVC Vent and Air Intake Components
(Installer Provided) required for Optional
Vertical (Roof) Termination.
b. Vent length restrictions are based on equivalent
length of vent/combustion air pipe (total length
of straight pipe plus equivalent length of
fittings). Maximum vent/combustion air lengths
are listed in Table 8. Do not exceed maximum
vent/combustion air lengths. Table 6 lists
equivalent lengths for fittings. Do not include
vent/combustion air terminals in equivalent
feet calculations. See “Combustion Air/Vent,
Equivalent Length Work Sheet”.
c. The vent termination location is restricted as per
'General Guidelines', Paragraph A, 6.
(Refer to Figure 4).
2. System Assembly
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
b. Do not exceed maximum Vent/Combustion Air
length. Refer to Table 8.

c. Design the Vent System to allow 3/8" of thermal
expansion per 10 feet of CPVC/PVC pipe. Runs
of 20 feet or longer that are restrained at both
ends must use an offset or expansion loop. Refer
to Figure 5 and Table 7.
d. Follow all manufacturer instructions and
warnings when preparing pipe ends for joining
and using the primer and the cement.
3. Field Installation of CPVC/PVC Two-Pipe

Vent System Connector

Refer to Figure 6 and Steps below:
a. Position the CPVC/PVC vent connector and
gasket onto boiler rear/bottom panel and insert
vent connector inner stainless steel vent pipe into
heat exchanger vent outlet.
b. Align vent connector plate and gasket clearance
holes with rear/bottom panel engagement holes;
than, secure the connector and gasket to the
panel with six mounting screws.
c. Apply supplied dielectric grease (grease pouch
attached to two-pipe vent connector) to gasket
inside vent section of two-pipe vent connector,
The grease will prevent gasket rupture when
inserting vent pipe and gasket deterioration due
to condensate exposure.

IV. Venting B. CPVC/PVC Venting (continued)
Table 6: Vent System and Combustion Air System Components Equivalent Length
vs. Component Nominal Diameter
Vent or Combustion Air System
Component Description

Equivalent Length (Ft.) for Vent or Combustion Air System Component
vs. Component Nominal Diameter (In.)

Component Nominal Diameter, In.

4”

6”

90° Elbow (Sch. 80 or Sch.40)

45° Elbow (Sch. 80 or Sch. 40)

4.5

7.5

Sch. 40 CPVC Pipe x 30 In. Long

2.5

Sch. 40 PVC Pipe x 1 Ft. Long

Sch. 40 PVC Pipe x 2 Ft. Long

Sch. 40 PVC Pipe x 3 Ft. Long

Sch. 40 PVC Pipe x 4 Ft. Long

Sch. 40 PVC Pipe x 5 Ft. Long

5
L
4

CHANGE OF DIRECTION
(VERTICAL OR HORIZONTAL)

OFFSET

LONG RUN OF PIPE

L
2

LOOP LENGTH (L)

KEY
RESTRAINT (RESTRICTS MOVEMENT)
L
4

HANGER (ALLOWS MOVEMENT)

LOOP
(HORIZONTAL ONLY)
(TOP VIEW)

Table 7: Expansion Loop Lengths
Nominal
Pipe
Dia. (In.)

Length of
Loop Length
Straight Run
“L” (In.)
(Ft.)
20
60
30

104

103

116

127

2L
5

6"
MIN

L
5

6"
MIN

Figure 5: Expansion Loop and Offset

WARNING
Apply supplied dielectric grease to gasket inside vent section of two-pipe vent connector. Failure to apply the
grease could result in gasket rupture during vent pipe installation and gasket deterioration due to condensate
exposure.

IV. Venting B. CPVC/PVC Venting (continued)

Figure 6: Field Installation of CPVC/PVC Two-Pipe Vent System Connector
4. Near-Boiler Vent/Combustion Air Piping
Refer to Figure 7 and the following Steps:

APX399 and APX500 Boiler Models:
a. 4” x 4” Two-Pipe CPVC/PVC Vent System
Connector (P/N 102183-03), used on APX399
and APX500 boiler models, has factory installed
internal sealing gaskets at both vent and air
intake sections.
b. Install provided 4” Schedule 40 x 30” long
CPVC pipe into the connector vent section with
a slight twisting motion and secure by tightening
the metal strap.
c. All CPVC vent components supplied with
boiler inside vent carton (4” Schedule 40 x 30”

long CPVC pipe and 4” Schedule 80 CPVC
90° Elbow) must be used for near-boiler piping
before transitioning to Schedule 40 PVC (ASTM
2665) pipe components for reminder of vent
system. The CPVC 30” long straight pipe may be
cut to accommodate desired vent configuration
provided both pieces are used in conjunction
with CPVC 90° Elbow before any PVC
components are used. Ensure that the CPVC 90°
Elbow is the first elbow used in the vent system
as it exits the boiler.
d. Insert 4” Schedule 40 PVC combustion air pipe
(installer provided) into the connector air intake
section with a slight twisting motion and secure
by tightening the metal strap.

Figure 7: Near-Boiler Vent/Combustion Air Piping

IV. Venting B. CPVC/PVC Venting (continued)
Table 8: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options
CPVC/PVC

Polypropylene (PP) or Polypropylene (PP)/PVC

Stainless Steel/PVC or Galvanized Steel)
4” Combustion Air Pipe
(Equivalent Length)

Boiler
Model

6” Combustion Air Pipe
(Equivalent Length)
Min.

6” Vent Pipe
(Equivalent Length)

Min.

Max.

Min.

Max.

30 In.

200 Ft.

Min.

Max.

APX399

30 In.

100 Ft.

30 In.

100 Ft.

APX500

30 In.

100 Ft.

30 In.

100 Ft.

APX800

Max.

4” Vent Pipe
(Equivalent Length)

30 In.

200 Ft.

Vent/Combustion Air Equivalent Length Calculation Work Sheet
Combustion Air

Vent

90° Elbow(s) PVC (Installer Supplied)

90° Elbow(s) CPVC (Supplied with Boiler)

Nominal
Diameter,
In.
4
6

Quantity
(Pc)

Equivalent
Length, Ft/Pc

Subtotal,
Equivalent
Ft. (A)

13
22

Nominal
Diameter,
In.
4
6

45° Elbow(s) PVC (Installer Supplied)
Nominal
Diameter,
In.
4
6

Quantity
(Pc)

Equivalent
Length, Ft/Pc

Subtotal,
Equivalent
Ft. (B)

4.5
7.5
Quantity
(Length,
Ft.)

Equivalent
Length,
Ft/Ft
1
1

* Total Equivalent Length, Ft. (A+B+C) =

Subtotal,
Equivalent
Ft. (C)

1
1

Subtotal,
Equivalent Length,
Equivalent Ft.
Ft/Pc
(D)
13
13
22
22

90° Elbow(s) PVC (Installer Supplied)
Nominal
Diameter,
In.
4
6

Straight Pipe, PVC (Installer Supplied)
Nominal
Diameter,
In.
4
6

Quantity
(Pc)

Subtotal,
Equivalent Length,
Equivalent Ft.
Ft/Pc
(A)
13
22

45° Elbow(s) PVC (Installer Supplied)
Subtotal,
Nominal
Quantity
Equivalent Length,
Equivalent Ft.
Diameter, In. (Length, Ft.)
Ft/Ft
(B)
4
4.5
6
7.5
30” (2.5 Ft.) Straight Pipe, CPVC (Supplied with Boiler)
Nominal
Diameter,
In.
4
6

Subtotal,
Quantity
Equivalent Length,
Equivalent Ft.
(Length, Ft.)
Ft/Ft
(E)
2.5
1
2.5
2.5
1
2.5

Straight Pipe, PVC (Installer Supplied)
Nominal
Diameter,
In
4
6

Subtotal,
Quantity
Equivalent Length,
Equivalent Ft.
(Length, Ft.)
Ft/Ft
(C)
1
1

* Total Equivalent Length, Ft. (A+B+C+D+E) =
* Note: Total Equivalent Length Calculated Value Cannot Exceed Max. Equivalent Length Values shown in Table 8.
Vent and Combustion Air Terminals Do Not Count Towards Total Equivalent Length.

IV. Venting B. CPVC/PVC Venting (continued)

e. Clean all vent and combustion air pipe joints
with primer and secure with transition cement
(4-oz. bottles of primer and cement are
supplied with boiler inside vent carton). Follow
application instructions provided on primer and
cement bottles.
APX800 Boiler Model:
f. 6” x 6” Two-Pipe CPVC/PVC Vent System
Connector (P/N 102183-03), used on APX800
boiler model, does not have factory installed
internal sealing gaskets at both vent and air
intake sections and requires use of supplied red
RTV silicon sealant to seal vent and combustion
air pipes to the connector.
g. Apply a coating of the sealant, at least 1” wide,
onto provided 6” Schedule 40 x 30” long CPVC
pipe.
h. Insert the coated end of the CPVC pipe with a
slight twisting motion into the connector vent
section and secure by tightening the metal strap.
i. All CPVC vent components supplied with
boiler inside vent carton (6” Schedule 40 x 30”
long CPVC pipe and 6” Schedule 80 CPVC
90° Elbow) must be used for near-boiler piping
before transitioning to Schedule 40 PVC (ASTM
2665) pipe components for remainder of vent
system. The CPVC 30” long straight pipe may be
cut to accommodate desired vent configuration
provided both pieces are used in conjunction
with CPVC 90° Elbow before any PVC
components are used. Ensure that the CPVC 90°
Elbow is the first elbow used in the vent system
as it exits the boiler.

Figure 8: Wall Penetration Clearances for PVC Vent Pipe
• PVC vent pipe must be installed in such
way as to permit adequate air circulation
around the outside of the pipe to prevent
internal wall temperature rising above
ANSI Z21.13 standard specified limit.
• Do not enclose PVC venting – use higher
temperature rated CPVC pipe in enclosed
spaces, or, to penetrate combustible or
non-combustible walls.
• PVC vent pipe may not be used
to penetrate combustible or noncombustible walls unless all following
three conditions are met simultaneously
(see Figure 8 “ Wall Penetration
Clearances for PVC Vent Pipe”):
- The wall penetration is at least 66
inches from the boiler as measured
along the vent

j. Apply a coating of the sealant, at least 1” wide,
onto 6” Schedule 40 PVC combustion air pipe
(installer provided).
k. Insert the coated end of the PVC pipe with a
slight twisting motion into the connector air
intake section and secure by tightening the metal
strap.
l. Clean all vent and combustion air pipe joints
with primer and secure with transition cement
(4-oz. bottles of primer and cement are
supplied with boiler inside vent carton). Follow
application instructions provided on primer and
cement bottles.
5. Horizontal Vent Termination
a. Standard Two-Pipe Termination
See Figures 8 through 11.
i. Vent Piping

Running PVC vent pipe inside Enclosures
and thru Walls:

Figure 9A: Direct Vent - Sidewall Terminations

IV. Venting B. CPVC/PVC Venting (continued)
WARNING
All CPVC pipe supplied with boiler vent carton
must be used as part of vent system prior to
connecting supplied PVC vent terminal.
Methods of securing and sealing terminals to
the outside wall must not restrain the thermal
expansion of the vent pipe.

Figure 9B: Direct Vent - Sidewall Terminations (Optional)

•

•
•

•

- The wall is 12” thick or less
- An air space of at least of that shown
in Figure 8 is maintained around
outside of the vent pipe to provide air
circulation
If above three conditions cannot be
met simultaneously when penetrating
a combustible wall, use a single wall
thimble [Burnham Commercial part
numbers 102181-01 (4”) and 103419-01
(6”)].
Thimble use is optional for noncombustible wall.
Insert thimble into cut opening from
outside. Secure thimble outside flange to
wall with nails or screws and seal ID and
OD with sealant material.
When thimble is not used for noncombustible wall, size and cut wall opening
such that a minimal clearance is obtained
and to allow easy insertion of vent pipe.
Apply sealant between vent pipe and
thimble or wall opening to provide weathertight seal. Sealant should not restrain the
expansion of the vent pipe.
Install Rodent Screen and Vent Terminal
(supplied with boiler). See Figure 10 for
appropriate configuration details.

ii. Combustion Air Piping
• Do not exceed maximum combustion air
pipe length. Refer to Table 8.
• Size combustion air pipe wall penetration
opening to allow easy insertion of the pipe.
• Install Rodent Screen and Combustion Air
Terminal (supplied with boiler). See Figure
10 for appropriate configuration details.
• Apply sealant between combustion air pipe
and wall opening to provide weather-tight
seal.
b. Optional Two-Pipe Snorkel Termination
See Figures 10 and 11.
This installation will allow a maximum of seven (7)
feet vertical exterior run of the vent/combustion air
piping to be installed on the CPVC/PVC horizontal
venting application.

Figure 10: Rodent Screen Installation

Figure 11: Direct Vent - Optional Sidewall
Snorkel Terminations

IV. Venting B. CPVC/PVC Venting (continued)
NOTICE
Exterior run to be included in equivalent vent/
combustion air lengths.
i.

Vent Piping
• After penetrating wall, install a Schedule
40 PVC 90° elbow so that the elbow leg is
in the up direction.
• Install maximum vertical run of seven (7)
feet of Schedule 40 PVC vent pipe. See
Figure 11.
• At top of vent pipe length install another
PVC 90° elbow so that elbow leg is opposite
the building’s exterior surface.
• Install Rodent Screen and Vent Terminal
(supplied with boiler), see Figure 10 for
appropriate configuration.
• Brace exterior piping if required.
ii. Combustion Air Piping
• After penetrating wall, install a Schedule
40 PVC 90° elbow so that elbow leg is in
the up direction.
• Install maximum vertical run of seven (7)
feet of Schedule 40 PVC vent pipe. See
Figure 11.
• At top of air pipe length install another PVC
90° elbow so that elbow leg is opposite the
building’s exterior surface.
• Install Rodent Screen and Combustion Air
Terminal (supplied with boiler), see Figure
10 for appropriate configuration.
• Brace exterior piping if required.

CAUTION
Vertical venting and combustion air roof
penetrations (where applicable) require the use
of roof flashing and storm collar, which are not
supplied with boiler, to prevent moisture from
entering the structure.
- Install storm collar on vent pipe
immediately above flashing. Apply
Dow Corning Silastic 732 RTV Sealant
between vent pipe and storm collar to
provide weather-tight seal.
• Install Rodent Screen and Vent Terminal
(supplied with boiler), see Figure 10 for
appropriate configuration.
• Brace exterior piping if required.

WARNING
All CPVC pipe and elbow supplied with boiler
vent carton must be used as part of vent
system prior to connecting supplied PVC vent
terminal.
Do not operate boiler without the rain cap
over vent pipe in place.
ii. Combustion Air Piping
• Locate combustion air termination on the
same roof location as the vent termination
to prevent nuisance boiler shutdowns.
Combustion air terminal can be installed
closer to roof than vent.

6. Vertical Vent Termination
a. Standard Two-Pipe Termination
Refer to Figures 10, 12 and 13.
i. Vent Piping
• Install fire stops where vent passes through
floors, ceilings or framed walls. The fire
stop must close the opening between the
vent pipe and the structure.
• Whenever possible, install vent straight
through the roof. Refer to Figures 12 and
13.
- Size roof opening to maintain minimum
clearance of 1" from combustible
materials.
- Extend vent pipe to maintain minimum
vertical and horizontal distance of
twelve (12) inches from roof surface.
Additional vertical distance for expected
snow accumulation. Provide brace as
required.

Figure 12: Direct Vent - Vertical Terminations

IV. Venting B. CPVC/PVC Venting (continued)

Figure 13: Direct Vent - Vertical Terminations
with Sloped Roof
Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of
twelve (12) inches (18 inches Canada) from roof surface. Allow additional vertical (‘X’) distance for expected
snow accumulation.
• Size roof opening to allow easy insertion

Polypropylene vent system manufactures are listed
of combustion air piping and allow proper
below:
installation of flashing and storm collar
Approved Polypropylene Vent System Manufacturers
to prevent moisture from entering the
Make
Model
structure.
PolyPro Single Wall Rigid Vent
- Use appropriately designed vent flashing
M&G/DuraVent PolyPro Flex Flexible Vent (APX399 and
when passing through roofs. Follow
APX500)
flashing manufacturers’ instructions for
Centrotherm InnoFlue SW Rigid Vent
installation procedures.
Eco Systems Flex Flexible Vent (APX399 and APX500)

- Extend combustion air pipe to maintain
NOTE:
Do
not
mix
vent
components
from
approved

minimum vertical and horizontal distance
manufacturers.
of twelve (12) inches from roof surface.
Allow additional vertical distance for

M&G/DuraVent PolyPro Single Wall Rigid Vent
expected snow accumulation. Provide
and PolyPro Flex Flexible Vent comply with the
brace as required.
requirements of ULC-S636-08 ‘Standard for Type BH
Gas Venting Systems’.
- Install storm collar on combustion

Centrotherm Eco Systems InnoFlue SW Rigid Vent
air pipe immediately above flashing.
and Flex Flexible Vent comply with the requirements
Apply Dow Corning Silastic 732
of UL 1738 ‘Standard for Safety for Venting Systems’
RTV Sealant between combustion
and ULC-S636-08 ‘Standard for Type BH Gas Venting
air pipe and storm collar to provide
Systems’.
weather-tight seal.
• Install Rodent Screen and Combustion

For polypropylene vent system installation details refer
Air Terminal (supplied with boiler), see
to an approved manufacturer either Rigid Single Wall
Figure 10 for appropriate configuration.
Polypropylene Vent Installation Instructions, or Flexible
Polypropylene Vent Installation Instructions provided
• Brace exterior piping if required.
with a manufacturer specific kits. See Tables 9 and 10.
C. Polypropylene Venting

Refer to Table 8 ‘Vent/Combustion Air Pipe Length –
Apex boilers have been approved for use with
Two-Pipe Direct Vent System Options’ for minimum
polypropylene vent system.
and maximum listed equivalent length values.

It is an installing contractor responsibility to

All terminations must comply with listed options for
procure listed below polypropylene vent system pipe
two-pipe venting system. See Figures 8 thru 12 for
and related components.
details.

IV. Venting C. Polypropylene Venting (continued)
Table 9: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent
Boiler
Model
APX399
APX500
APX800

Male Boiler Adapter,
PVC to PP

M&G / DuraVent Part Numbers/Sizes
Pipe Joint
Side Wall
Rigid Pipe
Flex Pipe
Locking Band Termination Tee

Chimney Kit for
Venting Only

4PPS-04PVCM-4PPF

100 mm

43PPS-LB

43PPS-TB

4PPS-FK

6PPS-06PVCM-6PPF

150 mm

N/A

6PPS-LBC

6PPS-E90B

N/A

Table 10: Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco
Boiler
Model
APX399
APX500
APX800

Male Boiler Adapter,
PVC to PP

Centrotherm Eco Part Numbers/Sizes
Pipe Joint
Side Wall
Rigid Pipe
Flex Pipe
Locking Band
Termination Tee

ISAA0404
ISSAL0404

110 mm

IANS04

ISTT0420

ISAA0606
ISSAL0606

160 mm

N/A

IANS06

ISTT0620

When using flexible polypropylene vent pipe (liner):

• Do not bend or attempt to install flexible pipe if
it has been stored at lower ambient temperature
without allowing the pipe to warm up to a higher
temperature first.

CAUTION

When flexible polypropylene pipe (liner) is

used for combustion product venting, it must
not be installed at an angle greater than 45
degrees from vertical plane. This will insure
proper condensate flow back towards the boiler.

CAUTION
Do not install flexible polypropylene pipe at an
angle greater than 45 degrees from vertical plane
when used for combustion product venting.
Failure to do so will result in improper condensate
drainage towards the boiler and possible
subsequent vent pipe blockage.
• When flexible polypropylene pipe (liner) is used
for combustion air supply to a boiler, the pipe
(liner) can be installed in vertical or horizontal
position.
• Follow flexible polypropylene pipe (liner)
manufacturer specific installation instructions
regarding application/listing, permits, minimum
clearances to combustibles; installation details

N/A

(proper joint assembly, pipe support and routing,
gasket and fitting installation, optional tooling
availability/usage, routing thru masonry chimney
for combustion product venting or, combination
of combustion product venting and combustion
air supply).
• When there is a conflict between flexible
polypropylene pipe (liner) manufacturer installation
instructions and Apex boiler Installation, Operating
and Service Instructions, the more restrictive
instructions shall govern.

• Flexible pipe must be treated carefully and stored at
temperatures higher than 41°F (5°C).

Bending or attempting to install flexible pipe if it
has been stored at ambient temperature below
41°F (5°C) will cause material to become brittle
and lead to cracks.

Chimney Kit for
Venting Only
IFCK0425
and
IFCK0435

Apex Boiler Two-Pipe Vent System Connector Field
Modification Procedure To Accept Polypropylene
Vent Piping:

Apex boilers are factory supplied with a model-specific
boiler two-pipe CPVC/PVC vent system connector
shipped within a model-specific boiler CPVC gasketed
vent kit carton.

Locate and remove a model-specific boiler two-pipe
CPVC/PVC vent system connector.

When using M&G/DuraVent polypropylene pipe for
combustion product venting and/or air supply, male
PVC to PP boiler adapter (4PPS-04PVCM-4PPF or
6PPS-06PVCM-6PPF as applicable) is installed into the
two-pipe vent system connector vent or combustion air
supply port as follows (see Figure 14):
1) APX399 and APX500 models - Apply provided
dielectric grease (grease pouch taped to the vent
system connector) all around to the vent or air
connection inner red silicon gasket.
2) APX399 and APX500 models - Push and twist
PVC to PP boiler adapter (4PPS-04PVCM-4PPF)
into two-pipe vent system connector vent connection
or air supply port until bottomed out.

IV. Venting C. Polypropylene Venting (continued)

Figure 14: Vent System Field Modification to Install PVC to PP Adapter (M&G/DuraVent Shown)
10) APX399 and APX500 models - Push and
3) Tighten the worm band clamp screw to secure PVC
twist PVC to PP boiler adapter (ISAA0404 or
to PP boiler adapter.
ISAAL0404) into two-pipe vent system connector
4) Do not install PVC to PP boiler adapter at the
vent connection or air supply port until bottomed
lower combustion air supply port of the two-pipe
out.
vent system connector when using PVC pipe for
11) Tighten the worm band clamp screw to secure PVC
combustion air supply to boiler.
to PP boiler adapter.
5) APX800 model - Apply a coating of supplied red
12) Do not install PVC to PP boiler adapter at the
RTV silicon sealant, at least 1” wide, to PVC to PP
lower combustion air supply port of the two-pipe
boiler adapter (6PPS-06PVCM-6PPF) male end,
vent system connector when using PVC pipe for
when used for combustion product venting.
combustion air supply to boiler.
If polypropylene pipe is also used for combustion air
13) APX800 model - Apply a coating of supplied red
supply, application of the silicon sealant to PVC to
RTV silicon sealant, at least 1” wide, to PVC to PP
PP boiler adapter (6PPS-06PVCM-6PPF) male end
boiler adapter (ISAA0606 or ISAAL0606) male
is not required.
end, when used for combustion product venting.
6) APX800 model - Push and twist PVC to PP boiler

If polypropylene pipe is also used for combustion air
adapter (6PPS-06PVCM-6PPF) into two-pipe vent
supply, application of the silicon sealant to PVC to
system connector vent port or air supply port until
PP boiler adapter (ISAA0606 or ISAAL0606) male
bottomed out.
end is not required.
7) Tighten the worm band clamp screw to secure PVC
14) APX800 model - Push and twist PVC to PP boiler
to PP boiler adapter.
adapter (ISAA0606 or ISAAL0606) into two-pipe
8) Do not install PVC to PP boiler adapter at the
vent system connector vent port or air supply port
lower combustion air supply port of the two-pipe
until bottomed out.
vent system connector when using PVC pipe for
15) Tighten the worm band clamp screw to secure PVC
combustion air supply to boiler.
to PP boiler adapter.
When using Centrotherm Eco polypropylene pipe
16) Do not install PVC to PP boiler adapter at the
for combustion product venting and/or air supply PVC
lower combustion air supply port of the two-pipe
to PP boiler adapter (ISAA0404 or ISAAL0404 and
vent system connector when using PVC pipe for
ISAA0606 or ISAAL0606 as applicable) is installed
combustion air supply to boiler.
into the two-pipe vent system connector vent or

Optional Two-pipe Vertical Venting Installation –
combustion air supply port as follows (see Figure 14):
Running Flexible Polypropylene Vent (Liner)
9) APX399 and APX500 models - Apply provided

Thru Unused Chimney Chase (see Figure 15).
dielectric grease (grease pouch taped to the vent
Apex APX399 and APX500 boilers are approved for
system connector) all around to the vent or air
vertical venting by installing Flexible Vent in an UNUSED
connection inner red silicon gasket.
masonry chimney/chase and supplying combustion air
thru a separate wall or roof air intake terminal.

IV. Venting C. Polypropylene Venting (continued)

Venting of Other Appliances (or Fireplace)
into Chase or Adjacent Flues Prohibited!

Figure 15: Flexible Vent in Masonry
Chimney with Separate Air Intake

WARNING

Follow installation instructions included by the original polypropylene venting component manufacturers,
M&G/DuraVent or Centrotherm, whichever applicable.
Flexible Polypropylene Vent must be installed in an UNUSED chimney. A chimney, either single or
multiple flue type, is considered UNUSED when none of the flues is being used for any appliance
venting.
Where one of the multiple flues is being used for an appliance venting, the flexible vent installation is
not permitted thru any of adjacent flues.
Observe all precautions outlined in either M&G/DuraVent or Centrotherm instructions in addition to
those outlined in these instructions.
Examine all components for possible shipping damage prior to installation.
Proper joint assembly is essential for safe installation.
The venting system must be free to expand and contract and supported in accordance with installation
instructions included by the original polypropylene venting component manufacturers, M&G/DuraVent
or Centrotherm, whichever applicable.
Do not mix vent components or joining methods for different vent systems.
Where a conflict arises between M&G/DuraVent or Centrotherm instructions and these instructions, the
more restrictive instructions shall govern.
Do not apply thermal insulation to vent pipe and fittings.
Do not obtain combustion air from within the building.

IV. Venting D. Stainless Steel Venting (continued)
D. Stainless Steel Venting

a. Push the stainless steel vent adapter onto the
CPVC/PVC connector with a slight twisting
motion. Make sure that the stainless steel vent
adapter is inserted at least 1” (refer to Figure 16).
b. Secure the adapter to the CPVC/PVC connector
by tightening the metal strap.

CAUTION
Vent systems made by Heat Fab, Protech and
Z-Flex rely on gaskets or proper sealing. When
these vent systems are used, take the following
precautions:
• Make sure that gasket is in position and undamaged in the female end of the pipe.
• Make sure that both the male and female
pipes are free of damage prior to assembly.
• Only cut vent pipe as permitted by the vent
manufacturer in accordance with their instructions. When pipe is cut, cut end must
be square and carefully de-burred prior to
assembly.

WARNING
All condensate that forms in the vent must be
able to drain back to the boiler.
1. Vent Length Restrictions
a. Vent length restrictions are based on equivalent
length of vent/combustion air pipe (total length
of straight pipe plus equivalent length of
fittings). Maximum vent/combustion air lengths
are listed in Table 8. Do not exceed maximum
vent/combustion air lengths. Do not include
vent/combustion air terminals in equivalent
feet calculations. See “Combustion Air/Vent,
Equivalent Length Work Sheet”.
b. The vent termination location is restricted as
per ‘General Guidelines’, Section A.5. (Refer to
Figure 4)
c. Where the use of “silicone” is called for in the
following instructions, use GE RTV 106 or
equivalent for the vent collar. Air inlet piping
sections are sealed with any general-purpose
silicone sealant such as GE RTV102. PVC air
inlet piping sections are connected with PVC
cement.
d. Longitudinal welded seams should not be placed
at the bottom of horizontal sections of exhaust
pipe.
e. Do not drill holes in vent pipe.
f. Do not attempt to mix vent components of
different vent system manufacturers.
2. Near Boiler Connection

To install the stainless steel vent adapter

[P/N 102220-01 (4”)]:

To install the stainless steel vent adapter
[P/N 103285-01 (6”)]:
c. Apply a coating of supplied red RTV silicone
sealant, at least 1” wide, all around male end of
the stainless steel vent adapter.
d. Afterwards, insert the male end of the adapter
with a slight twisting motion into vent section of
installed two-pipe CPVC/PVC vent connector.
e. Secure the adapter to the two-pipe CPVC/PVC
vent connector by tightening the metal strap.

3. System Assembly
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
b. Refer to Tables 11A and 11B for approved
AL29C Vent Systems.
c. Do not exceed maximum Vent/Combustion air
length. Refer to Table 8.
d. Follow all manufacturer instructions and
warnings when preparing pipe ends for joining
and using the primer and the cement.
e. Assemble the air intake system using either
galvanized or PVC pipe.
i. If PVC piping is used, use PVC cement
to assemble the PVC intake system
components. See Part B for air intake
installation instructions.
ii. If galvanized piping is used, use at least two
sheet metal screws per joint. Seal the outside
of all joints.
4. Horizontal Vent Termination
a. Standard Two-Pipe Termination
Refer to Figure 9A.
i. Vent Termination
• Use Burnham Commercial stainless
exhaust terminal [P/N 100184-01 (4”)].
The outer edge of this terminal must be
between 6” and 12” from the surface
of the wall. The joint between the
terminal and the last piece of pipe
must be outside of the building.
• Male end of terminal will fit into the
female end of any of the approved
stainless vent systems.

IV. Venting D. Stainless Steel Venting (continued)
i.

Figure 16: Field Installation of Two-Pipe Vent
System Adapter for Stainless Steel
• Apply a heavy bead of silicone to the
male end of the terminal before inserting
it into the last piece of pipe. Orient the
terminal so that the seam in the terminal
is at 12:00.
• Smooth the silicone over the seam
between the terminal and the last piece
of pipe, applying additional silicone if
necessary to ensure a tight seal.
• Allow the silicone to cure per the silicone
manufacturer’s instructions before
operating the boiler.
ii. Combustion Air Termination
• Horizontal intake terminal is a tee in the
upright position. Tee should protrude
the same distance from the wall as the
exhaust terminal. See Figure 9A.
• Install a rodent screen (not supplied) in
the inlet terminal. Use a screen having
1/2” x 1/2” mesh.
b. Optional Two-Pipe Snorkel Termination
Refer to Figure 11.
This installation will allow a maximum of
seven (7) feet vertical exterior run of the vent/
combustion air piping to be installed on the
approved AL29-4C Stainless Steel horizontal
venting application.

Vent Termination
• After penetrating wall, install the
appropriate manufacturer’s 90° elbow so
that the elbow leg is in the up direction.
• Install maximum vertical run of seven (7)
feet of appropriate manufacturer’s vent
pipe. See Figure 11.
• At top of vent pipe length install another
appropriate manufacturer’s 90° elbow
so that the elbow leg is opposite the
building’s exterior surface.
• Install horizontal vent terminal.
• Brace exterior piping if required.

Table 11A: Burnham Commercial Vent System
Components (Stainless Steel)
Part Numbers
APX399
Equivalent
and
APX800
Feet of Pipe
APX500
4" Vent
6” Vent

Vent System
Component
SS Vent Kit

102501-02

Horizontal Vent Terminal
(Included in Kit)

8116313

N/A

PVC to SS Vent Adapter
(Included In Kit)
Vertical Vent Terminal
Pipe x 1 Ft.
Pipe x 3 Ft.
Pipe x 5 Ft.

102680-02
100176-01
100177-01
100178-01

Pipe x Adjustable

100179-01

90° Elbow

100180-01

1
3
5
Equal to
Installed
Length
(1.06 to 1.64)
8.0 (4")

45° Elbow

100181-01

4.5 (4")

Horizontal Drain Tee
Vertical Drain Tee
Single Wall Thimble

100182-01
100183-01
100184-01

2
7½
N/A

102220-01

N/A

Table 11B: Alternate Vent Systems and Vent Components (Stainless Steel)
Manufacturer

Vent
System

Protech Systems Inc..

FasNseal

Z-Flex

SVE Series III
(“Z-Vent III”)

Flex-L Intl.

Star-34

Size

Wall Thimbles

FSWT4

Horizontal Termination
Tee: FSTT4
Tee: FSTT6

Vertical
Termination
FSBS4

FSWT6

2SVSWTEF04

Tee: 2SVSTTF04

24SVSTPF04

N/A

SR04WT15

N/A

Tee: SRTT-04

FSBS6

SRTP-04

N/A

NOTE: See vent system manufacturer’s literature for other part numbers that are required such as straight pipe, elbows, firestops
and vent supports.

IV. Venting D. Stainless Steel Venting (continued)

E. Concentric Polypropylene Venting

ii. Combustion Air Termination
• After penetrating wall, install a 90°
elbow so that the elbow leg is in the up
direction.
• Install maximum vertical run of seven (7)
feet of combustion air pipe. See Figure
11.
• At top of vent pipe length install another
90° elbow os that the elbow leg is
opposite the building’s exterior surface.
• Install Rodent Screen (not supplied) and
horizontal vent terminal.
• Brace exterior piping if required.

1. Vent Length Restrictions
a. Vent length restrictions are based on equivalent
length of vent pipe i.e. total length of straight
pipe plus equivalent length of fittings. See
Table 12 for specified vent length details. Do
not exceed maximum vent length. Table 13
lists available concentric vent components and
includes equivalent vent length for fittings.
b. The vent termination location is restricted as per
‘General Guidelines’, Paragraph A, 5 (refer to
Figure 4).
2. Field Installation of Boiler Concentric Vent

Collar

5. Vertical Vent Termination
a. Standard Two-Pipe Termination
Refer to Figures 12 and 13.
i. Vent Termination
• Use the terminal supplied by the vent
system manufacturer shown in Table
11B. Follow manufacturer’s instructions
to attach terminal to vent system.
ii. Combustion Air Termination
• Install vertical combustion air terminal.
Vertical combustion air terminal consists
of an 180° bend (comprised of two (2)
90° elbows) as shown in Figure 12.
• Install rodent screen (not supplied) in the
combustion air terminal. Use a screen
having 1/2” (2 x 2) or larger mesh.

a. Locate and remove six mounting screws from the
Miscellaneous Parts Carton.
b. Position the Collar onto jacket combination rear/
bottom panel and insert collar inner stainless
steel vent pipe into the heat exchanger vent
outlet.
Table 12: Concentric Vent Length
Vent Length
(Equiv. Ft.)

Boiler
Model

Inner/Outer
Pipe Dia., mm

APX399

100/150 mm

32 in.

APX500

100/150 mm

32 in

APX800

N/A

Minimum

* Maximum

Wall Opening
Diameter

6-1/2 in

N/A

* with optional concentric vent components, see Table 13 for details.

Table 13: Concentric Vent Components (Applicable to APX399 and APX500 only)
Part Number

Component Description

Size

101548-01
101549-01
101550-01
101551-01
101553-01
101809-01
101557-01
101558-01
101559-01
101560-01
101561-01

90° Elbow – Long Radius
45° Elbow - Long Radius
1 Cut -To-Length Extension, 500 mm (19-1/2”)
Cut -To-Length Extension, 1000 mm (39”)
Fixed Extension, 2000 mm (78”)
Horizontal (Wall) Terminal
Vertical (Roof) Terminal
Flat Roof Flashing
Sloped Roof Flashing
Support Elbow with Chimney Chase Bracket
Hanger Wall Bracket

100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm
100/150 mm

Notes:

1.
2.
3.

Component
Equivalent Vent
Length, Ft

Comments

8.0
3.0
1.63
3.25
6.5
* NA
* NA

** Can be cut
** Can be cut
*** Must not be cut
Supplied with boiler
See Note 1

10.0

See Note 2
See Note 3

* NA – do not include vent terminal into total vent length calculations.
** These sections have plain male end and beaded female end. See Figure 18 for details.
*** These sections have beaded male end and beaded female end. See Figure 19 for details.
Vertical terminal can be used with either of the roof flashings listed beneath it.
Sloped roof flashing suitable for roof angles between 25° and 45°.
Used at base of vertical run inside unused masonry chimney.

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 17: Field Installation of Boiler
Concentric Vent Collar

c. Align collar plate clearance holes with rear/
bottom panel engagement holes; then secure the
collar to rear/bottom panel with six mounting
screws. See Figure 17.
d. Flue temperature sensor, factory attached to the
boiler wiring harness, is secured to the left boiler
jacket panel with tape.
e. Remove the tape and push the sensor rubber plug
into Concentric Vent Collar sensor port until the
plug is securely engaged. See Figure 17.
The installation of the Concentric Vent Collar is now
completed.

3. System Assembly
a. Plan venting system to avoid possible contact
with plumbing or electrical wires. Start at
vent connector at boiler and work towards vent
termination.
b. Do not exceed maximum Concentric vent length.
Refer to Table 12.
c. If additional concentric vent piping is needed:
i. Concentric Vent Cut-To-Length Extension
pipes, identified in Table 13 CAN BE
CUT to required length when used as an
extension. These pipes have plain male
end and beaded female end. Always cut
the pipe from plain male end. See Figure
18 ‘Cut-To-Length Extension (Cuttable)”.

Figure 18: Cut-To-Length Extension (Cuttable)

ii. The remaining Concentric Vent Fixed
Extensions shown in Table 13 CANNOT
BE CUT. These pipes have beaded male and
beaded female ends. See Figure 19 “Fixed
Extension (Non-Cuttable)’.

Figure 19: Fixed Extension (Non-Cuttable)
d. To cut the Concentric Vent Straight pipe to
required length refer to Figure 20 “Cutting
Straight Pipe” and the following procedure:
i. Determine the required length of the outer
pipe. When doing this allow an additional
1” of length for insertion into the female end
of the adjoining pipe. Mark the cut line on
the outer pipe.
ii. Remove the plastic inner pipe by pulling it
out from the female end.
iii. Cut the OUTER PIPE ONLY at the point
marked in Step (a) using aviation shears, a
hacksaw, or an abrasive wheel cutter. Be
careful to cut the pipe square. De-burr the
cut end with a file or emery cloth.
iv. Make an insertion mark 1” from the male
end of the outer pipe.
v. Cut the plastic inner pipe so that it will
protrude 3/8” beyond the male end of the
outer pipe when reinstalled in the outer pipe.
Use a fine tooth hacksaw or a PVC saw to
cut the plastic pipe and be careful to cut the

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 20: Cutting Straight Pipe
pipe square. De-burr the cut edge of the
plastic pipe with a file, razor blade or fine
sandpaper.
vi. Reinstall the inner pipe.
e. To join Concentric Vent Pipe refer to Figure 21
“Joining Cuttable Pipe” and Figure 22 “Joining
Non-Cuttable Pipe” and follow the procedure
below:
i. Start assembly of the vent system at the
boiler. Lubricate the brown gasket in the
boiler vent collar with a few drops of water.
ii. Push the male end of the first fitting into the
boiler collar until it bottoms out. The male
end of cuttable sections should go 1” into
the collar until the insertion mark (made in
Step 4 above) is covered. On other fittings,
the bead on the male pipe will be bottom out
on the collar (see Figure 22).
iii. The male end of cuttable fittings must be
held to the collar with three (3) #10 x 1/2”
sheet metal screws. Drill a 1/8 hole through
both outer pipes to start this screw. Use a
drill stop or other means to ensure that
the drill bit does not penetrate more than
3/8” into the outer pipe. Do not use a
sheet metal screw longer than 1/2” (see
Figure 21).
iv. Use locking bands (provided with all
fittings) to secure non-cuttable pipe, as well
as fittings, to the boiler collar (see Figure
22).

Figure 21: Joining Cuttable Pipe

Figure 22: Joining Non-Cuttable Pipe

IV. Venting E. Concentric Polypropylene Venting (continued)
iii. For horizontal (sidewall) installation, the
Horizontal (Wall) Terminal will extend
past outer wall surface by 5½” (100/150
mm). See Figure 23 “Horizontal Concentric
Venting”.
iv. Install the Horizontal (Wall) Terminal:
• Cut a 6½” (for 100/150 mm) at the
planned location of the horizontal
terminal.
• Measure dimension “L” from exterior
wall outer surface to the end of the last
fitting. See Figure 24 ‘Dimension “L”’.

Figure 23: Horizontal Concentric Venting
v. Use the same method to join all remaining
vent components except for the terminal.
4. Horizontal Vent Termination
a. Standard Concentric Termination
Refer to Figure 23.
i. Permitted terminals for horizontal venting:

Horizontal (Wall) Terminal, [100/150 mm
(P/N 101809-01)] - see Table 13.
ii. Concentric Vent components supplied with
the boiler are packed inside boiler carton
and include the following:
• Horizontal (Wall) Terminal,
• Horizontal (Wall) Terminal consists
of Straight section having plain male
end with locking band clamp installed;
Terminal Assembly with offset vent
termination, and Outside Wall Plate,
both riveted on the opposite end; overall
length is approximately 28-1/8”.
• Separate Inside Wall Plate
• Two Hardware Bags (each bag contains
four screws and four anchors) to attach
vent terminal Outside Wall Plate to
exterior wall and Inside Wall Plate to
interior wall.

Figure 24: Dimension “L”
• When factory Horizontal (Wall)
Terminal needs to be shortened, measure
dimension “L” plus 1¼” from inside
of the attached Outside Wall Plate and
mark the Horizontal (Wall) Terminal
outer pipe. To achieve a square cut of the
outer pipe, place several marks around
the outer pipe to establish a cut line. See
Figure 25 ‘ Cutting Vent Terminal Pipe’.
• Carefully cut the outer pipe at the marked
line using aviation shears, a hacksaw etc.
Ensure the pipe is cut square and cut end
is de-burred.
• Mark the end of the Horizontal (Wall)
Terminal inner polypropylene vent pipe
to extend 3/8” past the cut end of the
outer pipe. To achieve a square cut of the
inner pipe, place several marks around
the inner pipe to establish a cut line.
• Cut off the marked end of inner
polypropylene vent pipe with a fine tooth
blade hacksaw etc. and de-burr. See
Figure 25 “Cutting Vent Terminal Pipe.
This pipe can be removed from the
terminal to ease cutting, if desired.

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 25: Cutting Vent Terminal Pipe

CAUTION
Exterior wall surface must be reasonably flat to
attach the Outside Wall Plate. When exterior wall
surface is not flat (covered with vinyl or wood
shingle siding etc.) the siding must be removed,
and a flat surface build up flash or above siding
exterior surface to secure/seal the terminal
Outside Wall Plate.
•. Install the supplied Inside Wall Plate onto
the shortened Horizontal (Wall) Terminal
interior end and move the plate to cover
interior wall cut opening. Secure the
plate with provided fasteners, then, apply
the sealant around plate sides to seal it to
interior wall (refer to Figure 26).
• Lubricate the brown gasket inside boiler
concentric vent collar or the last section
of the vent pipe with small amount of
water.
• Ensure that inner pipe of the terminal
is evenly engaged into the gasket all
around, then push the termination male
end inside boiler concentric vent collar or
the last section of the vent pipe, until the

mark (see Step v) is no longer visible.
• Re-install locking band clamp onto the
joint to secure the terminal to the collar
or the last section of the vent pipe.
5. Vertical Vent Termination
a. Standard Concentric Termination
Refer to Figures 27 thru 31.
i. In addition to the vertical terminal, either a
Flat Roof Flashing or Sloped Roof Flashing
is required for this installation. Refer to
Table 12 ‘Concentric Vent Components’ for
details.
• Determine the centerline of the terminal
location on the roof. For flat roof, cut
6½” (100/150 mm) for the terminal. For
sloped roof, cut a hole in the roof large
enough for the terminal to pass through
the roof while remaining plumb.

CAUTION
If the boiler is located directly under the hole,
cover it while cutting the hole to prevent debris
from falling onto boiler.

IV. Venting E. Concentric Polypropylene Venting (continued)

Figure 26: Completing Horizontal (Wall Terminal Installation)

Figure 27: Vertical Concentric Vent Installation

Figure 28: Dimension "H"

IV. Venting E. Concentric Polypropylene Venting (continued)
• Install the roof flashing using standard
practice on the roofing system of the
structure.
• If not already done, assemble the venting
system inside the building. The last
section of pipe needs to be on the same
center line as the terminal and within
19-1/4” of the top edge of the roof
flashing.
• Measure distance “H” from the top edge
of the storm collar to the end of the last
fitting as shown in Figure 28.
• Add 1” to distance “H”. Carefully mark
this length on the pipe as shown in Figure
29.
• Cut the outer pipe only at the point
marked in Step (e) using aviation shears,
a hacksaw, or an abrasive wheel cutter.
Be careful to cut the pipe square. De-burr
the cut end with a file or emery cloth.
• Place a mark on the plastic inner pipe
3/8” beyond the end of the outer pipe
(Figure 29). Use a fine tooth hacksaw to
cut the plastic pipe and be careful to cut
the pipe square. De-burr the cut edge of
the plastic pipe with a file or emery cloth.
• Make a mark on the terminal section
1” from the cut end of the outer pipe as
shown in Figure 29.

Figure 30: Completing Vertical Terminal Installation
b. Optional Concentric Chimney Chase Installation
Refer to Figure 31.
i. A vertical concentric vent system can be
installed in an UNUSED masonry chimney.
• The Chimney chase Support Elbow
with attached Mounting Bracket is used
at the base of the chimney. Refer to
Table 12 ‘Concentric Vent Components’
for details. Slip the elbow over the
M10 x 35 screw in the support bracket.
Determine the desired vertical location
of the support elbow in the chimney and
mark the location of the pin, positioned
on the back of the support bracket,
onto the chimney rear wall. Drill a
7/16” diameter x 3-1/2” deep hole in
the marked location, then, insert the
back bracket pin into the hole. The
front of the elbow mounting bracket
should be supported either by bottom
of the opening into chimney or installer
supplied spacer.
• Construct a weather-tight flat roof to
cover the top of the old chimney. Install
the vertical terminal through this roof
using the flat roof flashing.

Figure 29: Cutting Vertical Terminal
• Slip the terminal section through the
roof from the outside. Push into the last
section of vent pipe until the mark made
in Step (h) is not longer visible. Secure
the terminal to the last piece of pipe with
three #10 x 1/2” sheet metal screws.
Drill a 1/8” hole through both outer pipes
to start these screws. Use a drill stop or
other means to ensure that the drill
bit does not penetrate more than 3/8”
into the outer pipe. Do not use a sheet
metal screw longer than 1/2”.
• Secure the terminal section to the inside
of the roof structure using the mounting
bracket provided with the terminal
(Figure 30).

F. Removing the Existing Boiler

For installations not involving the replacement of an
existing boiler, proceed to Step B.

IV. Venting F. Removing the Existing Boiler (continued)

When an existing boiler is removed from a common
venting system, the common venting system is likely
to be too large for proper venting of the remaining
appliances. At the time of removal of an existing
boiler, the following steps shall be followed with each
appliance remaining connected to the common venting
system placed in operation, while the other appliances
remaining connected to the common venting system are
not in operation:

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
fireplace dampers.

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

4. Place in operation the appliance being inspected.
Follow the Lighting (or Operating) Instructions.
Adjust thermostat so appliance will operate
continuously.

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

5. Test for spillage at the draft hood relief opening
after five (5) minutes of main burner operation. Use
the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.

3. 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

6. After it has been determined that each appliance
remaining connected to the common venting system
properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and
any other gas burning appliance to their previous
conditions of use.
7. Any improper operation of the common venting
system should be corrected so the installation
conforms with the National Fuel Gas Code, NFPA
54/ANSI Z223.1. 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
Part II in the National Fuel Gas Code, NFPA 54/
ANSI Z223.1.

Figure 31: Chimney Chase Installation

IV. Venting G. Multiple Boiler Installation Venting (continued)
G. Multiple Boiler Installation Venting
1. CPVC/PVC or Polypropylene Venting
a. Multiple Boiler CPVC/PVC or polypropylene
direct venting is shown in Figure 32.
b. Each individual module (boiler) must have own
vent pipe and vent terminal. Refer to Paragraphs
B thru E (as applicable) for individual module
(boiler) venting guidelines and options.

WARNING
No common manifolded venting (vent piping and
vent terminals) is permitted.

c. The individual module (boiler) maximum vent
length - see Table 8.
d. For sidewall venting the minimum horizontal
distance between any adjacent individual module
(boiler) vent terminations is twelve (12) inches.
Additional horizontal spacing between any adjacent
individual module (boiler) vent terminations as well
as extending the distance from building surfaces
to vent termination end are recommended to avoid
frost damage to building surfaces where vent
terminations are placed.

CAUTION
Installing multiple individual module (boiler) vent
terminations too close together may result in
combustion product water vapor condensation
on building surfaces, where vent termination are
placed, and subsequent frost damage. To avoid/
minimize frost damage, extend the distance from
building surfaces to vent termination end and
increase the horizontal distance between adjacent
vent terminations.
e. Individual module (boiler) sidewall vent
terminals must be placed at least twelve (12)
inches above the ground plus the expected snow
accumulation.
f. Multiple individual module vertical vent pipes
may be piped through a common conduit or
chase so that one roof penetration may be made.
The minimum horizontal distance between any
adjacent individual module (boiler) roof vent
terminations is one (1) foot.
2. PVC Pipe Air Intake Piping

a. Multiple Boiler PVC air intake piping is shown
in Figure 32.
b. Each individual module (boiler) must have own
combustion air intake pipe and combustion air
intake terminal. Refer to Paragraphs B thru E
(as applicable) for individual module (boiler)
combustion air intake guidelines and options.

c. The individual module (boiler) maximum
combustion air intake pipe length - see Table 8.
d. If possible, locate each individual module
(boiler) both combustion air intake termination
and vent termination on the same sidewall, to
prevent nuisance boiler shutdowns.
However, if same sidewall placement is
problematic, an individual module (boiler) may
be installed using vertical venting and sidewall
combustion air intake termination (or, vice versa)
3. Concentric Combination Venting/Combustion
Air Intake Piping
a. Concentric Combustion Venting and air intake is
shown in Figure 33.
b. Each individual module (boiler) must have
own concentric vent pipe and vent termination.
Follow Section IV “Venting” of this manual for
individual module (boiler) concentric venting
guidelines.

WARNING
No common manifolded concentric venting is
permitted.
c. The individual module (boiler) maximum
concentric vent length - see Table 8.
d. For sidewall venting any adjacent individual
module (boiler) concentric vent terminals must
be spaced no closer than 12 inches horizontally
and three (3) feet vertically from each other to
prevent combustion air contamination.
Additional horizontal spacing between any
adjacent individual module (boiler) concentric
vent terminations and increased distance from
building surfaces to concentric vent termination
end are recommended to avoid frost damage to
building surfaces where vent terminations are
placed.
e. Individual module (boiler) sidewall concentric
vent terminals must be placed at least twelve
(12) inches above the ground plus the expected
snow accumulation.
f. For vertical through the roof venting any
adjacent individual module (boiler) vertical
vent terminals, if level with each other, must be
spaced no closer than 12 inches horizontally.
If vertical vent terminals cannot end in one
plane, they must be spaced no closer than three
(3) feet horizontally.
g. Chimney chase concentric venting is permitted
for modules, when stackable, providing
concentric vertical (roof) vent terminals, if level
with each other, are spaced no closer then 12
inches horizontally.

Figure 32: Multiple Boiler Direct Vent Termination

IV. Venting G. Multiple Boiler Installation Venting (continued)

42
Figure 33: Multiple Boiler Concentric Vent Termination

IV. Venting G. Multiple Boiler Installation Venting (continued)

If vertical vent terminals cannot end in one
plane, they must be spaced no closer then three
(3) feet horizontally.
h. When individual modules (boilers) are installed
in the same horizontal plane, chimney chase
vertical concentric venting is permitted provided:

Sufficient inside space available at the base
of the chimney to install multiple chimney
chase brackets and support elbows.
ii. Spacing between adjacent vertical vent
terminals is in accordance with Item ‘g’
above.

V. Condensate Disposal
A. Condensate Trap and Drain Line.
1. All condensate, which forms in the boiler or vent
system, collects in the sump under heat exchanger
and leaves the boiler through factory installed
condensate trap.
2. The trap allows condensate to drain from sump
while retaining flue gases in the boiler. The trap
has factory installed overflow switch, which shuts
down the boiler in the event the drain line becomes
obstructed, preventing proper condensate removal.
Refer to Section XI “Service and Maintenance” for
condensate trap and condensate overflow switch
removal and replacement procedure, if required.
3. Note the following when disposing of the
condensate:
a. Condensate is slightly acidic, typical pH around
3.5 - 4.5. Do not use metallic pipe or fittings in
the condensate drain line. Do not route the drain
line through areas that could be damaged by
leaking condensate.
b. Do not route or terminate the condensate drain
line in areas subject to freezing temperatures.
c. If the point of condensate disposal is above the
trap, a condensate pump is required to move
the condensate to the drain. Select a condensate
pump approved for use with condensing
furnaces. If overflow from the pump would
result in property damage, select a pump with an
overflow switch. Wire this switch in series with
installer provided external high limit, to shut off
the boiler, and, if desired, in series with installersupplied alarm, to trigger an alarm in the event
of overflow.
d. Do not attempt to substitute another trap for one
provided with the boiler.
e. In order for boiler to work properly, the boiler
must be leveled during installation.
4. The condensate trap stub is located at boiler left
side, below inlet and outlet water pipe connections.
Refer to Figures 1A and 1B.

5. Condensate trap must be filled up with water,
prior to boiler start-up and before connecting
any condensate line to the boiler, to insure
combustion products cannot escape from
operating boiler. To fill the trap, inject water in the
amount of 1 cup (8 fluid ounces) through condensate
trap stub opening. Do not overfill the trap.
6. If any additional condensate drain line is needed,
construct the extension from PVC or CPVC
Schedule 40 pipe. The factory supplied ¾” x 5-5/8”
long PVC coupling, located in the Part Carton, must
be used to connect drain line to the condensate trap
stub. Do not over tighten coupling compression nuts
when connecting drain line and condensate trap
stub.

WARNING
Failure to install the condensate trap and
condensate drain in accordance with the above
instructions could cause flue gas to enter the
building, resulting in personal injury or death.

CAUTION
Boiler condensate is corrosive. Route
condensate drain line in a manner such
that any condensate leakage will not cause
property damage.
Some jurisdictions may require that
condensate be neutralized prior to disposal.

NOTICE
Use materials approved by the authority having
jurisdiction.

B. Condensate Neutralizer Installation
1. Some jurisdictions may require that the condensate
be neutralized before being disposed of. Follow
local codes pertaining to condensate disposal.

V. Condensate Disposal (continued)
2. A Condensate Neutralizer Kit (P/N 101867-01)
is available as optional equipment. Follow local
codes and instructions enclosed with the kit for
Condensate Neutralizer installation.
3. Limestone chips will get coated by neutral salts
(product of chemical reaction between limestone
and acidic condensate) and lose neutralizing

effectiveness over time. Therefore, periodic
condensate neutralizer maintenance and limestone
chip replacement must be performed. A pH test or
acid test kits are available from HVAC/plumbing
distributors and should be used to measure
condensate acidity before/after neutralizer thus
indicating a need for service and chip replacement.

Figure 34: Condensate Trap and Drain Line

VI. Water Piping and Trim
WARNING
Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.
Install boiler so that the gas ignition system components are protected from water (dripping, spraying,
rain, etc.) during appliance operation and service (circulator replacement, etc.).
Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can
lead to boiler failure. Burnham Commercial’s Standard Warranty does not cover problems caused by
oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
Do not fill boiler with softened water to prevent chloride contamination.

A. Installation of Factory Supplied Piping and Trim

Components
Apex (APX) boilers have factory supplied
Miscellaneous Part Carton (P/N 102942-04 – APX399
& APX500; P/N 103259-01 – APX800), which includes
supply piping components, gas piping components,
Temperature & Pressure Gauge, Pressure Relief Valve
and Drain Valve. See Figure 35 “Factory Supplied
Piping and Trim Installation”.
Install these components prior to connecting boiler to
system piping as follows:

1. APX399 and APX500 Boiler Models
a. Locate and remove (1) ¾” NPT x close black
nipple, (1) ¾” NPT x 12” black nipple, ¾” NPT
black tee, ¾” FPT x ¾” FPT Pressure Relief
Valve, ¾” NPT Drain Valve.
b. Install close nipple into tee branch, then, screw
the assembly into boiler left side front ¾” FPT
tapping making sure tee run outlets are in vertical
plane and parallel to boiler side.
c. Install the ¾” NPT x 12” black nipple into tee
run top outlet.
d. Mount ¾” FPT x ¾” FPT Pressure Relief Valve
onto 12” nipple.
e. Install Drain Valve into the tee bottom outlet.

Figure 35: Factory Supplied Piping and Trim Installation

VI. Water Piping and Trim A. Factory Supplied Piping and Trim (continued)
f. Locate and remove 1½” NPT x 2” long black
nipple, 1½” x 1½” x ¾” NPT black tee, ¾” x ¼”
NPT black reducing bushing and Temperature &
Pressure Gauge.
g. Mount the nipple into 1½” FPT boiler supply
tapping (see Figures 1A and 1B), then, install the
tee onto the nipple, making sure ¾” branch outlet
is in horizontal plane and facing the boiler front.
h. Install ¾” x ¼” NPT black reducing bushing
into the tee branch, then, put in Temperature &
Pressure Gauge.
2. APX800 Boiler Model

b. Install close nipple into tee branch, then, screw
the assembly into boiler left side front ¾”
tapping making sure tee run outlets are in vertical
plane and parallel to boiler side.
c. Install the ¾” NPT x 12” black nipple into tee
run top outlet.
d. Mount ¾” FPT x 1” FPT Pressure Relief Valve
onto 12” nipple.
e. Install Drain Valve into the tee bottom outlet.
f. Locate and remove 2” NPT steel coupling, 2”
NPT x 2-1/2” long black nipple, 2” x 2” x ¾”
NPT black tee, ¾” x ¼” NPT black reducing
bushing and Temperature & Pressure Gauge.
g. Mount 2” NPT coupling onto 2” MPT boiler
supply stub (see Figure 1C), then, install 2”
NPT x 2-1/2” long black nipple into the coupling

a. Locate and remove (1) ¾” NPT x close black
nipple, (1) ¾” NPT x 12” black nipple, ¾” NPT
black tee, ¾” FPT x 1” FPT Pressure Relief
Valve, ¾” NPT Drain Valve.
Table 14: Flow Range Requirement Through Boiler

Boiler
Boiler
Minimum
Boiler
Required
Boiler
Required
Maximum
Boiler
Boiler Head
Boiler
Supply
Return
Required Head Loss,
Flow,
Head Loss,
Flow,
Required
Head
Loss, Ft. @
Model Connection, Connection, Flow (GPM)
Ft.
(GPM)
Ft.
(GPM)
Flow (GPM) Loss, Ft.
25°F DT
Inch, FPT Inch, FPT @ 35°F DT @ 35°F DT @ 30°F DT @ 30°F DT @ 25°F DT
@ 20°F DT @ 20°F DT
APX399

1½

21.5

6.1

25.1

7.9

30.2

10.8

37.7

15.9

APX500

1½

27.1

6.9

31.7

8.9

38.0

12.1

47.5

17.6

APX800

43.4

12.1

50.7

15.5

60.8

20.9

76.0

30.0

Notes: Required Flow (GPM) = ** Output (MBH) * 1000/500 * DT
** Output (MBH) - Select Value for specific Boiler Model from Table 2A or 2B
Using boiler antifreeze will result in higher fluid density and may require larger circulators.

Pressure Drop vs. Flow
30
800

Pressure Drop (Feet of Head)

20
399

500

0
0

40
50
Flow Rate (GPM)

VI. Water Piping and Trim B. Piping System To Be Employed (continued)
outlet, then, attach 2” x 2” x ¾” tee onto the
nipple opposite end, making sure ¾” branch
outlet is in horizontal plane and facing the boiler
front.
h. Install ¾” x ¼” NPT black reducing bushing
into the tee branch, then, put in Temperature &
Pressure Gauge.

B. Piping System To Be Employed.

Apex (APX) boilers are designed to operate in a closed
loop pressurized system. Minimum pressure in the
boiler must be 12 PSI. Proper operation of the Apex
(APX) boiler requires that the water flow through the
boiler remain within the limits shown in Table 14, any
time the boiler is firing.

NOTICE
Failure to maintain the flow through boiler within
specified limits could result in erratic operation or
premature boiler failure.
1. Near boiler piping must isolate APX boiler from
system piping via closely spaced tees to insure
specified flow range through boiler any time the
boiler is firing:
a. The flow rate through the isolated near-boiler
loop is maintained by factory recommended and
installer supplied boiler circulator.
b. The flow rate through the isolated near-boiler
loop is completely independent of the flow rate
through the heating system loop(s).
c. The flow rate through the heating system loop(s)
is controlled by installer sized/provided system
loop circulator(s).
d. This piping arrangement can be used either for
space heating-only applications or space heating
with indirect water heater(s) applications.

Space heating only - refer to Table 15 and
Figure 36 “Near Boiler Piping - Heating
Only” as applicable.
ii. Space heating plus indirect water
heater(s) - refer to Table 15 and Figure 37
“Near Boiler Piping - Heating Plus Indirect
Water Heater” as applicable.
i.

NOTICE
Where it is not possible to install a separate
boiler loop, the system circulator must be
sized to ensure that the flow through boiler
stays within the defined parameters to prevent
overheating when the boiler is fired at it’s full
rated input. Install a flow meter to measure the
flow, or fire the boiler at full rate and ensure the
boiler DT does not exceed 35°F.
2. Direct connection of Apex (APX) boiler to
heating system, similar to a conventional boiler, is
NOT RECOMMENDED because:
a. The flow rate through system must be the same
as through boiler and fall within limits specified
in Table 14.
b. Pressure drop through entire system must be
known, added to pressure drop through boiler,
and, a circulator selected to provide required
flow at total calculated pressure drop.
c. It is often very difficult to accurately calculate
the pressure drop through the system.
d. In replacement installations, it may be nearly
impossible to get an accurate measurement of
piping amount and number of fittings in the
system. If system is zoned, the system flow rate
may drop well below recommended minimum
flow when only a single zone is calling for heat.

Table 15: Recommended Circulator Models for Apex (APX) Boilers Based on 25°F Temperature Differential
and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator
Boiler Supply Boiler Return
Near-Boiler
Near-Boiler
Flow, GPM
Combined Boiler
* Recommended Circulator
Connection,
Connection, Piping Supply Piping Return @ 25°F Temp.
& Piping Loop
Make & Model
Inch, FPT
Inch, FPT
Pipe Size, Inch Pipe Size, Inch
Differential
Head Loss, Ft.
Taco 2400-20 Grundfos UPS
APX399
1½
1½
2
2
30.2
12.0
32-80/2 F (second speed)
Taco 2400-30
Grundfos UPS
APX500
1½
1½
2
2
37.8
13.9
32-80/2 F (third speed)
or
40-80/2 F (second speed)
Taco 1400-70 Grundfos UPS
APX800
2
2
2½
2½
60.8
21.5
50-80/2 F (third speed)
Notes:
* Circulator Models shown are not equipped with internal flow check valve (IFC).
When selecting Circulators with IFC contact Circulator Manufacturer for sizing information.
Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/Sec. velocity range to avoid potential noise and pipe erosion.
Boiler
Model

VI. Water Piping and Trim C. Standard Installation Requirements (continued)
C. Standard Installation Requirements.

Observe the following guidelines when making the
actual installation of the boiler piping:
1. Safety Relief Valve (Required) - The relief valve is
packaged loose with boiler and must be installed in
the location shown in Figure 35 “Factory Supplied
Piping and Trim Installation”. The relief valve
must be installed with spindle in vertical position.
Installation of the relief valve must comply with
ASME Boiler and Pressure Vessel Code, Section IV.
The standard factory shipped relief valve is rated
for 50 PSI maximum working pressure. Optional
80 PSI and 100 PSI maximum working pressure
rated relief valves are available. If the valve is to be
replaced, the replacement valve must have a relief
capacity equal or exceeding the boiler AHRI Gross
Output rating (model APX500). Pipe the relief valve
discharge to a location where hot water or steam will
not create hazard or property damage if the valve
opens. The end of the discharge pipe must terminate
in an unthreaded pipe. If the relief valve is not
piped to a drain, it must terminate at least 6” above
the floor. Do not run relief valve discharge piping
through an area prone to freezing. The termination
of discharge piping must be in an area where it will
not become plugged by debris.

WARNING
Safety relief valve discharge piping must be
piped such that the potential of severe burns
is eliminated. DO NOT pipe in any area where
freezing could occur. DO NOT install any shut-off
valves, plugs or caps. Consult Local Codes for
proper discharge piping arrangement.
2. Circulator (Required) – Usually at least two
circulators will be required to properly install a
Apex™ Series boiler. See Paragraph B above for
information on sizing the circulators.
3. Expansion Tank (Required) – If this boiler is
replacing an existing boiler with no other changes
in the system, the old expansion tank can generally
be reused. If the expansion tank must be replaced,
consult the expansion tank manufacturer’s literature
for proper sizing.

4. Fill Valve (Required) – Either manual
(recommended) or automatic fill valve may be used.
However, if automatic refill is employed, a water
meter must be added to evaluate the makeup water
volume taken after initial fill and eliminate any
water leakage as early as possible.
5. Automatic Air Vent (Required) –At least one
automatic air vent is required. Manual vents will
usually be required in other parts of the system to
remove air during initial fill.
6. Manual Reset High Limit (Required by some
Codes) - This control is required by ASME CSD-1
and some other codes. Install the high limit in the
boiler supply piping just above the boiler with no
intervening valves. Set the manual reset high limit
to 200°F. Wire the limit per Figures 44 and 45A, in
Section VIII “Electrical”.
7. Y-strainer (Recommended) – A Y-strainer or
equivalent strainer removes heating system debris
from hydronic systems and protects boiler heat
exchanger from fouling up. Install the strainer
downstream of full port isolation valve, at the inlet
side of the circulator, for easy service.
8. Flow Control Valve (Strongly Recommended) –
The flow control valve prevents flow through the
system unless the circulator is operating. Flow
control valves are used to prevent gravity circulation
or “ghost flows” in circulator zone systems through
zones that are not calling for heat.
9. Isolation Valves (Strongly recommended) –
Isolation valves are useful when the boiler must be
drained, as they will eliminate having to drain and
refill the entire system.
10. Drain Valve (Required) – Drain valve is packaged
loose with boiler and must be installed in the
location shown in Figure 35 “Factory Supplied
Piping and Trim Installation”.
11. Low Water Cutoff (Required by some Codes) –
LWCO with harness and LWCO transformer are
available as optional components. Order Complete
Kit (Part No. 102097-01) when required.

VI. Water Piping and Trim C. Standard Installation Requirements (continued)
Table 16: Fitting and Valve Equivalent Length
(cont’d)

Table 16: Fitting and Valve Equivalent Length
Copper Fitting and Sweat Valve Equivalent Length (Ft)
Copper Pipe or Valve Size
Fitting or Valve
Description
1
1¼
1½
2
90° Elbow
45° Elbow
Tee (thru flow)
Tee (Branch flow)
Diverter Tee (typical)
Gate Valve
Globe Valve
Angle Valve
Ball Valve (standard port)
Ball Valve (full port)
Swing Check Valve
Flow-Check Valve (typical)
Butterfly Valve

2.5
1.0
0.5
4.5
23.5
0.3
25.0
5.3
4.3
1.9
4.5
54.0
2.7

3.0
1.2
0.6
5.5
25.0
0.4
36.0
7.8
7.0
1.4
5.5
74.0
2.0

4.0
1.5
0.8
7.0
23.0
0.5
46.0
9.4
6.6
2.2
6.5
57.0
2.7

5.5
2.0
1.0
9.0
23.0
0.7
56.0
12.5
14.0
1.3
9.0
177.0
4.5

Threaded Fitting and Valve Equivalent Length (Ft)
Black Threaded Pipe or
Fitting or Valve
Valve Size
Description
1
1¼
1½
2
90° Elbow
Long Radius
Elbow (45° or 90°)
Tee (thru flow)
Tee (Branch flow)
Close Return Bend
Gate Valve (full open)
Globe Valve (full open)
Angle Valve (full open)
Swing Check Valve
(full open)
Flow-Check Valve (typical)

2.6

3.5

4.0

5.2

1.4

1.8

2.2

2.8

1.8
5.3
4.4
0.7
30.0
13.0

2.3
6.9
5.8
0.9
39.0
17.0

2.7
8.1
6.7
1.1
46.0
20.0

3.5
10.0
8.6
1.4
59.0
26.0

8.7

12.0

13.0

17.0

42.0

60.0

63.0

83.0

NOTE: Table 16 is provided as reference to assist in piping design and specifies equivalent length of typical piping fittings and

valves.

NOTICE
The Apex (APX) boiler heat exchanger is made from stainless steel tubular coil having relatively narrow
waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following
precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler
damage.
• Before connecting the boiler, insure the system is free of impurities, grease, sediment, construction

dust, sand, copper dust, flux and any residual boiler water additives. Flush the system thoroughly and
repeatedly, if needed, with clear water mixed with concentrated rinse agent to remove these contaminants
completely.

• Iron oxide (red oxide sludge Fe2O3) is produced during oxygenation. To minimize any oxygen presence

in the system, the system must be air free and leak tight. Do not connect the boiler to radiant tubing
without an oxygen barrier. Using automatic water refill is not recommended, however, if such refill is
employed, a water meter must be added to evaluate the makeup water volume taken after initial fill and
eliminate any water leakage as early as possible.

• Maintain the water pressure in the boiler at a minimum of 12 PSI.
• The boiler water pH must be within 7.5 < pH < 9.5. If the system contains any aluminum components,

pH must be less than 8.5.

• Black oxide sludge (magnetite Fe O ) forms as the result of continuous electrolytic corrosion in any
3 4

system not protected by an inhibitor.

• Scale deposit is made up of lime scale contained in most distributed water and settles over the warmest

surfaces of boiler heat exchanger causing subsequent overheating and eventual failure. Water hardness
must be maintained within 3 to 9 grain/gal range.

• Refer to Section XI “Service and Maintenance” for recommended heating system water treatment products

(corrosion/scale inhibitors, cleaners etc) and their suppliers.

50
Figure 36: Near Boiler Piping - Heating Only

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

Figure 37: Near Boiler Piping - Heating Plus Indirect Water Heater

VI. Water Piping and Trim C. Standard Installation Requirements (continued)

VI. Water Piping and Trim D. Special Situation Piping Installation Requirements (continued)
D. Special Situation Piping Installation Requirements

Observe the following guidelines when making the
actual installation of the boiler piping for special
situations:
1. Systems containing high level of dissolved oxygen
– Many hydronic systems contain enough dissolved
oxygen to cause severe corrosion damage to Apex
(APX) boiler heat exchanger. Some examples
include but not limited to:
• Radiant systems employing tubing without
oxygen barrier
• Systems with routine additions of fresh water
• Systems open to atmosphere
If the boiler is used in such a system, it must be
separated from oxygenated water being heated
with a heat exchanger as shown in Figures 38A and
38B. Consult the heat exchanger manufacturer for
proper heat exchanger sizing as well as flow and
temperature requirements. All components on the
oxygenated side of the heat exchanger, such as the
pump and expansion tank, must be designed for use
in oxygenated water.

2. Piping with a Chiller - If the boiler is used in
conjunction with a chiller, pipe the boiler and chiller
in parallel. Use isolation valves to prevent chilled
water from entering the boiler.
3. Boiler Piping with Air Handlers - Where the
boiler is connected to air handlers through which
refrigerated air passes, use flow control valves in the
boiler piping or other automatic means to prevent
gravity circulation during the cooling cycle.
Table 17: Multiple Boiler Water Manifold Sizing
Boiler Model
APX399
APX500
APX800

Number of Units
3
4
5
6
7
8
Recommended Minimum Common
Water Manifold Size (NPT)
2½”
3”
3”
4”
5”
5”
5”
3”
4”
4”
5”
5”
6”
6”
3”
5”
5
6”
6”
8”
8”
2

Figure 38A: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)

VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued)

Figure 38B: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)

E. Multiple Boiler Installation Water Piping - See Table 17
and Figures 39B and 40B.

1. Refer to this Section of this manual for:
a. Installation of Factory Supplied Piping and Trim
Components for an individual module (boiler).
b. Regarding an individual module (boiler) piping
system specific details.
c. Selection criteria for individual module (boiler)
space heating and/or DHW circulators.

2. For installations where indirect domestic hot water
heater is combined with space heating, the Alliance
SL™ model must be piped as a separate heating
zone off the system header. The circulator must be
sized based on the Alliance SL™ model coil flow and
combined coil pressure drop and the zone piping total
equivalent length. Refer to Alliance SL™ Indirect
Water Heater literature for a specific model coil flow
and pressure drop. Refer to Table 18 and Figures 40A
and 40B.

54
Figure 39A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

Installing a low water cutoff in the system piping
of Multiple boilers is strongly recommended and
may be required by Local Codes.

NOTICE

VI. Water Piping and Trim E. Multiple Boiler Installation Water Piping (continued)

NOTICE
Installing a low water cutoff in the system piping
of Multiple boilers is strongly recommended and
may be required by Local Codes.

Figure 39B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

Figure 40A: Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2)

It is the installers responsibility to select pumps
and boiler piping configurations that provide the
proper flow rates and performance for the boiler
and indirect water heater.
Refer to Table 15 for recommended Boiler Loop
Circulator.

CAUTION

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

Figure 40B: Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2)

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

APX800

APX500

APX399

Boiler
Model

1-1/2

2½

Near-Boiler
Boiler
Boiler
Piping
Supply
Return
Supply
Connection, Connection, Pipe Size,
Inch, FPT
Inch, FPT
Inch
(Note 2)

NearMax
Boiler
Min Req’d Alliance SL
Allowable
Piping
Flow, Flow thru Models to
Flow thru
Return
GPM
Boiler,
be installed
Boiler,
Pipe
@ 25°F
GPM
As Part of
GPM @
Size,
DT
@ 35°F
Near-Boiler
20°F
Inch
DT
Piping
DT
(Note 2)
SL27
SL35
37.7
30.2
21.5
SL50
SL70
SL119
2
SL27
SL35
47.2
37.8
27.0
SL50
SL70
SL119
SL27
SL35
2½
76.0
60.8
43.4
SL50
SL70
SL119
6
6
6
6
14
6
6
6
6
14
6
6
6
6
14

9
9
9.5
10
17.0
9
9
9.5
10
17.0
9
9
9.5
10
17.0

(see Notes 1
and 2)

*Not
Recommended

* The IWH may be installed as part of Boiler piping when boiler DHW modulation rate (input) is adjusted to closely match the IWH rated heating capacity required to satisfy DHW demand (see Figures 40A and 40B).

Note 3: Near-Boiler Piping Size shown is based on 2 to 5.5 Ft/sec velocity range to avoid potential noise and pipe erosion.

When the IWH parameter is set to “Primary Piped”, the Sequence Master will be sequencing all required boilers to satisfy the DHW setpoint (default 180°F). Do not use the “Boiler Piped” parameter for 500 and 800 models,
unless IWH is piped off an individual boiler having DHW modulation rate (input) adjusted to closely match the IWH rated heating capacity required to satisfy DHW demand. Otherwise, piping an IWH of an individual boiler could
cause higher than normal velocities or DT’s thru that boiler because of required IWH flow. For commercial applications, it is recommended to pipe IWH’s off the common header piping. A header sensor must be installed to
prevent rapid header temperature rise when the Sequence Master is sequencing all required boilers to satisfy the DHW setpoint (default 180°F).

IMPORTANT – Shared or Isolated DHW Demand

Note 2:

Note 1: All Alliance SL Coil Flow Rates are below Min Required Flow Rate thru Boiler corresponding to boiler maximum firing rate. These Alliance models can only be installed as separate heating zone off system header - see
Figure 39A and 39B for IWH piping.
Indirect Water Heater Circulator must be selected by an installer based on Alliance SL required coil flow and corresponding coil head loss shown as well as total equivalent length of such separate zone.

40A & 40B Note 2

40A & 40B Note 1

*Recommended
Combined
Alliance SL Alliance SL
Circulator Make &
Boiler,
Coil
Coil Head
Model for
Alliance SL
Reference
Required
Loss, Ft @
Alliance SL
Notes
& Piping
Figure
installed as Part
Flow Rate,
Required
Loop Head
GPM
Flow Rate
of Near-Boiler
Loss, Ft
Piping

Table 18: Recommended Circulator Models for Apex (APX) Boilers and Alliance SL Indirect Water Heaters
Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water Circulator

VI. Water Piping and Trim E. Multiple Boiler Installation (continued)

NOTES:

VII. Gas Piping
Minimum gas valve inlet pressure is stamped on
the rating label located in the boiler’s vestibule
compartment.

WARNING
Failure to properly pipe gas supply to boiler may
result in improper operation and damage to the
boiler or structure. Always assure gas piping is
absolutely leak free and of the proper size and
type for the connected load.
An additional gas pressure regulator may be
needed. Consult gas supplier.

2. Maximum gas demand. Refer to the boiler’s input as
printed on its rating label. Also consider existing and
expected future gas utilization equipment (i.e. water
heater, cooking equipment).
3. Length of piping and number of fittings. Refer
to Tables 19A (natural gas) or 19B (LP gas) for
maximum capacity of Schedule 40 pipe. Table 20
lists equivalent pipe length for standard fittings.

WARNING

4. Specific gravity of gas. Gas piping systems for gas
with a specific gravity of 0.60 or less can be sized
directly from Tables 19A or 19B, unless authority
having jurisdiction specifies a gravity factor be
applied. For specific gravity greater than 0.60,
apply gravity factor from Table 21. If exact specific
gravity is not shown choose next higher value.

Size corrugated stainless steel tubing (CSST)
to ensure proper capacity and minimize flow
restrictions.

A. Size gas piping. Design system to provide adequate gas
supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to
boiler. Maximum allowable system pressure is ½
psig. Actual point of delivery pressure may be less;
contact gas supplier for additional information.

For materials or conditions other than those listed
above, refer to National Fuel Gas Code, NFPA
54/ANSI Z223.1, or size system using standard
engineering methods acceptable to authority having
jurisdiction.
Table 19A: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures

of 0.5 psig or Less
Inlet Pressure 0.5 PSI or less; 0.3 Inch W.C. Pressure Drop
Nominal
Inside
Pipe Size, In. Diameter, In.
½

0.622

Length of Pipe, Ft.
10

100

131

0.824

273

188

151

129

114

104

1.049

514

353

284

243

215

195

179

167

157

148

1¼

1.380

1056

726

583

499

442

400

368

343

322

304

1½

1.610

1582

1087

873

747

662

600

552

514

482

455

2.067

3046

2094

1681

1439

1275

1156

1063

989

928

877

2½

2.469

4856

3337

2680

2294

2033

1842

1695

1576

1479

1397

3.068

8584

5900

4738

4055

3594

3256

2996

2787

2615

2470

100

Inlet Pressure 0.5 PSI or less; 0.5 Inch W.C. Pressure Drop
Nominal
Inside
Pipe Size, In. Diameter, In.

Length of Pipe, Ft.
10

0.622

172

118

0.824

360

247

199

170

151

137

126

117

110

104

1.049

678

466

374

320

284

257

237

220

207

195

1¼

1.380

1392

957

768

657

583

528

486

452

424

400

1½

1.610

2085

1433

1151

985

873

791

728

677

635

600

2.067

4016

2760

2217

1897

1681

1523

1402

1304

1223

1156

2½

2.469

6401

4400

3533

3024

2680

2428

2234

2078

1950

1842

3.068

11316

7778

6246

5345

4738

4293

3949

3674

3447

3256

* 1 CFH of Natural Gas is approximately equal to 1 MBH; contact your gas supplier for the actual heating value of your
gas.

VII. Gas Piping (continued)
B. Connect boiler gas valve to gas supply system.

WARNING

Failure to use proper thread compounds on all
gas connectors may result in leaks of flammable
gas.

Gas supply to boiler and system must be
absolutely shut off prior to installing or servicing
boiler gas piping.

Table 19B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures

of 0.5 psig or Less
Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop
Nominal
Inside
Pipe Size, In. Diameter, In.

Length of Pipe, Ft.
10

100

0.622

0.824

184

126

101

1.049

346

238

191

163

145

131

121

112

105

100

1¼

1.380

710

488

392

336

297

269

248

231

216

204

1½

1.610

1064

732

588

503

446

404

371

346

324

306

2.067

2050

1409

1131

968

858

778

715

666

624

590

2½

2.469

3267

2246

1803

1543

1368

1239

1140

1061

995

940

3.068

5776

3970

3188

2729

2418

2191

2016

1875

1760

1662

Inlet Pressure 11.0 Inch W.C.; 0.5 Inch W.C. Pressure Drop
Nominal
Inside
Pipe Size, In. Diameter, In.
½

Length of Pipe, Ft.

0.622

100

116

0.824

242

166

134

114

101

1.049

456

314

252

215

191

173

159

148

139

131

1¼

1.380

937

644

517

442

392

355

327

304

285

269

1½

1.610

1403

964

775

663

588

532

490

456

427

404

2.067

2703

1858

1492

1277

1131

1025

943

877

823

778

2½

2.469

4308

2961

2377

2035

1803

1634

1503

1399

1312

1239

3.068

7615

5234

4203

3597

3188

2889

2658

2472

2320

2191

* 1 CFH of LP Gas is approximately equal to 2.5 MBH; contact your gas supplier for the actual heating value of your gas.

Table 20: Equivalent Lengths of Standard Pipe Fittings & Valves
Nominal
Pipe Size,
Inc.

Inside
Diameter,
In.

Valves (Screwed) - Fully Open
Gate

Globe

Angle

Swing
Check

Screwed Fittings
45°
Elbow

90°
Elbow

180 Close
Return
Bend

90 Tee
Flow Thru
Run

90 Tee, Flow
Thru Branch

0.622

0.4

17.3

8.7

4.3

0.7

1.6

3.5

1.6

3.1

0.824

0.5

22.9

11.4

5.7

1.0

2.1

4.6

2.1

4.1

1.049

0.6

29.1

14.6

7.3

1.2

2.6

5.8

2.6

5.2

1¼

1.38

0.8

38.3

19.1

9.6

1.6

3.5

7.7

3.5

6.9

1½

1.61

0.9

44.7

22.4

11.2

1.9

4.0

9.0

4.0

8.0

2.067

1.2

57.4

28.7

14.4

2.4

5.2

11.5

5.2

10.3

2½

2.469

1.4

68.5

34.3

17.1

2.9

6.2

13.7

6.2

12.3

3.068

1.8

85.2

42.6

21.3

3.6

7.7

17.1

7.7

15.3

VII. Gas Piping (continued)
Table 21: Specific Gravity Correction Factors
Specific
Gravity

Correction
Factor

Specific
Gravity

Correction
Factor

0.60

1.00

0.90

0.82

0.65

0.96

1.00

0.78

0.70

0.93

1.10

0.74

0.75

0.90

1.20

0.71

0.80

0.87

1.30

0.68

0.85

0.81

1.40

0.66

1. Use methods and materials in accordance with local
plumbing codes and requirements of gas supplier. In
absence of such requirements, follow National Fuel
Gas Code, NFPA 54/ANSI Z223.1.
2. Use thread (joint) compounds (pipe dope) resistant
to action of liquefied petroleum gas.
3. Apex (APX) boilers have factory supplied
Miscellaneous Part Cartons (P/N 102942-03 –
APX500, or, P/N 103259-01 – APX800), which
include gas-piping components to connect boiler
gas valve(s) to gas supply system. Install these
components prior to connecting boiler to gas supply
system piping as follows:
APX500
a. Locate and remove the ¾” NPT x 6” long black
nipple and ¾” NPT external gas shutoff valve
(required for APX500).
b. APX500 boiler has ¾” NPT x 12” long black
nipple and left side panel grommet factory
installed (disregard the supplied ¾” NPT x 6”
long black nipple in the Miscellaneous Part
Carton).
c. Mount the ¾” NPT external gas shutoff valve
onto the nipple threaded end outside of the jacket
left side panel.
d. Install sediment trap, ground-joint union and
manual shut-off valve upstream of mounted
factory supplied manual shut-off valve. See
Figure 41 “ Recommended Gas Piping ”.
APX800
e. Locate and remove 1” NPT external gas shutoff
valve.
f. APX800 boiler has 1” NPT x 3” long black
nipple and left side panel grommet factory
installed.
g. Mount the 1” NPT external gas shutoff valve
onto the nipple threaded end outside of the jacket
left side panel.
h. Install sediment trap, ground-joint union and
manual shut-off valve upstream of mounted
factory supplied manual shut-off valve. See
Figure 41 “ Recommended Gas Piping”.

Figure 41: Recommended Gas Piping
4. All above ground gas piping upstream from manual
shut-off valve must be electrically continuous and
bonded to a grounding electrode. Do not use gas
piping as grounding electrode. Refer to National
Electrical Code, NFPA 70.

C. Pressure test. See Table 22 for Apex Min./Max.

Pressure Ratings. The boiler and its gas connection
must be leak tested before placing boiler in operation.
1. Protect boiler gas control valve. For all testing over
½ psig, boiler and its individual shutoff valve must
be disconnected from gas supply piping. For testing
at ½ psig or less, isolate boiler from gas supply
piping by closing boiler’s individual manual shutoff
valve.
2. Locate leaks using approved combustible gas noncorrosive leak detector solution.

Table 22: Min./Max. Pressure Ratings
LP Gas
Natural Gas
Min. Pressure
Min. Pressure
Inlet to Gas
Inlet to Gas Valve
Valve
(in. w.c.)
(in. w.c.)

Boiler
Model
No.

Natural/LP
Gas Max.
Pressure
(in. w.c.)

APX399

4,0

13.5

4.5

APX500
APX800

11.0

DANGER
Do not use matches, candles, open flames or
other ignition source to check for leaks.

D. Apex Models 500 and 800 (if equipped with optional
low and high gas pressure switches):

1. The low gas pressure switch must be reset after the
boiler is piped to the gas supply and before it is
fired.

VII. Gas Piping (continued)
2. For the low and high gas pressure switches proper
operation, the boiler inlet gas pressure must be
within 4.5” w.c. to 13.5” w.c range.
3. The gas pressure can be measured at the gas valve
inlet pressure port. Refer to Figure 42 “Gas Inlet
Pressure Tap and Pressure Switch Location “.
4. If either pressure switch is tripped, it must be
manually reset before the boiler can be restarted.

E. Gas Piping for Multiple Boiler Installation
1. Individual module (boiler) gas pipe sizing specific
details - see Paragraph A.
2. Individual module (boiler) recommended gas piping
detail - see Figure 41.

3. An additional gas pressure regulator(s) may need to
be installed to properly regulate inlet gas pressure at
the smallest individual module (boiler).

WARNING
If gas pressure in the building is above ½ psig,
an additional gas pressure regulator is required.
Using one additional regulator for multiple
boilers may result in unsafe boiler operation.
The additional regulator must be able to properly
regulate gas pressure at the input of the smallest
boiler. If the regulator cannot do this, two or
more additional regulators are required. Consult
regulator manufacturer and/or local gas supplier
for instructions and equipment ratings.

OUTLET
TEST
PORT (P2)

INLET
TEST
PORT (P1)

MANUAL RESET
BUTTON
HIGH PRESSURE
SWITCH

LOW PRESSURE
SWITCH

MANUAL RESET
BUTTON

HIGH PRESSURE
SWITCH
MANUAL RESET
BUTTON
SIZE 625 THRU 800
RIGHT SIDE PANEL & BLOWER
OMITTED FOR CLARITY

SIZE 500 ONLY
LEFT SIDE PANEL & BLOWER
OMITTED FOR CLARITY

4" NPT PIPE PLUG
(USED ON 625 THRU 800)
PART OF FACTORY
INSTALLED GAS TRAIN.

6" LONG PIPE NIPPLE
(USED ON 500 ONLY)
MANUAL
GAS SHUTOFF
VALVE

PRESSURE SWITCH
ASSEMBLY

Figure 42: Gas Inlet Pressure Tap and Pressure Switch Location

VIII. Electrical
DANGER
Positively assure all electrical connections are unpowered before attempting installation or service of
electrical components or connections of the boiler or building. Lock out all electrical boxes with padlock
once power is turned off.

WARNING
Failure to properly wire electrical connections to the boiler may result in serious physical harm.
Electrical power may be from more than one source. Make sure all power is off before attempting any
electrical work.
Each boiler must be protected with a properly sized over-current device.
Never jump out or make inoperative any safety or operating controls.
The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with
a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls
used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

NOTICE
This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler.
This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the
limit control. Certain Local Codes require an additional water temperature limit. In addition, certain types
of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.
If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat). Wire as indicated in
the Electrical Section of this manual.

NOTICE
All wire, wire nuts, controls etc. are installer supplied unless otherwise noted.

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in
the absence of such requirements, follow the National
Electrical Code, NFPA 70, and/or CSA C22.1 Electrical
Code.

B. A separate electrical circuit must be run from

the main electrical service with an over-current
device/disconnect in the circuit. A service switch is
recommended and may be required by some local
jurisdictions. Install the service switch in the line
voltage “Hot” leg of the power supply. Locate the
service switch such that the boiler can be shut-off
without exposing personnel to danger in the event of
an emergency. Connect the main power supply and
ground to the three (3) boiler wires (black, white and
green) located in the junction box at the inside top of
the boiler jacket.

C. Refer to Figures 43 and 44 or details on the internal
boiler wiring.

Line Voltage (120 VAC) Connections - see Figure 44.
1. The line voltage connections are located in the
junction box on the left side of the vestibule. The
terminal block TB-1 in conjunction with terminal
screw identification label is attached to the junction
box combination cover/inside high voltage bracket.
2. The conductor insulation colors are:
a. Black – L1 line voltage “Hot”
b. White – L2 line voltage “Neutral” for boiler and
circulators
c. Red – Line voltage “Hot” for “Heating”
circulator, “System” circulator and “DHW”
circulator
d. Green – Ground connection

VIII. Electrical (continued)
Low Voltage (24 VAC) Connections - see Figure 44.

WARNING

3. The terminal block TB-2 in conjunction with
terminal screw identification label is attached to
the junction box front and located inside Sage2.1
Control compartment on the left side.

When making low voltage connections, make
sure that no external power source is present
in the thermostat or limit circuits. If such a
power source is present, it could destroy the
boiler’s Microprocessor Control (Sage2.1). One
example of an external power source that could
be inadvertently connected to the low voltage
connections is a transformer in old thermostat
wiring.

4. The connections are (listed identification label top to
bottom):
• 1 – “Heating Thermostat”
• 2 – “Heating Thermostat”
• 3 – “DHW Temperature Switch”
• 4 – “DHW Temperature Switch”
• 5 – “Outdoor Sensor”
• 6 – “Outdoor Sensor”
• 7 – “Header Sensor”
• 8 – “Header Sensor”
• 9 – “Remote Firing Rate -”
• 10 – “Remote Firing Rate +”
• 11 – “External Limit”
• 12 – “External Limit”
5. If the outdoor sensor is connected to terminals 5 and
6 “Outdoor Sensor”, the boiler will adjust the target
space heating set point supply water temperature
downwards as the outdoor air temperature increases.
If used, this sensor should be located on the outside
of the structure in an area where it will sense the
average air temperature around the house. Avoid
placing this sensor in areas where it may be covered
with ice or snow. Locations where the sensor will
pick up direct radiation from the sun should also
be avoided. Avoid placing the sensor near potential
sources of electrical noise such as transformers,
power lines, and fluorescent lighting. Wire the
sensor to the boiler using 22 gauge or larger wire.
As with the sensor, the sensor wiring should be
routed away from sources of electrical noise. Where
it is impossible to avoid such noise sources, wire
the sensor using a 2 conductor, UL Type CM, AWM
Style 2092, 300Volt 60°C shielded cable. Connect
one end of the shielding on this cable to ground.

D. Power Requirements

Nominal boilers current draw is provided in Table
23. These values are for planning purposes only
and represent only the boiler’s power consumption.
To obtain total system power consumption add any
selected circulator and component current draws.
Table 23: Boiler Current Draw
Model Number

Nominal Current
(amps)

APX399

APX500

APX800

E. Multiple Boiler Wiring

Install over-current protection in accordance with
authority having jurisdiction or, in the absence of such
requirements, follow the National Electric Code, NFPA
70, and/or CSA C22.1 Electrical Code. Do not provide
over-current protection greater than 15 amperes. If it
becomes necessary to provide greater amperes (because
of the number of boilers provided) use separate circuits
and over-current protection for additional boilers.

F. External Multiple Boiler Control System

As an alternate to the Sage2.1 Control internal sequencer,
the Sage2.1 Control also accepts an input from an
external sequencer. Follow multiple boiler control system
manufacturer (Honeywell, Tekmar, etc.) instructions
to properly apply amultiple boiler control system. The
Tekmar Model 264 and Model 265 based control wiring
diagrams (Figures 44A and 44B) are provided as examples
of typical multiple boiler control systems.

VIII. Electrical (continued)

Figure 43: Ladder Diagram

VIII. Electrical (continued)

Figure 44: Wiring Connections Diagram

VIII. Electrical (continued)

Figure 45A: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

3
2
1

3
2
1
5

FLAIR "VJ"
ZONE VALVES
(SEE NOTE)

1 3

WHITE ROGERS
#1361-102
ZONE VALVES

2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.3 AMPS (40VA REQ'D
FOR EVERY 4 ZONE VALVES)

HONEYWELL V8043E
ZONE VALVES

2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.5 AMPS (40VA REQ'D
FOR EVERY 4 ZONE VALVES)

TACO ZONE VALVES
(SEE NOTE)

2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.9 AMPS (40VA REQ'D
FOR EVERY 3 ZONE VALVES)

Figure 45B: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

FIELD INSTALLED
40VA TRANSFORMER
(SEE NOTE)

2 WIRE (24V) THERMOSTATS
W/ HEAT ANTICIPATOR SET
AT 0.9 AMPS (40VA REQ'D
FOR EVERY 6 ZONE VALVES)

TO SAGE2
HEATING T-STAT

POWER L1
SUPPLY
120/60/1 N

NOTE:
CHECK FOR CROSS-PHASING BETWEEN BOILER TRANSFORMER AND FIELD SUPPLIED
TRANSFORMER ON TACO AND FLAIR ZONE VALVE CIRCUITS. IF CROSS-PHASING OCCURS,
CORRECT BY SWITCHING X1 AND X2 OR X3 AND X4. ALSO, BOILER SECONDARY SIDE (24V) IS
GROUNDED ON EI AND CANADIAN MODELS AND THE ZONE CIRCUIT MAY NOT OPERATE IF A
SEPARATE GROUND IS MADE IN THE ZONE CIRCUIT.

X4
X3
X2
X1

VIII. Electrical (continued)

Figure 46: Multiple Boiler Wiring Diagram
Internal Sage2.1 Multiple Boiler Control Sequencer
(Three Boilers Shown, Typical Connections for up to Eight Boilers)

Tekmar 265 Based Control System (or equal)
Sequence of Operation

Figure 47A: Multiple Boiler Wiring Diagram w/Tekmar 265 Control

The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control
will fire either one or more boilers in either parallel or sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor
temperature. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control and each boiler’s Sage2.1™ Control. The
boiler(s) and system supply water temperature will be reset together to maintain the input that is needed to the system. When a call for Indirect Hot Water is generated to the
Tekmar 265, the control will de-energize the zone pump control (ZC terminal), energize the Indirect pump and modulate the boiler firing to establish a setpoint temperature in the
main for the Indirect Heater using Priority. The Tekmar 265 also controls each boiler’s pump and a post purge of leftover temperature in the boilers will occur at the end of the
call for Indirect Hot Water.

VIII. Electrical (continued)

72
Tekmar 264 Based Control System (or equal)
Sequence of Operation

Figure 47B: Multiple Boiler Wiring Diagram w/Tekmar 264 Control

The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage firing. When a call for heat is received by the Tekmar 264
Control, the control will fire either one or more boilers in sequential firing mode to establish a required reset water temperature in the system supply main based on outdoor
temperature. The boilers will modulate on their own based on each boiler’s Sage2.1™ Control and will target a setpoint temperature to supply enough input to the system main
to satisfy the desired reset water temperature in the main established by the Tekmar 264 Control. When a call for Indirect Hot Water is generated to the Tekmar 264, the control
will de-energize the zone pump control (ZC terminal), energize the Indirect pump and sequentially fire the boilers to establish a setpoint temperature in the main for the Indirect
Heater using Priority. The Tekmar 264 Control will disable the stage firing and post purge the Indirect Pump to reduce the temperature in the Supply Main near the end of the
Indirect Mode to a point where it will need to be when it changes back to Space Heating Mode. The Tekmar 264 Control also has the ability to rotate the lead-lag firing of the
boilers to establish equal operating time for each boiler stage.

VIII. Electrical (continued)

VIII. Electrical (continued)
G. Multiple Boiler Operating Information
1. Required Equipment and Setup

a. Header Sensor (P/N 101935-01 or 103104-01)
A header sensor must be installed and wired
to the Master Sequencer “enabled” Sage2.1
Controller. The header sensor is installed on the
common system piping and provides blended
temperature information to the Sequence Master.
Refer to piping diagram Figures 39A and 40A
for installation location and Figure 48 or 49 for
installation detail.
b. RJ45 Splitters (P/N 103192-01)
RJ45 Splitters are required for installing
communications between three or more boilers.
When two boilers are connected the splitter is
not required.
c. Ethernet Cables
Ethernet cables are used to connect the boiler
network together. These are standard “straight
through” cables that can be purchased at
electrical distributors.
Alternately, the network can be wired together
by simply wiring terminal J3, Modbus 2,
terminals A, B and V- between each boiler.
Refer to Figures 43 and 44 terminal J3 for wiring
location.

Figure 48: Recommended Direct Immersion
Header Sensor Installation Detail

Figure 49: Alternate “Immersion” type Header
Sensor Installation Detail

VIII. Electrical (continued)
G. Multiple Boiler Operating Information (continued)
1. Required Equipment and Setup (continued)

Figure 50: RJ45 Splitter Installation Detail
d. Multiple Boiler Setup
Step

Description

Install and wire the Header
Sensor

Install Ethernet Cables
between boilers

Apply Power to All Boilers

Set Unique Boiler
Addresses

Enable 1 Boiler Master

Power Down All Boilers
Power Up Master
Sequencer
“Enabled” Boiler First
Power Up Other Boilers

Confirm Communication

Comments
Wire the header sensor to low voltage terminal strip terminals “Header sensor”.
NOTE
This step can not be skipped. The Sequence Master can not be “enabled” unless a Header
Sensor is installed.
Standard Ethernet type cables with RJ45 connectors are “plugged in” to the Boiler-to-Boiler
Communication Network connection located on the side of the boiler. When more than two
boilers are connected an RJ45 splitter may be used to connect the boilers. Refer to Figure
50.
Assign all boilers a unique Boiler Address using any number from 1 through 8.
WARNING
When two boiler’s addresses are the same undesirable simultaneous operation occurs.
Enable only one Sage2.1 Control’s Sequencer Master.
WARNING
When more than one Sequencer Master is enable erratic behavior will result.

From the Home Screen of the Sage2.1 Control with the Master Sequencer “enabled”, select
the Status button. The Sequencer display shows the boiler address of the communicating
boilers. Additionally, from the “Home” screen select the “Detail” button and then the
“Networked Boilers” buttons to view boiler communication status.
If a boiler is not shown, check Ethernet cable connections and confirm all boilers have unique
addresses.

IX. System Start-up
A. Verify that the venting, water piping, gas piping and

from gas supplier.

electrical system are installed properly. Refer to
installation instructions contained in this manual.

2. Apex gas valves have inlet and outlet pressure
taps with built-in shut off screw. Turn each
screw from fully closed position three to four
turns counterclockwise to open taps. Connect
manometers to pressure taps on gas valve.

B. Confirm all electrical, water and gas supplies are
turned off at the source and that vent is clear of
obstructions.

C. Confirm that all manual shut-off gas valves between

NOTICE

the boiler and gas source are closed.

If it is required to perform a long term pressure
test of the hydronic system, the boiler should
first be isolated to avoid a pressure loss due to
the escape of air trapped in the boiler.
To perform a long term pressure test including
the boiler, ALL trapped air must first be removed
from the boiler.
A loss of pressure during such a test, with no
visible water leakage, is an indication that the
boiler contained trapped air.

WARNING
Completely read, understand and follow all
instructions in this manual before attempting
start up.

D. If not already done, flush the system to remove

sediment, flux and traces of boiler additives. This must
be done with the boiler isolated from the system. Fill
entire heating system with water meeting the following
requirements:

3. Temporarily turn off all other gas-fired appliances.

NOTICE

4. Turn on gas supply to the boiler gas piping.
5. Open the field installed manual gas shut-off valve
located upstream of the gas valve on the boiler.

pH between 7.5 and 9.5.
Chlorides< 50 ppm
If system contains aluminum components, pH
must be less than 8.5
Total Dissolved Solids - less than 2500 PPM
Hardness - 3 to 9 grains/gallon.

6. Confirm that the supply pressure to the gas valve is
14 in. w.c. or less. Refer to Table 22 for minimum
supply pressure.
7. Using soap solution, or similar non-combustible
solution, electronic leak detector or other approved
method. Check that boiler gas piping valves, and
all other components are leak free. Eliminate any
leaks.

Pressurize the system to at least 12 PSI. Purge air from
the system.

WARNING
The maximum operating pressure of this boiler is
30 psig, 50 psig, 80 psig or 100 psig depending
on the model and relief valve option selected.
Never exceed these pressures. Do not plug or
change pressure relief valve.

E. Confirm that the boiler and system have no water
leaks.

F. Prepare to check operation.
1. Obtain gas heating value (in Btu per cubic foot)

DANGER
Do not use matches, candles, open flames or
other ignition source to check for leaks.
8. Purge gas line of air.

G. Operating Instructions

Start the boiler using the lighting instructions, see
Figure 51. After the boiler is powered up, it should go
through the following sequence. Refer to Section X,
“Operation” to locate and view sequence status.

IX. System Start-up (continued)
Apex™ Series Lighting and Operating Instructions

Figure 51: Lighting Instructions

IX. System Start-up (continued)
Status

Control Action

Initiate

Power-up

WARNING
The outlet pressure for the gas valve has been
factory set and requires no field adjustment. This
setting is satisfactory for both natural gas and
propane. Attempting to adjust the outlet pressure
may result in damage to the gas valve and cause
property damage, personal injury or loss of life.

This state is entered when a delay is
Standby Delay needed before allowing the burner control
to be available and for sensor errors.
Standby

Boiler is not firing. There is no call for
heat or there is a call for heat and the
temperature is greater than setpoint.

Safe Startup

Tests flame circuit then checks for flame
signal.

Drive Purge

Driving blower to purge rate setting and
waiting for the proper fan feedback.

Prepurge

Purges the combustion chamber for the
10 second purge time.

Driving blower to light-off rate setting and
waiting for the proper fan feedback.

L. Checking /Adjusting Gas Input Rate

Drive Light-off
Pre-ignition
Test

Tests the safety relay and verifies that
downstream contacts are off.

Pre-ignition

Energizes the igniter and checks for
flame.

Direct
Ignition

Opens main fuel valve and attempts
to ignite the main fuel directly from the
ignition source.

Running

Normal boiler operation. Modulation rate
depends on temperature and setpoint
selections and modulating control action.

Postpurge

Purges the combustion chamber for the
30 second purge time.

Lockout

Prevents system from running due to a
detected problem and records fault in
Lockout History.

H. Purge Air From Gas Train

Upon initial start-up, the gas train will be filled with air.
Even if the gas line has been completely purged of air,
it may take several tries for ignition before a flame is
established. If more than 5 tries for ignition are needed,
it will be necessary to press the reset button to restart
the boiler. Once a flame has been established for the
first time, subsequent calls for burner operation should
result in a flame on the first try.

I. Check Burner Flame

Inspect the flame visible through the window. On high
fire the flame should be stable and mostly blue (Figure
52). No yellow tipping should be present; however,
intermittent flecks of yellow and orange in the flame are
normal.

J. Check Gas Inlet Pressure

Check the inlet pressure and adjust if necessary. Verify
that the inlet pressure is between the upper and lower
limits shown on the rating plate with all gas appliances
on and off.

K. For LP Gas, perform procedure as described in

Paragraph R “Field Conversion From Natural Gas to LP
Gas” before starting Paragraph L “Checking/Adjusting
Gas Input Rate”.
For natural gas, proceed to Paragraph L “Checking/
Adjusting Gas Input Rate”.
1. Turn off gas supply to all appliances other than gasfired boiler.
2. Light main burner by adjusting thermostat to highest
setting.
3. Clock gas meter for at least two (2) revolutions
of the dial typically labeled ½ or 1 cubic foot per
revolution on a typical gas meter.
4. Determine gas flow rate in Cubic Feet per Hour
based on elapsed time for two revolutions.
Example:
Using a meter with dial labeled 1 cubic foot per
revolution, measured time is 72 Seconds for (2)
Revolutions, i.e. 36 seconds per 1 cubic foot.
Calculate hourly gas flow rate:
3600 sec/hr ÷ 36 sec/cu ft = 100 cu ft/hr
5. Obtain gas-heating value (Btu per cubic foot) from
gas supplier.
6. Multiply hourly gas flow rate by gas heating value
to determine the boiler input rate, BTU/hr
Example:
Natural gas heating value provided by local gas
utility is 1050 Btu per cubic foot.
Measured and calculated hourly gas flow rate is 100
cu ft/hr.
Measured boiler input rate is:
100 cu ft/hr * 1050 BTU/ cu ft = 105, 000 BTU/hr
7. Compare measured input rate to input rate value
stated on rating label. Strive to adjust the boiler
input rate within 88% to 100% of the value listed on
the boiler rating label.
8. If measured input is too high, reduce input rate by
rotating gas valve throttle screw clockwise (see
Figure 53) in ¼ turn increments and checking the
rate after every adjustment until the measured
input rate value falls within 88% to 100% of the

IX. System Start-up (continued)

Figure 52: Burner Flame
value listed on the boiler rating label. If a boiler
is equipped with two gas valves, throttle screw
adjustments must be done to both gas valves equally
and simultaneously.
9. If measured input is too low, increase input rate by
rotating gas valve throttle screw counterclockwise
(see Figure 53) in ¼ turn increments and checking
the rate after every adjustment until the measured
input rate value falls within 88% to 100% of the
value listed on the boiler rating label. If a boiler
is equipped with two gas valves, throttle screw
adjustments must be done to both gas valves equally
and simultaneously.
10. To lock the boiler in low fire, select “Low” from
manual control screen. If measured % O2 on LF,
is out of spec (see Table 24 or 26), then turn offset
screw clockwise (see Figure 53) to lower % O2 or
vice versa.

WARNING
Offset screw on each Apex Series boiler is
adjusted at the factory to the specification. DO
NOT touch the offset screw if measured 02 on Low
Fire is in the spec (see Table 24 or 26).
11. Once the boiler input rate adjusted/confirmed,
recheck main burner flame and perform combustion
test as described below (see Paragraph L “ Perform
Combustion Test”).
12. Upon completion, return other gas-fired appliances
to previous condition of use.

M. Perform Combustion Test

Boilers are equipped with Flue Temperature Sensor
installed into:
• Flue sensor port of boiler CPVC/PVC two-pipe
vent system connector - See Figures 5 and 16.
• Flue sensor port of boiler concentric vent collar see Figure 17.
Remove Flue Temperature Sensor and insert the
analyzer probe through Flue Temperature Sensor
silicon cap opening, or if required, remove also the Flue
Temperature Sensor silicon cap and insert the analyzer

probe directly into flue sensor port. Reinstall the sensor
and the cap upon combustion testing completion.
Check CO2 (or O2) and CO at both high and low fire.
The boiler may be locked into high of low fire as
follows:
1. To lock the boiler in high fire enter the Manual
control screen by first entering the Adjust screen. To
access the Adjust screen, touch the Adjust button,
then Login using the contractor password “076”.
Press Save and then select the adjust button. Enter
the Manual Control button and select “High”.
Allow the boiler to operate for approximately 5
minutes before taking combustion readings.
2. To lock the boiler in low fire select “Low” from
the Manual Control screen. Allow the boiler to
operate for approximately 5 minutes before taking
combustion readings.
3. Normal modulation of the boiler will only occur
after the “Auto” button is selected in the Manual
Control screen.
Typical CO2 readings are shown in Table 24 (Natural
Gas or Table 26 (LP Gas).

WARNING
Each Apex Series boiler is tested at the factory and
adjustments to the air fuel mixture are normally
not necessary. Improper gas valve or mixture
adjustments could result in property damage,
personal injury, or loss of life.
Table 24: Typical Combustion Settings,
Natural Gas
Boiler
Model

APX399

APX500
APX800

% CO2
9.9 - 8.2
(High Fire)

Altitude Range
0 - 7000 Ft.
% O2 Range

CO, PPM

3.5 - 6.5
(High Fire)

9.3 - 7.9
(Low Fire)
9.3 - 7.9
(High Fire)

4.5 - 7.0
(Low Fire)
4.5 - 7.0
(High Fire)

9.3 - 7.9
(Low Fire)

4.5 - 7.0
(Low Fire)

Less than
100 PPM

IX. System Start-up (continued)
N. Test External Limits

Test any external limits or other controls in accordance
with the manufacturer’s instructions.

O. Check Thermostat Operation

Verify that the boiler starts and stops in response to
calls for heat from the heating thermostat and indirect
water heater thermostat. Make sure that the appropriate
circulators also start and stop in response to the
thermostats.

P. Adjust Supply Water Temperature

As shipped, the heating set point supply temperature is
set to 180°F and, indirect water heater set point supply
temperature is set to 170°F. If necessary, adjust these to
the appropriate settings for the type of system to which
this boiler is connected. See Section X “Operation”
(parameter Table on page 97) of this manual for
information on how to do this.

Q. Adjust Thermostats

Adjust the heating and indirect water heater thermostats
to their final set points.

R. Field Conversion From Natural Gas to LP Gas

Apex boiler models APX399 and APX500 are factory
shipped as Natural Gas builds and can be field
converted to LP gas. Follow steps below for field
conversion from Natural Gas to LP Gas.
Boiler model APX800 is factory shipped as either
Natural Gas build or LP Gas build. Field conversions of
model APX800 are not permitted.
1. Conversion of Apex models APX399 and APX500
from one fuel to another is accomplished using the
throttle screw on the gas valve. Figure 53 “Dungs
Gas Valve Detail” shows the location of the throttle
screw on the Dungs valve. Locate the throttle screw
on the boiler being converted.

WARNING
This conversion should be performed by a
qualified service agency in accordance with the
manufacturer’s instructions and all applicable
codes and requirements of the authority
having jurisdiction. If the information in these
instructions is not followed exactly, a fire, an
explosion or production of carbon monoxide
may result causing property damage, personal
injury, or loss of life. The qualified service
agency is responsible for proper conversion of
these boilers. The conversion is not proper and
complete until the operation of the converted
appliance is checked as specified in this manual.
2. If conversion is being made on a new installation,
install the boiler in accordance with the installation
instructions supplied with the boiler. If an installed

Figure 53: Dungs Gas Valve Detail
boiler is being converted, connect the new gas
supply to the boiler, check for gas leaks, and purge
the gas line up to the boiler in accordance with
the National Fuel Gas Code (ANSI Z223.1) or the
requirements of the authority having jurisdiction.
3. Before attempting to start the boiler, make the
number of turns to the throttle screw called for in
Table 25.
4. Attempt to start the boiler using the lighting instructions
located inside the lower front cover of the boiler. If the
boiler does not light on the first try for ignition, allow
to boiler to make at least four more attempts to light.
If boiler still does not light, turn the throttle counter
clockwise in 1/4 turn increments, allowing the boiler
to make at least three tries for ignition at each setting,
until the boiler lights.
5. After the burner lights, force the burner to high fire.
Allow the boiler to operate for approximately 5 minutes
before taking combustion readings.
6. Check/adjust rate (see Paragraph L), then perform a
combustion test (see Paragraph M).

WARNING
The throttle adjustments shown in Table 25 are
approximate. The final throttle setting must be
found using a combustion analyzer. Leaving the
boiler in operation with a CO level in excess of
the value shown in Table 26 could result in injury
or death from carbon monoxide poisoning.
Table 25: Number of Clockwise Throttle Screw
Turns for LP Conversion
Boiler
Model
APX399
APX500
APX800

Gas Valve
Dungs
GB-057 HO
(¾” NPT)
Dungs
GB-057 HO
(¾” NPT)
Dungs GB-ND057
D01 S00 XP
(¾” NPT)

Throttle Screw Turns at
Altitude Range
0 - 7000 Ft.
1¾
1
N/A
See Tables 2A & 2B
Notes

IX. System Start-up (continued)
(including the converted boiler) both on and off.

WARNING

9. A label sheet is provided with the boiler for conversions
from natural to LP gas. Once conversion is completed,
apply labels as follows:
• Apply the “Rating Plate Label” adjacent to the
rating plate.
• Apply the “Gas Valve Label” to a conspicuous area
on the gas valve.
• Apply the “Boiler Conversion Label” to a
conspicuous surface on, or adjacent to, the outer
boiler jacket. Fill in the date of the conversion and
the name and address of the company making the
conversion with a permanent marker.

These instructions include a procedure for
adjusting the air-fuel mixture on this boiler.
This procedure requires a combustion analyzer
to measure the CO2 (or Oxygen) and Carbon
Monoxide (CO) levels in flue gas. Adjusting the
air-fuel mixture without a proper combustion
analyzer could result in unreliable boiler operation,
personal injury, or death due to carbon monoxide
poisoning.
7. While the burner is at high fire adjust the throttle as
needed to obtain the CO2 (or O2) settings shown in the
Table 26:
• To reduce the CO2 (increase the O2) turn the throttle
clockwise
• To increase the CO2 (reduce the O2) turn the throttle
counter-clockwise
Make adjustments in increments of 1/8 to 1/4 turn and
allow the boiler at least a minute to respond to each
adjustment before making another. In general, the CO
level will be at its lowest somewhere in the CO2 range
shown in this table.

Table 26: Typical Combustion Settings,
LP Gas
Altitude Range
0 - 5000 Ft.
5001 - 10000 Ft.

Boiler Model

8. Verify that the gas inlet pressure is between the upper and
lower limits shown in Table 22 with all gas appliances

APX399

APX500
APX800

% CO2

% O2 Range

11.4 - 9.5
(High Fire)

3.5 - 6.5
(High Fire)

11.4 - 9.1
(Low Fire)

3.5 - 7.0
(Low Fire)

10.8 - 9.1
(High Fire)

4.5 -7.0
(High Fire)

10.8 - 9.1
(Low Fire)

4.5 - 7.0
(Low Fire)

CO, PPM

Less than
100 PPM

NOTICE
If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be
running at 0% Excess Air or even with air deficiency.
At 0% Excess Air the CO2 readings will be either 11.9% CO2 for Natural Gas or 13.8% CO2 for LP Gas (O2 will
be 0%) and CO level will be extremely high (well over 1000 PPM).
If the burner operates with air deficiency, the following phenomena may be observed:
% CO2 will actually drop (% O2 will increase) as the throttle is turned counterclockwise

% CO2 will actually increase (% O2 will drop) as the throttle is turned clockwise

If the boiler appears to operate with air deficiency, turn the throttle clockwise to increase the amount of
Excess Air to the burner.
As the throttle is turned clockwise, the CO2 level will rise, eventually peaking @ 11.8% or 13.8%, depending
of the type of gas being used, before falling (conversely, O2 level will drop to 0% before rising). After this
happens, continue turning the throttle clockwise, until CO2 level drops (or O2 level increases) to the values
shown in Table 24 or Table 26.

WARNING
The pressure regulator (offset screw) has been factory set using precision instruments and must never
be adjusted in the field unnecessarily. The gas valve outlet pressure is the same for both natural gas and
propane. Make sure that all adjustments are made with the throttle, not the pressure regulator. Attempting
to adjust the pressure regulator unnecessary, will result in damage to the gas valve and may cause property
damage, personal injury or loss of life.

X. Operation
A. Overview
1. Sage 2.1 Controller
The Sage 2.1 Controller (Control) contains features and
capabilities which help improve heating system operation,
and efficiency. By including unique capabilities, the Control
can do more, with less field wiring, and fewer aftermarket
controls and components – improving the operation of both
new and replacement boiler installations.
2. Advanced Touch Screen Display

Status
Detail
Help

Boiler 1

180 F

Standby
Energy Save On

Adjust Max Efficiency On

Home Screen
Boiler status and setup selections are available from an
easy to use, dual color, LCD Touch Screen Display. Over
one hundred helpful information screens are provide to
explain status information and setup functions. In the event
of a fault condition the user is guided by “blinking” touch
buttons to Help screens that explain the problem cause and
corrective action. Operation evaluation and problem-solving
is enhanced by historical capability including graphic trends,
lockout history records as well as boiler and circulator cycle
counts and run time hours.
3. Advanced Modulating Control
The Control modulates the boiler input by varying the fan
speed. As the fan speed increases, so does the amount of
fuel gas drawn into the blower. As a result, a fairly constant
air-fuel ratio is maintained across all inputs. The Control
determines the input needed by looking at both current and
recent differences between the measured temperature and
the setpoint temperature. As the measured temperature
approaches the setpoint temperature, the fan will slow down
and the input will drop. The Control also utilizes boiler
return water and flue gas temperatures to adjust fan speed.
4. Built-in Safety Control
The Control includes safety controls designed to ensure safe
and reliable operation. In addition to flame safety controls
the Control includes supply water temperature, differential
water temperature, and stack temperature safety limits and
stepped modulation responses. Boiler modulation is adjusted
when required to help avoid loss of boiler operation due
to exceeding limits. Additionally, the Control accepts the
optional field installation of low water cut-off and auxiliary
safety limits.
5. Outdoor Air Reset
When selected the modulation rate setpoint is automatically
adjusted based on outside air temperature, time of day and
length of demand (boost) settings. Outdoor air “reset”
setpoint saves fuel by adjusting the water temperature of a
heating boiler lower as the outside air temperature increases.

6. Warm Weather Shutdown (WWSD)
Some boilers are used primarily for heating buildings,
and the boilers can be automatically shutdown when
the outdoor air temperature is warm. When outside air
temperature is above the WWSD setpoint, this function
will shut down the boiler, boiler pump and/or the system
pump.
7. Domestic Hot Water Priority (DHWP)
Some boilers are used primarily for building space heating,
but also provide heat for the domestic hot water users.
When the outdoor temperature is warm, the outdoor reset
setpoint may drop lower than a desirable domestic hot
water temperature. Also, often it is required to quickly
recover the indirect water heater. When DHWP is
enabled, heating circulators are stopped, the domestic
circulator is started and the domestic hot water setpoint is
established in response to a domestic hot water demand.
Priority protection is provided to allow the heating loop
to be serviced again in the event of an excessively long
domestic hot water call for heat.
8. Energy Management System (EMS) Interface
The control accepts a 4-20mAdc input from the EMS
system for either direct modulation rate or setpoint.
9. Circulator Control
The Control may be used to sequence the domestic hot
water, boiler and system circulators. Service rated relay
outputs are wired to a line voltage terminal block for easy
field connection. Simple parameter selections allow all
three pumps to respond properly to various hydronic
piping arrangements including either a boiler or primary
piped indirect water heater. Circulators are automatically
run for a 20 second exercise period after not being used
for longer than 7 days. Circulator exercise helps prevent
pump rotor seizing.
10. Multiple Boiler Sequencer Peer-To-Peer Network
The Control includes state-of-the-art modulating leadlag sequencer for up to eight (8) boilers capable of auto
rotation, outdoor reset and peer-to-peer communication.
The peer-peer network is truly “plug and play”.
Communication is activated by simply connecting a RJ45
ethernet cable between boilers. The Control provides
precise boiler coordination by sequencing boilers based
on both header water temperature and boiler modulation
rate. For example, the lead boiler can be configured to
start a lag boiler after operating at 50% modulation rate for
longer than an adjustable time. The boilers are modulated
in “unison” (parallel) modulation rate to ensure even heat
distribution
11. Modbus Communication Interface
A factory configured RS485 Modbus interface is available
for Energy Management System (EMS)monitoring when
not used for Multiple Boiler Sequencer Peer-To-Peer
Network. Consult factory if this interface must be used
in addition to the boiler Peer-to-Peer Network.

X. Operation B. Supply Water Temperature Regulation (continued)
B. Supply Water Temperature Regulation
1. Priority Demand
The Control accepts a call for heat (demand) from
multiple places and responds according to it’s “Priority”.
When more than 1 demand is present the higher priority
demand is used to determine active boiler settings.
For example, when Domestic Hot Water (DHW) has
priority the setpoint, “Diff Above”, “Diff Below” and
pump settings are taken from DHW selections. Active
“Priority” is displayed on the “Boiler Status” screen.
Table 27: Order of Priority
Priority
1st
2nd

3rd
4th

5th

6th

Status
Screen
Display
Sequencer
Control

Boiler Responding to:

The boiler is connected to the peerto-peer network. The boiler accepts
demand from the Sequencer Master.
Domestic Hot DHW call for heat is on and selected
Water
as the priority demand. DHW is
always higher priority than Central
Heat. It also has higher priority than
the Sequencer Control when DHW
priority is “enabled” and “Boiler Piped”
IWH is selected.
Central Heat Central Heat call for heat is on and
there is no DHW demand or DHW
priority time has expired.
Frost
Frost Protection is active and there is
Protection
no other call for heat. Frost protection
will be a higher priority than Sequencer
Control if the Sequence Master has
no active call for heat.
WWSD is active and the boiler will
Warm
Weather
not respond to central heat demands.
DHW demand is not blocked by
Shutdown
(WWSD)
WWSD.
Standby
There is no demand detected.

2. Setpoint Purpose
The Control starts and stops the boiler and modulates
the boiler input from minimum (MBH) to maximum
(MBH) in order to heat water up to the active setpoint.
The setpoint is determined by the priority (Central Heat
or Domestic Hot Water) and as described in the following
paragraphs.
3. Central Heat Setpoint
Upon a Central Heat call for heat the setpoint is either
the user entered Central Heat Setpoint or is automatically
adjusted by a thermostat’s “Sleep” or “Away” modes and/
or Outdoor Air Reset or a Energy Management System
(EMS) supplied 4-20mAdc setpoint.

4. Outdoor Air Reset
If an outdoor temperature sensor is connected to the boiler
and Outdoor Reset is enabled, the Central Heat setpoint
will automatically adjust downwards as the outdoor
temperature increases. When the water temperature is
properly matched to heating needs there is minimal chance
of room air temperature overshoot. Excessive heat is
not sent to the room heating elements by “overheated”
(supply water temperature maintained too high a setting)
water. Reset control saves energy by reducing room
over heating, reducing boiler temperature & increasing
combustion efficiency and reducing standby losses as a
boiler and system piping cool down to ambient following
room over heating.
5. Boost Time
When the Central Heat Setpoint is decreased by Outdoor
Air Reset settings the Boost function can be enabled to
increase the setpoint in the event that central heat demand
is not satisfied for longer than the Boost Time minutes.
The Boost feature increases the operating temperature
setpoint by 10°F every 20 minutes (field adjustable) the
central heat demand is not satisfied. This process will
continue until heat demand is satisfied (indoor air is at
desired temperature). Once the heat demand is satisfied,
the operating setpoint reverts to the value determined by
the Outdoor Air Reset settings. If Boost Time is zero,
then the boost function is not used.
6. Domestic Hot Water (DHW) Setpoint
Upon a DHW call for heat the setpoint is either the user
entered DHW setpoint or the Thermostat’s “Sleep” or
“Away” DHW setpoint. The optimal value of this setpoint
is established based on the requirements of the indirect
water heater.
7. Domestic Hot Water Priority (DHWP)
When domestic hot water priority is selected and there
is a DHW call for heat, the system pump will be turned
off (when system pump run pump for parameter is set for
“Central Heat Optional Priority”) and the DHW pump will
be turned on. Additionally, if outdoor reset is active, the
active setpoint is adjusted to the DHW Setpoint. Priority
protection is provided to ensure central heat supply in
the case of excessively long DHW call for heat.
8. “Setback” Setpoints
User adjustable Thermostat “Sleep” or “Away” Setback
Setpoints are provided for both Central Heat and
DHW demands. The Setback setpoint is used when the
EnviraCOM thermostat is in “leave” or “sleep” modes.
When setback is “on” the thermostat setback setpoint
shifts the reset curve to save energy while the home is
in reduced room temperature mode. The Honeywell
VisionPro IAQ (part number TH9421C1004) is a
“setback” EnviraCOM enabled thermostat.

X. Operation C. Boiler Protection Features (continued)
C. Boiler Protection Features
1. Supply Water Temperature High Limit
The boiler is equipped with independent automatic reset
and a manual reset High Limit devices. The automatic
reset high limit is provided by a supply manifold mounted
Limit Device. The automatic high limit is set to 200°F.
The Control monitors a supply water temperature sensor
that is also mounted in the supply water manifold and
supplies an internal, manual reset high limit. If supply
water temperature exceeds 190°F, the control begins
to reduce the blower maximum speed setting. If the
temperature exceeds 200°F, a forced recycle results.
If the temperature exceeds 210°F, a manual reset hard
lockout results. Additionally, if the supply temperature
rises faster than the degrees Fahrenheit per second limit
a soft lockout is activated.
2. High Differential Temperature Limit
The Control monitors the temperature difference between
the return and supply sensors. If this difference exceeds
43°F the control begins to reduce the maximum blower
speed. If temperature difference exceeds 53°F a forced
boiler recycle results. If the temperature difference
exceeds 63°F the control will shut the unit down. The
unit will restart automatically once the temperature
difference has decreased and the minimum off time has
expired.
3. Low Water Cut Off (LWCO)
The Control shuts down the boiler when either the
supply water temperature is too high or supply to return
temperature differential temperature is too high. This
ensures the boiler is shutdown in the event of a low water
level or low water flow condition.
Some codes and jurisdiction may accept these integral
features instead of requiring a low water cutoff. ADHERE
TO ALL LOCAL CODE REQUIREMENTS. Contact
your local code inspector prior to installation. If required, a
LWCO four-position wire harness connection is provided
for an external LWCO kit (p/n 102097-01) to be added.
If the LWCO opens, the boiler will shut down and an
open limit indication and error code is provided. If the
limit installed is a manual reset type, it will need to be
reset before the boiler will operate.
4. ReturnTemperature HigherThan SupplyTemperature
(Inversion Limit)
The Control monitors the supply and return temperature
sensors. If the return water temperature exceeds the
supply water temperature for longer than a limit time
delay the Control shuts down the boiler and delays
restart. If the inverted temperature is detected more than
five times the boiler manual reset Hard Lockout is set.
This condition is the result of incorrectly attaching the
supply and return piping.

5. External Limit
An external limit control can be installed between
terminals 11 and 12 on the low voltage terminal strip.
Be sure to remove the jumper when adding an external
limit control to the system. If the external limit opens, the
boiler will shut down and an open limit indication and
error code is provided. If the limit installed is a manual
reset type, it will need to be reset before the boiler will
operate.
6. Boiler Mounted Limit Devices
The Control monitors individual limit devices: pressure
switch, high limit device, condensate level switch,
Thermal Link, Burner Door Thermostat with manual
reset, low water cutoff (optional), fuel gas pressure
switches (optional) and external limit (optional). If any
of these limits opens, the boiler will shut down and an
individual open limit indication is provided.
7. Stack High Limit
The Control monitors the flue gas temperature sensor
located in the vent connector. If the flue temperature
exceeds 184°F, the control begins to reduce the maximum
blower speed. If the flue temperature exceeds 194°F, a
forced boiler recycle results. If the flue temperature
exceeds 204°F, the control activates a manual reset Hard
Lockout.
8. Ignition Failure
The Control monitors ignition using a burner mounted
flame sensor. In the event of an ignition failure:
• APX399 - the control retries five (5) times and
then goes into soft lockout for one hour.
• APX500 and APX800 - the control retries one (1)
time and then goes into hard lockout. Manual reset
is required to resume boiler operation.
9. Central Heating System Frost Protection
When enabled, Frost Protection starts the boiler and
system pump and fires the boiler when low outside air
and low supply water temperatures are sensed. The
Control provides the following control action when frost
protection is enabled:
Table 28: Frost Protection
Device
Started

Start
Temperatures

Stop
Temperatures

Boiler & System
Pump

Outside Air < 0°F
Supply Water < 45°F

Outside Air > 4°F
Supply Water > 50°F

Boiler

Supply Water < 38°F

Supply Water > 50°F

Frost Protection NOTE
The Control helps provide freeze protection for the boiler water.
Boiler flue gas condensate drain is not protected from freezing.
Since the Control only controls the system and boiler circulators
individual zones are not protected. It is recommended that the
boiler be installed in a location that is not exposed to freezing
temperatures.

X. Operation D. Multiple Boiler Control Sequencer (continued)
D. Multiple Boiler Control Sequencer
1. “Plug & Play” Multiple Boiler Control Sequencer
When multiple boilers are installed, the Control’s
Sequencer may be used to coordinate and optimize the
operation of up to eight (8) boilers. Boilers are connected
into a “network” by simply “plugging in” standard
ethernet cables into each boiler’s “Boiler-To-Boiler
Communication” RJ45 connection.
2. Sequencer Master
A single Control is parameter selected to be the Sequencer
Master. The call for heat, outdoor and header sensors,
and common pumps are wired to the Sequencer Master
“enabled” Control.
3. Lead/Slave Sequencing & Equalized Run Time
One boiler is a “Lead” boiler and the remaining networked
boilers are “Slaves”. When demand is increasing, the
Lead boiler is the first to start and the Slave boilers are
started in sequential order (1,2,3,…) until the demand
is satisfied. When demand is decreasing, the boilers are
stopped in reverse order with the Lead boiler stopped
last (…,3,2,1). To equalize the run time the sequencer
automatically rotates the Lead boiler after 24 hours of
run time.
4. Improved Availability
The following features help improve the heat availability:
a. Backup Header Sensor: In the event of a header sensor
failure the lead boiler’s supply sensor is used by the
Sequence Master to control firing rate. This feature
allows continued coordinated sequencer control even
after a header sensor failure.
b. “Stand Alone” Operation Upon Sequence Master
Failure: If the Sequence Master Control is powered
down or disabled or if communication is lost
between boilers, individual boilers may be setup to
automatically resume control as a “stand alone” boiler.
c. Slave Boiler Rate Adjustment: Each slave boiler
continues to monitor supply, return and flue gas
temperatures and modifies the Sequence Master’s
firing rate demand to help avoid individual boiler
faults, minimize boiler cycling and provide heat to
the building efficiently.
d. Slave Boiler Status Monitoring: The Sequence Master
monitors slave boiler lockout status and automatically
skip over disabled boilers when starting a new slave
boiler.
5. Customized Sequences
Normally, boilers are started and stopped in numerical
order. However, custom sequences may be established
to optimize the heat delivery. For example, in order to
minimize boiler cycling, a large boiler may be selected
to run first during winter months and then selected to
run last for the remainder of the year.

6. Multiple Demands
The Sequence Master responds to Central Heat, DHW
and frost protection demands similar to the stand alone
boiler. For example, when selected and DHW priority
is active, the sequence master uses DHW setpoint, “Diff
Above”, “Diff Below” and pump settings.
7. Shared or Isolated DHW Demand
When the Indirect Water Heater (IWH) parameter is set
to “Primary Piped” the Sequence Master sequences all
required boilers to satisfy the DHW setpoint (default 180
F). When “Boiler Piped” is selected only the individual
slave boiler, with the wired DHW demand and pump,
fires to satisfy the DHW setpoint.
8. DHW Two boiler Start
When the Indirect Water Heater (IWH) parameter is set to
“Primary Piped” and the DHW Two Boiler Start parameter
is set to “Enabled” two boilers are started without delay
in response to a DHW call for heat. This feature allows
rapid recovery of large IWH’s and multiple IWH’s.
9. Optimized Boiler Modulation
Boiler firing rate is managed to increase smoothly as
boilers are started. For example, when a second boiler is
started the initial firing rate is 100%/2 or 50%, when the
third boiler is started the firing rate starts at 200%/3 or
66%. After the initial start, the Sequence Master develops
a unison firing rate demand based on it’s setpoint and
sensed header temperature.
10. Innovative Condensing Boiler Control
During low loads, the Sequence Master limits firing rates
to a ‘Base Load Common Rate” to ensure peak operating
efficiency. Lower firing rates boost efficiency by helping
increase the amount of flue gas water vapor condensation.
The Control maintains a “Base Load Common Rate” until
the last lag boiler is started. At this point, the “Base Load
Common Rate” is released to allow boilers to modulated
as required to meet heat load.
11. Advanced Boiler Sequencing
After there is a Call For Heat input, both header water
temperature and boiler firing rate percent are used to start
and stop the networked boilers. The control starts and
stops boilers when the water temperature is outside the
user selected “Diff Above” and “Diff Below” settings.
Also, in order to minimize temperature deviations, the
control adjusts the number of boilers running based on
the firing rate. This combination allows the boilers to
anticipate slow load changes before they disrupt water
temperature yet still respond quickly to sudden load
changes. These special sequencer features help reduce
energy wasting system temperature swings and the
resulting unnecessary boiler cycling.
12. Stop All Boilers
All boilers are stopped without delay if the Call for Heat
input is removed or if the header temperature is higher
than 195°F (field adjustable).

X. Operation E. Boiler Sequence Of Operation (continued)
E. Boiler Sequence of Operation
1. Normal Operation
Table 29: Boiler Sequence of Operation
Status Screen Display

<
i

Boiler 1
140 F
140 F
Rate
0%

Supply
Setpoint

Priority: Standby
Status: Standby

Boiler 1
140 F
140 F
Rate
0%

Supply
Setpoint

Priority: Central Heat
Status: Standby

Boiler 1
132 F
140 F
Rate 98%

Supply
Setpoint

Priority: Central Heat
Status: Prepurge

Boiler 1
132 F
140 F
Rate 89%

Supply
Setpoint

>
10

Priority: Central Heat
Status: Direct Ignition

Boiler 1
132 F
140 F
Rate 100%

Supply
Setpoint

Priority: Central Heat
Status: Running

Boiler 1
132 F
180 F
Rate 100%

Supply
Setpoint

Priority: Domestic Hot Water
Status: Running

Priority:
Standby
Status:
Standby

Description
(burner Off, circulator(s) Off)
Boiler is not firing and there is no call for heat, priority equals standby. The boiler
is ready to respond to a call for heat.

Priority:
(burner Off, circulator(s) On)
Central Heat Boiler is not firing. There is a Central Heat call for heat and the Supply temperature
Status:
is greater than setpoint minus the “Diff Below”.
Standby
When supply temperature drops burner demand continues with following Status
Priority:
shown:
Central Heat Safe Startup:
Flame circuit is tested.
Drive purge:
The blower is driven to the fan purge speed.
Status:
Prepurge:
After the blower reaches the fan purge speed setting the 10
Prepurge
second combustion chamber purge is conducted.
After purge time is complete the following Status is shown:
Priority:
Central Heat Drive light-off: The blower is driven to light-off rate.
Pre-Ignition Test: After the blower reaches light-off rate a safety relay test is
Status:
conducted.
Direct
Pre-ignition:
Spark is energized and it is confirmed that no flame is present
ignition
Direct Ignition: Spark and Main fuel valve are energized.
Priority:
(burner On, circulator(s) On)
Central Heat
After flame is proven normal boiler operation begins. Modulation rate depending
Status:
on temperature and setpoint selections and modulating control action.
Running
Priority:
Domestic
Hot Water
Status:
Running
Priority:
Standby
Status:
Post-purge
Priority:
Standby
Status:
Standby
Delay
Priority:
Standby
Status:
Lockout

If the Central Heat call for heat is active and a Domestic Hot Water (DHW) call for
heat received the DHW demand becomes the “priority” and the modulation rate,
setpoint, “Diff Above” and “Diff Below” are based on DHW settings.
(burner Off, circulator(s) Off)
If there is no call for heat the main fuel valve is closed and the blower is driven
to the fan post-purge speed. After the blower reaches the fan post-purge speed
setting the 30 second combustion chamber purge is conducted.
This state is entered when a delay is needed before allowing the burner control to
be available. For example, when Anti-Short Cycle time is selected Standby delay
is entered after the Central Heat call for heat ends. Select “Help” button from the
“Home Screen” to determine the cause of the Standby Delay.
A lockout Status is entered to prevent the boiler from running due to a detected
problem. Select “Help” button from the “Home Screen” to determine the cause of
the Lockout. The last 10 Lockouts are recorded in the Lockout History.

X. Operation E. Boiler Sequence Of Operation (continued)
2. Using The Display

The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen
navigation “buttons” and symbols. Navigation features are shown below.
The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the
display reverts to the “Home Screen” after 4 minutes. The “Home Screen” displays boiler temperature, boiler status and
Efficiency Information. “Energy Save On” indication appears when the outdoor reset or setback features have lowered the
Central Heat Setpoint based on outside air temperature measurement or time of day. “Max Efficiency On” appears when
the boiler return temperature has been reduced low enough to cause energy saving flue gas condensation.

Menu Button

The Home Screen Menu Buttons connect the displays four main display
groups; Status, Detail, Help and Adjustment Screens.

Boiler 1

Status

180 F

Detail

Standby
Energy Save On

Help

Adjust Max Efficiency On

Home Screen
Close Symbol
The “Close” symbol returns to the display to previous menu or screen.
Repeatedly pressing the “Close” symbol will always return the display to the
“Home” screen.

Boiler 1 Active
180 F Fault
180 F
Rate
0%

Supply
Setpoint

Priority: Central Heat
Status: Standby

Status Screen

Arrow Symbol
The “Arrow” symbol links together all screens in the selected group. For
example, repeated pressing the right “Arrow” symbol will rotate the display
around all the screens in the Status group. Using this feature the user can
review all the boiler status and adjustment mode screens.
Fault Symbols
“Active Fault” and “Rate Limit” symbols provide a link to the cause of a boiler
fault or firing rate limit. The first boiler status screen provides an overview of
boiler operation including fault status.
Information Symbol
“Information” symbol links most screens to screen content explanations. New
terminology used in status and adjustment screens are explained in plain words.

Home Screen

Boiler 1

Status

180 F

Detail
Help

Standby
Energy Save On

Adjust Max Efficiency On

Boiler 1

Supply
Setpoint

180 F
180 F

0%
Rate
Priority:
Central Heat
Status: Standby

Status Screens
(see Figure 54)

Central Heat

Domestic
Hot Water
Outdoor
Reset Curve

Detail Menu
(see Figure 55)

Active Faults
Lockout
History

Sequencer
Setup

Service
Contract

Boiler Size
Setup

Help Menu
(see Figure 60)

Warning! Only Qualified Technicians
Should Adjust Controls, Contact Your
Qualified Heating Professional
Improper settings or service create risk of
property damage, injury, or death.
Service Contact

Adjust

Adjust Mode Screens
(see Figure 56)

X. Operation F. Viewing Boiler Status (continued)
F. Viewing Boiler Status
1. Status Screens
Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler
operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the
“Status” button from the “Home” screen.

Boiler 1

Supply
Setpoint

180 F
180 F

0%
Rate
Priority:
Central Heat

180 F
160 F
Stack 147 F
Rate 40 %

Supply

Heat Demand
Central Heat On
Domestic Hot Water Off
Sequence Master Off
Frost Protection Off

Return

Status: Standby

Trends

Status

Pump Status/Cycles
System On
Boiler On
DHW Off

Frost Protection On

98
23
0

Flame
2.5 hour trend

Supply / Return

Flame
5 minute trend

Firing Rate

Boiler Cycles/Hours
Boiler Cycles

2000

Run Time Hours

800

Exercise On

Figure 54: Status Screens
Active fault:
A hard lockout will cause the active
fault indication to appear. When
visible the text becomes a screen link
to the “Help” Menu.

Supply:
measured supply water temperature. This is the
temperature being used to start/stop and fire boiler
when there is a call-for- heat.
Setpoint:
this is the active setpoint. This temperature is the
result of Outdoor Air Reset, Setback and Domestic
Hot Water (DHW) selections.

Boiler 1 Active
180 F Fault
180 F
Rate
0%

Supply
Setpoint

Priority: Central Heat
Status: Standby

Rate:
The rate % value is equal to the actual fan speed
divided by the maximum fan speed.
Priority:
The selected Priority is shown. Available Priorities
are: Standby (no call for heat is present), Sequencer
Control, Central Heat, Domestic HW, Frost
Protection or Warm Weather Shutdown.

Status:
Information found at the
bottom of the Status screen
and on the Home screen.
Table 29 shows each status
and the action the control
takes during the condition.

Trends

Flame
2.5 hour trend

Supply / Return

Flame
5 minute trend

Firing Rate

Rate Limit:
The “ ” symbol appears to the right
of the Rate % when firing rate is
limited or overridden in any way.
During the start-up and shutdown
sequence it is normal for the rate to be
overridden by the purge and light-off
requirements. When a rate limit is the
result of boiler protection logic the
“ ” symbol blinks and becomes a
screen link

Data Logging
Real time graphic trends allow users to observe process
changes over time providing valuable diagnostic
information. For example, flame current performance
over start up periods and varying loads can be an indication
of gas supply issues. Additionally, supply and return
temperature dual pen trends brings a focused look at
heat exchanger and pump performance. For example,
studying a differential temperature trend may indicate
pump speed settings need to be changed.

Boiler Cycles/Hours
Boiler Cycles

2000

Run Time Hours

800

Cycles and Hours
Boiler cycles and hours are used to monitor the
boilers overall compatibility to the heating load.
Excessive cycling compared to run time hours
may be an indication of pumping, boiler sizing or
adjustment issues.

X. Operation F. Viewing Boiler Status (continued)
1. Status Screens (continued)

Pump Status/Cycles
System On
Boiler On
DHW Off
Frost Protection On

98
23
0

Heat Demand
Central Heat On
Domestic Hot Water Off
Sequence Master Off
Frost Protection Off

Exercise On

Pumping is a major part of any hydronic system. This screen
provides the status of the boiler’s demand to connected
pumps as well as the status of Frost Protection and pump
Exercise functions.

This screen provides the status of the boiler’s 4 possible
heat demands. When demand is off the Control has not
detected the call-for-heat.

2. Detail Screens

Detail screens are accessed by selected the “Detail”
button from the “Home” screen and provide in depth
operating parameter status such as “On Point”, “Off
Point” and Setpoint Source information.

Central Heat
Off Point + 5 F
Setpoint 180 F
On Point - 7 F

Supply
180 F

W
a
t
e
r

Firing Rate 22%
Setpoint: Outdoor Reset

Outdoor Reset

130
110
0

Setpoint 164 F
Outside Air 16 F
Status: Enabled

Outside Air

Demand detail screens are provided for Central Heat
(shown), DHW and Sequencer demands.

Outdoor Reset saves energy and improves home comfort
by adjusting boiler water temperature . This screen
presents the active reset curve. The curve shows the
relationship between outside air and outdoor reset
setpoint. The curve shown is adjustable by entering the
display’s adjust mode.

Figure 55: Detail Screens

180

X. Operation F. Viewing Boiler Status (continued)
3. Multiple Boiler Sequencer Screens

When the Sequence Master is enabled the following screens are available:

The Sequencer Status screen is selected by “pressing” “Status” button from the “Home” screen when Sequence Master is enabled.

Header:
measured header water temperature.
This is the temperature being used to
start, stop and fire boiler when there is
a call-for-heat.
Setpoint:
this is the active setpoint. This
temperature is the result of Outdoor
Air Reset, Setback and Domestic Hot
Water (DHW) selections.

Sequencer
132 F
180 F
Rate 100%

Header
Setpoint

Priority: Domestic Hot Water
Networked Boilers: 1 ,2 ,3 ,4 ,5 ,6 ,7 ,8

Rate:
The rate % value is equal to the
Sequence Master demand to the
individual boiler. Actual boiler firing
rate is found on the individual boiler
status pages.
Priority:
The selected Sequencer Priority is
shown. Available Priorities are:
Standby (no call for heat is present),
Central Heat, Domestic Hot Water,
Frost Protection or Warm Weather
Shutdown.

Networked Boiler Status:
Provides connected, start sequence and firing rate status information for all connected boiler addresses. The boiler number is
underlined if the boiler is running and blinks if the boiler has the start sequence in progress. For example the status for boiler
address 1 is provided as follows:
1 - Boiler 1 is connected to the network
1 - “Blinking underline” - boiler 1 is starting
1 - “Solid underline” - boiler 1 is running
The “Networked Boilers” screen is selected by “pressing” the “Detail” button from the “Home” screens and “pressing” Networked
Boilers” from the “Detail” screen.
Boiler Number:
Up to eight (8) boiler’s status is
shown
Lead Boiler:
Upon power up the lowest numbered
boiler becomes the lead boiler. The
lead boiler is the first to start and last
to stop. The lead boiler is
automatically rotated after 24 hours of
run time. Additionally, the lead is
rotated if there is a lead boiler fault.

Networked Boilers
Boiler 1

Lead

50% Firing

Boiler 2

50% Firing

Boiler 3

0 % Available

Boiler 4

0 % Available

Firing Rate:
Demanded firing rate is
provided.

Sequence Status:
Slave boiler status is provide as follows:
Boiler is ready and waiting to be started by the Sequencer Master.
Available:
Add Stage:

Boiler has begun the start sequence but has not yet reached the boiler
running status.

Running:

Boiler is running.
Boiler has left the network to service a DHW demand.

On Leave:
Recovering:

Boiler is in the process of returning to the network. For example, the
slave boiler is in the Postpurge state.
Note: The recovery time is normally 30 seconds. However, if the
slave boiler fails to start the recovery time increases from 30 seconds
to 5, 10 and 15 minutes.

Disabled:

Boiler has a lockout condition and is unable to become available to
the Sequencer Master.

X. Operation G. Changing Adjustable Parameters (continued)
G. Changing Adjustable Parameters

Adjust

1. Entering Adjust Mode

The Control is factory programmed
to include basic modulating boiler
functionality. These settings are password
protected to discourage unauthorized or
accidental changes to settings. User login is
required to view or adjust these settings:
- Press the “Adjust” button on the “Home”
screen.
- Press the “Adjust” button on the Adjust
Mode screen or Press Contractor for
service provider contact information.
- Press “Login” button to access password
screen.
- Press 5-digit display to open a keypad.
Enter the password (Installer Password
is 76) and press the return arrow to close
the keypad. Press the “Save” button.
- Press the “Adjust” button to enter
Adjustment mode.

Active
Fault
Warning! Only Qualified
Technicians Should Adjust
Controls, Contact Your
Qualified Heating Professional

For Service Contact:
CONTRACTOR NAME
ADDRESS LINE 1
ADDRESS LINE 2
PHONE NUMBER

Service Contact

Adjust

Password required
Installer Password = 76

Press 5-digit display to
Input Password

076

ES
C

B
S

Adjust

Press 5-digit display to
Input Password

000

CL
R

Press Save to enter password
Save

After inputting the
password press
to enter password

Adjust

After password is Saved
These buttons access
Adjust mode screens

Figure 56: Adjust Mode Screens
2. Adjusting Parameters

Editing parameters is accomplished as follows:

i
Accept Value
Press the
button to confirm
newly edited value.
The value modified with the
increase and decrease buttons is
not accepted unless this button is
also pressed

Value to be edited
(blinks while editing)

Central Heat
CH Setpoint
180

>
Cancel edit

Edit Value
Press the
buttons to edit a
value. While editing a value it will blink
until it has been accepted or cancelled. A
value is also cancelled by leaving the
screen without accepting the value.

Press the
button to cancel
newly edited value and go back
to the original

X. Operation G. Changing Adjustable Parameters (continued)
2. Adjusting Parameters (continued)

From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to
the previous page to review how to enter Adjustment mode):

System
Setup
Pump
Setup
Manual
Control

The following pages describe the
Control’s adjustable parameters.
Parameters are presented in the order
they appear on the Control’s Display,
from top to bottom and, left to right

Central
Heat
Outdoor
Reset
Sequence
Master

“Press”

System
Setup

Range /
Choices

Fahrenheit

Fahrenheit,
Celsius

0-14

Display Brightness
Display brightness is adjustable from 0 to 14.

0-14

Display Contrast
Display contrast is adjustable from 0 to 14.

Wired

Not Installed,
Wired
Wireless

Disabled

70°F

Domestic
Hot Water
Remote
4-20mA
Sequence
Slave

Parameter and Description
Temperature Units
The Temperature Units parameter determines whether temperature is represented in units of
Fahrenheit or Celsius degrees.

Outdoor Sensor Source
Not Installed Outdoor Sensor is not connected to the boiler, the sensor is not monitored for faults.
Wired
Outdoor Sensor is installed directly on the boiler terminal Strip-TB2.
Wireless
Outdoor sensor is installed and wireless.

Frost Protection
Disable
Frost Protection is not used.
Enable
Boiler and system circulators start and boiler fires when low outside air, supply and
return
temperatures are sensed as follows:
Enable/Disable
Device
Start
Stop
Started
Temperatures
Temperatures
Boiler & System

0 Secs

- More -

button to access the following parameters:

Factory
Setting

Enabled

Modulation
Setup
Contractor
Setup

0-900 Secs

Outside Air < 0°F

Outside Air > 4°F

Anti-Short Cycle Time
Anti-short cycle is a tool that helps prevent excessive cycling resulting from a fast cycling
Thermostat or Zone valves. It provides a minimum delay time before the next burner cycle. DHW
demand is serviced immediately, without any delay.

Warm Weather Shutdown Enable
Disable
Warm Weather Shutdown (WWSD) is not used.
Enable
The boiler will not be allowed to start in response to a central heat call for heat if the
Enable/Disable
outside temperature is greater than the WWSD setpoint. WWSD is initiated as soon
as outside air temperature is above WWSD Setpoint. The control does not require
call for heat to be satisfied.
The boiler will still start in response to a Domestic Hot Water call for heat.
0-100°F

Warm Weather Shutdown Setpoint
The Warm Weather Shutdown (WWSD) Setpoint used to shutdown the boiler when enabled by the
“WWSD Enable” parameter.

X. Operation G. Changing Adjustable Parameters (continued)
2. Adjusting Parameters (continued)

WARNING

Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are
installing a new or replacement Control. The boiler type setting determines minimum and maximum blower
speeds. Incorrect boiler type can cause hazardous burner conditions and improper operation that may result
in PROPERTY LOSS, PHYSICAL INJURY OR DEATH.

“Press”

Modulation
Setup

Factory
Setting

button to access the following parameters:

Range /
Choices

See Table
30

See Table 30

See Table
30

Minimum to
Maximum
Modulation

See Table
30

Minimum to
Maximum
Modulation

See Table
30

Minimum
- 100 to
Maximum

See Table
30

Parameter and Description
Boiler Type
Boiler Size Setup
To verify the boiler size selection, a qualified technician should do the following:
1. Check boiler’s label for actual boiler size.
2. Set “Boiler Type” to match actual boiler size.
3. Select “Confirm”.
The Boiler Type parameter changes the minimum and maximum modulation settings. This
parameter is intended to allow a user to set the parameters in a spare part Sage2.1 Controller to a
particular boiler type.
Central Heat Maximum Modulation
This parameter defines the highest modulation rate the Control will go to during a central heat call
for heat. If the rated input of the installed home radiation is less than the maximum output of the
boiler, change the Central Heat Maximum Modulation (fan speed) setting to limit the boiler output
accordingly.
Domestic Hot Water (DHW) Max Modulation
This parameter defines the highest modulation rate the Control will go to during a Domestic Hot
Water call for heat. If the rated input of the indirect water heater is less than the maximum output
of the boiler, change the DHW Maximum Modulation (fan speed) setting to limit the boiler output
accordingly.
Minimum Modulation
This parameter is the lowest modulation rate the Control will go to during any call for heat.

2500 - Maximum Lightoff Rate
Light-off Rate This is the blower speed during ignition and flame stabilization periods.

Table 30: Parameters Changed Using the Boiler Type Parameter Selections:

Maximum Modulation Rate

Sage2.1 Controller - P/N 104471-01
Maximum Light-off Rate
= 4000
0 -7000 ft.
399
-07
7600

Minimum Modulation Rate

2100

1400

1200

Absolute Maximum Modulation Rate

8500

6550

5900

5600

Spare Part:
Altitude
Boiler Type

Sage2.1 Controller - P/N 104471-04
Maximum Light-off Rate
= 4000
0 - 5000 ft.
500
800N
800P
-07
-05
-05
5900
5200
5150

NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F combustion air. Contact factory before

attempting to increase the Maximum Modulation Rate.

X. Operation G. Changing Adjustable Parameters (continued)
“Press”

Pump Setup

Factory Setting

Central Heat,
Optional Priority

Any Demand

Primary
Loop Pipe
IWH

button to access the following parameters:
Range / Choices

Never,
Any Demand,
Central heat, No Priority,
Central Heat, Optional
Priority

Any Demand,
Central heat, off DHW
demand

Never,
Primary Loop Piped IWH,
Boiler Piped IWH

Parameter and Description
System Pump run pump for:
Activates the system pump output according to selected function.
Never:
Pump is disabled and not shown on status screen.
Any Demand:
Pump Runs during any call for heat.
Central Heat, No Priority: Pump Runs during central heat and frost
protection call for heat. Pump does not start for a
DHW call for heat and continues to run during
Domestic Hot Water Priority.
Central heat, Optional
Priority:
Pump Runs during central heat and frost
protection call for heat. Pump does not start
for a DHW call for heat and will be forced off if
there is a DHW call for heat and Domestic Hot
Water Priority is active.
Boiler Pump run pump for:
Activates the boiler pump output according to selected function.
Any Demand:
Pump Runs during any call for heat.
Central heat, off DHW
demand:
Pump Runs during central heat and frost
protection call for heat. Pump does not start for
a DHW call for heat and will be forced off if there
is a DHW call for heat and Domestic Hot Water
Priority is active.
Domestic Pump run pump for:
Activates the Domestic pump output according to selected function.
Never:
Pump is disabled and not shown on status screen.
Primary Loop Piped IWH: Pump Runs during domestic hot water call for
heat. Domestic Hot Water Priority enable/disable
does not affect pump operation.
Boiler Piped IWH:
Pump Runs during domestic hot water call
for heat. Pump is forced off during a central
heat call for heat when Domestic Hot Water
Priority “disabled” is selected and when Domestic
Hot Water Priority “enable” has been selected
and the DHW call for heat has remained on for
longer than 1 hour (priority protection time).

Example Pump Parameter selections:
Single boiler with no Indirect Water Heater
Parameter Selections:
System Pump= “any demand”
Boiler Pump = “any demand”
DHW Pump = “never”
Explanation:
This piping arrangement only services
central heat. When there is any demand both boiler and system pumps
turn on.

X. Operation G. Changing Adjustable Parameters (continued)
Example Pump Parameter selections (continued):
Single boiler Indirect Water Heater Piped to Primary, Optional Domestic Hot Water Priority.

Parameter Selections:
System Pump= “Central Heat ,
Optional Priority”
Boiler Pump = “any demand”
DHW Pump = “Primary Loop Piped IWH”
DHW Priority Enable is optional
Explanation:
This piping arrangement permits the
system pump to run or not run when
there is a domestic hot water call for heat.
Domestic hot water priority is optional.
It is permissible for the domestic and
system pumps to run at the same time.
The boiler pump must run for every call
for heat.

Multiple Boilers with Boiler Piped IWH, System and DHW Wired to Master
Sequencer Master
(Boiler 1)

Boiler 2

Wiring locations:
Thermostat

DHW call for heat

System pump

DHW pump

Boiler Pump

Sequencer Master Parameter Selections:
Sequencer Master
Indirect Water
Heater

Enabled
“Boiler Piped”

Pump Parameter Selections:
Central Heat,
No Priority

Never

Boiler Pump =

Central Heat,
Off DHW Priority

Any
demand

DHW Pump =

Boiler Piped IWH

Never

System Pump =

Explanation:
This piping arrangement does not allow both the Slave 1’s boiler and domestic hot water pump to run at the same time.
When call for Domestic Hot Water is received the DHW pump is turned on and the boiler pump is turned off. However, the
system pumps may run to satisfy a central heat demand that is being satisfied by a different slave. The central heat demand
is ignored by Slave 1 until the domestic hot water demand is ended. If domestic hot water priority is enabled and priority
protection time is exceeded the domestic hot water pump turns off to allow the boiler pump to run.

X. Operation G. Changing Adjustable Parameters (continued)
Example Pump Parameter selections (continued):
Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority
Sequencer Master
(Boiler 1)

Boiler 2

Wiring locations:
Thermostat

DHW call for heat

System pump

DHW pump

Boiler Pump

Sequencer Master Parameter Selections:
Sequencer Master

Enabled

Indirect Water
Heater

“Primary Piped”

Pump Parameter Selections:
Central Heat,
Optional Priority

Never

Boiler Pump =

Any demand

Any
demand

DHW Pump =

Primary Loop
Piped IWH

Never

System Pump =

Explanation:
This piping arrangement permits the system pump to run or not run when there is a domestic hot water call for heat. Domestic
hot water priority is optional. It is permissible for the domestic and system pumps to run at the same time. The boiler pump
must run for every call for heat.

Multiple Boilers, IWH piped to primary, system pump required to run for any call for heat
Sequencer Master
(Boiler 1)

Boiler 2

Wiring locations:
Thermostat

DHW call for heat

System pump

DHW pump

Boiler Pump

Sequencer Master Parameter Selections:
Sequencer Master
Indirect Water
Heater

Enabled
“Primary Piped”

Pump Parameter Selections:
System Pump =

Any demand

Never

Boiler Pump =

Any demand

DHW Pump =

Primary Loop
Piped IWH

Never

Explanation:
This piping arrangement requires the system pump to be running for any calls for heat. Also the boiler pump must run for any
call for heat.

X. Operation G. Changing Adjustable Parameters (continued)
“Press”

Contractor
Setup

button to access the following parameters:

Contractor name

For Service Contact:
Bill Smith
12 Victory Lane
Plainview, New York
516 123-4567

Press box to input contractor information.

Bill Smith
Save
Press SAVE button to store revisions.

Example Screen
Enter Contractor Information

Bill Smith
1
A

2
B

3
C

ES
C

CL
R

Use Up and DOWN Arrows for More
Exit Screen without Saving
Clear Entire Field
Backspace
Save Field and Exit
Factory Setting

Range / Choices

Parameter and Description

Contractor Name

User defined

Contractor Name

Address Line 1

User defined

Contractor Address Line 1

Address Line 2

User defined

Contractor Address Line 2

Phone

User defined

Contractor Phone

Manual

Control
“Press”
button to access the following screen:
The Manual Speed Control speed screen allows the technician to set firing rate at low or high speed for combustion testing.

Manual Speed Control
0 RPM
0%
Status Auto
press to change mode
Low

“Press” “Low” to select
manual firing rate control
and Minimum firing rate %

High

Auto

“Press” “High” to select
manual firing rate control
and Central Heat
Maximum firing rate %

nOTE
Selecting “Low” or “High”
locks (manual mode) firing
rate at min or max Rate %.
After combustion testing select
“Auto” to return the boiler to
normal operation.
Press “Auto”
to return
firing rate to
Automatic
Mode

X. Operation G. Changing Adjustable Parameters (continued)
“Press”

Central
Heat

button to access the following parameters:

Factory
Setting

Range /
Choices

180°F

80°F to
190°F

Central Heat Setpoint
Target temperature for the central heat priority. Value also used by the outdoor air reset function.

170°F

80°F to
190°F

Central Heat Thermostat “Sleep” or “Away” Setback Setpoint
Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes
and sensed at E-COM terminals D, R, and C. When setback is “on” the thermostat setback setpoint
shifts the reset curve to save energy while home is in a reduced room temperature mode. The reset
curve is shifted by the difference between the High Boiler Water Temperature and the Thermostat
Setback Setpoint. Honeywell VisionPro IAQ part number TH9421C1004 is a “setback” EnviraCOM
enabled thermostat. When connected, it allows boiler water setback cost savings.

5°F

2°F to 10°F

Central Heat Diff Above
The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.

7°F

2°F to 30°F

Central Heat Diff Below
The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.

“Press”

Response Speed
This parameter adjusts the Central Heat temperature controller Proportion Integral Derivative (PID)
values. Higher values cause a larger firing rate change for each degree of temperature change. If
set too high firing rate “overshoots” required value, increases to high fire causing the temperature to
exceed the “Diff Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller
firing rate change for each degree of temperature change. If set too low, the firing rate response will
be sluggish and temperature will wander away from setpoint.

1 to 5

Domestic
Hot Water

Parameter and Description

button to access the following parameters:

Factory
Setting

Range /
Choices

170°F

80°F to
190°F

Domestic Hot Water Setpoint
The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water temperature setpoint that is used when DHW heat demand is “on”.
When the DHW heat demand is not “on” (the contact is open or not wired) this setpoint is ignored.

160°F

80°F to
190°F

Domestic Hot Water Thermostat “Sleep” or “Away” Setback Setpoint
Thermostat setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes
and sensed at E-COM terminals D, R, and C. When setback is “on” the thermostat setback setpoint
shifts the DHW setpoint to lower the DHW temperature and to save energy while home is in a reduced
room temperature mode.

5°F

2°F to 10°F

Domestic Hot Water Diff Above
The boiler stops when the water temperature rises ‘Diff Above’ degrees above the setpoint.

7°F

2°F to 30°F

Domestic Hot Water Diff Below
The boiler starts when the water temperature drops ‘Diff Below’ degrees below the setpoint.

Enable

Enable
Disable

60
Minutes

30 to 120
Minutes

1 to 5

Parameter and Description

Domestic Hot Water Priority (DHWP)
When Domestic Hot Water Priority is Enabled and Domestic Hot Water (DHW) heat demand is “on”
the DHW demand will take “Priority” over home heating demand. When the System and Boiler pumps
are configured as “Central Heat (off DHW priority)” or “Central Heat, Optional Priority” then they will
be forced “off” during DHW Priority. Priority protection time is provided to end DHWP in the event of a
failed or excessive long DHW demand.
Priority Time
When DHWP is Enabled the Priority Time Parameter appears and is adjustable.
Response Speed
This parameter adjusts the Domestic Hot Water temperature controller Proportion Integral Derivative
(PID) values. Higher values cause a larger firing rate change for each degree of temperature change.
If set too high firing rate “overshoots” required value, increases to high fire causing the temperature
to exceed the “Diff Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller
firing rate change for each degree of temperature change. If set too low, the firing rate response will
be sluggish and temperature will wander away from setpoint.

X. Operation G. Changing Adjustable Parameters (continued)
“Press”

Outdoor
Reset

Factory
Setting

Enabled

button to access the following parameters:
Range /
Choices

Enable Disable

Parameter and Description
Outdoor Reset Enable
If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically
adjust the heating zone set point temperature based on the outdoor reset curve in Figure 57.
The maximum set point is defined by the Central Heat Setpoint (factory set to 180°F) when
the outdoor temperature is 0°F or below. The minimum set point temperature shown is 130°F
(adjustable as low as 80 F) when the outdoor temperature is 50°F or above. As the outdoor
temperature falls the supply water target temperature increases. For example, if the outdoor
air temperature is 30°F, the set point temperature for the supply water is 150°F.
Disable
Enable

0°F

70°F

110°F

130°F

0 Minutes

Do Not Calculate setpoint based on outdoor temperature
Calculate the temperature setpoint based on outdoor temperature using a reset
curve defined by Low Outdoor Temp, High Outdoor Temp, Low Boiler Water
Temp, Min Boiler Temp and Central Heat Setpoint and Boost Time parameters.

-40°F to 100°F

Low Outdoor Temperature
The Low Outdoor Temperature parameter is also called “Outdoor Design Temperature”. This
parameter is the outdoor temperature used in the heat loss calculation. It is typically set to
the coldest outdoor temperature.

32°F to 100°F

High Outdoor Temperature
The High Outdoor Temperature parameter is the outdoor temperature at which the Low
Boiler Water Temperature is supplied. This parameter is typically set to the desired building
temperature.

70°F to 190°F

Low Boiler Water Temperature
The Low Boiler Water Temperature parameter is the operating setpoint when the High
Outdoor Temperature is measured. If the home feels cool during warm outdoor conditions,
the Low Boiler Water Temperature parameter should be increased.

80°F to 190°F

Minimum Boiler Temperature
The Minimum Boiler Temperature parameter sets a low limit for the Reset setpoint. Set this
parameter to the lowest supply water temperature that will provide enough heat for the type
radiation used to function properly. Always consider the type of radiation when adjusting this
parameter.

Boost Time
When the Central Heat Setpoint is decreased by Outdoor Reset settings, the Boost Time
0-1800 Seconds parameter is used to increase the operating setpoint when the home heat demand is not
satisfied after the Boost Time setting is exceeded. When heat demand has been “on”
(0-30 Minutes) continuously for longer than the Boost Time parameter the operating setpoint is increased
by 10°F. The highest operating setpoint from Boost Time is current Central Heat Setpoint
minus the Central Heat “Diff Above” setting. A setting of 0 seconds disables this feature.

X. Operation G. Changing Adjustable Parameters (continued)
Central Heat Setpoint
Low Outside Air Temp
=180 F & 0 F

200
195

Boost Maximum Off Point
= Central Heat Setpoint
minus Diff Above

190
185

180
175
170

160
155
150
145
140
135

130

10 F

Hot Water Setpoint

165

Default Boost Outdoor Air Reset Setpoint
(Shown with thin lines, typical)
(Reset setpoint increased by 10 F every
20 minutes that demand is not satisfied.
Boost Time is field selectable
between 0 to 30 minutes)

TOD Setback Setpoint
Default = 170 F

Minimum Water Temperature
Default = 130 F

125
Default Outdoor air reset Setpoint
(Shown Bold)

120
115

Low Boiler Water Temp
Default = 110 F
High Outside Air Temp
Default = 70 F

110

Outdoor Air Temperature
-20 -15 -10

-5

70 75

Figure 57: Outdoor Reset Curve

Central Heat
Setpoint

Heating Element Type

Central Heat
Setpoint

Heating Element Type

180 to 190°F

Fan Coil

100 to 140°F

In Slab Radiant High
Mass Radiant

160 to 190°F

Convection
Baseboard
Fin Tube
Convective

130 to 160°F

Staple-up Radiant
Low Mass Radiant

130 to 160°F

Radiant
Baseboard

140 to 160°F

Radiators

X. Operation G. Changing Adjustable Parameters (continued)
“Press”
Factory
Setting

Remote
4-20mA

button to access the following parameters:

Range /
Choices

Parameter and Description

Central Heat Modulation Source
This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off
Local,
demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler
Local
4-20mA
controller to control the Sage2.1 Control:
Local:
4-20mA Input on Terminal 9 & 10 is ignored.
4-20mA
4-20mA Input on Terminal 9 & 10 is used to control firing Rate % directly.
Central Heat Setpoint Source
Sets the remote (Energy Management System) control mode as follows:
Local,
Local
Local:
Local setpoint and modulation rate is used. 4-20mA input on Terminal 9 & 10 is ignored.
4-20mA
4-20mA
4-20mA Input on Terminal 9 & 10 is used as the temperature setpoint. The following two
parameters may be used to adjust the signal range.
80°F Central Heat 4-20mAdc Setup, 4 mA Water Temperature*
130°F
Central Heat Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on terminal 9 & 10. Current
Setpoint
below 4mA is considered invalid, (failed or incorrect wired input).
80°F Central Heat 4-20mAdc Setup, 20 mA Water Temperature*
180°F
Central Heat Sets the Central Heat Temperature Setpoint corresponding to 20mA for signal input on terminal 9 & 10. Current
Setpoint
above 20mA is considered invalid, (failed or incorrect wired input).
* Only visible when Central Heat Setpoint Source is set to 4-20mA.

“Press”

Sequence
Master

button to access the following parameters:

Factory
Setting

Range / Choices

Disable

Enable,
Disable

Boiler
Piped

Boiler Piped,
Primary Piped

Disabled

Enable,
Disable

120 Secs

120 - 1200 Secs

195°F

Central Heat
Setpoint,
195°F

50%

50% - 100%

1-5

“Press”

Sequence
Slave

Master Enable/Disable
The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! enable
ONLY one Sequence Master.
Indirect Water Heater (IWH)
Boiler Piped
Sequencer to respond to an Isolated DHW demand that is piped to a single boiler. The
individual boiler goes on “Leave” from the Sequencer Master and goes to DHW Service.
Primary Piped
The Sequence Master responds to the DHW Call For Heat. This allows one or more
boilers to provide heat to the IWH.
DHW Two Boiler Start
The Sequencer to immediately start two boilers for a DHW call for heat. Used when DHW is the largest
demand. Only visible when primary piped IWH is selected.
Boiler Start Delay
Slave boiler time delay after header temperature has dropped below the setpoint minus “Diff below” setpoint.
Longer time delay will prevent nuisance starts due to short temperature swings.
Stop All Boilers Setpoint
When this temperature is reached all boilers are stopped. This setpoint allows the Sequencer to respond to
rapid load increases.
Base Load Common Rate
To maximize condensing boiler efficiency, the firing rate is limited to an adjustable value. Boilers are kept at
or below this firing rate as long as the boilers can handle the load. After last available boiler has started, the
modulation rate limit is released up to 100%.
Response Speed
This parameter adjusts the Sequence Master temperature controller Proportion Integral Derivative (PID)
values. Higher values cause a larger firing rate change for each degree of temperature change. If set too
high firing rate “overshoots” required value, increases to high fire causing the temperature to exceed the “Diff
Above” setpoint and cycle the boiler unnecessarily. Lower values cause a smaller firing rate change for each
degree of temperature change. If set too low, the firing rate response will be sluggish and temperature will
wander away from setpoint.

button to access the following parameters:

Factory
Setting

Range / Choices

None

1-8

Normal

Use Boiler First,
Normal,
Use Boiler Last

100

Parameter and Description

Parameter and Description
Boiler Address
Each boiler must be given a unique address. When ”Normal” slave selection order is used, the boiler address
is used by the Master Sequencer as the boiler start order. The boiler address is also the Modbus Address
when a Energy Management System is connected.
Slave Selection Order
“Use Boiler First”; places the Slave in the lead permanently.
”Normal”; firing order follows boiler number (1,2,3,..) order.
”Use Boiler Last”; places the slave last in the firing order.

XI. Service and Maintenance
DANGER
This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high
pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool
before attempting any disassembly or service.
Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify,
remove or tamper with any control device.

WARNING
This boiler must only be serviced and repaired by skilled and experienced service technicians.
If any controls are replaced, they must be replaced with identical models.
Read, understand and follow all the instructions and warnings contained in all the sections of this
manual.
If any electrical wires are disconnected during service, clearly label the wires and assure that the wires
are reconnected properly.
Never jump out or bypass any safety or operating control or component of this boiler.
Read, understand and follow all the instructions and warnings contained in ALL of the component
instruction manuals.
Assure that all safety and operating controls and components are operating properly before placing
the boiler back in service.
Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.

NOTICE
Warranty does not cover boiler damage or
malfunction if the following steps are not
performed at the intervals specified.

A. Continuously:
1. Keep the area around the boiler free from
combustible materials, gasoline and other flammable
vapors and liquids.
2. Keep the area around the combustion air inlet
terminal free from contaminates .
3. Keep the boiler room ventilation openings open and
unobstructed.

B. Monthly Inspections:
1. Inspect the vent piping and outside air intake piping
to verify they are open, unobstructed and free from
leakage or deterioration. Call the service technician
to make repairs if needed.
2. Inspect the condensate drain system to verify it is
leak tight, open and unobstructed. Call the service
technician if the condensate drain system requires
maintenance.

3. Inspect the flue temperature sensor cap to verify that
it is free from leakage and deterioration. Call the
Service Technician to make repairs, if needed.
4. Inspect the water and gas lines to verify they are
free from leaks. Call the service technician to make
repairs if required.

CAUTION
Water leaks can cause severe corrosion damage
to the boiler or other system components.
Immediately repair any leaks found.

C. Annual Inspections and Service: In addition to

the inspections listed above the following should be
performed by a service technician once every year.
1. If equipped, test the low water cutoff by pressing the
“Test” button located at its end. The yellow light
should come on and “Limit Open” will flash in the
Active Faults screen on the display. Push the reset
button to restore normal operation. If yellow light
does not come on, determine why the low water
cutoff is not working properly.
2. Follow the procedure for turning the boiler off per
Figure 51 “Lighting Instructions”.
3. Inspect the wiring to verify the conductors are in
good condition and attached securely.

101

XI. Service and Maintenance (continued)
CAUTION
Label all wires prior to disconnection when
servicing controls. Wiring errors can cause
improper and dangerous operation. Verify
proper operation after servicing.
4. Remove the igniter assembly and flame sensor and
inspect them for oxide deposits. Clean the oxide deposits
from the igniter electrodes and flame sensor rod with
steel wool. Do not use sandpaper for the cleaning.
Inspect the ceramic insulators for cracks and replace
the igniter assembly and/or flame sensor if necessary.
Check the igniter electrode spacing gap. Refer to Figure
58 “Igniter Electrode Gap” for details.

If the condensate neutralizer is used, check pH before
and after the neutralizer to determine neutralizing
effectiveness. Replace limestone chips and clean out
the neutralizer if needed.

10. Inspect the flue temperature sensor cap to verify that
it is free from leakage and deterioration, replace, if
needed.
11. Inspect vent connections and vent connector to heat
exchanger seals to verify that they are free from leakage
and deterioration, repair as needed.
12. Reinstall the gas valve/blower/burner assembly and
secure with M6X1 hex flange nuts.
13. Reconnect any wiring which has been disconnected.
14. Inspect the heating system and correct any other
deficiencies prior to restarting the boiler.
15. Follow Section IX “System Start-up” before leaving
installation.
16. Perform the combustion test outlined in Section IX
“System Start-up”.
17. Verify that the system PH is between 7.5 and 9.5.

Figure 58: Igniter Electrode Gap
5. To gain access to boiler burner and combustion chamber
firstly disconnect and remove gas inlet piping from
gas valve, than, remove six M6X1 hex flange nuts and
take out the blower/gas valve/burner assembly from
the boiler.
6. Inspect the assembly for lint and dust presence. If
significant lint and dust accumulations are found,
disassemble the blower/gas valve assembly to expose the
swirl plate and blower inlet (see the exploded diagram
in the parts list at the back of this manual). Vacuum
these parts as required, being careful not to damage
the vanes on the swirl plate.
7. Vacuum any dust or lint from the burner if present. If
the burner shows any visual deterioration or corrosion
signs, replace it immediately. Inspect the burner gasket
and replace, if necessary.
8. Inspect the heat exchanger combustion chamber, clean
and vacuum any debris found on the surfaces. If
required, brush the coils of the heat exchanger using
a non-metal wire flexible brush. Any cleaning of the
combustion chamber with acid or alkali products
is prohibited. Remove insulation disc and clean the
surfaces by flushing with clean water. If the disc has
signs of damage, it must be replaced. Drain and flush the
inside of the heat exchanger and condensate collector.
Do not use any cleaning agents or solvents. Re-install
insulation disc upon cleaning completion..
9. Inspect the condensate trap to verify it is open and free
from debris. Inspect condensate line integrity between
boiler and condensate neutralizer (if used), condensate
neutralizer and the drain. Clean/repair if needed.

102

18. Check for vent terminal obstructions and clean as
necessary.

D. Recommended Heating System Water Treatment
Products:
1. System Cleaning and Conditioning:
a. The following heating system water treatment
products are recommended for an initial existing
heating system sludge removal, initial boiler
cleaning from copper dust, flux residue and any
boiler debris and for preventive treatment as
corrosion/scale inhibitors:
i. Fernox™ Restorer (universal cleaner, sludge
remover, scale remover, flux residue/debris
remover, corrosion inhibitor)
ii. Fernox™ Protector (Alphi 11, CH#, Copal)
(sludge remover, corrosion inhibitor)
Follow manufacturer application procedure
for proper heating system/boiler cleaning and
preventive treatment.
Above referenced products are available
from Cookson Electronics Company, 4100
Sixth Avenue, Altoona, PA 16602, Tel: (814)
946-1611 and/or selected HVAC distributors.
Contact Burnham Commercial for specific
details.
iii. Equivalent system water treatment products
may be used in lieu of products referenced
above.
2. System Freeze Protection:
a. The following heating system freeze protection
products are recommended for Apex boilers:

XI. Service and Maintenance (continued)
i. Fernox™ Protector Alphi 11 (combined
antifreeze and inhibitor).
Follow manufacturer application procedure
to insure proper antifreeze concentration and
inhibitor level.
Above referenced product is available from
Cookson Electronics Company, 4100 Sixth
Avenue, Altoona, PA 16602, Tel: (814) 9461611 and/or selected HVAC distributors.
Contact Burnham Commercial for specific
details.
b. Equivalent system freeze protection products
may be used in lieu of product referenced above.
In general, freeze protection for new or existing
systems must use specially formulated glycol,
which contains inhibitors, preventing the glycol
from attacking the metallic system components.
Insure that system fluid contains proper glycol
concentration and inhibitor level. The system should
be tested at least once a year and as recommended by
the manufacturer of the glycol solution. Allowance
should be made for expansion of the glycol solution.

CAUTION
Use only inhibited propylene glycol solutions
specifically formulated for hydronic systems.
Do not use ethylene glycol, which is toxic and
can attack gaskets and seals used in hydronic
systems.

E. Condensate Overflow Switch and Condensate Trap
Removal and Replacement:

For removal or replacement of the condensate overflow
switch and/or condensate trap follow the steps below. For
parts identification, refer to Section XIII “Repair Parts”.

1. Condensate Overflow Switch Removal and
Replacement:
a. Disconnect power supply to boiler.
b. Remove two (2) wire nuts and disconnect overflow
switch wire pigtails from boiler wiring.
c. Using pliers, release spring clip securing the
overflow switch to condensate trap body and remove
the switch. Note that the switch has factory applied
silicon adhesive seal, which may have to be carefully
cut all around to facilitate the switch removal.
d. Insure the trap overflow switch port is not obstructed
with silicon seal debris, clean as needed.
e. Apply silicon seal to the replacement switch
threads and install the switch into the trap body
making sure it is properly oriented - the arrow
molded into the switch hex end side must face
down for proper switch operation. See Figure
59 “Condensate Overflow Switch Orientation”
for details.
f. Reconnect the switch wire pigtails to the boiler
wiring and secure with wire nuts.
g. Restore power supply to boiler. Fill up the trap
(see Section V “Condensate Disposal”) and verify
the switch operation.
2. Condensate Trap Removal and Reinstallation:
a. Disconnect power supply to boiler.
b. Remove two (2) wire nuts and disconnect overflow
switch wire pigtails from boiler wiring.
c. Disconnect pressure switch hose from condensate
trap.
d. Disconnect outside condensate compression fitting
from condensate trap stab.

Figure 59: Condensate Overflow Switch Orientation

103

XI. Service and Maintenance (continued)
e. Using pliers, release spring clip securing the
overflow switch to condensate trap body and remove
the switch. Note that the switch has factory applied
silicon adhesive seal, which may have to be carefully
cut all around to facilitate the switch removal.
f. Using pliers, release spring clip securing condensate
trap body to the heat exchanger bottom drain stab.
g. Firstly, pull the trap downwards to release from
the heat exchanger bottom drain stab; secondly,
pull the trap end from left side jacket panel sealing
grommet and remove the trap from boiler.
h. To reinstall the trap, reverse above steps.
i. If the original condensate overflow switch is to
be re-used, follow the appropriate switch removal
steps from Condensate Overflow Switch Removal
and Replacement procedure above.
j. Insure that fresh silicon sealant is applied to
the overflow switch threads, and the switch is
properly oriented relative to the trap body the arrow molded into the switch hex side end
must face down for proper switch operation.
See Figure 59 “Condensate Overflow Switch
Orientation” for details. Insure that pressure
switch hose is reconnected to the trap.
Outdoor Air Temperature Sensor
Temperature versus Resistance
(P/N 102946-01)
(10kOhm NTC Sensor)
Outdoor Temperature

104

°F

°C

Ohms of
Resistance

-20

-28.9

106926

-10

-23.3

80485

-17.8

61246

-12.2

47092

-6.7

36519

-1.1

28558

4.4

22537

10.0

17926

15.6

14356

21.1

11578

24.4

10210

25.6

9795

26.7

9398

32.2

7672

100

37.8

6301

110

43.3

5203

120

48.9

4317

k. Restore power supply to boiler. Fill up the trap
(see Section V “Condensate Disposal”) and
verify the switch operation.
Header Temperature Sensor
Temperature versus Resistance
(P/N 101935-01 or 103104-01)
(10kOhm NTC Sensor), Beta of 3950
Temperature
°C

Ohms of
Resistance

32648

19898

12492

10000

8057

104

5327

122

3602

140

2488

158

1752

176

1256

194

916

212

100

697

248

120

386

°F

Supply, Return and Stack Temperature Sensor
Temperature versus Resistance
(12kOhm NTC Sensor), Beta of 3750
Temperature
°F

°C

Ohms of
Resistance

36100

22790

14770

12000

9810

104

6653

122

4610

140

3250

158

2340

176

1710

194

1270

212

100

950

230

110

730

248

120

560

XII. Troubleshooting
WARNING
Turn off power to boiler before working on wiring.

A. Troubleshooting problems where no error code is displayed.
Condition

Possible Cause

Boiler not responding to call for heat, “Status” and
“Priority” show “Standby”.
Boiler not responding to a call for heat, “Status”
shows “Standby” and “Priority” shows Central Heat
or Domestic Hot Water.

Boiler is not seeing call for heat. Check thermostat or zone wiring for loose connection,
miswiring, or defective thermostat/zone control.
Boiler is not firing, temperature is greater than setpoint.
• Check wiring for loose connection, miswiring
• When there is a Domestic Hot Water Heat Request the System or Boiler pumps will be
forced “off” when there “Run Pump for” parameter is set to “Central heat, off DHW
demand” or “Central Heat, Optional Priority”. This has been set to allow all of the heat
to be provided for fast indirect water heater recovery. After one hour of “priority
protection” or the end of the Domestic Hot Water Heat Request the system and boiler
pumps will be free to run.
• Increase Low Boiler Water Temperature parameter 5°F per day.
• Increase High Boiler Water Temperature parameter 5°F per day

Boiler Running but System or Boiler Circulator is
not running

Home is cold during mild weather days
Home is cold during cold weather days

B. Display Faults:

Faults are investigated by selecting the “Help” button from the “Home” screen. When a fault is active the “Help”
button flashes and the home screen turns a red color. Continue to select flashing buttons to be directed to the Fault
cause.
Home Screen

Status
Detail

Boiler **00FF

024 F

Sensor
Fault

Standby
Energy Save On

Help

Adjust Max Efficiency On

active Faults

Communication
Fault

Soft Lockout
(Hold)

Hard
Lockout

Lockout
History

Sequencer
Setup

Limit String
Status

Sensor
Status

Service
Contract

Boiler Size
Setup

Rate Limit
Status

Reset

Active Fault Screen

Help Screen

Figure 60: Help Menu
Indication

Condition

Possible Cause

Display Completely Dark
Fan off, LWCO lights off, no green power
light on Control

No 120Vac Power Check breaker and wiring between breaker panel and boiler.
at Boiler

Display Completely Dark, Fan running

No 24Vac
Power to Control

- Loose 120Vac connection wiring between boiler J-Box and transformer
- Loose 24 Vac connection wiring between transformer and Control.

Blinking Green power light on Control

Control
Fault

Display Completely Dark but Boiler fires

No 5 Vdc
Power to Display

- The green light is connected to internal power supply. The power supply
is repeatedly starting and stopping (not normal) making the light flash. The
microprocessors are not running.
- Try disconnecting all terminals except 24VAC to power the Control. The
green light should be steady. If it is not then the control is defective. If
steady, start plugging in all the connectors while watching the green light.
When faulty wiring reconnected green light will begin to flash.
- Loose 5 Vdc connection wiring between display and Control
- Defective display.

**00FF

Display lost
communication
with control
Adjustment Mode
Password Timeout

ER0011

Loose or defective display harness
Defective Display
Defective Control
The Control and Display are NOT defective. The password has timed out.
Simply cycle power to the Display to restore operation.

105

XII. Troubleshooting (continued)
C. Help Screen Faults
Indication

Condition
Sequencer
Setup
Fault

Sequencer
Setup
Flashing

Boiler
Size
Fault

Boiler Size
Setup
Flashing

Possible Cause
This alarm is active if the slave boiler has lost communication with the Sequence Master. Check
the following:
- RJ 45 peer-to-peer network disconnected
- Sequencer Master was Enabled and then Disabled
- Master’s Boiler has been powered down.
- To clear fault restore communication or cycle power
WARNING!
Boiler size setting may not match actual boiler size.
The Boiler size setting determines min, max and light-off blower speeds. Incorrect boiler size can
cause hazardous burner conditions and improper operation that may result in PROPERTY LOSS,
PHYSICAL INJURY, OR DEATH.
Refer to Page 92 for boiler size setting instructions.

D. Help Screen Diagnostic Features
Indication

Possible Cause

Lockout History 1 of 10 (newest)

Supply High Limit

When happened Current
Running
Lockout

Status
Run Time Hour

For Service Contact:
CONTRACTOR NAME
CONTRACTOR ADDRESS 1
CONTRACTOR ADDRESS 2
PHONE NUMBER

Lockout History is stored in a first-in, first-out basis. Each History file is stored with boiler run hour of when the
lockout occurred.
The “When happened” and “Current” provide:
- “Current” is the run hour and status the boiler just finished.
- “When happened” is the run hour and status when the lockout occurred.

The user is given the contact information of the responsible service provider. Refer to page 96 for data entry
instructions.

E. Active Fault Screen Faults
Indication

Condition

Limit String Status

Limit String
Fault

NOTE: Since the limit string items are wired in series, all limits downstream of the “open” limit will
also appear on the screen as “open” (blinking) icons regardless of whether or not they are actually
open.

Condensate (Gas Press Switch,
Air
Auto
Float Switch
LWCO,
Press Reset (& Thermal Link External Hi Limit
Switch Hi Limit on Size > 210) When provided)

Sensor Status

i Supply Sensor

180 F
Return Sensor 768 F
Stack Sensor 024 F
Outdoor Sensor 45 F
Header Sensor
4-20mA Input 4 mA

Normal
Shorted
Open
Normal
None
Normal

Sensor
Fault

Rate Limits

Active Rate Limiter:
High Stack Temp Rate Limit

Active Rate Override:
Burner Control Rate Override

106

The Sensor Status screen shows the status of all sensors. Possible states include:
None:
Feature requiring this sensor has not been selected.
Normal: Sensor is working normally.
Shorted: Sensor is shorted or is defective.
Open: There is a break in the wiring between the Control and the sensor or the sensor is
defective
Out of Range: Sensor is defective or is being subjected to electrical noise.
Unreliable:
Sensor is defective or is being subjected to electrical noise.
When a sensor fails “opened” or “shorted” the value is changed to reverse video (background
black and value white) “024” or “768” respectively to indicate that there is a fault with the sensor.

Rate Limit

Possible Cause
The Limit String Status screen shows the faulty safety limit. A contact icon, either “open” or
“closed”, graphically represents each safety limit. The “closed” contact icon is steady; the “open”
contact icon is blinking. For example, the screen shown to the left illustrates a “closed” Air
Pressure Switch contact and an “open’ Auto Reset High Limit contact. The Auto Reset High Limit
is causing the boiler to stop firing.

High Stack
Temperature
Rate Limit

The following messages appear when the firing rate is limited or reduced to help avoid a lockout.
Refer to lockout section for potential corrective action.
- High Stack Temperature Limit
- High Supply Temperature Limit
- High Differential Temperature Limit
The following messages appear as part of a normal start and stop sequence:
- Minimum Modulate (normal start/stop sequence)
- Forced Modulation (normal start/stop sequence)
- Burner Control Rate (normal start/stop sequence)
- Manual Firing Rate ( User selection)

XII. Troubleshooting (continued)

F. Troubleshooting problems where a Soft Lockout Code is displayed. When a soft lockout occurs, the boiler will shut

down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the
cause of the soft lockout. The boiler will automatically restart once the condition that caused the lockout is corrected.

Soft Lockout Codes Displayed
Lockout
Number

Condition

1
Anti Short Cycle

Minimum time between starts has not been reached.
Normal delay used to avoid excessive cycles.

2
Boiler Safety Limit
Open

Boiler Safety Limit wired to terminals J6-1, 2 or 3
OPEN:
• Condensate Trap Float Switch
contact open.
• Thermal Link Switch contact open.
• Burner Door Thermostat with manual reset
contact open.
• Air Pressure Switch contact open.
• Auto Reset High Limit contact open.

Possible Cause

•
•
•
•
•
•
•
•

Loose wiring to limit device.
Auto Reset Supply high limit sensor detected temperature in excess of 200°F.
Defective Auto Reset Supply High Limit Switch.
Plugged Condensate Trap - also check to ensure boiler is level.
Thermal Link Switch blown due to temperature rise above 604°F (318°C).
Burner Door Thermostat with manual reset contact open due to temperature rise
above 500°F (260°C) - check the cause of overheating (burner door insulation, loose
mounting, etc.).
Air Pressure Switch contact open - check for blocked vent.
See possible causes for “Hard Lockout 4”.

NOTE
Block Vent Special Note
Before a call for heat the air pressure switch is closed. When there is a call for heat
with a blocked vent the air pressure switch will open (due to excessive pressure of the
blower against a blocked flue pipe) after the blower starts. The control stops the start
sequence and stops the blower. After the blower stops the pressure switch re-closes
and the cycle continues. The displays shows the cause of trip for only the time the
pressure switch is open.

3
Boiler Safety Limit
Open

Boiler Safety Limit, or External Limit wired to
terminals J5-1 OPEN:
• Jumper for External Limit wired to terminals 11
and 12 or device connected to it open.
• Jumper for Low Water Cutoff (LWCO) Switch or
device connected to it open.
• Jumper for Low Gas Pressure Switch or device
connected to it open.

•
•
•
•
•
•
•

See possible causes for “Hard Lockout 4”.
Loose wiring to limit device.
External Limit defective or jumper not installed.
Low Gas Pressure Switch contact open (if installed).
LWCO switch not installed and jumper missing.
If yellow light on LWCO is on, system is low on water.
If neither yellow or green light is on, check LWCO harness.

7
Return sensor fault

Shorted or open return temperature sensor.

•
•

Shorted or mis-wired return sensor wiring.
Defective return sensor.

8
Supply sensor fault

Shorted or open supply temperature sensor.

•
•

Shorted or mis-wired supply sensor wiring.
Defective supply sensor.

9
DHW sensor fault

Shorted or open Domestic Hot Water (DHW)
temperature sensor.

•
•

Shorted or mis-wired DHW sensor wiring.
Defective DHW sensor.

10
Stack sensor fault

Shorted or open flue gas (stack) temperature sensor.

•
•

Shorted or mis-wired stack sensor wiring.
Defective stack sensor.

•
•
•
•
•
•
•

11
Ignition failure

Flame failure after 5 tries to restart.

•

No gas pressure.
Gas pressure under minimum value shown on rating plate.
Gas line not completely purged of air.
Defective Electrode.
Loose burner ground connection.
Defective Ignition Cable.
Defective gas valve (check for 24 Vac at harness during trial for ignition before
replacing valve).
Air-fuel mixture out of adjustment - consult factory.

•
•

Shorted or mis-wired flame rode wiring.
Defective flame rod.

•

Inadequate boiler water flow. Verify that circulator is operating and that circulator
and piping are sized per Section VI of this manual.

13
Flame rod
shorted to ground

Flame rod shorted to ground

14
DT inlet/outlet high

Temperature rise between supply and return is too
high.

15
Return temp higher
than supply

•
The Control is reading a return sensor temperature
•
higher than the supply sensor temperature. Condition
must be present for at least 75 seconds for this error
•
code to appear.
•

16
Supply temp has risen Supply water temperature has risen too quickly.
too quickly
17
Blower speed not
proved

•
•
•

Flow through boiler reversed. Verify correct piping and circulator orientation.
No boiler water flow. Verify that system is purged of air and that appropriate valves
are open.
Sensor wiring reversed.
Supply or return sensor defective.
See possible causes for “Hard Lockout 4”.
Inadequate boiler water flow.
Verify that circulator is operating and that circulator and piping are sized per
Section VI of this manual.

Normal waiting for blower speed to match purge and
light-off setpoint.

107

XII. Troubleshooting (continued)
G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut

down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the
cause of the Hard Lockout. Once the condition that caused the lockout is corrected, the boiler will need to be manually reset
using the Reset button on the “Active Fault” display or located on the Sage2.1 Control.

Hard Lockout Codes Displayed
Lockout Number

Condition

Possible Cause
•

4
Supply high limit

Sage2.1 supply sensor detected
temperatures in excess of 210°F.

5
DHW high limit

Sage2.1 DHW sensor detected
temperatures in excess of Setpoint.

6
Stack High limit

Sage2.1 Flue gas (Stack) sensor detected
temperatures in excess of 204°F.

•
•
•
•
•

DHW load at time of error was far below the minimum firing
rate of the boiler.
Control system miswired so that boiler operation is permitted
when no DHW are calling.

•
•
•

Heat exchanger needs to be cleaned.
Boiler over-fired.
Air-fuel mixture out of adjustment - consult factory.

A flame signal was present when there
should be no flame.

•

Defective gas valve - make sure inlet pressure is below
maximum on rating plate before replacing valve.

18
Light off rate proving failed

Blower is not running at Light-off rate
when it should or blower speed signal not
being detected by Sage2.1.

•
•
•

Loose connection in 120 VAC blower wiring.
Loose or miswired blower speed harness.
Defective blower

19
Purge rate proving failed

Blower is not running at Purge rate when
it should or blower speed signal not being
detected by Sage2.1.

•
•
•

Loose connection in 120 VAC blower wiring.
Loose or miswired blower speed harness.
Defective blower

20
Invalid Safety Parameters

Unacceptable Sage2.1 control Safety
related parameter detected.

Safety Parameter verification required. Contact factory.

Unacceptable Sage2.1 control Modulation
related parameter detected.

Reset the control.

Safety related parameter change has
been detected and a verification has not
been completed.

Safety related Sage2.1 control parameter has been changed and
verification has not been performed.

12
Flame detected out of sequence

21
Invalid Modulation Parameter
22
Safety data verification needed

23
24VAC voltage low/high

Sage2.1 control 24Vac control power is
high or low.

•
•
•
•
•
•

Loose connection in 24Vac VAC power wiring.
Loose or miswired 24Vac harness.
Miswired wiring harness causing power supply short to
ground.
Defective transformer.
Transformer frequency, voltage and VA do not meet
specifications.
Loose or defective gas valve harness. Check electrical
connections.
Defective gas valve (check for 24 Vac at harness during trial
for ignition before replacing valve).

24
Fuel Valve Error

Power detected at fuel valve output when
fuel valve should be off.

25
Hardware Fault

Internal control failure.

•

Reset the control. If problem reoccurs, replace the Sage.

26
Internal Fault

Internal control failure.

•

Reset the control. If problem reoccurs, replace the Sage.

•
•
•
•
•
•
•

No gas pressure.
Gas pressure under minimum value shown on rating plate.
Gas line not completely purged of air.
Defective Electrode.
Loose burner ground connection.
Defective Ignition Cable.
Defective gas valve (check for 24 Vac at harness during trial
for ignition before replacing valve).
Air-fuel mixture out of adjustment - consult factory.

27
Ignition failure

Model APX500 and APX800:
Flame failure after 1 try to restart.

•

108

Heating load at time of error was far below the minimum firing
rate of the boiler.
Defective system circulator or no flow in primary loop.
Defective boiler circulator or no flow in boiler loop.
Control system miswired so that the boiler operation is
permitted when no zones are calling.

XIII. Repair Parts
All Apex™ Series Repair Parts may be obtained through your local Burnham Commercial Cast Iron
Wholesale distributor. Should you require assistance in locating a Burnham Commercial Cast Iron
distributor in your area, or have questions regarding the availability of Burnham Commercial Cast Iron
products or repair parts, please contact Burnham Commercial Cast Iron Customer Service at
(888) 791-3790 or Fax (877) 501-5211.

109

XIII. Repair Parts (continued)

1D
1P-3

1P-1

110

1P-2

XIII. Repair Parts (continued)
1T

1W
Key
No.
1A
1B
1C
1D
1E
1F
1G
1H
1J
1K
1L
1M
1N
1P-1
1P-2
1P-3
1Q
1R
1S
1T
1U
1V
1W

Description
Bare Heat Exchanger
Burner Head Assembly
Replacement Igniter Kit
Replacement Flame Sensor Kit
Replacement Partially Assembled Burner Door
Air Vent Valve
Water Temp Sensor
High Limit
Gasket, Header (All Three)
Gasket, Header, 1” NPT
Gasket, Header, 1” & 3/4” NPT
Gasket, Header, 1-1/2” NPT
Gasket, Header, 3/4” NPT
Gas/Air Intake Duct Assembly
Gas/Air Intake Duct Assembly
Gas/Air Intake Duct Weldment
Burner Plate Insulation (Warning: Contains RCF, Not Shown)
Burner Plate Inner Seal
Burner Plate Outer Seal
Burner Head
Burner Head Seal
Insulation Disc (Warning: Contains RCF)
Burner Door Thermostat with Manual Reset
M6x1 Hex Flange Nut (Not Shown)
M5x14 mm Pan Hd Thread Forming Screw, T25 Drive (Not Shown)
M5x10mm Pan Hd Thread Forming Screw, Phillips Drive (Not Shown)
Thermal Link Switch (Backside of Duo Heat Exchanger) (Not Shown)
Flue Exit Gasket Kit (Inside of Vent Termination of Heat Exchanger),
(Not Shown)

(Quantity) Part Number
APX399
APX500
APX800
101931-06
101931-07
103261-01
101933-06
101933-07
103108-01
103005-01
103005-02
103308-01
103339-01
103310-01
102696-01
104597-01
101586-01
(2) 101685-01
101653-01
N/A
N/A
N/A
101372-03
101372-01
101725-02
N/A
N/A
N/A
N/A
103338-01
N/A
102615-01
N/A
101728-01
103610-01
101729-01
101730-01
101731-06
102658-01
104584-01
101732-01
101996-02
104569-01
(6) 101724-01
(4) 101742-01
N/A
N/A
(5) 102671-01
103321-01
104501-01

104502-01

111

XIII. Repair Parts (continued)
2F
(SIZE 500 ONLY)

APX399 and APX500 Only

2B
2B-1
2A
2D

(SIZE 500)

(SIZE 399)

2G
Key
Description
No.
2A

2E
(Quantity) Part Number
APX399
APX500
APX800
101530-01 101531-01
103222-01

Blower
Blower Inlet Shroud Assembly
(includes Gas Orifice; Gas Orifice O-Ring; (3x) M4x20 mm or (3x) M4x25 mm
2B Self-threading Screws; Injector Plate; (4x) M4 x 10 mm Flat Head Screws; 101704-04 101704-05
Air Intake Adapter - Air Connection Side; Swirlplate; (2x) M5 x 16 mm Phillips
Flat Head Screws; Blower Adapter Plate; Air Intake Adapter - Blower Side).
Blower Inlet Repair Kit (includes Blower Adapter Plate, Swirlplate and
2B-1
104620-04 104620-05
Mounting Hardware)
2C
2D
2E
2F
2G

Gas Valve
Gas Valve Harness with Plug
Gas Valve Harness with Two Plugs
Blower Outlet Gasket
Gas Valve Flange Kit
Rubber Grommet, Gas Line

APX800 Only

112

103223-01

N/A

(2) 103224-01
(Nat. Gas)
103299-01 (LP)
102971-01
103300-01 (LP)
N/A
103225-01 (Nat. Gas)
101345-01 102614-01
103263-01
N/A
102972-03
(4) 102972-03
101638-01
103252-01

102975-06 102975-07

XIII. Repair Parts (continued)

Key
No.

Description

(Quantity) Part Number
APX399

APX500

APX800

Low Gas Pressure Switch

N/A

102702-01

High Gas Pressure Switch

N/A

102703-01

Gas Pressure Switch Wire Harness

N/A

102704-01

113

XIII. Repair Parts (continued)

Key
No.

114

Description

Air Pressure Switch

Air Pressure Switch Tubing, Black

Condensate Trap, Blow Molded

(Quantity) Part Number
APX399

APX500

APX800

104426-01
7016041

102770-01
101239-01

Blocked Condensate Drain Switch

Spring Clip, Condensate Trap

101587-01

Rubber Grommet, Condensate Trap

101595-01

Condensate Comp. Fitting

101546-01

(2) 101632-01

103257-01

XIII. Repair Parts (continued)

Key
No.

Description

Sage2.1 (Programmed)

Programmed Display (with Mounting Hardware)

Transformer

(Quantity) Part Number
APX399

APX500

104472-01

APX800
104472-04

104427-01
102516-01

103193-01

115

XIII. Repair Parts (continued)

116

XIII. Repair Parts (continued)

Key
No.

Description

(Quantity) Part Number
APX399

APX500

APX800

Jacket, Rear/Bottom Panel

103406-02

103407-01

N/A

Jacket, Left Side Panel

102776-06

102776-07

103232-01

Jacket, Right Side Panel

101766-02

102610-01

103233-01

Partition Shelf Assembly

102831-06

102831-07

103237-01

Jacket, Top Panel

101218-06

101218-07

103234-01

Heat Exchanger Support Assembly, Right Side

101232-06

101232-07

103228-01

Heat Exchanger Support, Left Side

101224-06

101224-07

103227-01

Bracket, High Voltage Terminal

102780-01

Bracket, Rear HX Support

101381-01

Jacket Support Bracket

Lower Front Door Assembly

Jacket, Upper Front Panel

101509-01

Bracket, Right Clip

101508-01

Rubber Pad, Right Clip

101245-01

Draw Latch

101037-01

(2) 101593-01

(1) 101593-01

101227-02

N/A

101227-01

Bracket, Left Clip

101507-02

N/A

Bracket, HX Strap

N/A

103229-01

Access Panel (5’ x 16’)

N/A

102612-01

N/A

Gasket, Access Panel (5’ x 16’)

N/A

102613-01

N/A

Bracket, Gas Train

N/A

102611-01

103240-01

(2) 102877-01

(6) 102877-01

Gasket, Access Panel (5’ x 8’)

Jacket, Rear Panel

Access Panel (5’ x 8’)

Control, Slid Tray

(1) 102877-01
N/A
(1) 102873-01

103230-01
(2) 102873-01

(6) 102873-01

102777-01

103336-01

6AA

Gasket, Rear to Base & Partition

N/A

103241-01

6BB

Gasket, Rear to Side

N/A

103242-01

6CC

Gasket, Side to Base & Partition

N/A

103243-01

6DD

Gasket, Side to Base Support

N/A

103244-01

6EE

Gasket, Side to Header Strap

N/A

103245-01

6FF

Gasket, Side to HX Support

N/A

103246-01

6GG

Heat Exchanger Support, Front/Rear

N/A

103231-01

6HH

Base Pan

N/A

102226-01

6JJ

Bracket, Partition Shelf Support

N/A

103239-01

(4) 8186006

(6) 8186006

Nylon Glide

117

118

XIII. Repair Parts (continued)

Key
No.

Description

(Quantity) Part Number
APX399

APX500

APX800

Jacket, Rear/Bottom Panel

103406-02

103407-01

N/A

Jacket, Left Side Panel

102776-06

102776-07

103232-01

Jacket, Right Side Panel

102776-02

102610-01

103233-01

Partition Shelf Assembly

102831-06

102831-07

103237-01

Jacket, Top Panel

101218-06

101218-07

103234-01

Heat Exchanger Support Assembly, Right Side

101232-06

101232-07

103228-01

Heat Exchanger Support, Left Side

101224-06

101224-07

103227-01

Bracket, High Voltage Terminal

102780-01

Bracket, Rear HX Support

101381-01

Jacket Support Bracket

Lower Front Door Assembly

Jacket, Upper Front Panel

101509-01

Bracket, Right Clip

101508-01

Rubber Pad, Right Clip

101245-01

Draw Latch

101037-01

(2) 101593-01

(1) 101593-01

101227-02

N/A

101227-01

Bracket, Left Clip

101507-02

N/A

Bracket, HX Strap

N/A

103229-01

Access Panel (5’ x 16’)

N/A

102612-01

N/A

Gasket, Access Panel (5’ x 16’)

N/A

102613-01

N/A

Bracket, Gas Train

N/A

102611-01

103240-01

Gasket, Access Panel (5’ x 8’)

(2) 102877-01

(6) 102877-01

Jacket, Rear Panel

Access Panel (5’ x 8’)

Control, Slid Tray

(1) 102877-01
N/A
(1) 102873-01

103230-01
(2) 102873-01

(6) 102873-01

102777-01

103336-01

6AA

Gasket, Rear to Base & Partition

N/A

103241-01

6BB

Gasket, Rear to Side

N/A

103242-01

6CC

Gasket, Side to Base & Partition

N/A

103243-01

6DD

Gasket, Side to Base Support

N/A

103244-01

6EE

Gasket, Side to Header Strap

N/A

103245-01

6FF

Gasket, Side to HX Support

N/A

103246-01

6GG

Heat Exchanger Support, Front/Rear

N/A

103231-01

6HH

Base Pan

N/A

103226-01

6JJ

Bracket, Partition Shelf Support

N/A

103239-01

(4) 8186006

(6) 8186006

Nylon Glide

119

XIII. Repair Parts (continued)

Key
No.
7A

Vent System Components

Part Number

(Quantity) Part Number
APX399

APX500

APX800

4” Schedule 40 PVC Tee Vent/Combustion Air Terminal

102190-02

N/A

4” Stainless Steel Rodent Screens

102191-02

N/A

6” Stainless Steel Rodent Screens

102191-03

N/A

4” x 30” Schedule 40 CPVC Pipe

102193-02

N/A

6” x 30” Schedule 40 CPVC Pipe

103267-01

N/A

4” Schedule 80 CPVC 90° Elbow

102192-02

N/A

6” Schedule 80 CPVC 90° Elbow

103268-02

N/A

6” Schedule 40 PVC 90° Elbow

103313-01

N/A

8 oz. Bottle of Transition Cement

102195-01

8 oz. Bottle of Primer

102194-01

4” x 4” CPVC/PVC Vent System Connector

102183-03

N/A

6” x 6” CPVC/PVC Vent System Connector

103270-01

N/A

4” x 4” CPVC/PVC Vent System Connector Gasket

102185-02

N/A

6” x 6” CPVC/PVC Vent System Connector Gasket

103248-01

N/A

Flue Temperature Sensor Cap

102153-01

Flue Temperature Sensor (Not Shown)

101687-01

7B
7C

7G
7H
7J

120

XIII. Repair Parts (continued)

Key
No.

Description

MISCELLANEOUS PARTS CARTON

(Quantity) Part Number
APX399

APX500

APX800

102942-03

102942-04

Temperature/Pressure Gauge

External Gas Shut Off Valve

101615-01

816SOL0015

Relief Valve

81660302

81660375

Boiler Drain Valve

Boiler Stacking Brackets

(2) 101679-01

Boiler Stacking Bracket Screws

(8) 80860743

Outdoor Temperature Sensor (Not Shown)

100282-01

806603061

102946-01

121

XIII. Repair Parts (continued)

Part Number
APX500

Key
No.

Description

---

Complete Wiring Harness (includes 10A, 10B, 10C & 10D)

102701-02

10A
10B
10C
10D
10E
10F

Main (Low Voltage) Harness
High Voltage Harness
Blower Power Harness
Communication Harness
Igniter Harness
Wiring Harness, Thermal Link and Burner Door Thermostat

103009-02
103010-02
103012-01
103011-01
103486-01
104574-01

122

APX399

APX800

important Product Safety information
refractory Ceramic Fiber Product
Warning:
The Repair Parts list designates parts that contain refractory ceramic fibers
(RCF). RCF has been classified as a possible human carcinogen. When
exposed to temperatures about 1805°F, such as during direct flame contact,
RCF changes into crystalline silica, a known carcinogen. When disturbed as a
result of servicing or repair, these substances become airborne and, if inhaled,
may be hazardous to your health.

AVOID Breathing Fiber Particulates and Dust
Precautionary Measures:
Do not remove or replace RCF parts or attempt any service or repair work
involving RCF without wearing the following protective gear:
1. A National Institute for Occupational Safety and Health (NIOSH)
approved respirator
2. Long sleeved, loose fitting clothing
3. Gloves
4. Eye Protection
•
•
•
•

Take steps to assure adequate ventilation.
Wash all exposed body areas gently with soap and water after contact.
Wash work clothes separately from other laundry and rinse washing
machine after use to avoid contaminating other clothes.
Discard used RCF components by sealing in an airtight plastic bag. RCF
and crystalline silica are not classified as hazardous wastes in the United
States and Canada.

First aid Procedures:
•
•
•
•

If contact with eyes: Flush with water for at least 15 minutes. Seek
immediate medical attention if irritation persists.
If contact with skin: Wash affected area gently with soap and water.
Seek immediate medical attention if irritation persists.
If breathing difficulty develops: Leave the area and move to a location
with clean fresh air. Seek immediate medical attention if breathing
difficulties persist.
Ingestion: Do not induce vomiting. Drink plenty of water. Seek
immediate medical attention.

123

Appendix A - Figures
Figure
Number

Page
Number

Description

Section I - Product Description, Specifications & Dimensional Data
Figure 1A

Model APX399

Figure 1B

Model APX500

Figure 1C

Model APX800

Section III - Pre-Installation and Boiler Mounting
Figure 2

Clearances To Combustible and Non-combustible Material

Figure 3

Stacking Boiler Attachment Bracket Placement

Section IV - Venting
Figure 4

Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air
Inlets (Concentric Terminal Shown - Two-Pipe System Vent Terminal to be installed in same location
Two-Pipe System Air Intake Terminal Not Shown)

Figure 5

Expansion Loop and Offset

Figure 6

Field Installation of CPVC/PVC Two-Pipe Vent System Connector

Figure 7

Near-Boiler Vent/Combustion Air Piping

Figure 8

Wall Penetration Clearances for PVC Vent Pipe

Figure 9A

Direct Vent - Sidewall Terminations

Figure 9B

Direct Vent - Sidewall Terminations (Optional)

Figure 10

Rodent Screen Installation

Figure 11

Direct Vent - Optional Sidewall Snorkel Terminations

Figure 12

Direct Vent - Vertical Terminations

Figure 13

Direct Vent - Vertical Terminations w/ Sloped Roof

Figure 14

Vent System Field Modification to Install PVC to PP Adapter (M&G/DuraVent Shown)

Figure 15

Flexible Vent in Masonry Chimney with Separate Air Intake

Figure 16

Field Installation of Two-Pipe Vent System Adapter for Stainless Steel

Figure 17

Field Installation of Boiler Concentric Vent Collar

Figure 18

Cut-To-Length Extension (Cuttable)

Figure 19

Fixed Extension (Non-Cuttable)

Figure 20

Cutting Straight Pipe

Figure 21

Joining Cuttable Pipe

Figure 22

Joining Non-Cuttable Pipe

Figure 23

Horizontal Concentric Venting

Figure 24

Dimension “L”

Figure 25

Cutting Vent Terminal Pipe

Figure 26

Completing Horizontal (Wall Terminal Installation)

Figure 27

Vertical Concentric Vent Installation

Figure 28

Dimension “H”

Figure 29

Cutting Vertical Terminal

Figure 30

Completing Vertical Terminal Installation

Figure 31

Chimney Chase Installation

Figure 32

Multiple Boiler Direct Vent Termination

124

Appendix A - Figures (continued)
Figure
Number

Page
Number

Description

Section IV - Venting (continued)
Figure 33

Multiple Boiler Concentric Vent Termination

Section V - Condensate Disposal
Figure 34

Condensate Trap and Drain Line

Section VI - Water Piping and Trim
Figure 35

Factory Supplied Piping & Trim Installation

Figure 36

Near Boiler Piping - Heating Only

Figure 37

Near Boiler Piping - Heating Plus Indirect Water Heater

Figure 38A

Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped as Part of Boiler Piping)

Figure 38B

Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger
(IWH Piped Off System Header)

Figure 39A

Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

Figure 39B

Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

Figure 40A

Alternate Multiple Boiler Water Piping w/ Indirect Domestic Hot Water Heater (Page 1 of 2)

Figure 40B

Alternate Multiple Boiler Water Piping w/Indirect Domestic Hot Water Heater (Page 2 of 2)

Section VII - Gas Piping
Figure 41

Recommended Gas Piping

Figure 42

Gas Inlet Pressure Tap and Pressure Switch Location

Section VIII - Electrical
Figure 43

Ladder Diagram

Figure 44

66 & 67

Figure 45A

Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

Figure 45B

Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

Figure 46

Multiple Boiler Wiring Diagram, Internal Sage2.1 Multiple Boiler Control Sequencer (Three Boilers
Shown, Typical Connections for up to Eight Boilers)

Wiring Connections Diagram

Figure 47A

Multiple Boiler Wiring Diagram w/Tekmar 265 Control

Figure 47B

Multiple Boiler Wiring Diagram w/Tekmar 264 Control

Figure 48

Recommended Direct Immersion Header Sensor Installation Detail

Figure 49

Alternate “Immersion” type Header Sensor Installation Detail

Figure 50

RJ45 Splitter Installation Detail

Section IX- System Start-Up
Figure 51

Lighting Instructions

Figure 52

Burner Flame

Figure 53

Dungs Gas Valve Detail

125

Appendix A - Figures (continued)
Figure
Number

Page
Number

Description

Section X - Operation
Figure 54

Status Screens

Figure 55

Detail Screens

Figure 56

Adjust Mode Screens

Figure 57

Outdoor Reset Curve

Section XI - Service and Maintenance
Figure 58

102

Igniter Electrode Gap

Figure 59

103

Condensate Overflow Switch Orientation

Section XII - Troubleshooting
Figure 60

105

Help Menu

Section XIII - Repair Parts
N/A

126

Pages 110 thru 122

Appendix B - Tables
Table
Number

Page
Number

Description

Section I - Product Description, Specifications & Dimensional Data
Table 1

Dimensional Data (See Figures 1A, 1B and 1C)

Table 2A

Rating Data - Models APX500 and APX800 (0 to 5000 Feet Elevation Above Sea Level)

Table 2B

Rating Data - Models APX500 and APX800 (5001 to 10000 Feet Elevation Above Sea Level)

Section III - Pre-Installation and Boiler Mounting
Table 3

Apex (APX) Boiler Model Stacking Combinations

Section IV - Venting
Table 4

Vent/Combustion Air System Options

Table 5A

CPVC/PVC Vent & Air Intake Components Included With Boiler

Table 5B

CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal
(Snorkel) Termination

Table 5C

CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical (Roof)
Termination

Table 6

Vent System and Combustion Air System Components Equivalent Length vs. Component Nominal
Diameter

Table 7

Expansion Loop Lengths

Table 8

Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options (CPVC PVC and Stainless Steel/PVC or Galvanized Steel)

Table 9

Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

Table 10

Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

Table 11A

Burnham Commercial Vent System Components (Stainless Steel)

Table 11B

Alternate Vent Systems and Vent Components (Stainless Steel)

Table 12

Concentric Vent Length

Table 13

Concentric Vent Components (Applicable to APX500 Only)

Section VI - Water Piping and Trim
Table 14

Flow Range Requirement Through Boiler

Table 15

Recommended Circulator Models for Apex (APX) Boilers Based on 25°F Temperature Differential
and Up to 75 ft. Equivalent Length Near-Boiler Piping - Space Heating Circulator

Table 16

Fitting & Valve Equivalent Length

Table 17

Multiple Boiler Water Manifold Sizing

Table 18

Recommended Circulator Models for Apex (APX) Boilers and Alliance SL Indirect Water Heaters
Installed as Part of Near-Boiler Piping Up to 75 Ft. Equivalent Length - Domestic Hot Water
Circulator

Section VII - Gas Piping
Table 19A

Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 0.5
psig or Less

Table 19B

Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or
Less

Table 20

Equivalent Length of Standard Pipe Fittings & Valves

Table 21

Specific Gravity Correction Factors

Table 22

Min./Max. Pressure Ratings

127

Appendix B - Tables (continued)
Table
Number

Page
Number

Description

Section VIII - Electrical
Table 23

Boiler Current Draw

Section IX - System Start-Up
Table 24

Recommended Combustion Settings, Natural Gas

Table 25

Number of Clockwise Throttle Screw Turns for LP Conversion

Table 26

Recommended Combustion Settings, LP Gas

Section X - Operation
Table 27

Order of Priority

Table 28

Frost Protection

Table 29

Boiler Sequence of Operation

Table 30

Parameters Changed Using the Boiler Type Parameter Selections

Section XIII - Repair Parts
N/A

128

Pages 111 thru 122

SERVICE RECORD
DATE

SERVICE PERFORMED

129

SERVICE RECORD
DATE

130

SERVICE PERFORMED

SERVICE RECORD
DATE

SERVICE PERFORMED

131

For Commercial Grade Boilers

Limited Warranty

Using Cast Iron, Carbon Steel,
or Stainless Steel Heat Exchangers

and Parts / Accessories

Subject to the terms and conditions set forth below, Burnham Commercial, Lancaster,
Pennsylvania hereby extends the following limited warranties to the original owner of a
commercial grade water or steam boiler or Burnham Commercial supplied parts and/or
accessories manufactured and shipped on or after October 1, 2009:
ONE YEAR LIMITED WARRANTY ON COMMERCIAL GRADE BOILERS
AND PARTS / ACCESSORIES SUPPLIED BY BURNHAM COMMERCIAL.
Burnham Commercial warrants to the original owner that its commercial grade water
and steam boilers and parts/accessories comply at the time of manufacture with
recognized hydronic industry standards and requirements then in effect and will be
free of defects in material and workmanship under normal usage for a period of one
year from the date of original installation. If any part of a commercial grade boiler or
any part or accessory provided by Burnham Commercial is found to be defective in
material or workmanship during this one year period, Burnham Commercial will, at its
option, repair or replace the defective part (not including labor).
HEAT EXCHANGER WARRANTIES
Burnham Commercial warrants to the original owner that the heat exchanger of its
commercial grade boilers will remain free from defects in material and workmanship
under normal usage for the time period specified in the chart below to the original owner
at the original place of installation. If a claim is made under this warranty during the “No
Charge” period from the date of original installation, Burnham Commercial will, at its
option, repair or replace the heat exchanger (not including labor). If a claim is made
under this warranty after the expiration of the “No Charge” period from the date of
original installation, Burnham Commercial will, at its option and upon payment of the
pro-rated service charge set forth below, repair or replace the heat exchanger. The
service charge applicable to a heat exchanger warranty claim is based upon the number
of years the heat exchanger has been in service and will be determined as a percentage
of the retail price of the heat exchanger model involved at the time the warranty claim is
made as follows:

Service Charge as a % of Retail Price
Years in Service
1
2
3
4 5
6
7
8 9
Cast Iron
No Charge
100
Carbon Steel
No Charge
No Charge
Stainless Steel
20 40 60 80

10+
100
100

NOTE: If the heat exchanger involved is no longer available due to product obsolescence
or redesign, the value used to establish the retail price will be the published price as set
forth in Burnham Commercial Repair Parts Pricing where the heat exchanger last
appeared or the current retail price of the then nearest equivalent heat exchanger,
whichever is greater.
ADDITIONAL TERMS AND CONDITIONS
1. Applicability: The limited warranties set forth above are extended only to the
original owner at the original place of installation within the United States and
Canada. These warranties are applicable only to boilers, parts, or accessories
designated as commercial grade by Burnham Commercial and installed and
used exclusively for purposes of commercial space heating or domestic hot
water generation through a heat exchanger (or a combination for such purposes)
and do not apply to residential grade products or industrial uses.
2. Components Manufactured by Others: Upon expiration of the one year limited
warranty on commercial grade boilers, all boiler components other than heat
exchangers manufactured by others but furnished by Burnham Commercial
(such as oil burner, circulator and controls) will be subject only to the
manufacturer’s warranty, if any.
3. Proper Installation: The warranties extended by Burnham Commercial are
conditioned upon the installation of the commercial grade boiler, parts, and
accessories in strict compliance with Burnham Commercial installation
instructions. Burnham Commercial specifically disclaims liability of any kind
caused by or relating to improper installation.
4. Proper Use and Maintenance: The warranties extended by Burnham Commercial
conditioned upon the use of the commercial grade boiler, parts, and accessories
for its intended purposes and its maintenance accordance with Burnham
Commercial recommendations and hydronics industry standards. For proper
installation, use, and maintenance, see all applicable sections of the Installation
and Operating, and Service Instructions Manual furnished with the unit.
5. This warranty does not cover the following:
a. Expenses for removal or reinstallation. The owner will be responsible for
the cost of removing and reinstalling the alleged defective part or its
replacement and all labor and material connected therewith, and
transportation to and from Burnham Commercial.
b. Components that are part of the heating system but were not furnished by
Burnham Commercial as part of the commercial boiler.
c. Improper burner adjustment, control settings, care or maintenance.
d. This warranty cannot be considered as a guarantee of workmanship of an
installer connected with the installation of the Burnham Commercial boiler, or
as imposing on Burnham Commercial liability of any nature for unsatisfactory
performance as a result of faulty workmanship in the installation, which
liability is expressly disclaimed.

e. Boilers, parts, or accessories installed outside the 48 contiguous United
States, the State of Alaska and Canada.
f. Damage to the boiler and/or property due to installation or operation of the
boiler that is not in accordance with the boiler installation and operating
instruction manual.
g. Any damage or failure of the boiler resulting from hard water, scale buildup
or corrosion the heat exchanger.
h. Any damage caused by improper fuels, fuel additives or contaminated
combustion air that may cause fireside corrosion and/or clogging of the
burner or heat exchanger.
i. Any damage resulting from combustion air contaminated with particulate
which cause clogging of the burner or combustion chamber including but
not limited to sheetrock or plasterboard particles, dirt, and dust particulate.
j. Any damage, defects or malfunctions resulting from improper operation,
maintenance, misuse, abuse, accident, negligence including but not limited to
operation with insufficient water flow, improper water level, improper water
chemistry, or damage from freezing.
k. Any damage caused by water side clogging due to dirty systems or
corrosion products from the system.
l. Any damage resulting from natural disaster.
m. Damage or malfunction due to the lack of required maintenance outlined in
the Installation and Operating Manuals furnished with the unit.
6. Exclusive Remedy: Burnham Commercial obligation for any breach of these
warranties is limited to the repair or replacement of its parts (not including
labor) in accordance with the terms and conditions of these warranties.
7. Limitation of Damages: Under no circumstances shall Burnham Commercial be
liable for incidental, indirect, special or consequential damages of any kind
whatsoever under these warranties, including, but not limited to, injury or damage
to persons or property and damages for loss of use, inconvenience or loss of time.
Burnham Commercial liability under these warranties shall under no circumstances
exceed the purchase price paid by the owner for the commercial grade boiler
involved. Some states do not allow the exclusion or limitation of incidental or
consequential damages, so the above limitation or exclusion may not apply to you.
8. Limitation of Warranties: These warranties set forth the entire obligation of
Burnham Commercial with respect to any defect in a commercial grade boiler,
parts, or accessories and Burnham Commercial shall have no express obligations,
responsibilities or liabilities of any kind whatsoever other than those set forth
herein. These warranties are given in lieu of all other express warranties.
ALL APPLICABLE IMPLIED WARRANTIES, IF ANY, INCLUDING ANY
WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR
PURPOSE ARE EXPRESSLY LIMITED IN DURATION TO A PERIOD OF ONE
YEAR EXCEPT THAT IMPLIED WARRANTIES, IF ANY, APPLICABLE TO
THE HEAT EXCHANGER IN A COMMERCIAL GRADE BOILER SHALL
EXTEND TO THE ORIGINAL OWNER FOR THE TIME SPECIFIED IN THE
HEAT EXCHANGER SECTION SHOWN ABOVE AT THE ORIGINAL PLACE
OF INSTALLATION. SOME STATES DO NOT ALLOW LIMITATION ON HOW
LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY
NOT APPLY TO YOU.
PROCEDURE FOR OBTAINING WARRANTY SERVICE
In order to assure prompt warranty service, the owner is requested to complete
and mail the Warranty Card provided with the product or register product online
at www.burnhamcommercialcastiron.com within ten days after the installation of
the boiler, although failure to comply with this request will not void the owner’s
rights under these warranties. Upon discovery of a condition believed to be
related to a defect in material or workmanship covered by these warranties, the
owner should notify the installer, who will in turn notify the distributor. If this
action is not possible or does not produce a prompt response, the owner should
write to Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604, giving full
particulars in support of the claim. The owner is required to make available for
inspection by Burnham Commercial or its representative the parts claimed to be
defective and, if requested by Burnham Commercial to ship these parts prepaid
to Burnham Commercial at the above address for inspection or repair. In
addition, the owner agrees to make all reasonable efforts to settle any
disagreement arising in connection with a claim before resorting to legal
remedies in the courts.
THIS WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS AND YOU MAY
ALSO HAVE OTHER RIGHTS WHICH VARY FROM STATE TO STATE.

Commercial Boilers
Burnham Commercial, P.O. Box 3939, Lancaster, PA 17604

Pub. No. BCL1109041

Revised November 1, 2009

132

Form No. 188 - Effective 12/1/09

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History When                    : 2012:02:15 10:24:19-05:00, 2012:02:15 10:24:19-05:00, 2012:02:15 12:37:55-05:00, 2012:02:15 12:45-05:00, 2012:02:15 13:46:57-05:00, 2012:02:15 14:23:43-05:00, 2012:02:15 14:37:15-05:00, 2012:02:15 14:37:58-05:00, 2012:02:15 14:44:57-05:00, 2012:02:15 14:54:35-05:00, 2012:02:15 14:55:44-05:00, 2012:02:15 14:59:36-05:00, 2012:02:15 15:13:25-05:00, 2012:02:15 15:14:47-05:00, 2012:02:15 15:18:35-05:00, 2012:02:15 15:24:57-05:00, 2012:02:15 16:09:58-05:00, 2012:02:15 16:17:36-05:00, 2012:02:15 16:26:18-05:00, 2012:02:15 16:33:40-05:00, 2012:05:09 11:14:28-04:00, 2012:05:09 11:15:45-04:00, 2012:05:09 11:16:58-04:00, 2012:05:09 11:17:24-04:00, 2012:05:09 12:39:54-04:00, 2012:06:13 11:34:52-04:00, 2012:06:13 11:42:11-04:00, 2012:06:13 11:44:04-04:00, 2012:06:13 12:52:06-04:00, 2012:06:13 12:58:25-04:00, 2012:06:13 12:59:35-04:00, 2012:06:13 13:06:34-04:00, 2012:06:13 13:06:54-04:00, 2012:06:13 13:08:42-04:00, 2012:06:13 13:10:57-04:00, 2012:06:13 13:12:51-04:00, 2012:06:13 13:14:44-04:00, 2012:06:13 13:14:57-04:00, 2012:06:13 13:16:31-04:00, 2012:06:13 13:17:21-04:00, 2012:06:13 13:18:44-04:00, 2012:06:13 13:32:59-04:00, 2012:06:13 13:35:56-04:00, 2012:06:13 13:43:58-04:00, 2012:06:13 13:47:43-04:00, 2012:06:13 14:00:31-04:00, 2012:06:13 14:33:19-04:00, 2012:06:13 14:35:26-04:00, 2012:06:13 14:36:21-04:00, 2012:06:13 15:55:39-04:00, 2012:06:13 15:57:14-04:00, 2012:06:13 16:10:59-04:00, 2012:06:13 16:11:21-04:00, 2012:06:13 16:16:42-04:00, 2012:06:13 16:20:56-04:00, 2012:06:13 16:32:20-04:00, 2012:06:13 16:41:19-04:00, 2012:06:13 16:45:20-04:00, 2012:06:18 08:52:26-04:00, 2012:06:18 13:11:43-04:00, 2012:06:18 13:13:11-04:00, 2012:06:18 13:14:09-04:00, 2012:06:18 13:14:56-04:00, 2012:06:18 13:21:39-04:00, 2012:06:18 16:24-04:00, 2012:06:18 16:25:02-04:00, 2012:06:18 16:29:19-04:00, 2012:06:18 16:36:36-04:00, 2012:06:18 16:37:24-04:00, 2012:06:19 08:53:26-04:00, 2012:06:19 08:56:45-04:00, 2012:06:19 08:59:13-04:00, 2012:06:19 09:00:19-04:00, 2012:06:19 11:38:25-04:00, 2012:09:24 10:34:32-04:00, 2012:09:24 10:47:03-04:00, 2012:09:24 10:49:49-04:00, 2012:09:24 10:58-04:00, 2012:09:24 10:59:17-04:00, 2012:09:24 11:01:46-04:00, 2012:09:24 11:02:28-04:00, 2012:09:24 11:10:52-04:00, 2012:09:24 11:39:11-04:00, 2012:09:24 11:40:56-04:00, 2012:09:24 11:41:41-04:00, 2012:09:24 11:45:56-04:00, 2012:09:24 12:38:28-04:00, 2012:09:24 12:45:30-04:00, 2012:09:24 12:50:14-04:00, 2012:09:24 12:54:18-04:00, 2012:09:24 12:54:54-04:00, 2012:09:24 13:01:25-04:00, 2012:09:24 13:06:59-04:00, 2012:09:24 13:08:46-04:00, 2012:09:24 13:16:17-04:00, 2012:09:24 13:44:07-04:00, 2012:09:24 16:42:29-04:00, 2012:09:24 16:42:55-04:00, 2012:09:24 16:44:45-04:00, 2012:09:28 14:49:21-04:00, 2012:09:28 15:22:47-04:00, 2012:09:28 15:24:25-04:00, 2012:09:28 15:29:11-04:00, 2012:10:01 07:53:12-04:00, 2012:10:01 08:26:04-04:00, 2012:10:01 10:08:44-04:00, 2012:10:03 08:09:59-04:00, 2012:10:03 08:10:45-04:00, 2012:10:18 14:16:35-04:00, 2012:10:18 14:32:19-04:00, 2012:10:18 15:34:03-04:00, 2012:10:18 15:47:12-04:00, 2012:10:18 16:02:11-04:00, 2012:10:18 16:13:40-04:00, 2012:10:18 16:14:53-04:00, 2012:10:18 16:17:01-04:00, 2012:10:18 16:18:10-04:00, 2012:10:18 16:24:31-04:00, 2012:10:18 16:35:33-04:00, 2012:10:18 16:41:33-04:00, 2012:10:19 08:41:43-04:00, 2012:10:19 08:43:41-04:00, 2012:10:19 08:46:20-04:00, 2012:10:19 08:46:43-04:00, 2012:10:19 08:47:46-04:00, 2012:10:19 08:52:02-04:00, 2012:10:19 08:52:21-04:00, 2012:10:19 08:57:05-04:00, 2012:10:19 09:06:45-04:00, 2012:10:19 09:15:23-04:00, 2012:10:19 09:18:18-04:00, 2012:10:19 09:29:38-04:00, 2012:10:19 09:33:14-04:00, 2012:10:19 09:33:31-04:00, 2012:10:19 10:03-04:00, 2012:10:19 10:03:46-04:00, 2012:10:19 10:05:41-04:00, 2012:10:19 10:06:02-04:00, 2012:10:19 10:07:52-04:00, 2012:10:19 10:09:42-04:00, 2012:10:19 10:11:05-04:00, 2012:10:19 10:12:28-04:00, 2012:10:19 10:14:29-04:00, 2012:10:19 10:18:20-04:00, 2012:10:22 14:12:25-04:00, 2012:10:22 15:06:26-04:00, 2012:10:22 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Doc Change Count                : 16347
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Producer                        : Adobe PDF Library 9.9
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Page Count                      : 132

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Burnham Apex Installation And Operation Manual

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