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

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.

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.

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.

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.

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

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

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.

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.

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.

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.

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.

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

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

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

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

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.

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"

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

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

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.

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

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)

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

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.

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.

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

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.

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.

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