A.O. Smith ACB-110S-N, ACB-150S-N, ACB-199S-N Installation Manual

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Page 1

100298550_2000552608_Rev B

ProLine® XE

Combi Boiler

ProLine® XE Combi Boiler

Installation & Service Manual

Models: 110 - 150 - 199

 WARNING

Save this manual for future reference.

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

Page 2

Contents

HAZARD DEFINITIONS................................................................. 2

PLEASE READ BEFORE PROCEEDING .............................. 3

THE COMBI BOILER -- HOW IT WORKS ............................... 4-5

RATINGS ............................................................................................ 6

1. DETERMINE BOILER LOCATION

Provide Clearances .............................................................................. 7

Provide Air Openings to Room ......................................................... 9

Wall Mounting Location ................................................................... 9

Residential Garage Installation .......................................................... 9

Vent and Air Piping ............................................................................ 9

Prevent Combustion Air Contamination ........................................ 9

Corrosive Contaminants and Sources ............................................ 10

Using an Existing Vent System to Install a New Boiler ............... 10

Removing a Boiler from Existing Common Vent ........................ 11

2. PREPARE BOILER

Remove Boiler from Wood Pallet ................................................... 12

Gas Conversions .......................................................................... 12-13

Mounting the Boiler .......................................................................... 13

3. GENERAL VENTING

Direct Venting Options .................................................................... 14

Install Vent and Combustion Air Piping ....................................... 15

Sizing ................................................................................................... 16

Max. Allowable Vent Piping Lengths ............................................. 16

Materials .............................................................................................. 16

Optional Room Air ............................................................................ 17

PVC/CPVC ......................................................................................... 18

Polypropylene ......................................................................................19

Stainless Steel Vent ............................................................................ 20

4. SIDEWALL DIRECT VENTING

Vent/Air Termination - Sidewall .............................................. 21-23

Determine Location ............................................................... 21-22

Prepare Wall Penetrations .......................................................... 23

Multiple Vent/Air Terminations ..................................................... 23

Sidewall Termination - Optional Concentric Vent ................ 24-26

5. VERTICAL DIRECT VENTING

Vent/Air Termination - Vertical ............................................... 27-28

Determine Location ..................................................................... 27

Prepare Roof Penetrations .......................................................... 28

Multiple Vent/Air Terminations ..................................................... 28

Vertical Termination - Optional Concentric Vent ................. 29-30

Alternate Vertical Concentric Venting .................................... 31-32

6A. HYDRONIC PIPING

System Water Piping Methods ........................................................ 33

Low Water Cutoff Device ................................................................. 33

Chilled Water System ........................................................................ 33

Freeze Protection ............................................................................... 33

General Piping Information ............................................................. 33

Near Boiler Piping Components ..................................................... 34

Hydronic Piping Diagrams ......................................................... 36-39

6B. DOMESTIC WATER PIPING

Scalding ............................................................................................... 40

Water Chemistry ................................................................................ 40

Near Heater Piping Components .................................................... 40

Domestic Water Piping Diagrams ............................................ 41-43

7. GAS CONNECTIONS

Connecting Gas Supply Piping ........................................................ 44

Natural Gas ......................................................................................... 45

Pipe Sizing for Natural Gas ........................................................ 45

Natural Gas Supply Pressure Requirements ............................ 45

Propane Gas ........................................................................................ 45

Pipe Sizing for Propane Gas ....................................................... 45

Propane Supply Pressure Requirements ................................... 45

Check Inlet Gas Supply ............................................................... 46-47

Gas Pressure ....................................................................................... 47

Gas Valve Replacement .................................................................... 47

8. FIELD WIRING

Line Voltage Connections ................................................................ 48

Low Voltage Connections ................................................................ 48

9. CONDENSATE DISPOSAL

Condensate Drain .............................................................................. 51

10. STARTUP ............................................................................ 52-60

11. OPERATING INFORMATION

General ................................................................................................ 61

Menus ............................................................................................. 61-62

Control Inputs and Outputs .......................................................63-64

Cascade ................................................................................................. 65

Protection Features ....................................................................... 65-66

Sequence of Operation ................................................................ 66-68

12. MAINTENANCE

Maintenance and Annual Startup ............................................. 69-75

13. TROUBLESHOOTING .................................................... 76-87

14. DIAGRAMS

Ladder Diagram (Standard) ............................................................. 88

Wiring Diagram (Standard) ............................................................. 89

Revision Notes .................................................................... Back Cover

Hazard definitions

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

 DANGER

 WARNING

 CAUTION

CAUTION

NOTICE

DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.

Page 3

Please read before proceeding

ProLine® XE Combi Boiler

Installation & Service Manual

 WARNING

NOTICE

 WARNING

Installer – Read all instructions, in this manual before installing. Perform steps in the order given.

User – This manual is for use only by a qualified heating installer/ service technician. Refer to the User’s Information Manual for your reference.

Have this boiler serviced/inspected by a qualified service technician, at least annually.

Failure to comply with the above could result in severe personal injury, death or substantial property damage.

When calling or writing about the boiler – Please have the boiler model and serial number from the boiler rating plate.

Consider piping and installation when determining boiler location.

Any claims for damage or shortage in shipment must be filed immediately against the transportation company by the consignee.

Factory warranty (shipped with unit) does not apply to units improperly installed or improperly operated.

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

If the information in this manual is not followed exactly, a fire or explosion may result causing property damage, personal injury or loss of life.

This appliance MUST NOT be installed in any location where gasoline or flammable vapors are likely to be present.

WHAT TO DO IF YOU SMELL GAS

 WARNING

DO NOT install units in rooms or environments that contain corrosive contaminants (see Table 1A on page 10). Failure to comply could result in severe personal injury, death, or substantial property damage.

When servicing boiler –

• To avoid electric shock, disconnect electrical supply before performing maintenance.

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

Boiler operation –

• Do not block flow of combustion or ventilation air to the boiler.

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

• Do not use this boiler if any part has been under water. The possible damage to a flooded appliance can be extensive and present numerous safety hazards. Any appliance that has been under water must be replaced.

Boiler water –

• Thoroughly flush the system to remove debris. Use an approved pre-commissioning cleaner (see Start-Up Section), without the boiler connected, to clean the system and remove sediment. The high efficiency heat exchanger can be damaged by build-up or corrosion due to sediment. NOTE: Cleaners are designed for either new systems or pre-existing systems. Choose accordingly.

Freeze protection fluids –

• NEVER use automotive antifreeze. Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

• Do not try to light any appliance.

• Do not touch any electric switch; do not use any phone in your building.

• Immediately call your gas supplier from a near by phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the fire department.

• Installation and service must be performed by a qualified installer, service agency, or the gas supplier.

Page 4

ProLine® XE

Combi Boiler

The Combi Boiler - How it works...

Installation & Service Manual

1. Heat exchanger

Allows system water to flow through specially designed coils for maximum heat transfer, while providing protection against flue gas corrosion. The coils are encased in a jacket that contains the combustion process.

2. Blower

The blower pulls in air and gas through the venturi (item

5). Air and gas mix inside the blower and are pushed into the burner, where they burn inside the combustion chamber.

3. Gas valve

The gas valve senses the negative pressure created by the blower, allowing gas to flow only if the gas valve is powered and combustion air is flowing.

4. Venturi

The venturi controls air and gas flow into the burner.

5. Flue gas sensor (limit rated)

This sensor monitors the flue gas exit temperature. The control module will modulate and shut down the boiler if flue gas temperature gets too hot. This protects the flue pipe from overheating.

6. Boiler outlet temperature sensor (limit rated)

This sensor monitors boiler outlet water temperature (system supply). The control module will adjust boiler firing rate so the outlet temperature is correct.

7. Boiler inlet temperature sensor

This sensor monitors return water temperature (system return).

8. Temperature and pressure gauge (field installed, not shown)

Monitors the outlet temperature of the boiler as well as the system water pressure.

9. Electronic LCD display

The electronic display consists of five (5) buttons, and a liquid crystal display. The display is used to make adjustments and read boiler status.

10. Flue pipe adapter

Allows for the connection of the vent pipe system to the boiler.

11. Burner (not shown)

Made with metal fiber and stainless steel construction, the burner uses pre-mixed air and gas and provides a wide range of firing rates.

12. Boiler water outlet

The boiler water outlet is the boiler water connection for water leaving the boiler and entering the system.

13. DHW water outlet

The DHW water outlet is the DHW water connection for water leaving the boiler and entering the system.

14. Boiler water inlet

The boiler water inlet is the boiler water connection for water entering the boiler from the system.

15. DHW water inlet

The DHW water inlet is the DHW water connection for water entering the boiler from the system.

16. Gas connection pipe

Threaded pipe connection of 1/2". This pipe should be connected to the incoming gas supply for the purpose of delivering gas to the boiler.

17. Boiler control module

The boiler control responds to internal and external signals and controls the blower, gas valve, and pumps to meet the demand.

18. Air intake adapter

Allows for the connection of the air intake pipe to the boiler.

19. High voltage junction box

The junction box contains the connection points for the line voltage power and all pumps.

20. Low voltage connection board

The connection board is used to connect external low voltage devices.

21. Low voltage wiring connections

Conduit connection points for the low voltage connection board.

22. Condensate drain connection

The condensate drain connection provides a connection point to install a condensate drain line.

23. Front access cover

Provides access to all internal components.

24. Ignition / flame sense electrode

Used by the control module to detect the presence of burner flame.

25. Flame inspection window

The quartz glass window provides a view of the burner surface and flame.

26. Relief valve

Protects the heat exchanger from an over pressure condition. The relief valve provided with the unit is set at 50 psi.

27. Line voltage wiring connections (inside junction box)

Conduit connection points for the high voltage junction box.

28. Air pressure switch

The air pressure switch detects blocked conditions.

29. Transformer

The transformer provides 24V power to the integrated control.

30. Pump with automatic air vent

Provides flow through the unit for space heating and domestic water applications. Serves as the boiler and DHW pump.

31. Diverter valve

Diverts boiler water from the heating loop to the DHW heat exchanger.

32. Flow switch

The flow switch detects a DHW draw, and signals the boiler to fire.

33. DHW sensor

This sensor monitors DHW water temperature. The control module will adjust boiler firing rate so the DHW temperature is correct.

Page 5

ProLine® XE

Combi Boiler

Installation & Service Manual

The Combi Boiler - How it works... (continued)

Front Outside View

DIR #2000528036

LEFT RIGHT

DIR #2000528036 00

Bottom View

FRONT

BACK

Front Inside View

DIR #2000528036 00

Side_Rear View

Page 6

Ratings

ProLine® XE

Combi Boiler

Installation & Service Manual

LOW LEAD CONTENT

Combi

AHRI Rating

Model Number

Note: Change “N” to “L” for L.P. gas

models.

110(N,L) 11 110 102 89 95.0

150(N,L) 15 150 139 121 95.0

199(N,L) 20 199 185 161 95.0

NOTICE

Input MBH

(Note 5)

Min

Max

Maximum allowed working pressure is located on the rating plate.

Heating

Capacity

MBH

(Note 2, 7)

Net

AHRI

Ratings

Water,

MBH

(Note 3, 7)

Notes:

1. As an Energy Star Partner, the manufacturer has determined that Combi Boilers meet the Energy Star guidelines for energy efficiency.

2. The ratings are based on standard test procedures prescribed by the United States Department of Energy.

3. Net AHRI ratings are based on net installed radiation of sufficient quantity for the requirements of the building and nothing need be added for normal piping and pickup. Ratings are based on a piping and pickup allowance of 1.15.

4. Combi Boilers require special gas venting. Use only the vent materials and methods specified in the Combi Boiler Installation and Service Manual.

5. Standard Combi Boilers are equipped to operate from sea level to 4,500 feet only with no adjustments. The boiler will de-rate by 4% for each 1,000 feet above sea level up to 4,500 feet.

6. High altitude Combi Boilers are equipped to operate from 3,000 to 9,600 feet only. The boiler will not de-rate up to 5,000 feet and will de-rate 4.45% for each 1,000 feet above 5,000 feet. The operation given in this manual remains the same as the standard boilers. A high altitude label (as shown in FIG. A) is also affixed to the unit.

De-rate values are based on proper combustion calibration

and

CO2’s adjusted to the recommended levels.

AFUE

(Note 1, 7)

Other Specifications

Boiler Water

Content Gallons

1.4 1" 3/4" 1/2" 3"

2.0 1" 3/4" 1/2" 3"

2.7 1" 3/4" 1/2" 3"

SH Water

Connections

DHW Water

Connections

Gas

Connections

7. Ratings have been confirmed by the Hydronics Institute, Section of AHRI.

8. The manual reset high limit provided with the Combi Boiler is listed to UL353.

UNIT EQUIPPED FOR

HIGH ALTITUDE

3,000 FT. TO 9,600 FT.

Vent/Air

Size

(Note 4)

For installations above 9,600 feet, please consult the factory.

Figure A High Altitude Label Location

Page 7

1 Determine boiler location

ProLine® XE

Combi Boiler

Installation & Service Manual

Installation must comply with:

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

• National Fuel Gas Code, ANSI Z223.1 – latest edition.

• National Electrical Code.

• For Canada only: B149.1 Installation Code, CSA C22.1 Canadian Electrical Code Part 1 and any local codes.

NOTICE

The Combi Boiler gas manifold and controls met safe lighting and other performance criteria when the boiler underwent tests specified in ANSI Z21.13 – latest edition.

Before locating the boiler, check:

1. Check for nearby connection to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

2. Locate the appliance so that if water connections should

leak, water damage will not occur. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance. The pan must not restrict combustion air flow. Under no circumstances is the manufacturer to be held responsible for water damage in connection with this appliance, or any of its components.

3. Check area around the boiler. Remove any combustible

materials, gasoline and other flammable liquids.

 WARNING

4. The Combi Boiler must be installed so that gas control

system components are protected from dripping or spraying water or rain during operation or service.

5. If a new boiler will replace an existing boiler, check for

and correct system problems, such as:

• System leaks causing oxygen corrosion or heat exchanger cracks from hard water deposits.

• Incorrectly-sized expansion tank.

• Lack of freeze protection in boiler water causing system and boiler to freeze and leak.

• Debris left from existing piping, if not flushed and cleaned with an appropriate cleaner.

6. Check around the boiler for any potential air contaminants that could risk corrosion to the boiler or the boiler combustion air supply (see Table 1A on page

10). Prevent combustion air contamination. Remove any of these contaminants from the boiler area.

 WARNING

Failure to keep boiler area clear and free of combustible materials, gasoline, and other flammable liquids and vapors can result in severe personal injury, death, or substantial property damage.

 WARNING

This appliance is certified as an indoor appliance. Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to temperatures that exceed 100°F.

Failure to install the appliance indoors could result in severe personal injury, death, or substantial property damage.

This appliance requires a special venting system. The vent connection to the appliance is made of CPVC. Field supplied vent fittings must be cemented to the CPVC fitting on the boiler. Use only the vent materials, primer, and cement specified in the manual to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Closet and alcove installations

A closet is any room the boiler is installed in which is less than 93 cubic feet for 110 models, and 102 cubic feet for 150

- 199 models.

An alcove is any room which meets the criteria for a closet with the exception that it does not have a door.

Example: Room dimensions = 4 feet long, 3 feet wide, and 7 foot ceiling = 4 x 3 x 7 = 84 cubic feet. This would be considered a closet for a Combi Boiler.

 WARNING

For closet and alcove installations as shown in FIG.’s 1-1 and 1-2, CPVC, polypropylene or stainless steel vent material must be used inside the structure. The two ventilating air openings shown in FIG. 1-1 are required for this arrangement. Failure to follow this warning could result in fire, personal injury, or death.

Provide clearances:

Clearances from combustible materials

1. Hot water pipes—at least 1/4" from combustible materials.

2. Vent pipe – at least 1" from combustible materials.

3. See FIG.’s 1-1 and 1-2 on page 8 for other clearance minimums.

Clearances for service access

1. See page 9 for recommended service clearances. If you

do not provide the minimum clearances shown, it may not be possible to service the boiler without removing it from the space.

Page 8

1 Determine boiler location

Figure 1-1 Closet Installation - Minimum Required Clearances

LEFT

MINIMUM

1" MINIMUM CLEARANCE

AROUND VENT PIPE

TOP

MINIMUM

ProLine® XE

Combi Boiler

 WARNING

Installation & Service Manual

For closet installations, CPVC, polypropylene, or stainless steel vent material MUST BE used in a closet structure due to elevated temperatures. Failure to follow this warning could result in fire, personal injury, or death.

VENTING* OPENING

BOTTOM

MINIMUM

1/4"MINIMUM CLEARANCE

ROUND HOT WATER PIPES

FRONT

MINIMUM

VENTING* OPENING

DIR #2000534543 00

Figure 1-2 Alcove Installation - Minimum Required Clearances

1" MINIMUM CLEARANCE

LEFT

MINIMUM

AROUND VENT PIPE

TOP

MINIMUM

Minimum Clearances to Combustible

Materials

Location Clearances

From Top of the Unit 6"

From Front of the Unit 6"

From Flue or Vent Connector

in any Direction

From Back of the Unit 0"

From the Left Side of the Unit 0"

From the Right Side of the Unit 0"

Type of Floor - Combustible

Note: Service clearances are recommendations only.

 WARNING

For alcove installations, CPVC, polypropylene, or stainless steel vent material MUST BE used in an alcove structure due to elevated temperatures. Failure to follow

RIGHT 0" MINIMUM

this warning could result in fire, personal injury, or death.

OPEN DOOR

BOTTOM

MINIMUM

1/4"MINIMUM CLEARANCE AROUND HOT WATER PIPES

FRONT

MINIMUM

DIR #2000534544 00

Note: Service clearances are recommendations only.

Page 9

ProLine® XE

Combi Boiler

1 Determine boiler location (continued)

Installation & Service Manual

NOTICE

Recommended clearances for service access

- Front ............................................................................. 24"

- Left ................................................................................ 12"

- Right ............................................................................. 12"

- Bottom .......................................................................... 24"

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

Provide air openings to room:

Boiler alone in boiler room

1. No air ventilation openings into the boiler room are needed when clearances around the Combi Boiler are at least equal to the SERVICE clearances shown in FIG.’s 1-1 and 1-2. For spaces that do NOT supply this clearance, provide two openings as shown in FIG. 1-1. Each opening must provide one square inch free area per 1,000 Btu/hr of boiler input.

Boiler in same space with other gas or oil-fired appliances

1. Follow the National Fuel Gas Code (U.S.) or CSA B149.1 (Canada) to size/verify size of the combustion/ ventilation air openings into the space.

 WARNING

2. Size openings only on the basis of the other appliances in the space. No additional air opening free area is needed for the Combi Boiler because it takes its combustion air from outside (direct vent installation).

The space must be provided with combustion/ventilation air openings correctly sized for all other appliances located in the same space as the Combi Boiler.

Do not install the boiler in an attic.

Failure to comply with the above warnings could result in severe personal injury, death, or substantial property damage.

Wall mounting location

Ensure the wall for which the boiler is intended to be mounted is comprised of either, cement, brick, block, or wooden studs spaced 16" apart from center. Ensure the wall is capable of supporting at least 200 pounds.

If flooding is possible, elevate the boiler sufficiently to prevent water from reaching the boiler.

Ensure the boiler is installed in a location that minimizes the risk of water damage due to valves, pumps, etc.

Residential garage installation

Precautions

Take the following precautions when installing the appliance in a residential garage. If the appliance is located in a residential garage, it should be installed in compliance with the latest edition of the National Fuel Gas Code, ANSI Z223.1 and/or CAN/CGA-B149 Installation Code.

• Appliances located in residential garages and in adjacent spaces that open to the garage and are not part of the living space of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches (46 cm) above the floor.

• The appliance shall be located or protected so that it is not subject to physical damage by a moving vehicle.

Vent and air piping

The Combi Boiler requires a special vent system, designed for pressurized venting.

The boiler is to be used for either direct vent installation or for installation using indoor combustion air. When room air is considered, see Section 3, General Venting. Note prevention of combustion air contamination below when considering vent/ air termination.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Combi Boiler using any other means.

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

Prevent combustion air contamination

Install air inlet piping for the Combi Boiler as described in this manual. Do not terminate vent/air in locations that can allow contamination of combustion air. Refer to Table 1A, page 10 for products and areas which may cause contaminated combustion air.

 WARNING

You must pipe combustion air to the boiler air intake. Ensure that the combustion air will not contain any of the contaminants in Table 1A, page 10. Contaminated combustion air will damage the boiler, resulting in possible severe personal injury, death or substantial property damage. Do not pipe combustion air near a swimming pool, for example. Also, avoid areas subject to exhaust fumes from laundry facilities. These areas will always contain contaminants.

Page 10

1 Determine boiler location

ProLine® XE

Combi Boiler

Installation & Service Manual

Table 1A Corrosive Contaminants and Sources

Products to avoid:

Spray cans containing chloro/fluorocarbons

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

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

Adhesives used to fasten building products and other similar products

Areas likely to have contaminants

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

When using an existing vent system to install a new boiler:

 WARNING

Check the following venting components before installing:

• Material - For materials listed for use with this appliance, see Section 3 - General Venting.

• Size - To ensure proper pipe size is in place, see Table 3A. Check to see that this size is used throughout the vent system.

• Manufacturer - For a polypropylene or stainless steel application, you must use only the listed manufacturers and their type product listed in Tables 3D and 3F for CAT IV positive pressure venting with flue producing condensate.

• Supports - Non-combustible supports must be in place allowing a minimum 1/4" rise per foot. The supports should adequately prevent sagging and vertical slippage, by distributing the vent system weight. For additional information, consult the vent manufacturer’s instructions for installation.

• Terminations - Carefully review Sections 3 through 5 to ensure requirements for the location of the vent and air terminations are met and orientation of these fit the appropriate image from the Sidewall or Vertical options listed in the General Venting Section. For stainless steel vent, only use terminations listed in Table 3B for the manufacturer of the installed vent.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture refinishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

• Seal - With prior requirements met, the system should be tested to the procedure listed in parts (c) through (f) of the Removal of an Existing Boiler Section on page 11.

With polypropylene and stainless steel vent, seal and connect all pipe and components as specified by the vent manufacturer used; with PVC/CPVC vent, see the Installing Vent or Air Piping Section on page 18.

 WARNING

If any of these conditions are not met, the existing system must be updated or replaced for that concern. Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

Page 11

ProLine® XE

Combi Boiler

Installation & Service Manual

1 Determine boiler location (continued)

When removing a boiler from existing common vent system:

 DANGER

 WARNING

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.

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

b. Visually inspect the venting system for proper size and

horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, or other deficiencies, which could cause an unsafe condition.

c. Test vent system – Insofar as is practical, close all building

doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any appliance not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan. Close fireplace dampers.

Do not install the Combi Boiler into a common vent with any other appliance. This will cause flue gas spillage or appliance malfunction, resulting in possible severe personal injury, death, or substantial property damage.

Failure to follow all instructions can result in flue gas spillage and carbon monoxide emissions, causing severe personal injury or death.

g. Any improper operation of the common venting system

should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code. 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 11 of the National Fuel Gas Code, ANSI Z223.1/NFPA and/or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

d. Place in operation the appliance being inspected. Follow

the lighting instructions. Adjust thermostat so appliance will operate continuously.

e. Test for spillage at the draft hood relief opening after

5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar, or pipe.

f. After it has been determined that each appliance remaining

connected to the common venting system properly vents when tested as outlined herein, return doors, windows, exhaust fans, fireplace dampers, and any other gas-burning appliance to their previous conditions of use.

Page 12

2 Prepare boiler

ProLine® XE

Combi Boiler

Installation & Service Manual

Remove boiler from wood pallet

1. After removing the outer shipping carton from the boiler, remove the parts box.

2. To remove the boiler from the pallet:

a. Remove the two (2) lag bolts securing the

bottom of the unit to the pallet.

b. Lift the boiler off the wall bracket mounted to

the pallet (FIG. 2-1).

CAUTION

Do not attempt to use the water pipe fittings or gas pipe to lift the boiler.

CAUTION

Do not attempt to lift the boiler using the gas pipe as a handle.

Figure 2-1 Boiler Mounted on Shipping Pallet

REMOVE SHIPPING (WALL) BRACKET

DO NOT DISCARD.

WILL BE NEEDED TO SECURE THE BOILER TO THE WALL.

DIR #2000528206 00

3. Remove the two (2) lag bolts securing the wall bracket to the wood pallet. Be certain not to lose the wall bracket as it will be needed for securing the boiler to the wall (FIG. 2-4).

NOTICE

Do not drop the boiler. Damage to the boiler can result.

Gas conversions

 WARNING

You must install a propane venturi to operate the Combi Boiler on propane gas. Verify when installing that the venturi label marking matches the boiler size (see Table 2A).

Table 2A LP Conversion Table

Model Kit #

110 100296965 20 mm 2.45 mm 2.55 mm 100150947 150 100296966 24 mm 3.20 mm 2.95 mm 100150472 199 100296970 24 mm 3.30 mm 3.10 mm 100150434

For a boiler already installed, you must turn off gas supply, turn off power and allow boiler to cool before proceeding. You must also completely test the boiler after conversion to verify performance as described under Start-up, Section 10 of this manual.

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

Venturi Ø

(mm)

Orifice Ø

Bottom Top

1. If boiler is already installed, you must turn off the gas supply, turn off the power, and allow the boiler to cool before proceeding.

2. Remove the front access cover from the unit (no tools required for removal).

3. Using a 5/16" nut driver, loosen the rachet clamp securing the air intake fitting to the venturi assembly. Slide the rubber boot off the venturi.

4. Using an adjustable wrench, loosen the union between the gas valve adapter and the venturi assembly. Remove the gasket between the gas piping and venturi (FIG. 2-2).

5. Using a 3 mm Allen wrench, remove the three (3) screws securing the venturi to the fan assembly and proceed to remove the natural gas venturi from the unit, making sure not to damage the blower O-ring gasket (FIG. 2-2).

6. Install the air shutter (reference Table 2A for the model specific air shutter to be installed).

a. Disconnect the wiring from the fan and remove the

bolts securing the fan to the heat exchanger top plate.

b. Remove the fan and gasket, and install the air shutter

provided in the kit. Note: On 110 models, the air shutter MUST be installed in the proper direction. Install the air shutter so that the hole in the corner is oriented towards the back right corner of the unit (opposite the front door and gas piping).

c. Replace all torn or damaged gaskets. Reassemble the

fan assembly and reconnect the wiring harnesses before operation.

7. Install the propane venturi and verify the following:

a. The UP arrow on the plastic housing is pointing

upward.

b. The threaded connection for the gas piping is facing

towards the LEFT of the unit.

8. Reassemble the unit by following the previous steps in reverse order, taking care to ensure that the venturi adapter gasket is seated properly before tightening the nut on the venturi. NOTE: Replace any torn or damaged gasket(s) that may have been damaged or torn during installation.

9. After installation is complete, fill out the gas conversion label (in the conversion kit bag) and affix it to the unit to the right of the control display as shown in FIG. 2-3.

10. Replace the front access cover removed in Step 2 and resume operation.

 DANGER

When removing the natural gas venturi, inspect the gasket at the gas connection and the O-ring at the blower. These gaskets must be in good condition and must be installed. Failure to comply will cause a gas leak, resulting in severe personal injury or death.

Air

Shutter

Page 13

ProLine® XE

Combi Boiler

Installation & Service Manual

2 Prepare boiler (continued)

 WARNING

Figure 2-2 Remove Natural Gas Venturi

Figure 2-3 Gas Conversion Label Location

After converting to LP, check combustion per the Start-up procedure in Section 10 of this manual. Failure to check and verify combustion could result in severe personal injury, death, or substantial property damage.

NATURAL GAS VENTURI

DISCONNECT GAS PIPING

AIR SHUTTER

DIR #2000534767 00

GAS CONVERSION LABEL (AFFIX TO UNIT AS SHOWN)

DIR #2000536093 00

2. Mount the wall bracket using the 2 1/4" lag bolts provided. Make sure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) additional lag bolts provided.

 WARNING

The boiler is too heavy for a single person to lift. A minimum of two people is needed for mounting the boiler onto the bracket.

Mounting to a concrete wall:

1. Mount the wall bracket using the two (2) wedge anchor bolts provided with the bracket (FIG. 2-4). To mount the wedge anchor bolts, drill a 1/4" diameter hole 1 1/8" deep and insert anchor. Hang the bracket from the anchor and secure with the two nuts provided. Make sure the top edge of the bracket is away from the wall. Ensure bracket is level when mounted. Note: If wall thickness does not allow a 1 1/8" deep hole, field supplied hardware suitable for the application should be provided.

2. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) remaining anchors, following the instructions above.

Mounting to a metal studded wall:

1. The wall mount bracket is designed for a stud spacing of 16 inches from center (FIG. 2-4). For other stud spacing a solid mounting surface must be provided by the installer.

 WARNING

Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.

2. Mount the wall bracket using two (2) field supplied toggle bolts capable of supporting 100 pounds each. Ensure the top edge of the bracket is away from the wall. Ensure the bracket is level when mounted. Extreme care is needed to ensure the bolts are secured in the center of the studs.

3. Hang the boiler on the bracket and secure the bottom of the boiler with two (2) field supplied toggle bolts.

Mounting the boiler

See page 9 of this manual for boiler mounting location instructions.

NOTICE

Mounting to a wood studded wall:

1. The wall mount bracket is designed for a stud spacing of 16 inches from center (FIG. 2-4). For other stud spacing a solid mounting surface must be provided by the installer.

 WARNING

The Combi Boiler is not intended for floor installation.

Do not mount the boiler to a hollow wall. Be sure to mount the boiler to the studs only.

Figure 2-4 Mounting the boiler

FASTENERS APPROPRIATE FOR WALL TYPE

QTY: 4

WALL:

WOOD OR METAL STUDS ON 16" CENTERS -ORMASONRY / POURED CONCRETE

MOUNTING BRACKET (FACTORY SUPPLIED)

DIR #2000528235 00

Page 14

3 General venting

Direct venting options - Sidewall Vent

ProLine® XE

Combi Boiler

Installation & Service Manual

DIR #2000534593 00

Figure 3-1 Two-Pipe Sidewall Termination - See page 22 for more details

Direct venting options - Vertical Vent

DIR #2000534592 00

Figure 3-2 PVC/CPVC Concentric Sidewall Termination - See page 25 for more details

DIR #2000534588 00

Figure 3-3 Two-Pipe Vertical Termination - See page 28 for more details

DIR #2000534590 00

Figure 3-4 PVC/CPVC Concentric Vertical Termination - See page 30 for more details

DIR #2000534587 00

Figure 3-5 Vertical Vent, Sidewall Air

Page 15

3 General venting (continued)

Install vent and combustion air piping

ProLine® XE

Combi Boiler

Installation & Service Manual

 DANGER

 WARNING

NOTICE

 WARNING

 CAUTION

The Combi Boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 1 of this manual.

Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of applicable codes.

Failure to provide a properly installed vent and air system will cause severe personal injury or death.

This appliance requires a special venting system. Use only approved PVC, CPVC,

polypropylene or stainless steel pipe and fittings listed in Tables 3C, 3D, and 3F for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the

living space. Mixing of venting materials will void the warranty and certification of the appliance.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For closet and alcove installations, CPVC, polypropylene or stainless steel material MUST BE used in a closet/alcove structure. Failure to follow this warning could result in fire, personal injury, or death.

Improper installation of venting systems may result in injury or death.

The Combi Boiler vent and air piping can be installed through the roof or through a sidewall. Follow the procedures in this manual for the method chosen. Refer to the information in this manual to determine acceptable vent and air piping length.

You may use any of the vent/air piping methods covered in this manual. Do not attempt to install the Combi Boiler using any other means.

You must also install air piping from outside to the boiler air intake adapter unless following the Optional Room Air instructions on page 17 of this manual. The resultant installation is direct vent (sealed combustion) .

Air intake/vent connections

1. Combustion Air Intake Connector (FIG. 3-6)

- Used to provide combustion air directly to the unit from outdoors. A fitting is provided on the unit for final connection. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table 305.4 or as local codes dictate.

2. Vent Connector (FIG.'s 3-6 thru 3-10) - Used to provide a passageway for conveying combustion gases to the outside. A transition fitting is provided on the unit for final connection. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate.

Figure 3-6 Near Boiler Air Piping

AIR

NOTICE

 WARNING

Follow the instructions in Section 1, page 11 of this manual when removing a boiler from an existing vent system.

Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury, death, or substantial property damage.

DIR #2000528317 00

Page 16

3 General venting

ProLine® XE

Combi Boiler

Installation & Service Manual

Sizing

The Combi Boiler uses model specific combustion air intake and vent piping sizes as detailed in Table 3A below.

Table 3A Air Intake/Vent Piping Sizes

Model 2" Max Vent/Air 3" Max Vent/Air

110 100 feet 100 feet

150 60 feet 100 feet

199 N/A 100 feet

NOTICE

Minimum / Maximum allowable combustion air and vent piping lengths are as follows:

Combustion Air = 7 equivalent feet minimum / 100 equivalent feet maximum

Vent = 7 equivalent feet minimum / 100 equivalent feet maximum

When determining equivalent combustion air and vent length, add 5 feet for each 90° elbow and 3 feet for each 45° elbow.

EXAMPLE: 20 feet of PVC pipe + (4) 90° elbows + (2) 45° elbows + (1) concentric vent kit (100140480) = 49 equivalent feet of piping.

NOTICE

Table 3B Concentric Vent Kit Equivalent Vent Lengths

Model

110 - 150 100140485 3 feet 2 inch

110 - 199 100140480 3 feet 3 inch

Increasing or decreasing combustion air or vent piping sizes is not authorized.

The appliance output rating will reduce by up to 1.5% for each 25 feet of vent length.

Kit

Number

Equivalent Vent

Length

Vent

Size

Materials

Air inlet pipe materials:

The air inlet pipe(s) must be sealed. Choose acceptable combustion air inlet pipe materials from the following list:

PVC, CPVC, Polypropylene or ABS Galvanized steel vent pipe with joints and seams sealed as specified in this section. Type “B” double-wall vent with joints and seams sealed as specified in this section. AL29-4C, stainless steel material to be sealed to specification of its manufacturer.

 WARNING

NOTICE

Sealing of Type “B” double-wall vent material or galvanized vent pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System:

a. Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric.

b. Do not install seams of vent pipe on the bottom of horizontal runs.

c. Secure all joints with a minimum of three (3) sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe.

d. Ensure that the air inlet pipes are properly supported.

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS, or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or flex duct should use a screw type clamp to seal the vent to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

 DANGER

Using air intake materials other than those specified can result in personal injury, death or property damage.

The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

*Plastic pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the plastic air inlet pipe.

Page 17

3 General venting (continued)

Optional room air

NOTICE

Commercial applications utilizing the Combi Boiler may be installed with a single pipe carrying the flue products to the outside while using combustion air from the equipment room. In order to use the room air venting option the following conditions and considerations must be followed.

• The unit MUST be installed with the appropriate room air kit (Table 3C).

• The equipment room MUST be provided with properly sized openings to assure adequate combustion air. Please refer to instructions provided with the room air kit.

• There will be a noticeable increase in the noise level during normal operation from the inlet air opening.

• Using the room air kit makes the unit vulnerable to combustion air contamination from within the building. Please review Section 1, Prevent Combustion Air Contamination, to ensure proper installation.

• Vent system and terminations must comply with the standard venting instructions set forth in this manual.

Optional room air is intended for commercial applications. Combustion air piping to the outside is recommended for residential applications.

ProLine® XE

Combi Boiler

Please read the information given in Table 1A, page 10, listing contaminants and areas likely to contain them. If contaminating chemicals will be present near the location of the boiler combustion air inlet, have your installer pipe the boiler combustion air and vent to another location, per this manual.

 WARNING

Installation & Service Manual

If the boiler combustion air inlet is located in a laundry room or pool facility, for example, these areas will always contain hazardous contaminants.

To prevent the potential of severe personal injury or death, check for areas and products listed in Table 1A, page 10 before installing the boiler or air inlet piping.

If contaminants are found, you MUST:

• Remove contaminants permanently. —OR—

• Relocate air inlet and vent terminations to other areas.

 WARNING

Table 3C Optional Room Air Kit

Air contamination

Pool and laundry products and common household and hobby products often contain fluorine or chlorine compounds. When these chemicals pass through the boiler, they can form strong acids. The acid can eat through the boiler wall, causing serious damage and presenting a possible threat of flue gas spillage or boiler water leakage into the building.

When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

Model Kit Number Air Size

110 - 150 100297259 2" 110 - 199 100296893 3"

Page 18

3 General venting

PVC/CPVC:

This product has been approved for use with the PVC/CPVC vent materials listed in Table 3D.

Installing vent and air piping

 WARNING

NOTICE

 WARNING

Examples: 1. Seven (7) feet vertical

2. Connector + 90° elbow + 2 feet horizontal

3. One (1) foot vertical + 90° elbow + 1 foot horizontal

Use only the vent materials, primer, and cement specified in Table 3D to make the vent connections. Failure to follow this warning could result in fire, personal injury, or death.

Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

All PVC vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).

Insulation should not be used on PVC or CPVC venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

For installations using 2" vent, the first seven (7) equivalent feet of vent must be CPVC (field supplied). See examples below.

When transitioning from 2" to 3" vent diameter, a 2" pipe section and 2" to 3" increaser are required to be CPVC when PVC/CPVC vent is used.

ProLine® XE

Combi Boiler

Installation & Service Manual

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in this manual for the air or vent piping.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Chamfer outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and fittings using a clean dry rag. (Moisture will retard curing and dirt or grease will prevent adhesion.)

5. Dry fit vent or air piping to ensure proper fit up before assembling any joint. The pipe should go a third to two-thirds into the fitting to ensure proper sealing after cement is applied.

6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.

b. Apply a liberal even coat of primer to the fitting socket and to the pipe end to approximately 1/2" beyond the socket depth.

c. Apply a second primer coat to the fitting socket.

d. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket along with an even coat of approved cement to the fitting socket.

e. Apply a second coat of cement to the pipe. f. While the cement is still wet, insert the pipe into

the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.

g. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

Table 3D PVC/CPVC Vent Pipe and Fittings

Approved PVC/CPVC Vent Pipe and Fittings

Item Material Standard

PVC Schedule 40, 80 ANSI/ASTM D1785

Vent pipe

PVC - DWV ANSI/ASTM D2665

CPVC Schedule 40, 80 ANSI/ASTM F441

PVC Schedule 40 ANSI/ASTM D2466

Vent fittings

PVC Schedule 80 ANSI/ASTM D2467

CPVC Schedule 80 ANSI/ASTM F439

PVC - DWV ANSI/ASTM D2665

Pipe Cement /

Primer

NOTICE: DO NOT USE CELLULAR (FOAM) CORE PIPE

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

NOTE: In Canada, CPVC and PVC vent pipe,  ttings and cement/ primer must be ULC-S636 certi ed.

Figure 3-7 Near Boiler PVC/CPVC Venting

VENT

AIR

DIR #2000528318 00

Page 19

3 General venting (continued)

Polypropylene:

This product has been approved for use with polypropylene vent with the manufacturers listed in Table 3E.

All terminations must comply with listed options in this manual and be a single-wall vent offering.

For support and special connections required, see the manufacturer's instructions. All vent is to conform to standard diameter and equivalent length requirements established.

When determining equivalent combustion air and vent length for polypropylene single-wall piping:

• 1 foot of Duravent 4 inch single-wall pipe is equivalent to 1.6 feet of piping

Flexible polypropylene

For use of flex pipe, it is recommended to have the vent material in 32°F or higher ambient space before bending at installation. No bends should be made to greater than 45° and ONLY installed in vertical or near vertical installations (FIG. 3-8).

Figure 3-8 Near Boiler Flexible Polypropylene Venting

Duravent 3”

“A” DIM

3” FLEX

3” RIGID

10 FT

20 FT 30 FT 40 FT 50 FT

60 FT

70 FT 80 FT 90 FT

Centrotherm 3”

“A” DIM

3” FLEX

3” RIGID

10 FT 20 FT 30 FT 40 FT 50 FT 60 FT 70 FT 80 FT 90 FT

60 FT 53 FT

47 FT 40 FT 33 FT 27 FT 20 FT 13 FT

7 FT

45 FT 40 FT

35 FT 30 FT 25 FT

20 FT 15 FT

10 FT

5 FT

“B” DIM

4” FLEX

“B” DIM

4” FLEX

90 FT 80 FT 70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT

90 FT

80 FT 70 FT 60 FT 50 FT

40 FT

30 FT 20 FT 10 FT

CHIMNEY

CAP

*NOTES: 1) FLEX PIPE MAY ONLY BE RUN IN A VERTICAL ORIENTATION

2) ALL VENT LENGTHS REPRESENTED IN ABOVE CHARTS ARE EQUIVALENT LENGTHS.

3) SECTION A IS EQUIVALENT FEET OF RIGID PIPE, WHICH MAY INCLUDE 45 AND 90° ELBOWS. PLEASE SEE SIZING SECTION FOR DETERMINING EQUIVALENT FEET.

Table 3E Polypropylene Vent Pipe and Fittings

Approved Polypropylene Vent Manufacturers

Make Model

Centrotherm Eco Systems

Duravent (M & G Group)

PolyPro Single-Wall / PolyPro Flex

InnoFlue SW/Flex

Duravent 4”

“A” DIM

4” RIGID

10 FT

20 FT 30 FT 40 FT 50 FT

60 FT

70 FT 80 FT 90 FT

Centrotherm 4”

“A” DIM 4” RIGID

10 FT 20 FT 30 FT

40 FT 50 FT 60 FT 70 FT 80 FT 90 FT

“B” DIM

4” FLEX

30 FT 27 FT 23 FT 20 FT 17 FT 13 FT 10 FT

7 FT 3 FT

“B” DIM 4” FLEX

33 FT 29 FT 26 FT

22 FT

18 FT 15 FT 11 FT

7 FT 4 FT

5” FLEX

90 FT 80 FT

70 FT 60 FT 50 FT 40 FT 30 FT 20 FT 10 FT

IMG00840

ProLine® XE

Combi Boiler

NOTICE

Installation & Service Manual

The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3F for approved vent adapters. Discard CPVC starter piece.

NOTICE

All vent connections MUST be secured by the vent manufacturer's joint connector (FIG. 3-9).

 WARNING

Insulation should not be used on polypropylene venting materials. The use of insulation will cause increased vent wall temperatures, which could result in vent pipe failure.

 WARNING

Use only the adapters and vent system listed in Tables 3E and 3F. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE

Installations must comply with applicable national, state, and local codes. For Canadian installation, polypropylene vent must be listed as a ULC-S636 approved system.

NOTICE

Installation of a polypropylene vent system should adhere to the vent manufacturer’s installation instructions supplied with the vent system.

Figure 3-9 Near Boiler Polypropylene Venting Model 199

JOINT CONNECTOR REQUIRED AT ALL COMPONENT CONNECTIONS OF VENT SYSTEM

DIR #2000528329 00

Table 3F Approved Polypropylene Terminations and Adapters

Centrotherm InnoFlue SW

Model

110 - 199

* These parts are only needed if the alternate sidewall termination assembly is used.

Polypropylene Adapter/

Flue Clamp

Joint

Connector

Sidewall Retaining

Bracket*

Sidewall Adapter*

ISAG0303 w/IAFC03 IANS03 IATP0303 ISTAGL0303 3PPS-AD 3PPS-LB 3PPS-HLK

Duravent Polypro

Polypropylene

Adapter

Joint

Connector

Sidewall Kit

Page 20

3 General venting

ProLine® XE

Combi Boiler

Installation & Service Manual

Stainless steel vent:

This product has been approved for use with stainless steel using the manufacturers listed in Table 3G.

 WARNING

NOTICE

Use only the materials, vent systems, and terminations listed in Tables 3G and 3H. DO NOT mix vent systems of different types or manufacturers. Failure to comply could result in severe personal injury, death, or substantial property damage.

The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 3H for approved vent adapters. Discard CPVC starter piece.

Installations must comply with applicable national, state, and local codes. Stainless steel vent systems must be listed as a UL-1738 approved system for the United States and a ULC-S636 approved system for Canada.

NOTICE

Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

Figure 3-10 Near Boiler Stainless Steel Venting

VENT

UNIVERSAL ADAPTER

(FACTORY SUPPLIED)

DIR #2000528338 00

Table 3G Stainless Steel Vent Pipe and Fittings

Approved Stainless Steel Vent Manufacturers

Make Model

Dura Vent (M & G Group) FasNSeal Vent / FasNSeal Flex* Vent

Z-Flex (Nova Flex Group) Z-Vent

Heat Fab (Selkirk Corporation) Saf-T Vent

*Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only, taking precaution to ensure no sagging occurs of the vent system. Connect to the FasNSeal rigid vent using specially designed adapters and sealing method, see manufacturer’s instructions.

Table 3H Approved Stainless Steel Terminations and Adapters

ProTech Heat Fab Z Flex

FasNSeal Saf-T Vent Z-Vent

Model

110 - 199

**Boiler

Adapter

300715

(Intake Air)

Flue

Termination

FSBS3

FSRC3(R.C)

Intake

Air

Termination

303889 --

*Boiler

Adapter

Flue

Termination

9392

5300CI

Intake

Air

Termination

9314TERM --

**Boiler

Adapter

Flue

Termination

2SVSTP03

2SVSRCX03

Intake Air

Termination

2SVSTEX0390

*The stainless steel venting option is only available in 3" vent diameters.

Page 21

4 Sidewall direct venting

ProLine® XE

Combi Boiler

Installation & Service Manual

Vent/air termination – sidewall

 WARNING

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.

2. You must consider the surroundings when terminating

the vent and air:

a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable. b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views. c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants. d. Avoid possibility of accidental contact of flue products with people or pets. e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

Figure 4-1A PVC/CPVC/Polypropylene Sidewall Termination of Air and Vent w/Field Supplied Fittings

FROM BOILER

VENT PIPE

CONNECTION

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death, or substantial property damage.

A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property damage.

TO BOILER INTAKE AIR

CONNECTION

BIRD SCREEN

12” MIN

15” MAX

If using the sidewall termination:

3. The air piping must terminate in a down-turned elbow as shown in FIG. 4-1A. This arrangement avoids recirculation of flue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in FIG. 4-1A.

 WARNING

Do not exceed the maximum lengths of the outside vent piping shown in FIG. 4-1A. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

When venting out a sidewall using PVC, CPVC, or Polypropylene vent materials, an optional sidewall vent termination kit can be ordered (reference Table 4A for kit numbers).

Table 4A Alternate Sidewall Vent Kit

Model

Kit

Number

Air

Size

Vent

Size

Centerline

Width

110 - 150 100297260 2" 2" 5 5/8"

110 - 199 100296897 3" 3" 5 5/8"

Figure 4-1B Alternate PVC/CPVC/ Polypropylene Sidewall Termination of Air and Vent

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

POSSIBLE ORIENTATIONS

VENT / AIR

TERMINATION

GRADE OR

SNOW LINE

12"

MIN

TO OVER HANG

12"

MIN

TERMINATION

PLATE

BIRD SCREEN

GRADE OR

SNOW LINE

12”

MIN

Page 22

4 Sidewall direct venting

ProLine® XE

Combi Boiler

Installation & Service Manual

Vent/air termination – sidewall

Figure 4-1C Alternate Venting Arrangement (if Space Allows) w/Field Supplied Fittings

TO BOILER INTAKE AIR

CONNECTION

FROM BOILER

VENT PIPE

CONNECTION

BIRD

SCREEN

GRADE OR

SNOW LINE

ALTERNATE VENTING ARRANGEMENT

(IF SPACE PERMITS)

Figure 4-1D Alternate Venting Arrangement - Typical Stainless Steel Sidewall Termination of Air and Vent w/ Field Supplied Fittings

TO BOILER

INTAKE AIR

CONNECTION

FROM

BOILER

VENT PIPE

CONNECTION

BIRD SCREEN

GRADE OR SNOW LINE

5. Maintain clearances as shown in FIG.’s 4-1A thru 4-3B, pages 21 and 22. Also maintain the following:

a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet. b. Air inlet must terminate at least 12 inches above grade or snow line; at least 12 inches below the vent termination (FIG. 4-1B); and the vent pipe must not extend more than 24 inches vertically outside the building. c. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

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

12" MIN

COUPLING

12” MIN 15” MAX

BIRD SCREEN

12” MIN

12" MIN 15" MAX

Figure 4-2A Clearance to Gravity Air Inlets w/Field Supplied Fittings

12”

MIN

BIRD

SCREEN

(TYPICAL)

12”

MIN

12”

MIN

Figure 4-2B Clearance to Gravity Air Inlets using an Optional Vent Kit

12"

MIN.

VENT / AIR

TERMINATION

12"

MIN.

12"

MIN.

Figure 4-3A Clearance to Forced Air Inlets using an Optional Vent Kit

VENT / AIR

TERMINATION

7' MIN. ABOVE ANY

PUBLIC WALKWAY

IF LESS

THAN 10’

36"

MIN.

FORCED AIR

INLET

Figure 4-3B Clearance to Forced Air Inlets w/Field Supplied Fittings

IF LESS

THAN 10’

36”

MIN

FORCED AIR

INLET

BIRD

SCREEN

7’ MIN ABOVE ANY PUBLIC WALKWAY

(TYPICAL)

Page 23

ProLine® XE

Combi Boiler

4 Sidewall direct venting (continued)

Installation & Service Manual

Prepare wall penetrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter:

• 3½ inch hole for 2 inch vent pipe

• 4½ inch hole for 3 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole as shown in FIG. 4-4A.

3. Use the sidewall termination plate as a template for

correct location of hole centers.

4. Follow all local codes for isolation of vent pipe when

passing through floors or walls.

5. Seal exterior openings thoroughly with exterior caulk.

Figure 4-4A Sidewall Termination Assembly w/Field Supplied Fittings

ELBOW

AIR PIPING

VENT PIPING

BIRD SCREEN

Figure 4-5A Multiple Vent Terminations w/Field Supplied Fittings (must also comply with Figure 4-1A)

Figure 4-5B Alternate Multiple Vent Terminations (must also comply with Figure 4-1B)

12" MIN. BETWEEN EDGE OF AIR

INLET AND ADJACENT VENT OUTLET

VENT

AIR

GALVANIZED THIMBLE

SIDEWALL TERMINATION PLATE

ELBOW

BIRD SCREEN

Multiple vent/air terminations

1. When terminating multiple boilers terminate each vent/

air connection as described in this manual (FIG. 4-5A).

 WARNING

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in FIG. 4-5A for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

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

All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

VENT / AIR

TERMINATION

Page 24

ProLine® XE

Combi Boiler

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Description and usage

The manufacturer offers optional concentric combustion air and vent pipe termination kits (Factory Kit #100140480 - 3" or #100140485 - 2"). Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown below in FIG. 4-6.

The required combustion vent pipe and fittings are listed in Table 3B, on page 16 of this manual.

Figure 4-6 Concentric Sidewall Termination

3. Cut one (1) hole (5 inch diameter for #100140480 installations or 4 inch diameter for #100140485 installations) into the structure to install the termination kit.

4. Partially assemble the concentric vent termination kit. Clean and cement using the procedures found in these instructions.

a. Cement the Y concentric fitting to the larger kit pipe (FIG. 4-7). b. Cement the rain cap to the smaller diameter kit pipe (FIG. 4-7).

Figure 4-7 Kit Contents

Installation & Service Manual

Sidewall termination installation

1. Determine the best location for the termination kit (see FIG. 4-6).

2. Reference the Determine Location Section on page 21 of this manual for general termination considerations.

Page 25

ProLine® XE

Combi Boiler

Installation & Service Manual

4 Sidewall direct venting (continued)

Sidewall termination – optional concentric vent models

Figure 4-8 Concentric Vent Dimensional Drawing

NOTICE

 WARNING

Figure 4-9 Rain Cap to Vent Pipe Alternate Assembly

Instead of cementing the smaller pipe to the rain cap, a field-supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9).

When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

Do not operate the appliance with the rain cap removed or recirculation of combustion products may occur. Water may also collect inside the larger combustion air pipe and flow to the burner enclosure. Failure to follow this warning could result in product damage or improper operation, personal injury, or death.

5. Install the Y concentric fitting and pipe assembly through the structure’s hole.

NOTICE

6. Install the rain cap and small diameter pipe assembly into the Y concentric fitting and large pipe assembly. Ensure small diameter pipe is bottomed and cemented in the Y concentric fitting.

7. Secure the assembly to the structure as shown in FIG. 4-10 using field-supplied metal strapping or equivalent support material.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

Ensure termination location clearance dimensions are as shown in FIG. 4-6.

If assembly needs to be extended to allow sidewall thickness requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field-supplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8).

If assembly needs to be reduced, dimension D can be as short as possible.

Page 26

ProLine® XE

Combi Boiler

Installation & Service Manual

4 Sidewall direct venting

Sidewall termination – optional concentric vent

Figure 4-10 Concentric Vent Sidewall Attachment

CAUTION

8. Cement appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 4-10 for proper pipe attachment.

9. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

Multiventing sidewall terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 4-11). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 4-11. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

12" MINIMUM

VENT

COMBUSTION AIR

Figure 4-11 Concentric Vent and Combustion Air Termination

Page 27

5 Vertical direct venting

Vent/air termination – vertical

ProLine® XE

Combi Boiler

Installation & Service Manual

 WARNING

Follow instructions below when determining vent location to avoid possibility of severe personal injury, death or substantial property damage.

Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual.

2. Prepare the vent termination and the air termination elbow (FIG. 5-1A) by inserting bird screens. Bird screens should be obtained locally.

3. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

4. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of flue products into the combustion air stream.

5. The vent piping must terminate in an up-turned coupling as shown in FIG. 5-1A. The top of the coupling must be at least 1 foot above the air intake. When the vent termination uses a rain cap as illustrated in FIG. 5-1B maintain at least 36" (914 mm) above the air inlet. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet (.6 m) apart and with the vent termination at least 1 foot for PVC and 3 feet for stainless steel, above the air intake.

6. Maintain the required dimensions of the finished termination piping as shown in FIG. 5-1A.

Figure 5-1A PVC/CPVC/Polypropylene Vertical Termination of Air and Vent

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” OF VENT PIPE

BIRD SCREEN (TYPICAL)

VENT

COUPLING (FIELD SUPPLIED)

VENT OUTLET 12” MINIMUM ABOVE AIR INLET

COMBUSTION

AIR

6” MINIMUM ABOVE ROOF SNOW LINE

Figure 5-1B Stainless Steel Vertical Termination of Air and Vent

ALTERNATE INTAKE LOCATIONS: INTAKE PIPES MAY BE LOCATED ANYWHERE WITHIN 24” (610 MM) OF VENT PIPE

BIRD SCREEN

(TYPICAL)

6" (152 MM) MINIMUM

ABOVE ROOF /

SNOW LINE

VENT OUTLET

36” (914 MM) MINIMUM

ABOVE AIR INLET

VENT

COMBUSTION AIR

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

 WARNING

Rooftop vent and air inlet terminations must terminate in the same pressure zone, unless vertical vent sidewall air is set up, reference this section, page 28 and Section 4 - Air Intake Clearances.

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

Page 28

5 Vertical direct venting

Vent/air termination – vertical

ProLine® XE

Combi Boiler

Installation & Service Manual

Prepare roof penetrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

• 4½ inch hole for 3 inch vent pipe

• 5½ inch hole for 4 inch vent pipe b. Insert a galvanized metal thimble in the vent pipe hole.

3. Space the air and vent holes to provide the minimum

spacing shown in FIG. 5-1A, page 27.

4. Follow all local codes for isolation of vent pipe when

passing through floors, ceilings, and roofs.

5. Provide flashing and sealing boots sized for the vent pipe

and air pipe.

Figure 5-2 Vertical Terminations with Multiple Boilers

Figure 5-3 Alternate Vertical Terminations with Multiple

Boilers

Multiple vent/air terminations

1. When terminating multiple boilers, terminate each vent/

air connection as described in this manual (FIG. 5-2).

 WARNING

2. Place roof penetrations to obtain minimum clearance of

12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see FIG. 5-2). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet of a Combi Boiler is part of a direct vent

connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury, death, or substantial property damage.

Page 29

ProLine® XE

Combi Boiler

Installation & Service Manual

5 Vertical direct venting (continued)

Vertical termination – optional concentric vent

Description and usage

The manufacturer offers an optional concentric combustion air and vent pipe termination kit. Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in FIG. 5-4.

Field supplied pipe and fittings are required to complete the installation.

The required combustion air and vent pipe fittings are listed in Table 3B, on page 16 of this manual.

Vertical termination installation

1. See Section 5, Vertical Direct Venting - Determine Location (where applicable).

Figure 5-4 Concentric Vertical Termination

2. Cut one (1) hole (5 inch diameter for #100140480 installations or 4 inch diameter for #100140485 installations) into the structure to install the termination kit.

3. Partially assemble the concentric vent termination kit.

Clean and cement following the cleaning procedures in these instructions.

a. Cement the Y concentric fitting to the larger

diameter kit pipe (see FIG. 4-7, page 24).

b. Cement rain cap to the smaller diameter kit pipe (see

FIG. 4-7, page 24).

NOTICE

 WARNING

Instead of cementing the smaller pipe to the rain cap, a field supplied stainless steel screw may be used to secure the two (2) components together when field disassembly is desired for cleaning (see FIG. 4-9, page

25). When using the alternate screw assembly method, drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size being used. Failure to drill adequate holes may cause cracking of PVC components, allowing combustion products to be recirculated. Failure to follow this warning could result in personal injury or death.

Figure 5-5 Do Not Install U-Bend to Rain Cap

Page 30

ProLine® XE

Combi Boiler

Installation & Service Manual

5 Vertical direct venting

Vertical termination – optional concentric vent

 WARNING

4. Install the Y concentric fitting pipe assembly through the structure’s hole and field supplied roof boot/flashing.

NOTICE

Do not allow insulation or other materials to accumulate inside the pipe assembly when installing through the hole.

5. Secure the assembly to the roof structure as shown below in FIG. 5-6 using field supplied metal strapping or equivalent support material.

Figure 5-6 Concentric Vent Roof Installation

CAUTION

DO NOT use field-supplied couplings to extend pipes. Airflow restriction will occur.

6. Install the rain cap and the small diameter pipe assembly into the roof penetration assembly. Ensure the small diameter pipe is cemented and bottomed in the Y concentric fitting.

7. Cement the appliance combustion air and vent pipes to the concentric vent termination assembly. See FIG. 5-6 for proper pipe attachment.

8. Operate the appliance through one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see FIG. 5-7). NEVER common vent or breach vent this appliance. When two (2) or more direct vent appliances are vented near each other, two (2) vent terminations may be installed as shown in FIG. 5-7. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

Figure 5-7 Concentric Vent and Combustion Air Vertical Termination

NOTICE

Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in FIG. 5-4, page 29.

If assembly is too short to meet height requirement, the two (2) pipes supplied in the kit may be replaced by using the same diameter, field supplied SDR-26 PVC (D2241) pipe. Do not extend dimension D more than 60 inches (see FIG. 4-8, page

25).

12” (18” FOR CANADA)

MINIMUM CLEARANCE

ABOVE HIGHEST

ANTICIPATED SNOW

LEVEL. MAXIMUM OF

24” ABOVE ROOF.

12”

MINIMUM

COMBUSTION AIR (TYPICAL)

Page 31

ProLine® XE

Combi Boiler

5 Vertical direct venting (continued)

Alternate vertical concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion

air routing.

Figure 5-8 Concentric Vent Example 1

Installation & Service Manual

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.

The minimum size of the existing vent system required to achieve enough annular space for combustion air can be found in Table 5A below.

The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in FIG.’s 5-8 and 5-9.

Approved venting materials must be used as specified in Table 3D on page 18.

Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section.

If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Table 1A on page 10 for a list of corrosive contaminants and sources.

FLUE EXHAUST

SEAL

AIR INLET

12”

MIN

SEALED

CAP

DIR #2000534607 00

*For concept illustration only. Individual installations may vary

due to job site specific equipment.

COMBUSTION AIR

EXISTING

Figure 5-9 Concentric Vent Example 2

FLUE EXHAUST

SEAL

COMBUSTION AIR

IR INLET

WITH SCREEN

EXISTING

SEAL

are shown for illustrative purposes in FIG.’s 5-8 and 5-9.

Two example scenarios of a concentric venting arrangement

SEALED CAP

Table 5A Alternate Vertical Concentric Vent / Chase Sizes

Model

Vent / Air

Inlet Size

Minimum Existing

Vent / Chase Size

DIR #2000534609 00

110 - 150 2" 4"

110 - 199 3" 5"

*For concept illustration only. Individual installations may vary

due to job site specific equipment.

Page 32

5 Vertical direct venting

Existing vent as a chase

Follow all existing termination and clearance requirements and allowable pipe lengths. Use only approved venting materials listed in the General Venting Section of this manual.

Figure 5-10 Existing Vent as a Chase

FLUE EXHAUST

IR INLET

WITH SCREEN

SEALED CAP

SEAL

EXISTING

SEAL

ProLine® XE

Combi Boiler

Installation & Service Manual

DIR #2000534613 00

*For concept illustration only. Individual installations

may vary due to job site specific equipment.

Page 33

6A Hydronic piping

ProLine® XE

Combi Boiler

Installation & Service Manual

System water piping methods

The Combi Boiler is designed to function in a closed loop pressurized system not less than 12 psi (Non-metallic system piping must have an oxygen barrier to be considered a closed loop). A temperature and pressure gauge is included to monitor system pressure and outlet temperature and should be located on the boiler outlet.

Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.

Observe a minimum of a 1/4 inch clearance around all un-insulated hot water pipes when openings around the pipes are not protected by non-combustible materials.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

Chilled water system

If the boiler supplies hot water to heating coils in air handler units, flow control valves or other devices must be installed to prevent gravity circulation of heater water in the coils during the cooling cycle. A chilled water medium must be piped in parallel with the heater.

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose. This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol solution in the system piping.

 WARNING

Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

Heating fluid and Domestic Hot Water (DHW) piping

The diameter of the heating fluid (hot boiler water) and DHW piping will depend on the model number and size of the water heater being installed.

General piping information

IMPORTANT

Basic steps are listed below along with illustrations on the following pages (FIG.’s 6-2 through 6-5), which will guide you through the installation of the Combi Boiler.

1. Connect the system return marked “Boiler Inlet”.

2. Connect the system supply marked “Boiler Outlet”.

3. Install purge and balance valve or shutoff valve and drain on system return to purge air out of each zone.

4. Install a backflow preventer on the cold feed make-up water line.

5. Install a pressure reducing valve on the cold feed makeup water line, (15 psi nominal). Check temperature and pressure gauge (shipped separately), which should read a minimum pressure of 12 psi.

6. Install a system pump if necessary as shown on the piping diagrams in this section. Make sure the circulator is properly sized for the system and friction loss.

7. Install an expansion tank on the system supply. Consult the tank manufacturer’s instruction for specific information relating to tank installation. Size the expansion tank for the required system volume and capacity.

8. Install an air elimination device on the system supply.

9. Install a drain valve at the lowest point of the system. Note: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.

10. This appliance is supplied with a relief valve sized in accordance with ASME Boiler and Pressure Vessel Code, Section IV (“Heating Boilers”). Pipe the discharge of the safety relief valve to prevent injury in the event of pressure relief. Pipe the discharge to a drain. Provide piping that is the same size as the safety relief valve outlet. Never block the outlet of the safety relief valve.

11. Install a field supplied strainer to prevent damage to the heat exchanger caused by debris entering from the system piping. When installing in a pre-existing system, a strainer/ filter capable of removing debris left in the system is recommended.

See the *piping illustrations included in this section, FIG.’s 6-2 through 6-5 for suggested guidelines in piping the Combi Boiler with either zone valves or circulator pumps.

NOTICE

All boiler piping must contain an oxygen barrier. This will help prevent any excess oxygen from entering the system.

*Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 34

6A Hydronic piping

ProLine® XE

Combi Boiler

Installation & Service Manual

Near boiler piping components

1. Boiler system piping:

Boiler system piping MUST be sized per the pipe requirements listed in Table 6A. Reducing the pipe size can restrict the flow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance.

2. Boiler circulating pump:

Factory supplied. System piping must be sized to meet the minimum requirements in Table 6A on page 35.

3. Boiler isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

4. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-2 through 6-5. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.

5. Unions:

Field supplied. Recommended for unit serviceability.

6. Temperature and pressure gauge:

Factory supplied. The temperature and pressure gauge is shipped loose. It is the responsibility of the contractor to install the temperature and pressure gauge on the boiler water outlet.

7. Pressure relief valve:

Factory supplied. The pressure relief valve is sized to ASME specifications. Install the 3/4" NPT fitting on the top right side of the boiler (images in this manual show relief valve installed).

 WARNING

10. Water Meter:

Field supplied. A water meter to monitor makeup water is recommended. Makeup water volume should not exceed 5% of total system per year.

11. Y-Strainer:

Field supplied. Install a Y-strainer or equivalent multi-purpose strainer just before the boiler pump at the inlet of the heat exchanger. This item is used to remove system debris from older hydronic systems and to protect newer systems.

The National Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products,

Edition.

8. Boiler purge valve:

Field supplied. The boiler purge valve is used to remove entrapped air from the heat exchanger during start-up.

9. System temperature sensor (optional):

Factory supplied with the unit. The manufacturer offers a system temperature sensor (100296899). The sensor is to be installed in the heating loop downstream from the boiler hot water piping and heating loop junction. Typically the sensor will be located far enough downstream to sense system diluted water temperature.

Page 35

6A Hydronic piping (continued)

Figure 6-1 Pressure Drop vs. Flow

ProLine® XE

Combi Boiler

Installation & Service Manual

Table 6A Temperature Rise Applications

110

Delta T GPM FT/HD Eq Ft of 1" Pipe

19.1°F 10.6 4.0 53

20°F 10.1 6.0 85 25°F 8.1 13.4 287 30°F 6.7 17.4 523 35°F 5.8 19.9 789 40°F 5.1 21.4 1085 45°F 4.5 22.5 1410

199

Delta T GPM FT/HD Eq Ft of 1" Pipe

34.7°F 10.6 4.0 53

40°F 9.2 9.6 162 45°F 8.2 13.1 277

150

Delta T GPM FT/HD Eq Ft of 1" Pipe

26.0°F 10.6 4.0 53

30°F 9.2 9.6 162 35°F 7.9 14.1 317 40°F 6.9 17.0 490 45°F 6.1 19.0 679

Assumed Equivalent Lengths (1" Pipe)

Fitting / Component Eq Ft

90° Elbow 2.5 45° Elbow 1.0

Tee (straight run) 0.5

Tee (side port) 4.5

Ball Valve 4.3

Swing Check 4.5

Flow Check Valve (typical) 54.0

Y-Strainer 4.5

NOTICE

All equivalent pipe lengths are based on the minimum pipe size of one inch.

The data provided takes into account the boiler and integral pump. Flow determination is based solely on piping external to the boiler.

In Primary/Secondary, only the boiler loop is considered when determining flow. In full flow applications, all piping and equipment must be considered.

Page 36

6A Hydronic piping

Figure 6-2 Single Boiler - Primary / Secondary Piping

PRESSURE

REDUCING VALVE

PRESSURE GAUGE

WATER METER

BACKFLOW

PREVENTER

ProLine® XE

Combi Boiler

Installation & Service Manual

MAKE UP WATER

SYSTEM SUPPLY

SYSTEM

BALL VALVE

(TYPICAL)

BOILER

SENSOR

(OPTIONAL)

SYSTEM

CIRCULATOR

EXPANSION

TANK

DRAIN POINT

(TYPICAL)

AIR SEPARATOR

MAY SUBSTITUTE LOW LOSS HEADER

FROM SYSTEM

NOT TO EXCEED 4 PIPE DIA OR MAX. OF 12" APART

Y-STRAINER

CHECK VALVE

NOTICE

UNION

(TYPICAL)

TEMPERATURE / PRESSURE GAUGE

DRAIN

DIR #2000529680

DHW piping omitted for clarity.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 37

6A Hydronic piping (continued)

Figure 6-3 Single Temperature Zoned with Circulators

ProLine® XE

Combi Boiler

ZONE #1

Installation & Service Manual

BOILER

WATER METER

MAKE UP WATER

PRESSURE

REDUCING VALVE

BACKFLOW

PREVENTER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

(TYPICAL)

PRESSURE

GAUGE

SYSTEM SUPPLY

SENSOR

(WHEN USED)

ZONE #2

EXPANSION

TANK

MAY SUBSTITUTE LOW LOSS HEADER

Y-STRAINER

CHECK VALVE

ZONE #3

ZONE #4

FLOW CHECK

VALVE

(TYPICAL)

ZONE CIRCULATORS

(TYPICAL)

NOTICE

TEMPERATURE / PRESSURE GAUGE

UNION (TYPICAL)

DIR #2000533824

DRAIN

DHW piping omitted for clarity.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 38

ProLine® XE

Combi Boiler

6A Hydronic piping

Figure 6-4 Multiple Boilers - Single Temperature Zoned with Circulators

Model

110 1" 1-1/4" 1-1/4" 1-1/2" 2" 2" 2" 150 1-1/2" 2" 2" 2-1/2" 2-1/2" 3" 3" 199 2" 2" 2-1/2" 2-1/2" 3" 3" 3-1/2"

2345678

ZONE #1

Installation & Service Manual

Number of Units

Required Pipe Sizes

BOILER 2

REDUCING VALVE

BACKFLOW

PREVENTER

WATER METER

MAKE UP

WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

PRESSURE

SYSTEM SUPPLY

SENSOR

(OPTIONAL)

DRAIN POINT

(TYPICAL)

BOILER 1

TEMPERATURE / PRESSURE GAUGE

EXPANSION

TANK

ZONE #2 ZONE #3 ZONE #4

FLOW CHECK

(TYPICAL)

ZONE CIRCULATORS

MAY SUBSTITUTE LOW LOSS HEADER NOT TO EXCEED 4 PIPE DI A OR MAX. OF 12" APART

Y-STRAINER

(TYPICAL)

NOTICE:

CASCADE IS FOR

SPACE HEAT ONLY.

VALVE

(TYPICAL)

CAUTION

NOTICE

TEMPERATURE / PRESSURE GAUGE

UNION

(TYPICAL)

DIR #2000529699

Mixing valves are required for the protection of low temperature loops.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 39

6A Hydronic piping (continued)

Figure 6-5 Single Temperature Piped with Air Handler

ProLine® XE

Combi Boiler

Installation & Service Manual

BOILER

REDUCING VALVE

BACKFLOW

PREVENTER

WATER METER

MAKE UP WATER

AIR SEPARATOR

BALL VALVE

(TYPICAL)

DRAIN POINT

PRESSURE

(TYPICAL)

PRESSURE

GAUGE

EXPANSION

TANK

Y-STRAINER

SYSTEM SUPPLY

SENSOR

(OPTIONAL)

AIR

HANDLER

NOTICE

TEMPERATURE / PRESSURE GAUGE

DIR #2000530076 00

UNION (TYPICAL)

DHW piping omitted for clarity.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

Page 40

6B Domestic water piping

ProLine® XE

Combi Boiler

Installation & Service Manual

Scalding

This combi heater can deliver scalding temperature water at any faucet in the system. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased temperature water. By setting the thermostat on this combi heater to obtain the increased temperature water required by these appliances, you may create the potential for scald injury. To protect against injury, you MUST install an ASSE 1070 anti-scald mixing valve in the water system. This valve will reduce point of discharge temperature by mixing cold and hot water in branch supply lines. Such valves are available from the local plumbing supplier.

 WARNING

An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.

Water chemistry

Any damage or failure resulting from improper water chemistry, or heating anything other than potable water. DEFINITION OF POTABLE WATER - Potable water is defined as drinkable water supplied from utility or well water in compliance with EPA secondary maximum contaminant levels (40 CFR Part 143.3) as shown in Table 6C - Potable Water.

Table 6C Potable Water

Potable Water Levels

Contaminant Level

Aluminum 0.05 to 0.2 mg/l

Chloride 250 mg/l

Color 15 color units

Copper 1.0 mg/l

Corrosivity Non-corrosive

Fluoride 2.0 mg/l

Foaming Agents 0.5 mg/l

Iron 0.3 mg/l

Manganese 0.05 mg/l

Odor 3 threshold odor number

pH 6.5 - 8.5

Silver 0.1 mg/l

Sulfate 250 mg/l

Total Dissolved Solids (TDS) 500 mg/l

Zinc 5 mg/l

The following table (Table 6B) details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

Table 6B Approximate Time / Temperature Scald Chart

APPROXIMATE TIME / TEMPERATURE

RELATIONSHIPS IN SCALDS

120°F More than 5 minutes

125°F 1 1/2 to 2 minutes 130°F About 30 seconds

135°F About 10 seconds 140°F Less than 5 seconds

145°F Less than 3 seconds 150°F About 1 1/2 seconds 155°F About 1 second

Near heater piping components

1. Recirculation pump (optional):

Field supplied. The recirculation pump shuts off flow at the desired DHW set point.

2. Check valves:

Field supplied. Check valves are recommended for installation as shown in FIG.’s 6-6 through 6-8. Failure to install check valves could result in a reverse flow condition during pump(s) off cycle.

3. Domestic hot water isolation valves:

Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted flow rate through the boiler.

4. Anti-scald mixing valve:

Field supplied. For use when utilizing the DHW option. An ASSE 1070 anti-scald mixing valve is required.

5. Unions:

Field supplied. Recommended for unit serviceability.

6. Temperature and pressure gauge:

Field supplied. It is the responsibility of the contractor to provide and install the temperature and pressure gauge on the boiler water outlet.

7. Pressure relief valve:

Field supplied. The pressure relief valve is sized to ASME specifications.

Page 41

ProLine® XE

Combi Boiler

Installation & Service Manual

6B Domestic water piping (continued)

Figure 6-6 Combi DHW Piping

BOILER

EXPANSION TANK

PRESSURE

RELIEF VALVE

(REQUIRED,

FIELD SUPPLIED)

ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)

UNION

(TYPICAL)

TEMPERATURE / PRESSURE GUAGE

HOT

WATER

SUPPLY

FLOW

CHECK

COLD

WATER

SUPPLY

NOTICE

 WARNING

DIR #2000534676 00

Hydronic piping omitted for clarity.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.

Page 42

6B Domestic water piping

Figure 6-7 DHW Recirculation w/Dedicated Return

BOILER

Note: Aquastat for DHW

recirculation pump or thermostatic shut off valve must be used to stop recirculation water ﬂ ow once the desired temperature has been reached.

ProLine® XE

Combi Boiler

Installation & Service Manual

For best performance, Pre-Heat Mode should be enabled when using DHW recirculation.

(TYPICAL)

PRESSURE

RELIEF VALVE

(REQUIRED,

FIELD SUPPLIED)

ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)

TEMPERATURE / PRESSURE GAUGE

HOT WATER

FIXTURES

QUASTAT

UNION

FLOW

CONTROL

VALVE

EXPANSION TANK

FLOW CHECK

WATER METER

COLD

WATER

SUPPLY

RECIRCULATION

NOTICE

 WARNING

PUMP

Hydronic piping omitted for clarity.

DIR #2000534677 00

flow once the desired DHW temperature has been reached can result in serious injury or death due to

NOTICE

 WARNING

scalding.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.

Page 43

ProLine® XE

Combi Boiler

6B Domestic water piping (continued)

Figure 6-8 DHW Piping w/Recirculation Return Through Cold Line

BOILER

Note: Aquastat for DHW

recirculation pump or thermostatic shut off valve must be used to stop recirculation water ﬂ ow once the desired temperature has been reached.

For best performance, Pre-Heat Mode should be enabled when using DHW recirculation.

UNION

(TYPICAL)

Installation & Service Manual

EXPANSION TANK

COLD

WATER

SUPPLY

RECIRCULATION

WATER METER

FIELD SUPPLIED)

AQUASTAT

PUMP

PRESSURE

RELIEF VALVE

(REQUIRED,

HOT WATER

FIXTURES

ASSE 1070 ANTI-SCALD MIXING VALVE (REQUIRED)

TEMPERATURE / PRESSURE GAUGE

FLOW

CONTROL

VALVE

HOT

WATER

SUPPLY

DIR #2000534675 00

FLOW

CHECK

NOTICE

 WARNING

NOTICE

 WARNING

Hydronic piping omitted for clarity.

To prevent scalding from DHW recirculation temperature creep, a suitable method to stop recirculation flow once water in the loop has reached the desired temperature must be used. Failure to stop water flow once the desired DHW temperature has been reached can result in serious injury or death due to scalding.

Please note that these illustrations are meant to show system piping concept only, the installer is responsible for all equipment and detailing required by local codes.

An ASSE 1070 anti-scald mixing valve is REQUIRED. Failure to comply could result in property damage, severe injury, or death.

Page 44

7 Gas connections

Connecting gas supply piping

ProLine® XE

Combi Boiler

Installation & Service Manual

1. Remove the front access panel and refer to FIG. 7-1 to pipe gas to the boiler.

a. Install a field supplied sediment trap / drip leg

upstream of the boiler gas controls.

Figure 7-1 Gas Supply Piping

MANUAL SHUTOFF VALVE

UNION

GAS SUPPLY

DRIP LEG

DIR #2000528364 00

2. Support piping with hangers, not by the boiler or its accessories.

 WARNING

The gas valve and blower will not support the weight of the piping. Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

3. Purge all air from the gas supply piping.

4. Before placing the boiler in operation, check the boiler and its gas connection for leaks.

a. Close manual main shutoff valve during any

pressure testing at more than 14 inches w.c.

b. Disconnect the boiler and gas valve from the gas

supply piping during any pressure testing greater than 14 inches w.c.

 WARNING

Do not check for gas leaks with an open flame – use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

5. Use pipe sealing compound compatible with propane gases. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas flow.

Page 45

7 Gas connections (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

 WARNING

Failure to apply pipe sealing compound as detailed in this manual can result in severe personal injury, death, or substantial property damage.

Combi Boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by installing an LP venturi (see page 12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

Use two wrenches when tightening gas piping at boiler (FIG. 7-2), using one wrench to prevent the boiler gas line connection from turning. Failure to support the boiler gas connection pipe to prevent it from turning could damage gas line components.

Natural gas:

Pipe sizing for natural gas

1. Refer to Table 7A for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain cubic feet per hour).

a. Table 7A is only for natural gas with specific gravity

0.60 inches, with a pressure drop through the gas piping of 0.3 inches w.c.

b. For additional gas pipe sizing information, refer to

ANSI Z223.1 (or B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with boiler on.

• Minimum 4 inches w.c. with gas flowing (verify during boiler startup).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 14 inches w.c. at any time. Adjust lockup regulator for 14 inches w.c. maximum.

Figure 7-2 Inlet Pipe with Backup Wrench

USE BACK UP WRENCH

TO PREVENT PIPE FROM

ROTATING

NOTICE

Maximum inlet gas pressure must not exceed the value specified. Minimum value listed is for the purposes of input adjustment.

DIR #2000528388 00

Propane Gas:

 WARNING

Pipe sizing for propane gas

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

Propane Supply Pressure Requirements

1. Adjust propane supply regulator provided by the gas supplier for 14 inches w.c. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 14 inches w.c. with no flow (lockup) or with boiler on.

• Minimum 8 inches w.c. with gas flowing (verify during boiler startup).

 WARNING

Ensure that the high gas pressure regulator is at least 6 - 10 feet upstream of the appliance.

Page 46

7 Gas connections

Table 7A Natural Gas Pipe Size Chart

Capacity of Schedule 40 Metallic Pipe in Cubic Feet of Natural Gas Per Hour

(based on .60 specific gravity, 0.30" w.c. pressure drop)

ProLine® XE

Combi Boiler

Installation & Service Manual

Pipe

Size

(Inches)

1/2 131 90 72 62 55 N/A N/A N/A N/A N/A N/A N/A N/A N/A

3/4 273 188 151 129 114 104 95 89 83 79 70 63 58 N/A

1 514 353 284 243 215 195 179 167 157 148 131 119 109 102

1 1/4 1,060 726 583 499 442 400 368 343 322 304 269 244 224 209

1 1/2 1,580 1,090 873 747 662 600 552 514 482 455 403 366 336 313

2 3,050 2,090 1,680 1,440 1,280 1,160 1,060 989 928 877 777 704 648 602

2 1/2 4,860 3,340 2,680 2,290 2,030 1,840 1,690 1,580 1,480 1,400 1,240 1,120 1,030 960

3 8,580 5,900 4,740 4,050 3,590 3,260 3,000 2,790 2,610 2,470 2,190 1,980 1,820 1,700

4 17,500 12,000 9,660 8,270 7,330 6,640 6,110 5,680 5,330 5,040 4,460 4,050 3,720 3,460

 WARNING

10 20 30 40 50 60 70 80 90 100 125 150 175 200

12). In order to operate on LP gas, an LP venturi MUST BE installed. Failure to comply could result in severe personal injury, death, or substantial property damage.

Check inlet gas supply

NOTICE

 WARNING

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1 inch w.c., the meter, regulator, or gas line is undersized or in need of service. Perform the steps below when checking inlet gas supply:

1. Shut OFF power at source.

2. Shut off gas supply at the manual gas valve in the gas piping to the appliance.

CSA or UL listed flexible gas connections are acceptable, but you must exercise caution to ensure that the line has adequate capacity to allow your boiler to fire at full rate. Consult with local codes for proper installation or service procedures.

DO NOT adjust gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Length of Pipe in Straight Feet

3. Loosen the set screw one (1) full turn from inside the pressure tap on top of the gas valve. Place the tubing of the manometer over the tap once the set screw is loosened as shown in FIG. 7-3.

4. Slowly turn on the gas supply at the field installed manual gas valve.

5. Turn ON power at source.

6. Press and hold the RIGHT and DOWN buttons simultaneously for five (5) seconds to place the boiler into Service Mode. In Service Mode, the boiler will fire at ignition speed and will then modulate up to full fire.

7. Adjust the temperature set point on the control panel of the boiler control module to call for heat.

8. Observe the gas supply pressure as the burner fires at 100% of rated input. Percent of burner input will be displayed on the control panel.

9. Ensure inlet pressure is within specified range. Minimum and maximum gas supply pressures are specified in this section of the manual.

10. If gas supply pressure is within normal range and no adjustments are needed, proceed on to Step 11.

11. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the control.

12. Exit Service Mode.

13. Turn OFF power at source.

Page 47

7 Gas connections (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

14. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

15. Remove the manometer from the pressure tap on top of the gas valve. Re-tighten the set screw inside the pressure tap.

 WARNING

When re-tightening the set screw, be sure to tighten securely to prevent gas leaks.

Do not check for gas leaks with an open flame -- use the bubble test. Failure to use the bubble test or check for gas leaks can cause severe personal injury, death, or substantial property damage.

16. Turn on the gas supply at the manual gas valve.

17. Turn ON power at source.

18. Adjust the temperature set point on the control panel of the boiler control module to the desired water temperature so the appliance will call for heat.

19. Check burner performance by cycling the system while you observe burner response. The burner should ignite promptly. Flame pattern should be stable. Turn system off and allow burner to cool, then cycle burner again to ensure proper ignition and flame characteristics.

Figure 7-3 Inlet Gas Supply Check

DETAIL A

Gas Pressure

The gas pressure must remain between 4 inches w.c. (natural), 8 inches w.c. (LP) minimum and 14 inches w.c. (natural and LP) maximum during stand-by (static) mode and while in operating (dynamic) mode. If an in-line regulator is used, it must be a minimum of 10 feet from the Combi Boiler. It is very important that the gas line is properly purged by the gas supplier or utility company. Failure to properly purge the lines or improper line sizing, will result in ignition failure.

The problem is especially noticeable in NEW LP installations and also in empty tank situations. This can also occur when a utility company shuts off service to an area to provide maintenance to their lines.

Gas valve replacement

The gas valve MUST NOT be replaced with a conventional gas valve under any circumstances.

 WARNING

Failure to follow all precautions could result in fire, explosion, or death!

LOOSEN SET SCREW ONE (1) FULL TURN THEN PLACE TUBING

DIR #2000529636 00

OVER PRESSURE TAP

Page 48

8 Field wiring

NOTICE

 WARNING

NOTICE

 CAUTION

Figure 8-1 Remove Metal Junction Box Cover

For field wiring on Combi units, reference the Combi Installation and Service Manual provided with the unit.

ELECTRICAL SHOCK HAZARD – For your safety, turn off electrical power supply before making any electrical connections to avoid possible electric shock hazard. Failure to do so can cause severe personal injury or death.

Wiring must be N.E.C. Class 1.

If original wiring as supplied with boiler must be replaced, use only type 105°C wire or equivalent.

Boiler must be electrically grounded as required by National Electrical Code ANSI/NFPA 70 – latest edition.

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation.

ProLine® XE

Combi Boiler

Installation & Service Manual

Installation must comply with:

1. National Electrical Code and any other national, state, provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.

Line voltage connections

1. Remove the cover of the metal junction box as shown in

FIG. 8-1.

2. Connect 120 vac power wiring using wire nuts (field

supplied) to the labeled line voltage terminal wires in the junction box.

3. Provide and install a fused disconnect or service switch

(15 amp recommended) as required by the code.

4. To activate a system pump, wire as shown in FIG. 8-2. If

the motor is larger than 2 amps, you must isolate with a relay.

Low voltage connections

1. Route all low voltage wires through the holes in the bottom

front right side, just under the control panel, as shown in FIG. 8-3.

2. Connect low voltage wiring to low voltage connection

board as shown in FIG. 8-4 on page 50 of this manual and the boiler wiring diagram.

HIGH VOLTAGE JUNCTION BOX

DIR #2000529321 00

Figure 8-2 Line Voltage Field Wiring Connections

SYSTEM PUMP

(OPTIONAL)

NOTICE

Do not run low voltage wires next to high voltage wires in the same conduit.

Figure 8-3 Routing Field Wiring

LOW VOLTAGE CONNECTION BOARD

DIR #2000536085 00

LOW VOLTAGE WIRING HOLES

DIR #2000529643 00

Page 49

8 Field wiring (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

Thermostat

1. Connect the room thermostat or end switch (isolated contact only) to the room thermostat as shown in FIG. 8-4.

2. Install the thermostat on the inside wall, away from influences of drafts, hot or cold water pipes, lighting fixtures, televisions, sunlight or fireplaces.

3. Thermostat anticipator (if applicable):

a. If connected directly to boiler, set for 0.1 amps. b. If connected to relays or other devices, set to match

total electrical power requirements of connected devices. See device manufacturers’ specifications and thermostat instructions for details.

Outdoor temperature sensor

In accordance with the United States Energy Policy and Conservation Act, this boiler is equipped with outdoor air reset, a feature that saves energy by reducing boiler water temperature as heating load decreases. To use this feature, the outdoor air sensor provided with the boiler must be properly installed.

1. Mount the sensor on an exterior wall, shielded from direct sunlight or flow of heat or cooling from other sources.

2. Route sensor wires through a designated wiring hole in the bottom front right side of the boiler (see FIG. 8-3).

3. Connect outdoor temperature sensor (FIG. 8-4) to the outdoor sensor terminals on the connection board to enable outdoor reset operation of the Combi Boiler.

System supply sensor

1. By installing the optional system supply sensor into the supply of the primary loop, the temperature of the primary supply can be controlled. The boiler control automatically detects the presence of this sensor, and controls the boiler firing rate to maintain the system supply temperature to the set point.

 CAUTION

2. The 100170581 sensor provided with the boiler must be used for the system sensor.

3. Connect the system supply sensor to these terminals (FIG. 8-4).

Do not install the system supply sensor into the system return.

Wiring of the cascade

When wiring the boilers for Cascade operation, select one boiler as the Leader boiler. The remaining boilers will be designated as Members.

Connect the system supply sensor and outdoor air sensor (if used) to the Leader boiler. For the Cascade system to work properly the system supply sensor must be installed. The location of the system supply sensor should be downstream of the boiler connections in the main system loop. The system supply sensor should be wired to the Low Voltage Connection Board at the terminals marked for the system sensor (see FIG. 8-4). The Leader control will use the water temperature at the system supply sensor to control the operation of the Cascade.

Auxiliary limit switch

A field supplied auxiliary limit switch can be used for the gas pressure switch. When installing the auxiliary limit switch, please follow the kit instructions provided with the switch and then proceed as follows:

1. If the auxiliary switch is mounted to the exterior of the boiler, run the wires through a knockout in the bottom front right side of the boiler. If the auxiliary limit switch is mounted on the interior of the boiler, route the wires to the connection board.

2. Once the wires are inside the boiler and near the connection board, connect the wires to the auxiliary limit switch terminals.

Air handler contacts

A set of un-powered contacts are available on the low voltage connection board (FIG. 8-4) that can be used to turn off the fan on an air handler when the diverter valve is in the DHW position and therefore not providing hot water to the space heating system. These contacts are normally open and will close when the diverter valve is in the space heat position.

Page 50

8 Field wiring

Figure 8-4 Low Voltage Field Wiring Connections

CUT OFF

LOW WATER

OUTDOOR SENSOR

SYSTEM SUPPLY SENSOR

(OPTIONAL)

ProLine® XE

Combi Boiler

Installation & Service Manual

AUXILIARY LIMIT

(FIELD SUPPLIED)

ROOM THERMOSTAT

DIR #2000534741 00

Page 51

9 Condensate disposal

ProLine® XE

Combi Boiler

Installation & Service Manual

Condensate drain

1. This boiler is a high efficiency appliance that produces condensate.

2. The bottom of the boiler has a 3/4 inch pipe for connection of a 3/4 inch PVC pipe (FIG. 9-1).

3. Slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter. Condensate from the Combi Boiler will be slightly acidic (typically with a pH from 3 to 5). Install a neutralizing filter if required by local codes.

A Neutralizer Kit is available from the factory.

4. Do not expose condensate line to freezing temperatures.

5. Use only plastic tubing or piping as a condensate drain line (FIG. 9-1).

NOTICE

6. A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces. The pump should have an overflow switch to prevent property damage from condensate spillage.

Use materials approved by the authority having jurisdiction. In the absence of other authority, PVC and CPVC pipe must comply with ASTM D1785 or D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

To allow for proper drainage on large horizontal runs, a second line vent may be required and tubing size may need to increase to 1 inch.

The condensate line must remain unobstructed, allowing free flow of condensate. If condensate is allowed to freeze in the line or if the line is obstructed in any other manner, condensate can exit from the boiler tee, resulting in potential water damage to property.

Figure 9-1 Condensate Disposal

Page 52

10 Start-up

ProLine® XE

Combi Boiler

Installation & Service Manual

Pre-Commissioning Cleaning

1. Prior to fill and start-up, flush the entire heating system.

2. Clean the entire heating system with an approved precommissioning cleaner (comparable to Sentinel X300 or Fernox F3) in accordance with the manufacturer’s recommendation to remove debris and prolong the life of the heat exchanger.

3. Clean all water filtering devices in the system.

4. Flush the cleaning solution out of the entire system and refill.

Fill water

Check/control fill water chemistry

IMPORTANT

The manufacturer recommends the following for properly filling your boiler with the appropriate water chemistry for closed loop boilers. Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and corrosion in closed loop systems.

Hardness between 5 and 12 grains per gallon

1. Consult local water treatment companies for hard water areas (above 12 grains per gallon hardness).

2. Hardness levels that are above 12 grains/gallon can lead to lime scale buildup throughout the boiler system. If the fill water is below 5 grains/gallons, usually due to use of a water softener, it is recommended to mix in some potable water at the inlet to increase the hardness of the water to above 5 grains/gallons.

pH between 6.5 and 8.5

1. pH levels below 6.5 can cause an increase in the rate of corrosion. pH of 8.5 or higher can potentially cause lime scale buildup.

Total Dissolved Solids (TDS) less than 350 ppm

1. Total dissolved solids are all minerals, salts, metals, and charged particles that are dissolved in water.

2. The greater the amounts of TDS present, the higher the corrosion potential due to increased conductivity in the water.

Chlorine concentration less than 150 ppm

1. Do not fill boiler or operate with water containing chlorine in excess of 150 ppm.

2. Filling with fresh drinking water should be acceptable.

Conduct water quality testing prior to installing the appliance. Various solutions are available to adjust water quality.

Boiler water

 CAUTION

Table 10A Boiler Water Chemistry

Speci cation Range

Dissolved Solids < 2000 ppm

• Monitoring pH, chlorides, TDS, and hardness levels can prolong the life of the appliance by reducing lime scale buildup, corrosion, and erosion. Check for leaks to ensure that fresh water is not entering the system.

• Continual fresh makeup water will reduce boiler life.

• Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure.

• The addition of oxygen carried in by makeup water can cause internal corrosion in system components.

• Leaks in the boiler or piping must be repaired at once to prevent excessive makeup water. For this purpose, it is recommended to install a water meter to easily check the amount of makeup water entering the system. Makeup water volume should not exceed 5% of the total system volume per year. NOTE: When makeup water is added, make sure the chemical additives are added to maintain the correct level.

• An approved multi-metal corrosion inhibitor (comparable to Sentinel X100 or Fernox F1) is recommended at the correct concentration and in the manner recommended by the manufacturer.

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

DO NOT use "homemade cures" or "boiler patent medicines". Serious damage to boiler, personnel, and/or property may result.

BOILER WATER CHEMISTRY

pH Level 6.5 to 9.5

Chloride < 150 ppm

Freeze protection

 WARNING

Ethylene glycol is toxic, DO NOT use as your freeze protection. Ethylene glycol has a sweet aroma which children and pets could mistake as food and ingest; leading to death.

3. Do not use the boiler to directly heat swimming pool or spa water.

Page 53

10 Start-up (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

1. Use glycol only if needed for freeze protection.

2. Propylene glycol is the recommended freeze protection.

3. Make sure to flush the boiler system before adding glycol.

4. Determine the freeze protection fluid quantity using system water content, following the fluid manufacturer's instructions. Boiler water content is listed on page 6. Remember to include expansion tank water content.

5. Local codes may require a backflow preventer or actual disconnect from city water supply.

6. When using freeze protection fluid with automatic fill, it is suggested to install a water meter to monitor water makeup. Freeze protection fluid may leak before the water begins to leak, causing the concentration to drop, which reduces the freeze protection level.

7. The freeze protection set points may be lowered when freeze protection fluid is used.

8. Consult the glycol manufacturer for details on the suggested mix of glycol and water for the desired freeze protection level and the de-rate effect it will have on the boiler output.

Test / replace freeze protection fluid

1. For systems using freeze protection fluids, follow the fluid manufacturer's instructions.

2. Freeze protection fluid must be replaced periodically due to degradation of inhibitors over time.

3. It is recommended to test the glycol concentration annually and adjust within the desired set points.

Oxygen prevention

CAUTION

Dissolved oxygen can have a negative effect on the boiler system. Oxygen can cause iron oxide to generate iron deposits. Oxygen may also increase the rate of corrosion on non-stainless steel parts of the system. A low pH level combined with oxygen further enhances its corrosive effects. After boiler installation, check for air leaks in the following areas:

• Suction gasket

• Pump

• Air valve

• O-ring gaskets

Eliminate all system leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in the heat exchanger, reducing heat transfer, overheating the heat exchanger, and causing heat exchanger failure.

Fill and test water system

1. Fill system only after ensuring the water meets the requirements of this manual.

2. Close automatic and manual air vents and boiler drain valve.

3. Fill to correct system pressure. Correct pressure will vary with each application.

a. The minimum cold water fill pressure for a system is

12 psi.

b. Pressure will rise when the boiler is turned ON and

system water temperature increases.

4. At initial fill and during boiler startup and testing, check the system thoroughly for any leaks. Repair all leaks before proceeding further.

Purge air from water system

1. Purge air from system:

a. Connect a hose to the purge valve. Route the hose to

an area where water can drain and be seen.

b. Close the boiler or system isolation valve between the

purge valve and fill connection to the system.

c. Close zone isolation valves. d. Open the quick-fill valve on the cold water makeup

line.

e. Open purge valve. f. Open the isolation valves one zone at a time. Allow

water to run through the zone, pushing out the air. Run until no noticeable air flow is present. Close the zone isolation valves and proceed with the next zone. Follow this procedure until all zones are purged.

g. Close the quick-fill water valve and purge valve and

remove the hose. Open all isolation valves. Watch that system pressure rises to correct cold-fill pressure.

h. After the system has operated for a while, eliminate

any residual air by using the manual air vents located throughout the system.

i. If purge valves are not installed in the system, open the

manual air vents in the system one at a time, beginning with the lowest floor. Close the vent when water squirts out. Repeat with remaining vents.

2. Open the automatic air vent (diaphragm-type or bladder type expansion tank systems only) one turn.

3. Open other vents:

a. Starting on the lowest floor, open air vents one at a

time until water squirts out.

b. Repeat with remaining vents.

4. Refill to correct pressure.

Precautions include installing a water meter to evaluate the fresh water volume entering the system (should be no more than 5% system volume). Additional volumes of fresh water could indicate that a leak is present.

Page 54

10 Start-up

ProLine® XE

Combi Boiler

Installation & Service Manual

Check for gas leaks

 WARNING

Before starting the boiler, and during initial operation, smell near the floor and around the boiler for gas odorant or any unusual odor. Remove the front access panel and smell the interior of the boiler enclosure. Do not proceed with startup if there is any indication of a gas leak. Use an approved leak detection solution. Repair any leaks at once.

DO NOT adjust gas valve outlet pressure. The gas valve is factory set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Propane boilers only – Your propane supplier mixes an odorant with the propane to make its presence detectable. In some instances, the odorant can fade, and the gas may no longer have an odor. Before startup (and periodically thereafter), have the propane supplier verify the correct odorant level in the gas.

Check thermostat circuit(s)

1. Disconnect the external wire connected to the room thermostat terminal on the connection board.

2. Connect a voltmeter across these two incoming wires. Close each thermostat, zone valve, and relay in the external circuit one at a time and check the voltmeter reading across the incoming wires.

3. There should NEVER be a voltage reading.

4. If a voltage does occur under any condition, check and correct the external wiring. (This is a common problem when using 3-wire zone valves.)

5. Once the external thermostat circuit wiring is checked and corrected if necessary, reconnect the external thermostat circuit wires to the connection board.

Inspect condensate system

Inspect/check condensate lines and fittings

Inspect the condensate drain line, condensate PVC fittings and

condensate trap (FIG. 10-1).

Clean/Inspect Trap Assembly

Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

Figure 10-1 Condensate Trap

HOSE BARB

MOUNTING NUT

FLOAT BALL

REMOVABLE CAP TO CLEAN OUT TRAP

CONDENSATE DRAIN

DIR #2000529332 00

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10 Start-up (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

Final checks before starting the boiler

 Read this manual to familiarize yourself with boiler

control module operation. Reference page 56 for proper steps to start boiler.

 Verify the boiler and system are full of water and all

system components are correctly set for operation.

 Verify the preparation procedures of Section 10, pages

52 - 54 have been completed.

 Verify electrical connections are correct and securely

attached.

 Inspect vent piping and air piping for signs of deterioration

from corrosion, physical damage or sagging. Verify air piping and vent piping are intact and correctly installed per this manual.

Start the boiler

1. Read and follow the Operating instructions in FIG. 10-2, page 56.

If boiler does not start correctly

1. Check for loose connections, blown fuse or service switch off?

2. Is boiler water temperature above 200°F?

3. Is thermostat set below room temperature?

4. Is gas turned on at meter or boiler?

5. Is incoming gas pressure less than 4 inches w.c.?

If none of the above corrects the problem, refer to the Troubleshooting Section.

Check system and boiler

 Check water piping

1. Check system piping for leaks. If found, shut down the boiler and repair immediately. (See WARNINGS on pages 52 and 54 (startup) regarding failure to repair leaks.)

2. Vent any remaining air from the system using manual vents. Air in the system will interfere with circulation and cause heat distribution problems and noise.

3. Ensure an ASSE 1070 anti-scald mixing valve is installed on the outlet of the domestic hot water piping.

 Check gas piping

1. Check around the boiler for gas odor following the procedure on page 44 of this manual (connecting gas supply piping).

 WARNING

 Propane boilers – verify conversion

1. Verify propane conversion has been completed per the Propane Conversion instructions.

 WARNING

If you discover evidence of any gas leak, shut down the boiler at once. Find the leak source with a bubble test and repair immediately. Do not start the boiler again until corrected. Failure to comply could result in severe personal injury, death, or substantial property damage.

 Check vent piping and air piping

1. Check for gastight seal at every connection, seam of air piping, and vent piping.

 WARNING

Venting system must be sealed gastight to prevent flue gas spillage and carbon monoxide emissions, which will result in severe personal injury or death.

Page 56

10 Start-up

Figure 10-2 Operating Instructions

ProLine® XE

Combi Boiler

Installation & Service Manual

Move switch to the “OFF” position.

Page 57

ProLine® XE

Combi Boiler

Installation & Service Manual

10 Start-up (continued)

Combi Boiler control module

Use the control panel (FIG. 10-3) to set temperatures, operating conditions, and monitor boiler operation.

Figure 10-3 Control Panel

RESET BUTTON

DISPLAY WINDOW

RIGHT BUTTONLEFT BUTTON

UP BUTTON

DOWN BUTTON

- Indicates that the unit has a Space Heating demand.

- Indicates that the unit has a DHW demand. This icon will flash if the unit has a Pre-heat demand (if enabled). (Combi Only)

- Indicates that the integral boiler pump is running. This pump is used for both Space Heating and DHW demands.

- Indicates the burner is firing and a flame signal is detected.

- Indicates that the system pump contacts are being powered.

- Indicates that the unit is running in Service Mode.

- Indicates that Freeze Protection is active.

Home screen

 e Home Screen can be used to view the current operating information of the Combi Boiler.  e ▲ and ▼ buttons can be used to page through the screen sequence, displaying various operating statistics.

Figure 10-4 Screen Sequence

Page 58

10 Start-up

Setup wizard

 e Combi Boiler control has a Setup Wizard feature that can be used to help with the initial start-up of the unit.  is Setup Wizard will walk an installer through the most commonly required parameters.

 e Setup Wizard is automatically accessed the  rst time the unit is powered up from the factory and will allow setting of certain parameters without the need to enter the installer password. Once the Setup Wizard is completed or canceled, it can only be accessed again by going through the Installer Menu.

Figure 10-5 Installer Menu

ProLine® XE

Combi Boiler

MAX SH SETPT

Installation & Service Manual

•  e MAX SH SETPT should be set to the highest space

heating water set point that can be used for the speci c space heating system.  is parameter is the upper limit of what the user can adjust the SH SETPT (COLD DAY) parameter to.  is parameter also serves as a limit of space heat set point that can be generated by the outdoor reset curve in the event that outdoor temperature falls

below the coldest day outdoor temperature setting.

• Range: 60°F – 190°F

• Default: 185°F

- OUTDOOR TEMP COLDEST DAY

• When outdoor reset is used, this is the outdoor temperature used on the reset curve corresponding to the SPACE HEAT SETPT (COLDEST DAY).  is parameter should be set to the outdoor temperature used in the heat load calculation for the cold design day.

• Range: -40°F – 75°F

• Default: 10°F

Button functions in the setup wizard

▲/▼ - Change value of current parameter ► - Move to the next parameter or finish Setup

Wizard on last parameter ◄ - Save changes and exit the Setup Wizard. This will bypass the remaining parameters in the Wizard.

To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.

Parameters in the setup wizard

- TIME/DATE

- SPACE HEAT SETPT (COLDEST DAY)

• This is the space heating water temperature set point that will be used in Space Heating Mode. If outdoor reset is used, this parameter represents the water temperature on the reset curve corresponding to the coldest day outdoor temperature. When outdoor reset is in use, if outdoor temperature falls below the OUTDOOR TEMP COLDEST DAY parameter, space heating set point can go higher than this setting.

• Range: 68°F – MAX SH SETPT (185°F by default)

• Default: 125°F

- OUTDOOR TEMP – WARM WEATHER

SHUTDOWN

• When the outdoor temperature rises above this point, the control will block all space heating demands (DHW demands will still be active). Space heating operation will resume when outdoor temperature falls 10°F below this point.

• Range: 32°F – 104°F

• Default: 70°F

- AUTO RESET HI LIMIT

• When the outlet temperature exceeds the Automatic Reset High Limit setting, automatic high limit action occurs.  e boiler shuts down until the outlet water temperature cools below 10°F under this setting and a 60 second timer has elapsed. Note that this setting applies to both SH and DHW Modes.

• Range: 32°F – 200°F

• Default: 200°F

- MAN. RESET HI LIMIT

• If the outlet temperature continues to increase a er automatic reset high limit action, the Manual Reset High Limit action occurs when the outlet water temperature exceeds this setting.  is will require a manual reset before operation can resume. Note that this setting applies to both SH and DHW Modes.

• Range: 32°F – 210°F

• Default: 210°F

Page 59

10 Start-up (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

- DHW SETPT

•  is is the desired set point temperature of Domestic Hot Water (DHW) generated by the unit. Note that the required anti-scald mixing valve will likely require a setting greater than the desired DHW temperature.

• Range: 60°F – MAX DHW SETPT

• Default: 120°F

- SPACE HEAT RATE LIMITING

•  is feature is used when the maximum space heating load is less than the maximum input rating of the unit.  is setting will limit the maximum input rate of the unit for a space heating demand only (DHW demands will not be limited).

• Range: 10% – 100%

• Default: 100%

- COMBI PRE-HEAT

•  e Combi Pre-Heat function can be used to improve DHW performance and comfort by maintaining boiler water at an elevated temperature to be able to immediately serve a DHW demand. In certain applications, the Pre Heat function can also reduce water usage compared to not using Pre-Heat. Enabling Pre-Heat, however, can increase fuel usage as the unit will periodically  re to maintain heated water.

• Settings: ENABLED/DISABLED

• Default: ENABLED

Figure 10-6 Service Menu

Button functions in Service Mode

▲/▼ - Change the target fan speed in increments of 100 rpm. ► - Toggle between operating at high  re and low  re. ◄ - Exit Service Mode and return to the Home Screen.

Check flame and combustion

1. Turn the main power off to the boiler.

2. Remove the flue plug from the vent pipe adapter. Note: Combustion measurements will be made at this point.

Figure 10-7 Flue Plug Removal

Service mode

 WARNING

 e Combi Boiler includes a Service Mode feature that can be used to force the unit to run at a particular  ring rate.  is feature can be used by quali ed service technicians for adjusting combustion or troubleshooting the unit.

Service Mode can be accessed by holding ► and ▼ buttons simultaneously for 5 seconds.

In Service Mode, the unit will operate with the diverter valve in the space heating position; therefore, zone(s) in the heating system must be actively running in order to reject the heat generated.

Entering Service Mode will immediately cause the boiler to fire. Failure to ensure that the unit is fully assembled and installed and in safe working condition; including having properly installed venting, all air purged from the heat exchanger, and with proper water supply and flow, can result in serious injury, death, significant property damage, or destruction of the heater.

DIR #2000534695 00

REMOVE THE FLUE PLUG FROM THE VENT PIPE ADAPTER

Page 60

10 Start-up

ProLine® XE

Combi Boiler

Installation & Service Manual

3. Press the ► and ▼ buttons (simultaneously) for 5

seconds to enter Service Mode.

4. Insert the probe from a combustion analyzer into the hole on the vent adapter.

5. Once the boiler has modulated up to full fire, measure the combustion. The values should be in the range listed in Table 10A below. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range,

reference Section 13 - Troubleshooting for possible causes and corrective actions.

Table 10A Flue Products Chart

Natural Gas Propane

Goal

Range 8.5% - 10.5% 2.3% - 5.7% 10.0% - 11% 4.1% - 5.6%

Target 9.0% 4.9% 10.5% 4.9%

6. Once the combustion analysis is complete, exit Service

Mode.

Set domestic hot water (DHW) operation

Verify DHW operation

The DHW Heating Mode controls the boiler pump and the diverter valve. When the boiler control receives a DHW call for heat from the DHW flow switch, it turns on the boiler pump and puts the diverter valve in the DHW position to route boiler water through the brazed plate heat exchanger. During the call, the boiler control will modulate to maintain the DHW outlet temperature to the DHW set point.

After the DHW call for heat ends, the boiler pump continues to run for a short period of time. This pump delay is factory set to 30 seconds.

7. Turn the main power off to the boiler and replace the

plug into the vent adapter.

8. Place the boiler back into normal operation.

 WARNING

You must replace the flue gas temperature sensor to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

Set space heating operation

Determine controlling sensor

For space heating systems, the temperature control can be based on the outlet or the system supply sensor (optional). The control will automatically switch to the system supply sensor once it is connected.

Verify space heat circulator operation

The Space Heating Mode controls the boiler pump and the diverter valve. When the boiler control receives a space heating call for heat and the boiler is not heating a DHW (Domestic Hot Water) call, and the set point is not met, it turns on the boiler pump and places the diverter valve in the space heating position. After the space heating call for heat ends, the boiler pump continues to run for a short period of time. This pump delay is factory set to 30 seconds. After this pump delay, the pump is turned off and the diverter valve is placed into the DHW position.

Page 61

11 Operating information

ProLine® XE

Combi Boiler

Installation & Service Manual

General

How the boiler operates

The Combi Boiler uses an advanced stainless steel heat exchanger and electronic control module that allows fully condensing operation. The blower pulls in air and pushes flue products out of the boiler through the heat exchanger and flue piping. The control module regulates blower speed to control the boiler firing rate. The gas valve senses the amount of air flowing into the boiler and allows only the right amount of gas to flow.

How the control module operates

The boiler control module receives inputs from boiler sensors and external devices. The control module activates and controls the blower and gas valve to regulate heat input. Switches the boiler pump on and off and controls the diverter valve as needed. The user programs the module to meet system needs by adjusting control parameters. These parameters set operating temperatures and boiler operating modes. Boiler operation can be based on boiler outlet water temperature or system supply temperature.

Menus

CAUTION

NOTICE

Set points menu (user access)

The Set Points Menu can be accessed by pressing the ◄ button.

Figure 11-1 Set Point Menu

Before changing parameters, note the settings so that the unit can be returned to its original operating parameters.

Parameters will be automatically saved after menu timeout.

Parameters in the set points menu:

- SH SETPT (COLD DAY)

• Space heating water set point temperature, or the space heating water set point temperature when outdoor temperature is at the cold day setting if outdoor reset is used.

• Range: 68°F – MAX SH SETPT

• Default: 125°F

- DHW SETPT

• This is the desired set point temperature of domestic hot water generated by the unit. Note that the required anti-scald mixing valve will likely require a setting greater than the desired domestic hot water temperature.

• Range: 60°F – MAX DHW SETPT

• Default: 120°F

- TEMPERATURE UNITS

• This parameter can be used to select temperature units to be displayed on the screen (°F/°C)

- AUTO RESET HI LIMIT

• When the outlet temperature exceeds the Automatic Reset High Limit setting, automatic high limit action occurs. The boiler shuts down until the outlet water temperature cools below 10°F under this setting and a 60 second timer has elapsed. Note that this setting applies to both SH and DHW Modes.

• Range: 32°F – 200°F

• Default: 200°F

- MAN. RESET HI LIMIT

• If the outlet temperature continues to increase after automatic reset high limit action, the Manual Reset High Limit action occurs when the outlet water temperature exceeds this setting. This will require a manual reset before operation can resume. Note that this setting applies to both SH and DHW Modes.

• Range: 32°F – 210°F

• Default: 210°F

Button functions in the set points menu

▲/▼ - Change value of current parameter. ► - Move to the next parameter. ◄ - Save changes and exit the menu.

To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.

Installer menu (installer only access)

 e Installer Menu can be accessed by pressing the ► button and then entering the installer password.

Figure 11-2 Installer Menu

Page 62

11 Operating information

ProLine® XE

Combi Boiler

Installation & Service Manual

Enter the installer password

To enter the installer password, use the ▲ and ▼ buttons to change the value of the  rst digit to 5, then press ► to move to the next digit. Repeat this process to  ll in the remaining digits and enter the password 5-3-0-9. Once the  nal digit has been entered, press the ► button to access the installer menu.

Entering the installer password will allow future access to the installer menu without requiring the password for up to an hour a er the last button is pressed.

Installer main menu

 e Installer Menu is arranged in a menu/sub-menu structure to help with navigation to the desired settings.  e installer

main menu gives a list of available sub-menus.

Figure 11-3 Installer Main Menu

Button functions in the installer main menu

▲/▼ - Move the cursor through the list of available sub menus. ► - Access the currently selected sub-menu.

◄ - Save changes and exit the menu.

To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.

Button functions in the installer sub-menus

▲/▼ - Change value of current parameter. ► - Move to next parameter or return to main menu on last parameter in the sub-menu. ◄ - Return to Main Menu or save all changes and return to Home Screen on the last parameter in the sub menu.

To exit the menu without saving changes, you must cycle power to the unit before exiting the menu.

Note: Certain settings in the Installer Menu can be accessed in multiple sub-menus for ease of navigation.  e Installer Menu also contains settings that can also be found in the Set Points Menu to allow full programming of the boiler within the Installer Menu.

Parameters in the installer menu:

- GENERAL Submenu MAX SH SETPT – also found in OUTDOOR RESET Sub-menu

• Default: 185°F

• Minimum: 60°F

• Maximum: 190°F

- MAX DHW SETPT

• Default: 150°F

• Minimum: 60°F

• Maximum: 190°F

- AUTO RESET HI LIMIT – also found in Set Points Menu

• Default: 200°F

• Minimum: 32°F

• Maximum: 200°F

- MAN. RESET HI LIMIT – also found in Set Points Menu

• Default: 210°F

• Minimum: 32°F

• Maximum: 210°F

- SH MAX RATE LIMITING

• Default: 100%

• Minimum: 10%

• Maximum: 100%

- OUTDOOR RESET Sub-menu SH SETPT (COLD DAY) – also found in Set Points Menu

• Default: 125°F

• Minimum: 68°F

• Maximum: MAX SH SETPT OUTDOOR TEMP COLDEST

• Default: 10°F

• Minimum: -40°F

• Maximum: 75°F WARM WEATHER SHUTDOWN

• Default: 70°F

• Minimum: 32°F

• Maximum: 104°F SHIFT RESET

• Default: 0°F

• Minimum: -18°F

• Maximum: 18°F OUTDOOR TEMP – WARM

• Default: 75°F

• Minimum: 10°F

• Maximum: 104°F SH SETPT (WARM DAY)

• Default: 75°F

• Minimum: 68°F

• Maximum: 190°F TIME/DATE Sub-menu FAULT LOG

Page 63

ProLine® XE

Combi Boiler

11 Operating information (continued)

- SETPOINTS Sub-menu – Set Points Menu duplicate SH SETPT

• Default: 125°F

• Minimum: 68°F

• Maximum: MAX SH SETPT DHW SETPT

• Default: 120°F

• Minimum: 60°F

• Maximum: MAX DHW SETPT TEMPERATURE UNITS

• Default: °F

- CASCADE Sub-menu CASCADE ADDRESS CASCADE TYPE – only available if address is 0

• Boiler size settings – only available if address is 0

- ADVANCED COMBI Sub-menu DHW RESPOND TIME

• Default: 2 minutes

• Minimum: 0 minutes

• Maximum: 15 minutes PRE-HEAT – (ENABLED/DISABLED)

• Default: ENABLED DHW BLW WATER TEMP

• Default: 180°F

• Minimum: 68°F

• Maximum: 190°F DHW OPERATING MODE

• Default: NORMAL

- SET-UP WIZARD – Access Set-up Wizard after it has been completed.

System supply temperature sensor (optional)

An optional factory supplied and field installed system supply temperature sensor may be used with the Combi Boiler. When installed, this sensor is used to control modulation of the boiler during a space heat call for heating.

Boiler inlet temperature sensor

The Combi Boiler is factory equipped with a boiler inlet temperature sensor.

Combi DHW outlet temperature sensor

The Combi Boiler is factory equipped with a combi DHW outlet temperature sensor. This sensor is used to control modulation of the boiler during a DHW call for heat. When this sensor is missing, limited operation in DHW Mode is possible by controlling the boiler outlet temperature to the DHW set point.

DHW flow switch

The Combi Boiler is factory equipped with a DHW flow switch connected to the control that detects the presence of DHW water flow rates greater than 0.32 gpm. This input tells the boiler to provide heat for DHW heating.

Combi diverter valve

The Combi Boiler is factory equipped with a diverter valve used to route boiler water to the heating system when in the Space Heating Mode or through the brazed plate heat exchanger when in DHW Mode. This diverter valve is normally in the DHW position, thus isolating the boiler from flow in the heating system.

Installation & Service Manual

Control inputs and outputs

Room thermostat

The room thermostat input tells the boiler to provide heat for space heating.

DHW Priority

If a DHW call for heat is received while a Space Heating call is in progress, the control will start operating in DHW Mode to move the diverter valve to the DHW position. The control will not resume Space Heating operation until the DHW call has ended.

Anti-cycling

After the burner turns off, the control will delay the next burner cycle for a set time period. The time delay will be bypassed if the inlet water temperature drops too far during the delay. The anticycling delay does not apply to DHW calls for heat.

Modulation

The Combi Boiler is capable of modulating its firing rate from a minimum of 10% to a maximum of 100%. The firing rate is dictated by the call for heat (i.e., space heating or domestic hot water), the heating load, and various other temperature limitations.

Boiler outlet temperature sensor

The Combi Boiler is factory equipped with a boiler outlet temperature sensor which is also used as the limit sensor for the heater. During a space heat call for heat, the outlet temperature sensor is used to control modulation of the boiler unless a system supply sensor is field installed.

Boiler pump control

The Combi Boiler is factory shipped with an internal boiler pump used to generate flow for both space heating and DHW operation. The boiler pump will run whenever the burner is firing. The boiler pump will also run during Freeze Protection and Combi Pre-Heat Modes. The boiler pump will continue to run for a short time after the burner turns off, the Freeze Protection Mode ends, or the Combi Pre-Heat Mode ends.

System pump control

The Combi Boiler is capable of controlling a field supplied and installed space heating system pump. The system pump will run whenever there is a space heating call for heat, or the boiler goes into Freeze Protection Mode. The system pump will continue to run for a short time after the end of the heat demand or the Freeze Protection Mode.

Gradient limiting

If during operation of the boiler the outlet water temperature is rising too quickly, the control will reduce the firing rate to its lowest setting.

SH rate limiting

The Combi Boiler includes an SH Rate Limiting feature that limits the maximum modulation during a space heating call.

Page 64

11 Operating information

ProLine® XE

Combi Boiler

Installation & Service Manual

Outdoor air reset

The Combi Boiler uses an advanced non-linear outdoor reset curve to improve system efficiency by reducing the boiler water set point as the outdoor temperature warms up. The installer can set the reset curve by setting both the SH SETPT (COLD DAY) parameter to the water temperature required for the coldest design day outdoor temperature and the COLDEST OUTDOOR TEMP parameter to the coldest design day outdoor temperature. The installer should limit the maximum set point for the system using the MAX SH SETPT parameter. The user can adjust the SH SETPT (COLD DAY) parameter up to the MAX SH SETPT as needed to modify the reset curve. For advanced configuration, the installer can also adjust the warm day point on the curve using the installer menu, however because of the non-linear curve, these settings typically do not need to be adjusted.

With the outdoor air sensor connected, the control module will calculate the space heating demand water set point based on the programmed reset curve to automatically match the required heat load. For advanced configuration, the installer can also adjust the warm day point from the Installer Menu, however because of the non-linear curve, these settings typically do not need to be adjusted.

Outdoor Air Shutdown

Outdoor air shutdown speci es the outdoor air temperature at which the Space Heating demand is blocked. DHW demands will still be active. Space heating operation will resume once the outdoor temperature falls below 10°F less than the Outdoor Air Shutdown setting.

Space Heat Rate Limiting

Space Heat Rate Limiting can be used when the maximum required space heating load is lower than the maximum input rate of the unit.  is feature limits the maximum input rate during a space heating demand to help keep the unit running at lower input rates. Space Heat Rate Limiting does not a ect DHW operation.

Flame current support

To prevent nuisance shutdowns when the boiler is firing at low rates, the control will increase the firing rate when the flame signal drops too low.

Figure 11-4 Outdoor Reset Curve

MAX SH SETPT

(DEFAULT = 185°F)

CURVE MAY BE LIMITED TO A

LOWER SET POINT

SH SETPT (COLD DAY)

(DEFAULT = 125°F)

USER ADJUSTABLE

SH SETPT (WARM DAY)

(DEFAULT = 75°F)

NOT TYPICALLY ADJUSTED

TEMPERATURE

OUTDOOR RESET CURVE

WILL BE AUTOMATICALLY LIMITED

AT 15°F BELOW COLD DAY

OUTDOOR TEMPERATURE

Combi Pre-Heat

 e Combi Boiler includes an optional Pre-Heat feature which is intended to maintain the boiler water temperature within a pre-de ned range to improve the time it takes for the unit to supply heated DHW water.  e Pre-Heat feature can also be used to satisfy low  ow DHW demands or for heating water during DHW recirculation where  ows through the unit may be less than the setting of the  ow switch.  e Pre-Heat feature will  rst try to satisfy these demands using the integral boiler pump before  ring. Pre-heat operation will be indicated on the display by a  ashing DHW icon. When the unit  res for a Pre-Heat demand, it will immediately ramp to low  re. PreHeat demands will only occur when no other heating demand is present.

WATER

SET POINT

OUTDOOR TEMP (COLDEST) (DEFAULT = 10°F)

WARM WEATHER

SHUTDOWN

(DEFAULT = 70°F)

OUTDOOR TEMP -

WARM

(DEFAULT = 75°F)

NOT TYPICALLY ADJUSTED

DHW Respond

 e Combi Boiler includes a DHW respond feature to help eliminate cold water sandwich issues associated with repeated DHW demands. A er any DHW demand, the unit will go into pre-purge for a pre-determined time a er post-purge has ended. If a new demand occurs during this DHW respond time, the unit will be able to immediately enter ignition, reducing the time it takes for the unit to respond to the subsequent demand. DHW respond time can be set by the installer for a duration of 0 minutes (disabled) up to 15 minutes.

Page 65

ProLine® XE

Combi Boiler

11 Operating information (continued)

Cascade

When multiple Combi Boilers are installed, they can be wired together in a Cascade sequence. A maximum of eight (8) boilers can be controlled from a single control. In this application one boiler would be designated as the Leader control and all others would be designated as Member controls. The Leader control can be programmed to use Lead/Lag or Efficiency Optimization control methods. Combi Boilers can only control Space Heating demands. A Combi Boiler in a Cascade must have its own DHW circuit, as DHW will be controlled individually.

Once the Leader receives a call for heat from a room thermostat, the control will determine what the set point will be. If outdoor air reset is desired, connect the outdoor air sensor to the terminals on the Low Voltage Connection Board on the Leader boiler. The set point will be calculated based on the programmed reset curve of the Leader. If the water temperature at the system supply sensor is less than the set point – 10°F, then the control will initiate a call for heat on the Cascade.

When a Combi Boiler in a Cascade receives a DHW call for heat, it will be taken out of the Cascade to satisfy its own DHW demand. Once its DHW demand has ended, it will be put back into the Cascade.

To equalize the run time of all boilers on the Cascade, the firing sequence will automatically be changed at set intervals.

Protection features

Outlet temperature, flue temperature, and temperature rise limiting

The outlet temperature is monitored by the boiler outlet temperature sensor. When the outlet temperature exceeds 185°F, the unit will reduce the maximum fan speed. If the outlet water temperature exceeds 195°F the control will shut the unit down until it cools off.

The control module monitors the flue temperature by a sensor located in the flue exhaust. If the flue temperature exceeds 215°F the control will reduce the maximum fan speed. If the flue temperature exceeds 240°F the control will shut the unit down. The unit will restart automatically once the flue temperature drops 25°F and the minimum off time has expired.

The control module monitors the change in the temperature after the burner fires to ensure that the flue sensor is properly installed. In the event that the control module does not detect the required change in the temperature, modulation will be limited to 50% or less. Once the required flue temperature change is observed, the boiler will be allowed to modulate

above 50% on the next call for heat or after the ● (RESET) button is pressed.

The control monitors the temperature difference between the inlet and the outlet sensor. If this difference exceeds 55°F the control will reduce the maximum fan speed. If the temperature difference exceeds 60°F the control will shut the unit down. The unit will restart automatically once the temperature difference has dropped below 55°F and the minimum off time has expired.

Freeze protection

DO NOT install the boiler in a room likely to freeze.

The following integral feature of the boiler control module provides some protection for the boiler only -- not for the system.

The boiler control module provides freeze-up protection as follows:

• Below an inlet temperature of 45°F, the boiler pump operates constantly.

• Below an inlet temperature of 37°F, the burner fires.

• Boiler and pumps turn off if boiler water inlet temperature rises above 45°F.

NOTICE

 CAUTION

Low voltage blocking

The blower and gas valve require a minimum amount of voltage in order to operate properly. If an ignition attempt is made when the line voltage is temporarily low (such as during a brownout), the control could enter a manual reset lockout. To prevent this, the control monitors the voltage and blocks any heat demands until the voltage returns to an acceptable level.

Monitor external limits

Connections are provided on the connection board for external limits such as a flow switch or low water cutoff and AUX limit. The boiler control will shut off the burner and inhibit relighting whenever any of these external limits open.

Error logging

The control will hold the last 10 lockouts in memory. The date and time of the occurrence will be recorded as well. Only the 10 most current occurrences will be held in memory.

Installation & Service Manual

When system return temperatures are maintained below the dew point, condensation will form on the inside of the boiler jacket causing some internal sheet metal components to rust.

This feature of the boiler control module does not eliminate the possibility of freezing. The installation must still use recognized design, installation and maintenance practice to prevent freeze potential for the boiler and system.

Page 66

11 Operating information

ProLine® XE

Combi Boiler

Installation & Service Manual

Space heat temperature regulation

Operating temperature (target)

The boiler control module senses water temperature and regulates boiler firing rate to achieve a target temperature. The target temperature is calculated as described in this section under "Outdoor Reset Operation" when the outdoor sensor is connected. The maximum target temperature can be limited by the installer using the MAX SH SETPT. This temperature can be set between 32°F and 190°F. If the outdoor sensor is shorted or not properly installed, the target temperature is fixed at the SH SETPT (Cold Day).

High limit operations

The Combi Boiler is equipped with an adjustable automatic reset high limit and a manual reset high limit. The automatic reset high limit has a maximum set point of 200°F and the manual reset high limit has a maximum set point of 210°F.

Low water cutoff protection

1. The boiler control module uses temperature sensing of both supply and return ports of the heat exchanger. If the flow rate is too low or the outlet temperature too high, the control module modulates and shuts the boiler down. This ensures boiler shutdown in the event of low water or low flow conditions.

2. Some codes and jurisdiction may accept these integral features of the control in lieu of requiring an additional limit control or low water cutoff. Consult local jurisdiction to determine. A low water cutoff is available from the factory (100173646).

Sequence of operation

 e cold domestic water enters the plate heat exchanger through the DHW inlet connection,  ow switch, and strainer. Cold water  ows through the plate heat exchanger, where it is heated by hot boiler water, and then discharged through the Domestic Hot Water (DHW) outlet connection.

Heated boiler water is supplied from the primary combustion heat exchanger through the diverter valve into the plate heat exchanger.  e boiler water heats the colder domestic water, and is then returned to the primary heat exchanger through the pump.

While operating in DHW Mode, the diverter valve prevents water from  owing through the boiler outlet connection to the heating system. Boiler water is circulated inside the unit between the plate heat exchanger and the primary combustion heat exchanger.

 e diverter valve is normally in the DHW position when the unit is in Standby, thus isolating boiler water from  owing to the heating system. When there is a space heating call, the diverter valve will move to the space heat position allowing boiler water to  ow from the primary combustion heat exchanger through the boiler outlet connection to the heating system, bypassing the plate heat exchanger.  e internal pump is used to circulate water in both Space Heating and DHW Modes.

Page 67

ProLine® XE

Combi Boiler

11 Operating information (continued)

OPERATION DISPLAY

1. Upon a call for heat, the control turns on the appropriate pumps. The flow switch and/or LWCO must close.

2. Once the LWCO has closed, the auxiliary limit switch must close.

Installation & Service Manual

3. The control starts the pre-purge cycle by initiating the blower.

4. The control starts the trial for ignition by firing the spark electrode and opening the gas valve.

5. If flame is not detected after the sparking ends, the control will perform a postpurge, then start another prepurge cycle and try to light the burner again. The control will perform a total of 4 attempts before locking out.

Page 68

11 Operating information

OPERATION DISPLAY

6. If flame is detected, it holds the firing rate steady for a few seconds to let the flame stabilize, then it begins to modulate the firing rate based on a set point or some other command.

7. If the space heating call for heat is active and the combi flow switch starts a DHW call for heat, the diverter valve will move to the DHW position and the boiler will switch to the DHW Mode. This will divert the boiler's outlet water from the heating system to the brazed plate heat exchanger. The control will then modulate to maintain the DHW outlet temperature at the DHW set point.

ProLine® XE

Combi Boiler

Installation & Service Manual

8. Once all calls for heat are satisfied, the control will turn off the burner. The blower will continue to run during the postpurge period.

9. Any pumps that are running will continue to run for their respective pump delay times before turning off. A 60 second anti-cycle period will start, which will delay any new space heating call for heat until it times out.

10. In Standby, ready to start a new cycle.

Page 69

ProLine® XE

Combi Boiler

12 Maintenance

Maintenance and annual startup

Table 12A Service and Maintenance Schedules

Installation & Service Manual

Service technician

(see the following pages for instructions)

General:

• Address reported problems

• Inspect interior; clean and vacuum if necessary;

• Clean condensate trap

• Check for leaks (water, gas, flue, condensate)

• Verify flue and air lines in good condition and sealed tight

• Check system water pressure/system piping/expansion tank

• Check fill water meter

• Test boiler water. When test indicates, clean system water with approved system restorer following manufacturer’s information.

• Check control settings

• Check ignition electrodes (sand off any

ANNUAL START-UP

deposits; clean and reposition)

• Check wiring and connections

• Perform start-up checkout and performance verification per Section 10 of this manual.

• Flame inspection (stable, uniform)

• Flame signal (at least 10 microamps at high fire)

• Clean the heat exchanger if flue temperature is more than 54°F above return water temperature.

• Inspect and clean the flow switch filter and sanitary bypass filter in the Combi waterset.

Owner maintenance

(see the Combi Boiler User’s Information Manual for

instructions)

• Check boiler area

Daily

Monthly

Periodically

Every

6 months

• Check pressure/temperature gauge

• Check vent piping

• Check air piping

• Check air and vent termination screens

• Check relief valve

• Check condensate drain system

• Check air vents

• Test low water cutoff (if used)

• Reset button (low water cutoff)

• Check boiler piping (gas and water) for leaks

• Operate relief valve

If combustion or performance indicate need:

• Clean heat exchanger

• Remove and clean burner using compressed air only

End

of season

months

• Shut boiler down (unless boiler used for domestic hot water)

Page 70

12 Maintenance

ProLine® XE

Combi Boiler

Installation & Service Manual

 WARNING

Follow the Service and maintenance procedures given throughout this manual and in component literature shipped with the boiler. Failure to perform the service and maintenance could result in damage to the boiler or system. Failure to follow the directions in this manual and component literature could result in severe personal injury, death, or substantial property damage.

 WARNING

The boiler should be inspected annually only by a qualified service technician. In addition, the maintenance and care of the boiler designated in Table 12A and explained on the following pages must be performed to assure maximum boiler efficiency and reliability. Failure to service and maintain the boiler and system could result in equipment failure.

 WARNING

Electrical shock hazard – Turn off power to the boiler before any service operation on the boiler except as noted otherwise in this instruction manual. Failure to turn off electrical power could result in electrical shock, causing severe personal injury or death.

Address reported problems

1. Inspect any problems reported by the owner and correct before proceeding.

Inspect boiler area

1. Verify that boiler area is free of any combustible materials, gasoline and other flammable vapors and liquids.

2. Verify that air intake area is free of any of the contaminants listed in Section 1 of this manual. If any of these are present in the boiler intake air vicinity, they must be removed. If they cannot be removed, reinstall the air and vent lines per this manual.

Inspect boiler interior

1. Remove the front access cover and inspect the interior of the boiler.

2. Vacuum any sediment from inside the boiler and components. Remove any obstructions.

Clean condensate trap

1. Remove the clean out cap on the bottom of the trap. Let the condensate and any debris drain out.

2. Replace the clean out cap and resume operation.

Figure 12-1 Condensate Trap

HOSE BARB

MOUNTING NUT

FLOAT BALL

CONDENSATE DRAIN

REMOVABLE CAP TO CLEAN OUT TRAP

DIR #2000529332 00

Check all piping for leaks

 WARNING

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

3. Check gas line using the procedure found in Section 7 - Gas Connections.

Eliminate all system or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in tubes, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

Flue vent system and air piping

1. Visually inspect the entire flue gas venting system and air

piping for blockage, deterioration or leakage. Repair any joints that show signs of leakage. Verify that air inlet pipe is connected and properly sealed.

2. Verify that boiler vent discharge and air intake are clean

and free of obstructions.

 WARNING

Failure to inspect for the above conditions and have them repaired can result in severe personal injury or death.

Check water system

1. Verify all system components are correctly installed and operational.

2. Check the cold fill pressure for the system. Verify it is correct (must be a minimum of 12 psi).

3. Watch the system pressure as the boiler heats up (during testing) to ensure pressure does not rise too high. Excessive pressure rise indicates expansion tank sizing or performance problem.

4. Inspect air vents and air separators. Remove air vent caps and briefly press push valve to flush vent. Replace caps. Make sure vents do not leak. Replace any leaking vents.

Check expansion tank

1. Expansion tanks provide space for water to move in and out as the heating system water expands due to temperature increase or contracts as the water cools. Tanks may be open, closed or diaphragm or bladder type. See Section 6 - Hydronic Piping for suggested best location of expansion tanks and air eliminators.

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12 Maintenance (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

Check fill water meter

1. Check fill water meter for water usage. If the amount exceeds 5% of your system volume, you could have a leak. Have the system checked for leaks and fixed by a qualified service technician.

Test boiler water

1. Test boiler water. Reference the Installation and Operation Manual for guidelines. When test indicates, clean system water with approved system restorer following the manufacturer’s information.

Check boiler relief valve

1. Inspect the relief valve and lift the lever to verify flow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section 6 - Hydronic Piping before proceeding further.

 WARNING

Following installation, the valve lever must be operated AT LEAST ONCE A YEAR to ensure that waterways are clear. Certain naturally occurring mineral deposits may adhere to the valve, rendering it inoperative. When manually operating the lever, water will discharge and precautions must be taken to avoid contact with hot water and to avoid water damage. Before operating lever, check to see that a discharge line is connected to this valve directing the flow of hot water from the valve to a proper place of disposal. Otherwise severe personal injury may result. If no water flows, valve is inoperative. Shut down the boiler until a new relief valve has been installed.

Safety relief valves should be re-inspected AT LEAST ONCE EVERY THREE YEARS, by a licensed plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the owner. Failure to re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

2. After following the warning directions in this manual, if the relief valve weeps or will not seat properly, replace the relief valve. Ensure that the reason for relief valve weeping is the valve and not over-pressurization of the system due to expansion tank waterlogging or undersizing.

Inspect ignition / flame sense electrodes

1. Remove the ignition / flame sense electrode from the boiler heat exchanger access cover.

2. Remove any deposits accumulated on the ignition/flame sense electrode using sandpaper. If the electrode cannot be cleaned satisfactorily, replace the ignition/flame sense electrode with a new one.

3. Replace ignition/flame sense electrode, making sure gasket is in good condition and correctly positioned.

Check ignition ground wiring

1. Inspect boiler ground wire from the heat exchanger access cover to ground terminal strip.

2. Verify all wiring is in good condition and securely attached.

3. Check ground continuity of wiring using continuity meter.

4. Replace ground wires if ground continuity is not satisfactory.

Check all boiler wiring

1. Inspect all boiler wiring, making sure wires are in good condition and securely attached.

Check control settings

1. Set the boiler control module display to Parameter Mode and check all settings. Adjust settings if necessary. See Section 11 - Operating Information for adjustment procedures.

2. Check settings of external limit controls (if any) and adjust if necessary.

Perform start-up and checks

1. Start boiler and perform checks and tests specified in

Section 10 - Start-up.

2. Verify cold fill pressure is correct and that operating

pressure does not go too high.

Check burner flame

1. Inspect flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire,

turn off boiler and allow boiler to cool down. Remove the burner and clean it thoroughly using a vacuum cleaner or compressed air. Do not use compressed air to clean burner if performed inside a building.

3. Remove the burner, reference FIG. 12-2 (page 72).

4. When replacing the burner, ensure gasket is in good

condition and positioned correctly (FIG. 12-2).

Page 72

12 Maintenance

ProLine® XE

Combi Boiler

Installation & Service Manual

Figure 12-2 Burner Assembly

TOP PLATE

GASKET

BURNER

DIR #2000534736 00

Check flame signal

1. At high fire the flame signal shown on the display should be at least 10 microamps.

2. A lower flame signal may indicate a fouled or damaged ignition / flame sense electrode. If cleaning the ignition/ flame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the ignition / flame sense electrode.

3. See Section 13 - Troubleshooting for other procedures to deal with low flame signal.

Review with owner

1. Review the Combi Boiler User’s Information Manual with the owner.

2. Emphasize the need to perform the maintenance schedule specified in the Combi Boiler User’s Information Manual (and in this manual as well).

3. Remind the owner of the need to call a licensed contractor should the boiler or system exhibit any unusual behavior.

Handling ceramic fiber materials

REMOVAL OF COMBUSTION CHAMBER LINING

 WARNING

to cristobalite in very high temperature applications. The International Agency for Research on Cancer (IARC) has concluded, “Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans (Group 1).” Normal operating temperatures in this appliance are below the level to convert ceramic fibers to cristobalite. Abnormal operating conditions would have to be created to convert the ceramic fibers in this appliance to cristobalite.

The ceramic fiber material used in this appliance is an irritant; when handling or replacing the ceramic materials it is advisable that the installer follow these safety guidelines.

Avoid breathing dust and contact with skin and eyes.

• Use NIOSH certified dust respirator (N95). This type of respirator is based on the OSHA requirements for cristobalite at the time this document was written. Other types of respirators may be needed depending on the job site conditions. Current NIOSH recommendations can be found on the NIOSH website at http://www.cdc.gov/niosh/homepage.html. NIOSH approved respirators, manufacturers, and phone numbers are also listed on this website.

• Wear long-sleeved, loose fitting clothing, gloves, and eye protection.

Apply enough water to the combustion chamber lining to prevent airborne dust.

 Remove the combustion chamber lining from the appliance and place it in a plastic bag for disposal.

 Wash potentially contaminated clothes separately from other clothing. Rinse clothes washer thoroughly.

NIOSH stated First Aid.

 Eye: Irrigate immediately.  Breathing: Fresh air.

The combustion chamber insulation in this appliance contains ceramic fiber material. Ceramic fibers can be converted

4. Remind the owner to follow the proper shutdown procedure and to schedule an annual start-up at the beginning of the next heating season.

Page 73

12 Maintenance (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

Cleaning the boiler heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Combi Boiler Installation and Operation Manual.

• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2. Allow time for the boiler to cool to room temperature if it has been firing.

3. Remove the front access panel.

4. Disconnect the wiring and reference hose from the gas valve.

5. Disconnect the wiring from the fan assembly.

6. Disconnect the ignition cable and ground wire from the igniter.

7. Using a 3 mm Allen wrench, remove the four (4) screws securing the gas valve flange to the gas valve assembly.

8. Using a 5/16" nut driver, loosen the ratchet clamp connecting the air intake to the venturi.

9. Using a 10 mm wrench, remove the six (6) nuts securing the heat exchanger top plate to the heat exchanger.

10. Remove the heat exchanger top plate, gas valve, fan and venturi as one assembly and set aside.

 WARNING

11. Remove the condensate trap from the bottom of the heat exchanger. Place a bucket underneath the condensate fitting attached to the heat exchanger for drainage.

12. Use a vacuum cleaner to remove any accumulation on the boiler heating surfaces. Do not use any solvent.

13. Using a clean cloth dampened with warm water, wipe out the combustion chamber. Do NOT use a metal bristled brush.

14. Rinse out debris with a low pressure water supply.

15. Allow the heat exchanger to thoroughly dry.

16. Reassemble the unit in reverse order of component removal and reinstall the condensate trap.

 CAUTION

17. Perform start-up and check-out procedures in the Check Flame and Combustion - Section 10 Startup of this

manual.

18. Resume operation.

The boiler contains ceramic fiber materials. Use care when handling these materials per instructions on page 72. Failure to comply could result in severe personal injury.

Damaged gaskets and seals in the system can result in substantial property damage. Ensure that damaged or torn gaskets are replaced.

Cleaning the combi boiler brazed plate heat exchanger

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Combi Boiler Installation and Operation Manual.

• Do not drain the boiler unless it will be exposed to freezing temperatures. If using freeze prevention fluid in system, do not drain.

2. Shut off domestic water supply.

3. Isolate/disconnect the domestic water piping leading to the domestic water inlet and outlet.

4. Flush the brazed plate heat exchanger.

5. Follow the above steps in reverse order to place the boiler back into service.

6. Resume operation.

DHW flow switch filter cleaning

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Combi Boiler Installation and Operation Manual.

2. Allow time for the boiler to cool to room temperature if it has been firing.

3. Remove the front access panel.

4. Locate the flow sensor on the flow switch (as shown in FIG. 12-3 on page 74). Slide the flow sensor off the flow switch.

5. Using an 18 mm hex/socket wrench, remove the flow switch

assembly from the unit (FIG. 12-3).

6. Remove the filter from the flow switch and clean by either

blowing water or air into the open end of the filter as shown in FIG. 12-4.

7. Clean the O-ring seat and verify that it is not damaged.

Apply a small amount of grease to the flow switch O-ring seat as shown in FIG. 12-5. Reinstall the filter to the flow switch. Reinstall the flow switch back into the unit and torque to 10 - 14 Nm (7.4 - 10.3 ft. lbf).

8. Place the flow sensor back onto the flow switch.

9. If cleaning is unsuccessful, replace the flow switch assembly.

10. Reinstall the front access panel removed in Step 3 and

resume operation.

NOTICE

When maintaining the flow switch, it is also recommended to maintain the bypass (see page 74 for a detailed description of cleaning the bypass filter).

Page 74

12 Maintenance

ProLine® XE

Combi Boiler

Installation & Service Manual

Figure 12-3 Remove flow sensor and flow switch assembly

FLOW SWITCH

ASSEMBLY

DIR #2000536540 00

REMOVE FLOW SENSOR

Figure 12-4 Clean flow switch filter

Bypass filter cleaning

1. Shut down boiler:

• Follow the “To Turn Off Gas to Appliance” instructions for the boiler in Section 10 - Startup of the Combi Boiler Installation and Operation Manual.

2. Allow time for the boiler to cool to room temperature if it has been firing.

3. Remove the front access panel.

4. Use a 16 mm 5/8" wrench to unscrew and remove the bypass assembly (see FIG. 12-6). If needed, use water to clean the metallic filter.

5. Reinstall the bypass assembly. Torque the bypass to 7 - 10 Nm

(5.2 - 7.4 ft. lbf).

6. If cleaning is unsuccessfully, replace the bypass assembly.

7. Reinstall the front access panel removed in Step 3 and

resume operation.

Figure 12-6 Remove bypass assembly

BLOW AIR OR WATER INTO THE OPEN END OF THE FLOW SWITCH FILTER

Figure 12-5 Clean O-ring seat

CLEAN O-RING SEAT

DIR #2000542758 00

DIR #2000536591 00

REMOVE BYPASS ASSEMBLY

DIR #2000542775 00

Page 75

12 Maintenance

Test low water flow conditions

NOTICE

Test procedure

1. Place the boiler into the active position by pressing the UP button for five (5) seconds (see page 57).

2. Hold the ► button plus the ▼ button for five (5)

seconds to enter Service Mode, allowing the unit to fire up to 100% modulation.

This test is to be carried out once the Combi Boiler is completely piped in with adequate gas and water flow. Once the test is completed, ensure that the isolation valve is opened up to allow full water flow.

ProLine® XE

Combi Boiler

Installation & Service Manual

Figure 12-7 Adjust outlet isolation valve

3. Allow the unit to progress through its normal diagnostics and pre-purge programming.

4. Allow the unit to fire and operate until the temperatures stabilize. This occurs when the inlet and outlet temperatures are rising together and the Delta T ( T) is maintained.

5. When the unit stabilizes, begin to slowly shut off the isolation valve on the outlet piping of the boiler (see FIG. 12-7). This will begin to restrict the flow and simulate a low flow condition.

6. While slowly shutting off the isolation valve, refer to the Status Screen to watch the behavior of the boiler. This screen allows you to monitor the inlet temperature, outlet temperature, and T.

7. When the  T reaches 55˚F, the control will attempt to modulate the firing rate down to protect it from low flow conditions.

8. When the T reaches 60°F, the control module will turn off the burner. If the control module shuts down, the test was successful.

9. Completely open the isolation valve on the outlet piping of the boiler.

DJUST OUTLET

ISOLATION VALVE ONLY

DIR #2000528875 00

10. Resume operation.

Page 76

13 Troubleshooting

ProLine® XE

Combi Boiler

Installation & Service Manual

 WARNING

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation. Always disconnect power to the boiler before servicing. Failure to comply could result in severe personal injury, death, or substantial property damage.

 WARNING

Never jumper (bypass) any device except for momentary testing as outlined in the Troubleshooting chart. Severe personal injury, death, or substantial property damage can result.

Before troubleshooting:

1. Have the following items: a. Voltmeter that can check 120 vac, 24 vac, and 12 vdc. b. Continuity checker. c. Contact thermometer.

2. Check for 120 vac (minimum 102 vac to maximum

132 vac) to boiler.

3. Make sure thermostat is calling for heat and contacts

(including appropriate zone controls) are closed. Check for 24 vac between thermostat wire nuts and ground.

Check control module fuses

NOTICE

1. Turn OFF the power to the boiler at the external line switch.

2. Remove front door/cover.

3. Remove the control module cover.

4. Inspect fuses F1, F2, and F3, see FIG 13-1 below.

Figure 13-1 Control Module Fuses

F3 - 0.8 AMP FUSE

24V DC POWER SUPPLY

F1 - 6.3 AMP FUSE

F2 - 3.15 AMP FUSE

ALWAYS check control module fuses before replacing control module or any major components (blower, etc.). If one of these fuses is blown, it can prevent the control module or other components from operating.

PUMPS

BLOWER

IMG00260

4. Make sure all external limit controls are installed

and operating.

Check the following:

1. Wire connectors to control module are securely

plugged in at the module and originating control.

2. Gas pressures:

• Maximum: 14 inches w.c. (natural and LP) with no flow (lockup) or with boiler on

• Minimum: 4 inches w.c. (natural), 8 inches w.c. (LP) with gas flowing (verify during boiler startup)

5. The boiler is shipped with three (3) spare fuses in a plastic bag provided with the unit.

6. If necessary, replace open fuse (F3 is .80 amps, F2 is 3.15 amps, and F1 is 6.3 amps).

Note: Fuses F1, F2 and F3 are all slow blow fuses.

 WARNING

Do not jumper fuse or replace with any fuse except as specified. Failure to comply could result in severe personal injury, death, or substantial property damage.

7. Install control module cover and front door/cover after fuse inspection.

8. Restore power to the boiler at the external line switch and verify boiler operation (Section 10 - Start-up) after completing boiler service.

Page 77

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting (continued)

Checking temperature sensors

The boiler temperature sensors (inlet water, outlet water, system water, flue, and outdoor air) are all resistance type devices. The following tables show the correct values for the sensors at various temperatures. Use an ohmmeter to read the resistance of the sensor at a known temperature. If the resistance of the sensor does not closely match its corresponding table, replace the sensor

It is important to note that the flue and outlet water sensors have two temperature sensing devices in one housing. These devices are designated as S1a/S1b, outlet sensor and S3a/S3b, flue sensor. Please reference the wiring diagram in Section 14 of this manual for correct terminal location.

Table 13-1A - Inlet Water/System/DHW Sensor Resistance vs. Temperature

Temperature Resistance Temperature Resistance

50 18,780 158 1,990

68 12,263 176 1,458

86 8,194 194 1,084

104 5,592 212 817

122 3,893

140 2,760

Table 13-1C - Outlet Water Sensor Resistance vs. Temperature

S1a

(Wire Color - R/BK and Y)

Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance

50 19,553 158 2,004 50 40,030 158 3,478

68 12,690 176 1,464 68 25,030 176 2,492

86 8,406 194 1,084 86 16,090 194 1,816 104 5,715 212 816 104 10,610 212 1,344 122 3,958 122 7,166 140 2,786 140 4,943

Table 13-1B - Outdoor Air Sensor Resistance vs. Temperature

Temperature Resistance Temperature Resistance

-50 490,813 20 46,218

-40 336,606 30 34,558

-30 234,196 40 26,099

-20 165,180 50 19,900 10 118,018 60 15,311

0 85,362 70 11,883

10 62,465 80 9,299

S1b

(Wire Color - G and Y)

Table 13-1D - Flue Sensor Resistance vs. Temperature

S3a

(Wire Color - W/B and Y)

Temperature Resistance Temperature Resistance Temperature Resistance Temperature Resistance

50 40,030 158 3,478 50 258,500 158 16,870

68 25,030 176 2,492 68 125,500 176 12,000

86 16,090 194 1,816 86 80,220 194 8,674 104 10,610 212 1,344 104 52,590 212 6,369 122 7,166 122 35,270 140 4,943 140 24,160

(Wire Color - PR and Y)

S3b

Page 78

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting

Table 13-2 Troubleshooting Chart - Noisy System

FAULT CAUSE CORRECTIVE ACTION

Noisy

Operation

No Pump

Operation -

Boiler / DHW

Pump

Supply gas problem. Natural gas pressures should be between 4 inches w.c. and 14 inches w.c. LP gas pressures should be between 8 inches w.c. and 14 inches w.c.

Gas/air mixture problem.

Dirty/damaged burner. • Refer to page 72 in this manual for the burner removal

Low water flow through the heat exchanger. • Refer to Section 6A - Hydronic Piping for minimum

Air in the piping system. • Properly purge all air from the piping system.

Low system water pressure. • Verify system pressure is a minimum of 12 psi.

Blown fuse.

• Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.

• Refer to the Gas Valve Adjustment Procedure on page 87 of this manual for the proper gas valve setting. Verify that the vent/air intake lengths do not exceed the maximum listed in Section 3 - General Venting.

and inspection procedure. Clean or replace the burner door assembly as necessary.

flow rates. Verify that the boiler and system pump are running on a call for heat.

• Replace fuse F1 on the control board, see page 76 of this manual.

Note: Make sure pump amperage does not exceed

1.8 amps.

Relief Valve

Opening

Faulty pump.

Internal fault on control board.

-System pressure exceeds relief valve setting.

• Replace pump.

• Replace main control board.

• Lower the system pressure below the 30 psi rating of the supplied relief valve or replace the standard relief valve with a higher rated valve up to the maximum pressure of the heat exchanger.

• Improperly sized expansion tank.

Page 79

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting (continued)

Table 13-3 Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT DESCRIPTION CORRECTIVE ACTION

MEMORY

ERROR

FAN SPEED

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

Flow Switch/

LWCO

(will require a manual

reset once condition has

been corrected. Press

the RESET button on the

display to reset.)

The control module has detected parameter settings that are corrupted.

The actual fan RPM is outside of the tolerance of the fan speed RPM target.

Blown fuse.

The low water cutoff (LWCO) is not making.

Blown fuse.

• Replace control module.

• Vent/air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting for proper lengths.

• Check for obstruction or blockage in the vent/air intake pipes or at terminations.

• Check the wiring connections at the fan and at the main control board.

• Replace the fan.

• Replace the main control board.

• Replace fuse F2 on the control board, see page 76 of this manual.

• Check boiler pump operation on a call for heat.

• Check for closed valves or obstructions in the boiler piping.

• Verify system is full of water and all air has been purged from the system.

• Check for a loose or misplaced jumper if flow switch is not installed.

• Replace LWCO.

• Replace fuse F3 on the control board, see page 76 of this manual.

FLAME

SEQUENCE

(will require a manual

reset once the condition

has been corrected. Press

the RESET button on the

display to reset.)

The flame detector circuit is seeing a flame signal when the gas valve is OFF.

• Verify flame is not present. If present, turn off gas supply and replace gas valve.

• Check supply voltage for proper polarity.

• Check external wiring for voltage feedback.

• Check the flame rod and make sure it is clean.

• Check the internal wiring for bad connections.

• Replace main control board.

Page 80

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• Adjust the set point of the auto reset limit to a higher setting up to a maximum of 200°F. Reference Section 11 - Operating Information for adjusting procedures.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping for the proper piping methods for the Combi Boiler.

• Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.

• Replace the main control board if necessary.

• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.

• If operating on something other than an outlet sensor, check temperature setting of the main control board.

• If the optional manual reset high limit has tripped, check setting of the device.

• Check resistance of water sensors and compare to Table 13-1A on page 77 of this manual. Replace sensor if necessary.

• Check operation of diverter valve motor. Replace if necessary.

OUTLET ARHL

The outlet water temperature has exceeded the setting of the automatic reset high limit.

AIR PRESSURE

SWITCH

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

BLOCKED

DRAIN

AUX LIMIT

FAULT

Air pressure switch contacts are open.

Thermal fuse on heat exchanger has opened.

Aux limit device open.

• Check the wiring connections to switch. Wires should be connected to the common and normally closed terminals.

• Air intake lengths exceed the maximum allowed lengths. Refer to Section 3 - General Venting for proper lengths.

• Check for obstruction or blockage in the air intake pipes or at terminations.

• Check reference hoses connected to the air pressure switch for blockage or obstruction.

• Inspect the burner. Reference page 72 of this manual for removal and cleaning procedures. Replace if necessary.

• Inspect the heat exchanger. Reference page 73 of this manual for removal and cleaning procedures.

• Faulty air pressure switch. Replace switch.

• Check the wiring connections to the fuse on the heat exchanger.

• Check continuity across the thermal fuse. If open, replace heat exchanger.

• Check wiring to aux limit device.

• Check aux limit device.

Page 81

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting (continued)

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT DESCRIPTION CORRECTIVE ACTION

• Inspect spark electrode and associated wiring for damage and connection. Reference page 71 of this manual for removal and cleaning procedures. Replace if necessary.

• Check for proper electrical grounding of the unit.

FLAME FAIL:

RUNNING

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

FLAME FAIL:

IGNITION

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The unit has lost flame signal four (4) times during a call for heat.

The unit has failed to prove main burner ignition after several attempts.

• Check incoming supply gas pressure. Natural gas pressures should be between 4 - 14 inches w.c. and LP gas pressures should be between 8 - 14 inches w.c. Refer to Section 7 - Gas Connections for detailed information concerning the gas supply.

• Verify that the plastic hose from the gas valve to the air inlet is connected and is not damaged.

• Verify that the vent/air intake pipes are correctly installed and that there are no obstructions.

• Check for 24 vac to the gas valve at the 2-pin connection on the side of the main control board during the ignition attempt. If no voltage is present, replace the main control board.

• If 24 vac is present at the main control board, check the wiring between the main control board and the gas valve. Replace the wiring if necessary. Do not disconnect the wiring from the gas valve and attempt to measure voltage at that point. The main control board can detect if the gas valve is not connected and will display the Gas Valve or Gas Valve Fail fault.

• If 24 vac is present, check the outlet of the valve to ensure the valve is flowing gas. With a manometer connected to the outlet tap of the gas valve, when the unit is in the prepurge period, there should be a negative pressure present. When the valve is energized a change in pressure should occur. If the pressure change does not occur, the gas valve is not opening. Replace the gas valve.

• Inspect flame sensor and associated wiring. Reference page 71 of this manual for removal and cleaning procedures. Replace if necessary.

• Inspect and clean the heat exchanger as necessary. Reference page 73 of this manual for cleaning procedures.

• Inspect the burner. Reference page 72 of this manual for removal and cleaning procedures. Replace if necessary.

• Replace the main control board.

Page 82

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT DESCRIPTION CORRECTIVE ACTION

FLUE TEMP

LIMIT

FLUE TEMP

HIGH

OUTLET MRHL

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the

display to reset.)

OUTLET TEMP

HIGH

The stack temperature has exceeded the Flue Temp Limit set parameters.

The stack temperature has exceeded the set parameters for the boiler.

The outlet water temperature has exceeded the setting of the manual reset high limit.

Outlet water temperature has exceeded the maximum outlet water temperature.

• Inspect the heat exchanger. Reference page 71 of this manual for the procedure on how to clean the flue side of the heat exchanger.

• Inspect the flue sensor and associated wiring. Measure the resistance of the flue sensor and compare to Table 13-1D on page 77 of this manual. Replace the sensor if necessary.

• Verify that the vent/air intake pipes are properly installed and that there are no obstructions.

• Replace the main control board.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the boiler is piped properly into the heating system. Refer to Section 6A - Hydronic Piping for the proper piping methods for the Combi Boiler.

• Check 120 vac to boiler pump motor on a call for heat. If voltage is not present, check wiring back to the main control board.

• Replace the main control board if necessary.

• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.

• If operating on something other than an outlet sensor, check temperature setting of the main control board.

• Check resistance of water sensors and compare to Table 13-1A on page 77 of this manual. Replace sensor if necessary.

OUTLET TEMP

DIFF

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

FLUE SENSOR

FAULT

(will require a manual

reset once the condition

has been corrected.

Press the RESET button

on the display to reset.)

The temperature difference between the two (2) outlet sensors is too high.

One or both of the flue sensors is open or shorted.

• Check operation of diverter valve motor. Replace if necessary.

• Check wiring to sensor. Make sure wiring is connected and not damaged. Reconnect / repair wiring if necessary.

• Measure the resistance of the sensor and compare to the resistance in Table 13-1C on page 77 of this manual. Replace sensor if necessary.

• Replace control module.

• Inspect the flue sensor and associated wiring. Measure the resistance of the flue sensor and compare to Table 13-1D on page 77 of this manual. Replace the sensor if necessary.

• Replace the main control board.

Page 83

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting (continued)

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT DESCRIPTION CORRECTIVE ACTION

OUTLET SENSOR

FAULT

(will require a manual

reset once the condition

has been corrected.

Press the RESET

button on the display to

reset.)

INLET SENSOR

FAULT

(will require a manual

reset once the condition

has been corrected.

Press the RESET

button on the display to

reset.)

One or both of the outlet sensors has opened or shorted.

The inlet sensor is open.

• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.

• Measure the resistances of the sensors and compare the resistances to the tables on page 77. Replace if necessary.

• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.

SET POINT MET

ANTI-CYCLING

DELTA T HIGH

The temperature has reached the set point + 10°F.

The main control board has received a call for heat too quickly after the previous call for heat has ended.

The temperature rise across the heat exchanger has exceeded the set parameters for the boiler.

The fan speed is being limited due to the temperature rise across the heat exchanger exceeding 55°F.

• None

• The control board will release the call for heat after 60 seconds.

• The control board will release the call for heat if the outlet temperature drops 10°F.

• Verify that the system is full of water and that all air has been properly purged from the system.

• Verify that the boiler is piped properly into the heating system. Refer to Section 6 - Hydronic Piping for the proper piping methods for the Combi Boiler.

• Check for 120 vac to the boiler pump motor on a call for heat. If voltage is not present, check the wiring back to the main control board. Replace the main control board if necessary.

• If 120 vac is present on a call for heat and the boiler pump is not operating, replace the pump.

• Verify that the boiler pump is set to the proper speed or that the pump is the proper size. Reference Section 6 - Hydronic Piping for boiler pump specifications.

Page 84

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

ERROR CODE DESCRIPTION CORRECTIVE ACTION

• Check 120 vac supply to the transformer.

• Check wiring connections at the low voltage terminal strip.

• Check the wire size/length to remote devices.

• Replace the transformer.

• Check 24V.

LOW VOLTAGE

120 vac input to the main control board has dropped below 80 vac.

NO FLUE TEMP

CHANGE

COMBI SENSOR

FAULT

LOCKOUT INLET

SENSOR FAULT

The flue temperature did not change after the burner started firing.

DHW sensor is not connected (combi only).

The inlet sensor has been disconnected.

• Verify that the flue sensor is installed.

• Check the sensor and its associated wiring. Repair or replace the sensor or wiring if damaged.

• Check the DHW sensor and its associated wiring. Repair or replace as needed.

• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare the resistance to the tables on page 77 of this manual.

• Replace the sensor if necessary.

• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.

OUTDOOR

SENSOR MISSING

The inlet sensor has been shorted.

The outdoor sensor has opened or shorted.

• Measure the resistance of the sensors and compare the resistance to the tables on page 77 of this manual.

• Replace the sensor if necessary.

• Check the sensors and their associated wiring. Repair or replace the sensor or wiring if damaged.

• Measure the resistance of the sensors and compare the resistance to the tables on page 77 of this manual.

• Replace the sensor if necessary.

Page 85

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting (continued)

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT CAUSE CORRECTIVE ACTION

• Verify DHW flow is at least 0.4 gpm.

• Check wiring harness connections between the low voltage connection board connector CN4 and the flow switch sensor.

• Verify that voltage between wires CN4-8 (Blue) and CN4-3 (Red) is 9 - 10 Vdc. If no voltage, replace Low Voltage Connection Board.

• Replace flow switch sensor.

• Check wiring harness connections between the Low Voltage Connection Board and the main control board.

• Replace Low Voltage Connection Board.

• Replace Main Control Board.

No Hot Water

at Faucets

Flow switch is not triggering a DHW demand (red light on flow switch sensor does not turn on during a DHW draw).

Flow switch input not received by main control board (red light on flow switch sensor turns on during a DHW draw, but combi boiler does not start a DHW Call for Heat).

DHW Water

is not Hot

Enough

Diverter valve is not in DHW position (heated boiler water is being provided to the space heating system rather than to the combi plate heat exchanger.

DHW set point is too low.

Anti-scald mixing valve set point is too low.

DHW flow rate is too high (combi boiler is firing at 100% in DHW Mode, but DHW temperature on screen is lower than the DHW Setpt on the screen).

• Check wiring harness connections between the Low Voltage Connection Board (CN4) and the combi diverter valve motor.

• Check that diverter valve motor is operating.

• Verify that the voltage between wire CN4-2 (Black) and ground is 24 Vac during a DHW demand.

• Replace combi diverter valve motor, Low Voltage Connection Board, or wire harness.

• Set DHW Setpt to the appropriate temperature based on the anti-scald mixing valve set point.

• Verify the anti-scald mixing valve is set to the desired temperature.

• During maximum flow conditions at all fixtures, adjust the field supplied flow control valve at the outlet of the mixing valve (or combi DHW outlet) to reduce the hot water flow until the DHW temperature reaches the DHW set point.

Combi DHW sensor fault (display unit will show "Combi Sensor Fault").

• See Combi Sensor Fault.

Page 86

ProLine® XE

Combi Boiler

Installation & Service Manual

13 Troubleshooting

Table 13-3 (continued from previous page) Troubleshooting Chart - Fault Messages Displayed on Boiler Interface

FAULT CAUSE CORRECTIVE ACTION

• Wait until DHW demand has ended, then combi unit should provide heated water to the space heating system. The Combi Boiler does not provide heated water during a DHW demand.

• Check wiring harness connections between the Low Voltage Connection Board (CN4) and the combi diverter valve motor.

• Check that diverter valve motor is operating.

• Verify that the voltage between wire CN4-1 (Brown) and ground is 24 Vac during a space heating demand.

Combi Boiler

is Running

but Does

Not Supply

Heated Water

to Space

Heating

System

A DHW demand is present.

Diverter valve is not in DHW position (heated boiler water is being provided to the combi plate heat exchanger rather than to the space heating system).

Space

Heating

System Heat

Emitters Get

Hot During

a DHW

Draw and

the Combi Boiler does not Provide

Hot Enough

Domestic

Hot Water

Diverter valve not operating correctly.

• Replace combi diverter valve motor, Low Voltage Connection Board, or wire harness.

• Verify diverter valve motor operation. If combi diverter valve motor is operating correctly, replace the flow group on the combi water set.

• Verify wiring harness connections between the Low Voltage Connection Board, and the diverter valve motor, and between the main control board and the Low Voltage Connection Board.

• Verify that voltage between CN4-2 (Black) and ground is 24 Vac and that voltage between CN4-1 (Brown) and ground is 0 Vac. If voltages are incorrect, replace the Low Voltage Connection Board, wire harness, or main control board.

• If voltages are correct and diverter valve motor is not operating correctly, replace the combi diverter valve motor.

Page 87

13 Troubleshooting (continued)

ProLine® XE

Combi Boiler

Installation & Service Manual

Combustion Analysis Procedure

1. Turn the main power off to the boiler.

2. Hold the ► plus the▼ button for five (5) seconds to

enter Service Mode.

3. Once the boiler has modulated up to full fire, measure the combustion. Place the analyzer probe in the fitting on the flue adapter. The values should be in the range listed in Table 13-4. The CO levels should be less than 150 ppm for a properly installed unit.

If the combustion is not within the specified range,

reference Table 13-5 for possible causes and corrective actions.

Table 13-4 Flue Products

Natural Gas Propane

Goal

Range 8.5% - 10.5% 2.3% - 5.7% 10.0% - 11% 4.1% - 5.6%

Target 9.0% 4.9% 10.5% 4.9%

4. Once the combustion analysis is complete, test the safety shutoff device by turning the manual shutoff switch to the OFF position and ensuring that the boiler shuts down and registers an alarm. Turn the manual gas valve to the ON position and reset the control.

5. Turn the main power off to the boiler and replace the cap on the sample port.

6. Place the boiler back into normal operation.

 WARNING

You must replace the cap on the vent adapter to prevent flue gas spillage into the room. Failure to comply could result in severe personal injury, death, or substantial property damage.

Gas valve adjustment procedure

If adjustment of the gas valve is deemed necessary, use the following procedure:

CAUTION

Locate the throttle adjustment screw on the top of the gas valve, see FIG. 13-2. Using a 2.5 mm Allen wrench, turn the screw 1/8 turn counterclockwise to increase CO2 levels or 1/8 turn clockwise to decrease CO2 levels. After one adjustment on the valve, follow the Combustion Analysis to measure the combustion.

If combustion is still not within the specified range, repeat the procedure. This procedure SHOULD NOT be performed more than four (4) times. If after four (4) adjustments and the combustion is still not within the specified range, revisit the possible causes in Table 13-5 (this page) or replace the gas valve.

Figure 13-2 Gas Valve Adjustment

THROTTLE

ADJUSTMENT

SCREW

Under normal operating conditions this valve should not need adjusting.

DETAIL A

THROTTLE ADJUSTMENT SCREW

Table 13-5 Troubleshooting Chart - Combustion Levels

POSSIBLE CAUSE CORRECTIVE ACTION

Vent/Air Intake Length

or Obstruction

Gas Supply Pressure

Dirty/Damaged Burner

Gas Valve Adjustment

• Refer to Section 3 - General Venting for the proper venting and air intake methods for the Combi Boiler.

• Check for obstructions at the vent/air intake terminals.

• Refer to Section 7 - Gas Connections for the proper gas supply for the Combi Boiler.

• Refer to page 72 of this manual for burner removal.

• Replace burner if necessary.

• Refer to this page of the manual for the gas valve adjustment procedure.

DIR #2000534505 00

Page 88

14 Diagrams

Figure 14-1 Ladder Diagram (Standard)

120VAC NEUTRAL GROUND

120V SUPPLY "L"

INTEGRATED CONTROL

X1-6

X5-9

X4-3

CN3.2

DIV VALVE RELAY

DISPLAY

INLET

SENSOR S2

OPERATING

SENSOR S1a

HIGH LIMIT

SENSOR S1b

FLUE

SENSOR S3a

FLUE

SENSOR S3b

CN4-1

CN4-2

SUPPLY

-9V

SYSTEM PUMP

6.3A

3.15A

0.8A

120 VAC

24 VAC

RELAY

BOILER PUMP

RELAY

24VDC

SUPPLY

CONNECTION BOARD

FLOW SW ITCH

UNUSED

AUX SWITCH

HEAT/LOOP

DEMAND

COMBI

DIVERTER

VALVE

CN4-3

DHW FLOW

SWITCH

CN4-8

-T

CN4-4

X5-6

X5-4

X5-12

X5-5

X5-13

X5-14

X1-2

X1-4

X1-1

X5-1

VALVE RELAY

X1-8

DIV

JUNCTION BOX

BLOWER

X1-5

CN6-1

CN4-7

INTEGRATED

CONTROL

ProLine® XE

Combi Boiler

SYSTEM PUMP "L"

LWCO

24 VAC

AIR HANDLER

ENABLE

120V SUPPLY "N"

SYSTEM

PUMP

BOILER

PUMP

SPARK ROD

Installation & Service Manual

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

INTEGRATED

CONTROL

CN3-5 X4-8

4-6NC3-6NC

CN3-8

CN6-2

DIV VALVE RELAY

COIL

AIR PRESSURE

SWITCH

GASVALVE

BLOWER

X4-12

CN3-7 X4-10

CN3-3 X4-4

CN3-1 X4-1

CN3-6 X4-9

CN3-4 X4-5

X5-2

X5-10

X5-11

X2-2

X2-1

X5-7

X5-16

X5-8

X5-15

TR2

GAS VALVE

RELAYS

HIGH VOLTAGE SPARK LEADCAUTION

CONNECTION BOARD

SHIELD

CASCADE

SHIELD

UNUSED

OUTDOOR

SENSOR

SYSTEM

SENSOR

COMBI DHW

SENSOR

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requirements per either N.E.C. in USA or C.S.A. in Canada.

2. If any original equipment wire as supplied with wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchased from the factory. Use of a non-approved spark lead or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components block locations when using diagrams to troubleshoot unit.

CN5

2 3 4 5 6

7 8 9

CN4-5

CN4-6

CN5

the appliance must be replaced, it must be replaced

LOW VOLTAGE

120 VAC

HIGH VOLTAGE

with wir e having same

for proper connector

LABEL,LADDER,COMBI

100274889 REV B

Page 89

14 Diagrams (continued)

Figure 14-2 Wiring Diagram (Standard)

DISPLAY

ProLine® XE

Combi Boiler

Installation & Service Manual

LOW VOLTAGE 120 VAC

HIGH VOLTAGE

CASCADE

SHIELD

SYSTEM SENSOR

OUTDOOR

SENSOR

SHIELD

WATER

CUT OFF

LOW

24 VAC

COM

CONNECTION BOARD

CN1

1 2 3 4 5 6 7 8 9

CN6-1 CN6-2 CN6-3 CN6-4

INTEGRATED

CONTROL

X1-3

X-7

X1-2

CN5

X1-6

X1-5

X1-8

X1-4

X1-1

1 2G3

JUNCTION

BOX

TRANSFORMER

BOX DEPICTS OPTONAL ITEMS

SYSTEM PUMP

120V

GND

SUPPLY

BOILER

PUMP

BLOWER

1 2 3 4 5

CN4-5

SENSOR

CN3

CN3-8 CN3-7 CN3-6 CN3-5 CN3-4 CN3-3 CN3-2 CN3-1

FLOW

SWITCH

CIRCUIT

CN4-8

CN4-3

CN4-4

CN4-6

DHW FLOW

SWITCH

X4-12

X4-10

X4-9

X4-8

X4-5

X4-4

X4-3

X4-1

X5-7

X5-16

X5-8

X5-15

X5-9

X5-1

X5-2

X5-10

X5-11

O/BK

R/BK

X5-4

X5-12

X5-6

P/BK

X5-5

W/BK

X5-13

X5-14

X2-2

X2-1

X1-7

W/R

TR2

BOX DEPICTS

OPTIONAL ITEMS

BOX DEPICTS

DUAL SENSOR

SINGLE HOUSING

ements per either N.E.C. in USA or C.S.A. in Canada

AIR PRESSURE SWITCH

-T

OPERATING SENSOR S1a

-T

HIGH LIMIT SENSOR S1b

-T

INLET SENSOR S2

-T

FLUE SENSOR S3a

-T

FLUE SENSOR S3b

GAS VALVE @24VAC

FLAME SENSOR SPARK

ROD

HIGH VOLTAGE SPARK LEADCAUTION

d from the factory. Use of a non-approved spar k le

FLOW

SWITCH

AUX LIM

HEAT/LOOP

DEMAND

AIR HANDLER

CONTACTS

COMBI DIVERTER

VALVE

Notes:

1. All wiring must be installed in accordance with: local, state, provincial and national code requir

2. If any original equipment wire as supplied with the appliance must be replaced, it must be replaced with wire having same wire gauge (AWG) and rated for a minimum of 105°C. Exceptions: Replacement high voltage spark lead and ribbon cables must be purchase or ribbon cables can lead to operational problems which could result in non-repairable damage to the integrated controller or other components.

3. Actual connector block locations may vary from those shown on diagrams. Refer to actual components for proper connector block locations when u sing diagrams to troubleshoot unit.

CN2

11 12 13 14 15 16 17 18 19 20

COM

CN4-1

CN4-2

CN4-7

COMBI DHW

LABEL,WIRING,COMBI

100273313 REV B

Page 90

Notes

ProLine® XE

Combi Boiler

Installation & Service Manual

Page 91

Notes

ProLine® XE

Combi Boiler

Installation & Service Manual

Page 92

Revision A (PCP #3000022264 / CN #500012232) initial release. Revision B (PCP #3000020794 / CN# 500011202) reflects changes made to

Table 2A on page 12.

MM #100298550_DIR #2000552608_Rev B

02/18

A.O. Smith ACB-110S-N, ACB-150S-N, ACB-199S-N Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual