Crown Boiler Phantom-X PHNTM210, Phantom-X PHNTM285 Installation And Operating Instructions Manual

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Page 1

Series

High Efciency Gas-Fired Hot Water Direct Vent Condensing Boilers

INSTALLATION AND OPERATING INSTRUCTIONS

These instructions must be afxed on or adjacent to the boiler and retained for future reference.

9700609

Models:

• PHNTM210

• PHNTM285

This manual is for use with boilers having a part number ending in “B” (example: PHNTM285HNT1SUB).

Manufacturer of Hydronic Heating Products

105357-05 -7/15

WARNING: Improper installation, adjustment, alteration,

service or maintenance can cause property damage, injury, or loss of life. For assistance or additional information,

consult a qualied installer, service agency or the gas supplier. This boiler requires a special venting system. Read these instructions carefully before installing.

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.crownboiler.com

Page 2

IMPORTANT INFORMATION - READ CAREFULLY

NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the

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

All wiring on boilers installed in the USA shall be made in accordance with the National Electrical Code and/or local regulations.

All wiring on boilers installed in Canada shall be made in accordance with the Canadian Electrical Code and/or local regulations.

The City of New York requires a Licensed Master Plumber supervise the installation of this product.

The Massachusetts Board of Plumbers and Gas Fitters has approved the Phantom Series boiler. See the Massachusetts Board of Plumbers and Gas Fitters website, http://license.reg.state.ma.us/pubLic/pl_products/pb_pre_form.asp for the latest Approval Code or ask your local Sales Representative.

The Commonwealth of Massachusetts requires this product to be installed by a Licensed Plumber or Gas Fitter.

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

DANGER

Indicates an imminently hazardous situation which, if not avoided, will result in death, serious injury or substantial property damage.

Indicates a potentially hazardous situation which, if not avoided, may result in moderate or minor injury or property damage.

CAUTION

NOTICE

WARNING

Indicates a potentially hazardous situation which, if not avoided, could result in death, serious injury or substantial property damage.

Indicates special instructions on installation, operation, or maintenance which are important but not related to personal injury hazards.

DANGER

DO NOT store or use gasoline or other ammable vapors or liquids in the vicinity of this or any other appliance.

If you smell gas vapors, NO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in the building. Immediately, call the gas supplier from a remotely located phone. Follow the gas supplier’s instructions or if the supplier is unavailable, contact the re department.

Page 3

Special Installation Requirements for Massachusetts

A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or

in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the

following requirements shall be satised:

1. If there is no carbon monoxide detector with an alarm already installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code in the residential unit served by the sidewall horizontally vented gas fueled equipment, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

2. In addition to the above requirements, if there is not one already present, a carbon monoxide detector with an alarm and a battery back-up shall be installed and located in accordance with the installation requirements supplied with the

detector on the oor level where the gas equipment is installed. The carbon monoxide detector with an alarm shall

comply with 527 CMR, ANSI/UL 2034 Standards or CSA 6.19 and the most current edition of NFPA 720. In the event that the requirements of this subdivision can not be met at the time of the completion of the installation of the equipment, the installer shall have a period of thirty (30) days to comply with this requirement; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code. In the event that the sidewall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the carbon monoxide detector

may be installed on the next adjacent habitable oor level. Such detector may be a battery operated carbon monoxide

detector with an alarm and shall be installed in compliance with the most current edition of NFPA 720, NFPA 70 and the Massachusetts State Building Code.

3. A metal or plastic identication plate shall be permanently mounted to the exterior of the building at a minimum height

of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fueled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. A nal inspection by the state or local gas inspector of the sidewall horizontally vented equipment shall not be performed

until proof is provided that the state or local electrical inspector having jurisdiction has granted a permit for installation of carbon monoxide detectors and alarms as required above.

B. EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current edition of NFPA 54 as adopted by the Board; and

2. Product Approved sidewall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

C. When the manufacturer of Product Approved sidewall horizontally vented gas equipment provides a venting system design

or venting system components with the equipment, the instructions for installation of the equipment and the venting system shall include:

1. A complete parts list for the venting system design or venting system; and

2. Detailed instructions for the installation of the venting system design or the venting system components.

D. When the manufacturer of a Product Approved sidewall horizontally vented gas fueled equipment does not provide the parts

for venting ue gases, but identies “special venting systems”, the following shall be satised:

1. The referenced “special venting system” instructions shall be included with the appliance or equipment installation instructions; and

2. The “special venting systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

E. A copy of all installation instructions for all Product Approved sidewall horizontally vented gas fueled equipment, all venting

instructions, all parts lists for venting instructions, and/or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

Page 4

TABLE OF CONTENTS

I. Product Description, Specications and Dimensional Data...................... 5

II. Unpacking Boiler........................................................................................ 8

III. Pre-Installation and Boiler Mounting ........................................................ 9

IV. Venting...................................................................................................... 14

A. General Guidelines............................................................................... 14

B. CPVC/PVC Venting.............................................................................. 19

C. Polypropylene Venting......................................................................... 25

D. Stainless Steel Venting........................................................................ 28

E. Removing the Existing Boiler............................................................... 31

F. Multiple Boiler Installation Venting....................................................... 32

V. Condensate Disposal................................................................................. 34

VI. Water Piping and Trim............................................................................... 36

VII. Gas Piping ............................................................................................... 46

VIII. Electrical ................................................................................................... 50

IX. System Start-up ....................................................................................... 62

X. Operation...................................................................................................... 70

A. Overview............................................................................................... 70

B. Supply Water Temperature Regulation................................................ 71

C. Boiler Protection Features.................................................................... 72

D. Multiple Boiler Control Sequencer........................................................ 73

E. Boiler Sequence of Operation.............................................................. 74

1. Normal Operation........................................................................... 74

2. Using The Display.......................................................................... 75

F. Viewing Boiler Status............................................................................ 76

1. Status Screens.............................................................................. 76

2. Detail Screens............................................................................... 78

3. Multiple Boiler Sequencer Screens................................................ 79

G. Changing Adjustable Parameters........................................................ 80

1. Entering Adjust Mode.................................................................... 80

2. Adjusting Parameters..................................................................... 80

XI. Service and Maintenance ........................................................................ 98

XII. Troubleshooting........................................................................................ 104

XIII. Repair Parts ............................................................................................. 109

Page 5

I. Product Description, Specications and Dimensional Data

Phantom Series boilers are condensing high efciency gas-red direct vent hot water heating boilers designed

for use in forced hot water space heating systems requiring supply water temperatures of 190°F or less. These boilers have special coil type stainless steel heat exchangers, constructed, tested and stamped per Section IV ‘Rules for Construction of Heating Boilers’ of ASME Boiler and

Table 1A: Specications

Specication

Altitude (ft. above sea level) - USA 0-10000* 0-10000*

Altitude (ft. above sea level) - Canada 0-4500* 0-4500*

Fuel Shipped for Natural Gas, Field Converted for LP Gas*

Max. Setpoint Water Temperature (°F) 190

Max. Allowable Working Pressure (psi) 160

Factory supplied Safety Relief Valve (psi) * 30

Boiler Water Volume (gal.) 1.7

Heat Transfer area (sq. ft.) 21.8

Approx. Shipping weight (lb.) 206

Pressure Vessel Code, which provide a maximum heat

transfer and simultaneous protection against ue gas product

corrosion. These boilers are not designed for use in gravity hot water space heating systems or systems containing

signicant amount of dissolved oxygen (swimming pool

water heating, direct domestic hot water heating, etc.).

This manual is for use with boilers having a part number ending in “B” (example: PHNTM285HNT1SUB).

Boiler Model

PHNTM210 PHNTM285

* Special congurations required above 2000ft. Boilers not suitable for LP gas above 7000ft.

Table 1B: Dimensional Data (See Figures 1A and 1B)

Dimension

A - Inch (mm) 23-15/16 (608) 21-13/16 (554)

B - Inch (mm) 5-13/16 (147) 7-5/16 (185)

C - Inch (mm) 7-5/16 (186) 14-1/8 (358)

D - Inch (mm) 17-1/8 (435) 18 (456)

E - Inch (mm) 5-15/16 (151) 12-1/4 (312)

Gas Inlet F (FPT) 1/2” 3/4”

Return G (FPT) 1” 1-1/4” Supply H (FPT) 1” 1-1/4”

Condensate Drain J *

Boiler Two-Pipe CPVC/PVC Vent Connector

(Figs. 1A, 1B) - Inch

* Factory Provided Socket End Compression Pipe Joining Clamp

PHNTM210 PHNTM285

for 3/4” Schedule 40 PVC Pipe

3 x 4 4 x 4

Boiler Model

Page 6

(24 VOLTS)

LOW VOLTAGE

KNOCKOUTS

'F' GAS VALVE INLET

TAPPING

" FPT RELIEF/DRAIN

'H' SUPPLY TAPPING

TRAP DRAIN

'J' CONDENSATE

Figure 1A: Model PHNTM210

(115 VOLTS)

KNOCKOUTS

LINE VOLTAGE

I. Product Description, Specications and Dimensional Data (continued)

3X4 PVC/CPVC

VENT ADAPTER

'G' RETURN TAPPING

Page 7

I. Product Description, Specications and Dimensional Data (continued)

Figure 1B: Model PHNTM285

Page 8

I. Product Description, Specications and Dimensional Data (continued)

Table 2: Ratings

Phantom Series Gas-Fired Boilers

Model Number

PHNTM210 42 210 194 169 95.0

PHNTM285 57 285 262 228 95.0

Ratings shown are for installations at sea level and elevations up to 2000 ft. For elevations above 2000 ft., the boiler will naturally derate by 2.5% for each 1000 ft. above sea level. Boilers not suitable for use with LP gas above 7000ft.

Net AHRI Water Ratings based on piping and pickup allowance of 1.15. The manufacturer should be consulted before selecting a boiler for installations having unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

Input (MBH)

Min. Max.

Output

(MBH)

Net AHRI Ratings Water

(MBH)

AFUE

(%)

II. Unpacking Boiler

CAUTION

Do not drop boiler.

A. Move boiler to approximate installed position.

B. Remove all crate fasteners.

C. Lift and remove outside container.

D. Remove boiler from cardboard positioning sleeve on

shipping skid.

WARNING

Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency.

E. Move boiler to its permanent location.

Page 9

III. Pre-Installation and Boiler Mounting

WARNING

Explosion Hazard. Asphyxiation Hazard. Electrical Shock Hazard. Installation of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency. Follow these instructions exactly. Improper installation, adjustment, service, or maintenance can cause property damage, personal injury or loss of life.

NOTICE

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

service clearance is 24 in. (610 mm) from left side, front, top and rear of the boiler. Recommended front clearance may be reduced to the combustible material clearance providing:

1. Access to boiler front is provided through a door

or removable front access panel.

2. Access is provided to the condensate trap

located underneath the heat exchanger.

3. Access is provided to thermal link located at

boiler rear.

D. Protect gas ignition system components

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

E. Provide combustion and ventilation air in

accordance with applicable provisions of local building codes, or: USA - National Fuel Gas Code, ANSI Z223.1/NFPA 54, Air for Combustion and Ventilation;

Canada - Natural Gas and Propane Installation Code,

CAN/CSA-B149.1, Venting Systems and Air Supply for Appliances.

WARNING

Asphyxiation Hazard. Models with Two-Pipe Vent Connector: Apply supplied dielectric grease to gasket inside

vent section of two-pipe vent connector. Failure to apply the grease could result in ue gas leaks from gasket rupture during vent pipe installation or gasket deterioration due to condensate exposure.

A. Installation must conform to the requirements

of the authority having jurisdiction in or, in the absence of such requirements, to the National Fuel Gas Code, ANSI Z223.1/NFPA 54, and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

Where required by the authority having jurisdiction, the

installation must conform to the Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/ASME CSD1.

B. Boiler is certied for installation on

combustible ooring. Do not install boiler on

carpeting.

C. Provide clearance between boiler jacket and

combustible material in accordance with local re

ordinance. Refer to Figure 2 for minimum listed clearances from combustible material. Recommended

WARNING

Asphyxiation Hazard. Adequate combustion and ventilation air must be provided to assure proper combustion. Install combustion air intake per Section IV “Venting”.

F. The boiler should be located so as to minimize

the length of the vent system. The combustion air piping must terminate where outdoor air is available for combustion and away from areas that may contaminate combustion air. In particular, avoid areas near chemical

products containing chlorines, chlorouorocarbons,

paint removers, cleaning solvents and detergents.

Avoid areas containing saw dust, loose insulation bers,

dry wall dust etc.

NOTICE

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

Page 10

III. Pre-Installation and Boiler Mounting (continued)

G. General

1. Phantom boilers are intended for installations in an area with a oor drain or in

a suitable drain pan to prevent any leaks or relief valve discharge to cause property damage.

2. Phantom boilers are not intended to support

external piping and venting. All external piping and venting must be supported independently of the boiler.

3. Phantom boilers must be installed level to

prevent condensate from backing up inside the boiler.

4. Boiler Floor Standing Installation:

a. For basement installation provide a solid base

such as concrete, where oor is not level or water may be encountered on the oor around boiler.

Floor must be able to support weight of boiler,

water and all additional system components.

b. Boiler must be level to prevent condensate from

backing up inside the boiler.

c. Provide adequate space for condensate piping or

a condensate pump if required.

Boiler Clearances to Combustible (and NonCombustible) Material:

All models are listed for closet installation with the

following minimum clearances – Top = 1 in. (25 mm), Front = 1 in. (25 mm), Left Side = 10 in. (250 mm), Right Side = 2 in. (50 mm), Rear = *6 in. (150 mm)

* Note:

When boiler is vented vertically, the minimum

clearance from the rear of the jacket is increased to 18 in. (460 mm) with a short radius 90° elbow in order to provide adequate space at boiler rear for installation of vent and air intake piping and service access.

Boiler Service Clearances – Applicable to all Boiler Models:

Top = 24 in. (610 mm), Front = 24 in. (610 mm), Left

Side = 24 in. (610 mm), Right Side = 24 in. (610 mm), Rear = 24 in. (610 mm)

The above clearances are recommended for service

access but may be reduced to the Combustible Material Clearances provided:

a. The boiler front is accessible through a door.

b. Access is provided to the condensate trap located

on the left side of boiler.

c. Access is provided to thermal link located at the

boiler rear (PHNTM285 only).

Page 11

III. Pre-Installation and Boiler Mounting (continued)

Listed Direct Vent System

Factory Standard

Two-Pipe CPVC/PVC Vent and PVC Combustion

Air Intake

Available Optional

Two-Pipe Rigid Polypropylene Vent (or, Flexible Polypropylene Liner for Vertical Venting only) and Rigid Polypropylene or PVC Combustion Air Intake

Available Optional

Two-Pipe Stainless Steel Vent and Galvanized Steel

or PVC Combustion Air Intake

Vent Pipe Material

* CPVC/PVC

Pipe Rigid Polypropylene

Vent (or, Flexible

Polypropylene Liner for

Vertical Venting only)

Stainless Steel

Vent Pipe Direction

Vertical or Horizontal

Enclosure

Unenclosed

at all Sides

Vent Pipe

Nominal Diameter

3 in. (80 mm)

4 in.( 100 mm)

3 in. (80 mm)

or (110 mm)

4 in. (100 mm)

or (110 mm)

3 in. (80 mm)

4 in.( 100 mm)

Minimum Clearance to Combustible

Material

1 in. (25 mm)

Figure 2: Clearances To Combustible and Non-combustible Material, Floor Standing

Page 12

III. Pre-Installation and Boiler Mounting (continued)

H. Boiler Stacking

1. For installations with unusually high space

heating and/or domestic hot water heating loads,

where employing two (2) Phantom boilers will offer

the benets of greater operational efciency, oor

space savings and boiler redundancy, the Phantom boilers may be installed stacked one on the top of the other. Refer to Table 3 “Phantom Boiler Model Stacking Combinations” for details.

Table 3: Phantom Boiler Model Stacking Combinations

Bottom

Boiler Model

PHNTM210 PHNTM210 PHNTM285 PHNTM285

2. To eld assemble individual Phantom boilers into a stackable conguration, use the steps

below:

a. Position the bottom boiler rst. Refer to Sections

II “Unpacking Boiler” and III “Pre-Installation & Boiler Mounting” of the manual for details.

Always position higher input boiler model as

bottom boiler.

b. Each Phantom boiler is factory packaged with

two (2) Stacking Boiler Attachment Brackets (P/N 101679-01) and the bracket mounting hardware [six (6) self-drilling hex washer head plated #8 x ½” long screws]. Locate and remove the brackets and the hardware. The Stacking Boiler Attachments Bracket has three 7/32” diameter holes punched in a triangular pattern. See Figure 3 “Stacking Boiler Attachment Bracket Placement”.

c. Phantom boiler left and right side panels have a

series of dimples at panel top and bottom. These dimples are positioning dimples for Stacking Boiler Attachment Bracket mounting screws. Side panel bottom positioning dimples are evenly spaced from boiler front and back, while side

panel top positioning dimples follow specic

pattern to compensate for Phantom boiler model variable depth.

d. Position the upper boiler on the top of the bottom

boiler and align boiler front doors and sides ush

with each other.

• Place rst Stacking Boiler Attachment

Bracket onto the upper boiler left side panel, at the panel lower left corner and align bracket two upper holes with corresponding side panel lower dimples.

Top Boiler Model

• The remaining lower bracket hole must align with a matching bottom boiler left side panel top positioning dimple.

• Once bracket holes and side panel dimple

alignment is veried, attach the bracket to

top and bottom boiler left side panels with the mounting screws.

e. Repeat above procedure to install second

Stacking Boiler Attachment Bracket and secure the stacked boiler right side panels together at the front right corner.

f. Install the third Stacking Boiler Attachment

Bracket to secure top and bottom boiler left side panels at the rear left corner. Align the bracket holes with corresponding positioning dimples in the top boiler and bottom boiler left side panels, then secure bracket with the screws.

g. Repeat above procedure to install the forth

Stacking Boiler Attachment Bracket to secure stacked boiler right side panels at the rear right corner.

3. When installing stackable boiler combinations observe the following

guidelines:

a. Venting - Top and bottom boilers must have their

individual vent piping and vent terminals.

WARNING

Asphyxiation Hazard. No common manifold venting is permitted. Each boiler must have its own individual vent and combustion air pipes and terminals.

For side-wall venting individual model vent

terminals must terminate not closer than 12 inches horizontally and three (3) feet vertically from each other in order to prevent combustion air contamination. For vertical through the roof venting, individual vertical vent terminals, if level with each other, must be spaced no closer than 12 inches horizontally. If vertical terminals cannot end in one plane, they must be spaced no closer than three (3) feet horizontally.

Follow instructions in Section IV “Venting”

of the manual for specics of individual boiler

vent termination. Follow instructions in Section V “Condensate Disposal” for each individual

boiler ue gas condensate line construction and

condensate disposal. Terminating individual boiler condensate lines into common pipe prior

Page 13

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

to drain disposal is permissible, providing

common pipe has sufcient ow capacity

to handle combined condensate volume of stackable combination.

b. Gas Piping - Follow instructions in Section

VII “Gas Piping” of the manual for sizing and installation of an individual boiler. When common gas piping is sized, insure it will have

adequate capacity for combined input (CFH gas ow) of the selected stackable boiler

combination.

c. Water Piping and Trim - Follow instructions

in Section VI “Water Piping and Trim” of the manual for system piping and boiler secondary

piping selection/sizing based on combined

heating capacity and/or gross output of the selected stackable boiler combination.

Follow instructions of Section VI “Water Piping and Trim” for each individual boiler trim installation.

d. Electrical - Follow instructions in Section VIII

“Electrical” of the manual to wire individual boilers.

Figure 3: Stacking Boiler Attachment Bracket Placement

Page 14

IV. Venting

WARNING

Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death.

Do not use a barometric damper, draft hood or vent damper with this boiler. Do not locate vent termination under a deck. Do not locate vent termination where exposed to prevailing winds. Do not locate combustion air termination where chlorines, chlorouorocarbons (CFC’s), petroleum

distillates, detergents, volatile vapors or other chemicals are present. Severe boiler corrosion and failure will result.

Use outdoor air for combustion. Do not obtain combustion air from within the building. Use specied vent and combustion air pipe diameters. Do not reduce specied diameters of vent and

combustion air piping. Do not interchange vent systems or materials unless otherwise specied. Do not apply thermal insulation to vent pipe or ttings. Moisture and ice may form on surface around vent termination. To prevent deterioration, surface must

be in good repair (sealed, painted, etc.). Do not allow low spots in the vent where condensate may pool. The CPVC vent materials supplied with this boiler do not comply with Natural Gas and Propane

Installation Code, CAN/CSA B149.1.S1-07 and are not approved for use in Canadian jurisdictions that require vent systems be listed to ULC S636-2008. In these jurisdictions, vent this boiler using either stainless steel Special Gas vent or a listed ULC S636 Class IIB venting system.

A. General Guidelines

1. Listed Vent/Combustion Air Systems

a. Install vent system in accordance with National

Fuel Gas Code, ANSI Z223.1/NFPA 54 or Natural Gas and Propane Installation Code,

CAN/CSA B149.1 Installation Code for Canada, or, applicable provisions of local building codes.

Contact local building or re ofcials about

restrictions and installation inspection in your area.

b. The Phantom is a Direct Vent (sealed

combustion) boiler. Combustion air must be supplied directly to the burner enclosure from

outdoors and ue gases must be vented directly

outdoors.

c. The following combustion air/vent system

options are listed for use with the Phantom boilers (refer to Table 4):

i. Two-Pipe CPVC/PVC Vent/Combustion

Air System - Separate CPVC/PVC pipe serves to expel products of combustion and separate PVC pipe delivers fresh outdoor

combustion air. Refer to Part B for specic

details.

ii. Two-Pipe Polypropylene Vent/Combustion

Air System - Separate rigid or exible

polypropylene pipe serves to expel

products of combustion and separate rigid polypropylene or PVC pipe delivers fresh outdoor combustion air. Refer to Part C for

specic details.

iii. Two-Pipe Stainless Steel Vent/Combustion

Air System - Separate stainless steel pipe serves to expel products of combustion and separate PVC or galvanized steel pipe delivers fresh outdoor combustion air. Refer

to Part D for specic details.

2. Vent/Combustion Air Piping

a. Do not exceed maximum vent/combustion air

lengths listed in Table 5. Vent/combustion air length restrictions are based on equivalent length of vent/combustion air pipe (total length of

straight pipe plus equivalent length of ttings). Table 6A lists equivalent lengths for ttings.

Do not include vent/combustion air terminals in equivalent feet calculations. Use vent/ combustion air equivalent length worksheet provided in Table 6B.

b. Maintain minimum clearance to combustible

materials. See Figure 2 for details.

c. Enclose vent passing through occupied or

unoccupied spaces above boiler with material

having a re resistance rating at least equal to the rating of adjoining oor or ceiling.

Page 15

IV. Venting A. General Guidelines (continued)

Table 4: Vent/Combustion Air System Options

Approved Direct

Vent System

Factory Standard

Two-Pipe,

CPVC/PVC Vent and

PVC Air Intake

Available Optional

Two-Pipe, Rigid

Polypropylene Vent (or Flexible Polypropylene

Liner for Vertical

venting only) and Rigid

Polypropylene or PVC

Pipe Air Intake

Vent

Material

CPVC/PVC

Rigid

Polypropylene

(or Flexible

Polypropylene

Liner for vertical

Venting only)

Orientation Termination Description Figures

Standard

(through sidewall)

Horizontal

Optional

Snorkel

(through sidewall)

Optional

Vertical

Horizontal

Optional

Vertical

(through roof)

Standard

(through sidewall)

Optional Snorkel

(through sidewall)

Vertical

(through roof or chimney/chase)

The system includes separate CPVC vent

pipe and PVC air intake pipe terminating

through sidewall with individual penetrations for the vent and air intake piping and separate terminals (tees).

Same as above but separate snorkel type

terminals.

The system includes separate CPVC vent

pipe and PVC air intake pipe terminating

through roof with individual penetrations for the vent and air intake piping and separate

vertical terminals.

The system includes separate Rigid

Polypropylene vent pipe and Rigid Polypropylene or PVC air intake pipe

terminating through sidewall with individual penetrations for the vent and air intake piping and separate terminals (tees).

Same as above but separate snorkel type

terminals.

The system includes separate Flexible

Polypropylene vent liner and Rigid

Polypropylene vent pipe combination for

venting and Rigid Polypropylene or PVC

air intake pipe terminating through roof with individual penetrations for the vent and air

intake and separate terminals.

4, 5, 6A, 6B,

9 through 13

4, 6A, 6B

9 through 13

7 through 11

4, 5, 6A, 6B

9, 12, 14

4, 6A, 6B

9, 12, 14

7 through 9

14, 15

Compo-

nent

Table

10A, 10B

Part

The system includes separate stainless

steel vent pipe and PVC/galvanized steel

air intake pipe terminating through sidewall with individual penetrations for the vent and

air intake piping and separate terminals.

Same as above but separate snorkel type

terminals.

The system includes separate Flexible

stainless steel vent liner and Rigid stainless steel vent pipe and PVC/galvanized steel

air intake pipe terminating through roof with individual penetrations for the vent and air

intake piping and separate terminals.

Available Optional

Two-Pipe,

Stainless Steel Vent and

PVC/Galvanized Steel

Air Intake

Stainless Steel

Horizontal

Optional

Vertical

Standard

(through sidewall)

Optional Snorkel

(through sidewall)

Vertical

(through roof or chimney/chase)

Table 5: Vent/Combustion Air Pipe Length – Two-Pipe Direct Vent System Options

• CPVC/PVC

• Polypropylene (PP) or Polypropylene (PP)/PVC

• Stainless Steel/PVC or Galvanized Steel

Combustion Air Vent

Boiler Model

PHNTM210

PHNTM285

Nominal

Pipe

Diameter

4 in.

(100 mm or 110 mm)

Minimum

Equivalent

Length

2.5 ft.

(760 mm)

Maximum

Equivalent

Length

135 ft.

(41.1)

100 ft.

(30.5 m)

Nominal

Pipe

Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

4, 5, 6A, 6B

9, 12, 16

4, 6A, 6B

9, 12, 16

7 through 9

17, 17A

Minimum

Equivalent

Length

2.5 ft.

(760 mm)

11A, 11B D.

Maximum

Equivalent

Length

135 ft.

(41.1)

100 ft.

(30.5 m)

Page 16

IV. Venting A. General Guidelines (continued)

Figure 4: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air Inlets - Two-Pipe System Vent Terminal (Shown) Two-Pipe System Air Intake Terminal (Not Shown)

Table 6A: Vent System and Combustion Air System Components Equivalent Length vs. Component Nominal Diameter

Vent or Combustion Air System

Component Description

Component Nominal Diameter 3 in. (80 mm) 4 in. (100 mm or 110 mm)

90° Elbow (Short Radius) 10 ft. (3.0 m) 13 ft. (4.0 m)

45° Elbow (Short Radius) 3.0 ft. (0.9 m) 4.5 ft. (1.4 m)

Note: For one or two family dwellings, re

resistance rating requirement may not need to be met, but is recommended.

d. Slope horizontal vent pipe minimum 1/4 in/ft (21 mm/m) downward towards the boiler.

Les chaudières de catégories I, II et IV doivent

présenter des tronçons horizontaux dont la pente montante est d’au moins 1/4 po par pied (21 mm/m) entre la chaudière et l’évent.

e. If possible, slope horizontal combustion air

pipe minimum 1/4 in/ft (21 mm/m) downward towards terminal. If not, slope towards boiler.

f. Use noncombustible ¾ in. pipe strap to support

horizontal runs and maintain vent location and slope while preventing sags in pipe. Do not restrict thermal expansion or movement of vent system. Maximum support spacing 4 ft. (1.2 m). Avoid low spots where condensate may pool.

Equivalent Length for Vent or Combustion Air System Component

vs. Component Nominal Diameter

Les instructions d´installation du système

d´évacuation doivent préciser que les sections horizontales doivent être supportées pour

prévenir le échissement. Les méthodes et les intervalles de support doivent être spéciés.

Les instructions divent aussi indiquer les renseignements suivants:

les chaudières de catégories II et IV doivent être

installées de façon à empêcher l´accumulation de condensat: et

si nécessaire, les chaudières de catégories II et IV

doivent être pourvues de dispositifs d´évacuation du condensat.

g. For multiple boiler installations with vertical

roof terminals, separate vent pipes from multiple boilers may be piped through a common conduit or chase so that one roof penetration may be made.

Do not penetrate any part of the vent system with fasteners.

Page 17

IV. Venting A. General Guidelines (continued)

Table 6B: Vent/Combustion Air Equivalent Length Calculation Work Sheet

Combustion Air Vent

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

Subtotal,

Equivalent

Length (A)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

(Pc)

Equivalent Length,

per Pc

1 10 ft. (3.0 m) 10 ft. (3.0 m)

1 13 ft. (4.0 m) 13 ft. (4.0 m)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

(Pc)

Equivalent

Length, per Pc

10 ft. (3.0 m)

13 ft. (4.0 m)

45° Elbow(s) (Installer Supplied) 90° Elbow(s) (Installer Supplied)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

(Pc)

Equivalent

Length, per Pc

3.0 ft. (.09 m)

4.5 ft. (1.4 m)

Subtotal,

Equivalent

Length (B)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

(Pc)

Equivalent Length,

per Pc

10 ft. (3.0 m)

13 ft. (4.0 m)

Straight Pipe, (Installer Supplied) 45° Elbow(s) (Installer Supplied)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

Length,

ft or m

Equivalent

Length,

ft/ft or m/m

Subtotal,

Equivalent

Length (C)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

Length,

ft or m

Equivalent Length,

ft/ft or m/m

3.0 ft. (.09 m)

4.5 ft. (1.4 m)

* Total Equivalent Length (A+B+C) = 2.5 Ft. (760 mm) Straight Pipe, (CPVC Supplied with Boiler)

* Notes:

1. Calculated total equivalent length cannot exceed maximum equivalent length shown in Table 5.

2. Vent and combustion air terminals do not count towards total equivalent length.

3. Pressure drop for exible polypropylene liner is 20% greater than for rigid pipe. Multiply measured exible polypropylene liner length by 1.2 to obtain equivalent length.

Example Measure length of exible polypropylene liner = 35 ft. Equivalent length of exible polypropylene liner = 35 ft. x 1.2 = 42 ft.

4. Maximum equivalent length of exible polypropylene liner is 48 ft. (14.6 m).

5. All elbows referenced are short radius.

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Nominal Diameter

3 in.

(80 mm)

4 in.

(100 mm or 110 mm)

Quantity

Length,

ft or m

2.5 ft.

(0.76 m)

2.5 ft.

(0.76 m)

Equivalent Length,

ft/ft or m/m

1 2.5 ft.

Straight Pipe, (Installer Supplied)

Quantity

Length,

Equivalent Length,

ft/ft

* Total Equivalent Length (A+B+C+D+E) =

Subtotal,

Equivalent

Length (D)

Subtotal,

Equivalent

Length (A)

Subtotal,

Equivalent

Length (B)

Subtotal,

Equivalent

Length (E)

2.5 ft.

(0.76 m)

Subtotal,

Equivalent

Length (C)

3. Vent/Combustion Air Terminals

Install venting system components on exterior

of building only as specically required by these

instructions (refer to Figure 4).

a. Use only listed vent/combustion air terminals.

i. Horizontal Sidewall Venting: Use tee

terminals for both vent and combustion air as shown in Figure 5. Alternate snorkel terminations are shown in Figure 6A and Figure 6B.

ii. Vertical Roof Venting: Use straight

coupling on vent and two 90° elbows turned downwards for combustion air as shown in Figure 7 and Figure 8.

Figure 5: Direct Vent - Sidewall Tee Terminations

Page 18

IV. Venting A. General Guidelines (continued)

Figure 6A: Direct Vent - Optional Vent Sidewall

Snorkel Termination

Figure 6B: Direct Vent - Optional Vent and

Combustion Air Sidewall Snorkel Terminations

b. Maintain correct clearance and orientation

between vent and combustion air terminals.

i. Space centerlines of vent and combustion

air terminals minimum 12 in. (300 mm) apart. More than 12 in. (300 mm) spacing is recommended.

ii. If possible, locate vent and combustion

air terminals on the same wall to prevent nuisance shutdowns. If not, boiler may be installed with roof vent terminal and sidewall combustion air terminal.

iii. When installed on the same wall, locate

vent terminal at same height or higher than combustion air terminal.

iv. When using tee terminals, do not locate vent

terminal directly above air intake as dripping condensate may freeze on and block intake.

c. Locate bottom of vent and combustion air

terminals at least 12 in. (300 mm) [18 in.

(460 mm) in Canada] above the normal snow line

and at least 12 in. (300 mm) above grade level.

d. Locate vent and combustion air terminals at

least 12 in. (300 mm) from any door, window, or gravity inlet into the building.

e. Do not install vent terminal directly above

windows or doors.

f. Locate bottom of vent terminal at least 3 ft. (900

mm) above any forced air inlet located within 10 ft. (3.0 m).

g. If window and/or air inlet is within 4 ft. (1.2 m)

of an inside corner, maintain at least 6 ft. (1.8 m) spacing between terminal and adjoining wall of inside corner.

h. Locate bottom of vent terminal at least 7 ft. (2.1 m) above a public walkway.

i. Maintain minimum clearance of at least 4 ft.

(1.2 m) [3 ft. (900 mm)in Canada] horizontally between vent terminal and gas meters, electric meters, regulators, and relief equipment. Do not install vent terminal above or below this equipment.

j. Do not locate the vent terminal under decks or

similar structures.

k. Top of terminal must be at least 24” below

ventilated eves, softs, and other overhangs. In no case may the overhang exceed 48”. Where permitted by the authority having jurisdiction and local experience, the terminal may be located closer to unventilated softs. The minimum vertical separation depends upon the depth of the

soft. See Figure 4 for details.

l. Maintain minimum 12 in. (300 mm) horizontal

spacing between vent terminal and a building corner.

Page 19

IV. Venting A. General Guidelines - B. CPVC/PVC Venting (continued)

m. Under certain conditions, water in the ue gas

may condense, and possibly freeze, on objects around the terminal including on the structure itself. If these objects are subject to damage by

ue gas condensate, they should be moved or

protected.

n. If possible, install the vent and combustion air

terminals on a wall away from the prevailing wind. Reliable operation of this boiler cannot be guaranteed if terminals are subjected to winds in excess of 40 mph (64 km/hr).

o. Do not locate combustion air terminal in areas

that might contain combustion air contaminates, such as near swimming pools.

p. For multiple boiler installations with horizontal

wall terminals, maintain minimum 12 in.

(300 mm) horizontal distance between adjacent

boiler vent terminals. Maintaining greater spacing is recommended to avoid frost damage to building surfaces where vent terminations are placed.

q. For multiple boiler installations with vertical

roof terminals, maintain minimum 12 in.

(300 mm) horizontal distance between adjacent

boiler vent terminals.

B. CPVC/PVC Venting

WARNING

Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury, or death.

Use all CPVC vent components (supplied with boiler) for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.

Use CPVC vent components within any interior space where air cannot circulate freely, including through vertical or horizontal chase ways, inside a stud wall, in closets, and through wall penetrations.

The use of cellular core PVC (ASTM F891), cellular core CPVC or Radel (polyphenolsulfone) is prohibited.

All condensate that forms in the vent must be able to drain back to the boiler.

Figure 7: Direct Vent - Vertical Terminations

Do not exceed maximum vent/combustion air system length. Refer to “2. Vent/ Combustion Air Piping” under “A. General Guidelines” of this section for maximum vent/combustion air system length.

Use only vent and combustion air terminals and terminal locations shown in “3. Vent/ Combustion Air Terminals” under “A. General Guidelines” of this section.

1. Components

a. See Table 7A for CPVC/PVC vent and

combustion air components included with boiler.

b. See Table 7B for CPVC/PVC installer provided

vent and combustion air components required for optional horizontal snorkel terminals shown in Figure 6B.

c. See Table 7C for CPVC/PVC installer provided

vent and combustion air components required for optional vertical roof terminals shown in Figure 7.

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

Refer to Figure 9 and following steps:

a. Position the CPVC/PVC vent connector and

gasket onto boiler rear panel and insert vent connector inner stainless steel vent pipe into heat exchanger vent outlet.

b. Align vent connector plate and gasket clearance

holes with rear panel engagement holes. Then, secure the connector and gasket to the panel with six mounting screws.

NOTICE

Page 20

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

Figure 8: Direct Vent - Vertical Terminations

with Sloped Roof

Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation.

Table 7A: CPVC/PVC Vent & Air Intake Components Included With Boiler

Quantity

Vent & Air Intake Components

3” Schedule 40 PVC Tee (Vent & Air Intake Terminals)

4” Schedule 40 PVC Tee (Vent & Air Intake Terminals)

3” Stainless Steel Rodent Screen 230833 1 N/A

4” Stainless Steel Rodent Screen 230834 1 2

3” x 30” Schedule 40 CPVC Pipe 230823 1 N/A

4” x 30” Schedule 40 CPVC Pipe 230824 N/A 1

3” Schedule 80 CPVC 90° Elbow 230813 1 N/A

4” Schedule 80 CPVC 90° Elbow 230814 N/A 1 3" Vent/3" Combustion Air CPVC/PVC Connector

with Flue Temperature Sensor and Sensor Cap 3" Vent/4" Combustion Air CPVC/PVC Connector with Flue Temperature Sensor and Sensor Cap 4" Vent/4" Combustion Air CPVC/PVC Connector with Flue Temperature Sensor and Sensor Cap 3" Vent/3" Combustion Air CPVC/PVC Connector

Gasket

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

Gasket

Part

Number

230803 1 N/A

230804 1 2

105133-01 N/A N/A

105133-02 1 N/A

105133-03 N/A 1

230841 N/A N/A

102185-02 1 1

Standard Termination Vent Kit

PHNTM210

Standard Termination Vent Kit

(P/N 105179-02)

includes

PHNTM285

(P/N 105179-03)

includes

Asphyxiation Hazard. Apply supplied dielectric grease to gasket inside vent section of two-pipe vent connector. Failure to apply the grease could result in ue gas leaks from gasket rupture during vent pipe installation or gasket deterioration due to condensate exposure.

WARNING

Page 21

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

Table 7B: CPVC/PVC Vent & Air Intake Components (Installer Provided) Required for Optional Horizontal (Snorkel) Termination

Quantity

Vent Components

3 in. Schedule 40 PVC Pipe x up to 7 ft. max. vertical run 4 in. Schedule 40 PVC Pipe x up to 7 ft. max. vertical run 1 2 3 in. Schedule 40 PVC 90° Elbow 2 N/A 4 in. Schedule 40 PVC 90° Elbow 2 4 3 in. Schedule 40 PVC Pipe x ½ ft. min. horizontal run 1 N/A 4 in. Schedule 40 PVC Pipe x ½ ft. min. horizontal run 1 2

Part

Number

N/A

Supplied

Others

Table 7C: CPVC/PVC Vent & Air Intake Components (Installer Provided) Required for Optional Vertical (Roof) Termination

Vent Components

3" Schedule 40 PVC Coupler 4" Schedule 40 PVC Coupler 1 1 3" Schedule 40 PVC 90° Elbow N/A N/A 4" Schedule 40 PVC 90° Elbow 2 2 3" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run N/A N/A 4" Schedule 40 CPVC Pipe x ½ ft. min. horizontal run 1 1

Part

Number

N/A

Supplied by

Others

PHNTM210

Horizontal (Snorkel)

Termination

1 N/A

PHNTM210

Vertical (Roof)

Termination

N/A N/A

PHNTM285

Horizontal (Snorkel)

Termination

Quantity

PHNTM285

Vertical (Roof)

Termination

Figure 9: Field Installation of CPVC/PVC Two-Pipe Vent Connector with Factory Installed

Flue Temperature Sensor and Sensor Cap

Page 22

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

Figure 10: Near-Boiler Vent/Combustion Air Piping - Floor Mounted Boiler Builds

c. Attach ue temperature sensor wiring harness

(taped to boiler rear panel) female connectors to the sensor male spade terminals. Failure to do so will prevent boiler from starting and boiler

display will ash Red and display Limit String

Fault (see Section XII “Troubleshooting” for details).

NOTICE

Flue temperature sensor harness must be connected to ue temperature sensor for the boiler to start-up and operate properly. The installation is not complete unless the harness and the sensor are interconnected.

3. Near-Boiler Vent/Combustion Air Piping

Refer to Figure 10 and the following Steps:

a. Apply supplied dielectric grease (grease pouch

attached to two-pipe vent connector) to gasket inside vent section of 3 in. x 3 in., 3 in. x 4 in. or 4 in. x 4 in. two-pipe vent connector. The grease will prevent gasket rupture when inserting vent pipe and gasket deterioration due to condensate exposure.

b. Install provided Schedule 40 x 30 in. (760 mm)

long CPVC pipe into the vent section of the connector with a slight twisting motion and secure by tightening the worm band clamp screw.

c. All CPVC vent components supplied with boiler

inside vent carton [Schedule 40 x 30 in. (760 mm) long CPVC pipe and Schedule 80 CPVC 90° Elbow] must be used for near-boiler piping before transitioning to Schedule 40 PVC (ASTM

2665) pipe components for remainder of vent system. The 30 in. (760 mm) long CPVC straight pipe may be cut to accommodate desired vent

conguration provided both pieces are used

in conjunction with CPVC 90° Elbow before any PVC components are used. Ensure that the

CPVC 90° Elbow is the rst elbow used in the

vent system as it exits the boiler.

d. Insert Schedule 40 PVC combustion air pipe

(installer provided) into the combustion air section of the connector with a slight twisting motion and secure by tightening the worm band clamp screw.

e. Clean all vent and combustion air pipe joints

with primer and secure with cement. Use a eld

supplied cement and primer that is listed for use with the materials being joined (CPVC and/or PVC). The following, or its equivalent, may be used to join CPVC to PVC:

• IPS Corporation #P-70 Primer

• IPS Corporation #790 Multi-Purpose Solvent Cement.

Always use primer on both the pipe and tting

before applying the cement. Assemble the pipe in accordance with the instructions on the cans of primer and cement.

4. System Assembly

WARNING

Asphyxiation Hazard. CPVC/PVC vent piping and ttings rely on glued joints for proper sealing. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and the cement.

a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

b. Design the vent system to allow 3/8 in. (9.5 mm) of thermal expansion per 10 ft. (3.0 m)

of CPVC/PVC pipe. Runs of 20 ft. (6.1 m) or longer that are restrained at both ends must use an offset or expansion loop. Refer to Figure 11 and Table 8.

Page 23

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

Table 8: Expansion Loop Lengths

Nominal

Pipe Dia.

(In.)

c. All CPVC/PVC vent and combustion air

5. Horizontal Sidewall Termination

a. Standard Two-Pipe Termination

See Figure 5.

Length of

Straight Run

(Ft.)

20 53 30 65 40 75 50 84 60 92

20 60 30 74 40 85 50 95 60 104

Loop Length

“L” (In.)

Figure 12: Wall Penetration Clearances

for PVC Vent Pipe

pipe joints must be cleaned with primer and glued with cement. Follow all manufacturer instructions and warnings when preparing pipe ends for joining and using the primer and the cement.

i. Vent Piping

Running PVC vent pipe inside Enclosures

and through Walls:

Figure 11: CPVC/PVC Expansion Loop and Offset

• PVC vent pipe must be installed in such way as to permit adequate air circulation around the outside of the pipe to prevent internal wall temperature rising above

ANSI Z21.13 standard specied limit.

• Do not enclose PVC venting. Use higher temperature rated CPVC pipe in enclosed spaces or to penetrate combustible or noncombustible walls.

• PVC vent pipe may not be used to penetrate combustible or non-combustible walls unless all following three conditions are met simultaneously (see Figure 12):

- The wall penetration is at least 66 in. (1680 mm) from the boiler as

measured along the vent

- The wall is 12 in. (300 mm) thick or

less

- An air space of at least of that shown in Figure 12 is maintained around outside of the vent pipe to provide air circulation

• If above three conditions cannot be met simultaneously, use CPVC for the wall penetration.

• Size and cut wall opening such that a minimal clearance is obtained and to allow easy insertion of vent pipe.

• Apply sealant between vent pipe and wall

Page 24

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

opening to provide weather-tight seal. Sealant should not restrain the expansion of the vent pipe.

• Install contractor provided optional trim plate on outside surface of wall to cover opening (see Figure 12).

• Secure trim plate to wall with nails or screws and seal ID and plate OD or perimeter with sealant material.

• Install rodent screen and vent terminal (supplied with boiler). See Figure 13 for

appropriate conguration details.

NOTICE

Methods of securing and sealing terminals to the outside wall must not restrain the thermal expansion of the vent pipe.

ii. Combustion Air Piping

• Size combustion air pipe wall penetration opening to allow easy insertion of the pipe.

• Install rodent screen and combustion air terminal (supplied with boiler). See Figure

13 for appropriate conguration details.

• Apply sealant between combustion air pipe and wall opening to provide weather-tight seal.

b. Optional Two-Pipe Snorkel Termination

See Figures 6A and 6B.

This installation will allow a maximum of 7

ft. (2.1 m) vertical exterior run of the vent/ combustion air piping to be installed on the CPVC/PVC horizontal venting application.

i. Vent Piping

• After penetrating wall, install a Schedule 40 PVC 90° elbow so that the elbow leg is in the up direction.

• Install maximum vertical run of 7 ft.

(2.1 m) of Schedule 40 PVC

vent pipe. See Figure 6A.

• At top of vent pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface.

• Install rodent screen and vent terminal (supplied with boiler), see Figure 13 for appropriate

conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• After penetrating wall, install a Schedule 40 PVC 90° elbow so that elbow leg is in the up direction.

• Install maximum vertical run of 7 ft.

(2.1 m) of Schedule 40 PVC air pipe. See

Figure 6B.

• At top of air pipe length install another PVC 90° elbow so that elbow leg is opposite the building’s exterior surface.

• Install rodent screen and combustion air terminal (supplied with boiler). See Figure

13 for appropriate conguration.

• Brace exterior piping if required.

7. Vertical Roof Termination

a. Standard Two-Pipe Termination

See Figures 7 and 8.

i. Vent Piping

• Install re stops where vent passes through oors, ceilings or framed walls. The re

stop must close the opening between the vent pipe and the structure.

• Whenever possible, install vent straight through the roof. Refer to Figures 7 and 8.

- Size roof opening to maintain minimum clearance of 1 in. (25 mm) from combustible materials.

- Extend vent pipe to maintain minimum vertical and horizontal distance of 12 in. (300 mm) from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required.

NOTICE

Vertical venting and combustion air roof penetrations (where applicable) require the use of roof ashing and storm collar, which are not supplied with boiler, to prevent moisture from entering the structure.

Figure 13: Rodent Screen Installation

Page 25

IV. Venting B. CPVC/PVC Venting - C. Polypropylene Venting (continued)

- Install storm collar on vent pipe

immediately above ashing. Apply

Dow Corning Silastic 732 RTV Sealant or equivalent between vent pipe and storm collar to provide weather-tight seal.

• Install rodent screen and vent terminal (supplied with boiler). See Figure 13 for

appropriate conguration.

• Brace exterior piping if required.

ii. Combustion Air Piping

• If possible, locate combustion air termination on the same roof location as the vent termination to prevent nuisance boiler shutdowns. Combustion air terminal may be installed closer to roof than vent. Alternatively, boiler may be installed with vertical roof vent terminal and sidewall combustion air terminal.

• Size roof opening to allow easy insertion of combustion air piping and allow proper

installation of ashing and storm collar

to prevent moisture from entering the structure.

- Use appropriately designed

vent ashing when passing through roofs. Follow ashing manufacturers’

instructions for installation procedures.

- Extend combustion air pipe to maintain minimum vertical and horizontal distance of 12 in. (300 mm) from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required.

- Install storm collar on combustion air pipe immediately above

ashing. Apply Dow Corning Silastic

732 RTV Sealant or equivalent between combustion air pipe and storm collar to provide weather-tight seal.

• Install rodent screen and combustion air terminal (supplied with boiler). See Figure

13 for appropriate conguration.

• Brace exterior piping if required.

C. Polypropylene Venting

WARNING

Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original polypropylene venting component manufacturers, M&G/ DuraVent or Centrotherm, whichever applicable. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Where a conict arises between M&G/ DuraVent or Centrotherm instructions and these instructions, the more restrictive instructions shall govern.

Do not mix vent components or joining methods for listed manufacturers.

Examine all components for possible shipping damage prior to installation.

All condensate that forms in the vent must be able to drain back to the boiler.

1. Components

a. Listed polypropylene vent system manufacturers

are shown in Table 9. It is the responsibility of the installing contractor to procure polypropylene vent system pipe and related components.

i. M&G/DuraVent PolyPro Single Wall Rigid

Vent and PolyPro Flex Flexible Vent comply with the requirements of ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’.

Table 9: Listed Polypropylene Vent System

Manufacturers

Make Model

M&G/DuraVent

Centrotherm Eco

Systems

PolyPro Single Wall Rigid Vent

PolyPro Flex Flexible Vent

InnoFlue SW Rigid Vent

Flex Flexible Vent

NOTICE

Do not exceed maximum vent/combustion air system length. Refer to “2. Vent/Combustion Air Piping” under “A. General Guidelines” of this section for maximum vent/combustion air system length.

Use only vent and combustion air terminals and terminal locations shown in “3. Vent/ Combustion Air Terminals” under “A. General Guidelines” of this section.

Page 26

IV. Venting C. Polypropylene Venting (continued)

Table 10A: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent

M&G / DuraVent Part Numbers/Sizes

Boiler Model

PHNTM210

PHNTM285 4PPS-AD PPS-PAC 4PPS-04PVCM-4PPF 100 mm 100 mm 4PPS-LB 4PPS-TB 4PPS-FK

Boiler

Adapter, PVC

to PP

3PPS-AD

and 4PPS-AD

Boiler

Adapter

Connector

PPS-PAC

Male Boiler

Adapter,

PVC to PP

3PPS-03PVCM3PPFand 4PPS-

04PVCM-4PPF

Rigid Pipe Flex Pipe

80 mm

and 100 mm

80 mm

and 100 mm

Pipe Joint

Locking

Band

3PPS-LB

and 4PPS-LB

Side Wall

Termination

Tee

3PPS-TB 4PPS-TB

Table 10B: Approved Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

Centrotherm Eco Part Numbers/Sizes Boiler Model

PHNTM210

PHNTM285

Boiler Adapter,

PVC to PP

ISAA0303

ISSAL0303

ISAA0404

ISSAL0404

ISAA0404

ISSAL0404

Boiler

Adapter

Connector

N/A

Rigid Pipe Flex Pipe

80 mm

and 110 mm

110 mm 110 mm IANS04 ISTT04

80 mm

and 110 mm

Pipe Joint

Locking Band

IANS03

and

IANS04

Side Wall

Termination Tee

ISTT03

ISTT04

and

Chimney

Kit for

Venting

Only

3PPS-FK

Chimney Kit for

Venting Only

IFCK0325

and

IFCK0335

IFCK0425

and IFCK0435

ii. Centrotherm Eco Systems InnoFlue SW

Rigid Vent and Flex Flexible Vent comply with the requirements of UL 1738 ‘Standard for Safety for Venting Systems’ and ULC-S636-08 ‘Standard for Type BH Gas Venting Systems’.

b. See Table 10A for specic M&G Duravent

components.

c. See Table 10B for specic Centrotherm Eco

Systems components.

2. Field Installation of CPVC/PVC Two-

Pipe Vent System Connector and PVC to Polypropylene Adapter

a. Install CPVC/PVC two-pipe vent system

connector. Follow instructions in “2. Field Installation of CPVC/PVC Two-Pipe Vent System Connector” under “B. CPVC/PVC Venting.” See Figures 9 and 14.

b. Apply provided dielectric grease (grease pouch

taped to the vent system connector) all around to the vent or air connection inner red silicon gasket.

c. Push and twist PVC to PP adapter into two-pipe

vent system connector vent or combustion air supply port until bottomed out.

d. Tighten the worm band clamp screw to secure

PVC to PP adapter.

e. Do not install PVC to PP adapter at the lower

combustion air supply port of the two-pipe vent system connector when using PVC pipe for combustion air supply to boiler.

3. System Assembly

a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

b. Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and when assembling the vent/combustion air system.

c. Use locking band clamps at all vent pipe joints.

Figure 14: Vent System Field Modication to

Install PVC to PP Adapter (M&G/DuraVent Shown)

Page 27

IV. Venting C. Polypropylene Venting (continued)

WARNING

Asphyxiation Hazard. Vent systems made by M&G/DuraVent and Centrotherm Eco Systems rely on gaskets for proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and un- damaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their instructions. When pipe is cut, cut end must be square and carefully de-burred prior to assembly.

• Use locking band clamps at all vent pipe joints.

NOTICE

The venting system must be free to expand and contract and supported in accordance with installation instructions included by the original polypropylene venting component manufacturers, M&G/DuraVent or Centrotherm, whichever applicable. Polypropylene pipe sections must be disengaged 1/4 to 5/8 in. (6 mm to 16 mm) per joint to allow for thermal expansion.

4. Running Flexible Polypropylene Vent (Liner) Through Unused Chimney Chase

WARNING

Asphyxiation Hazard. Flexible polypropylene vent must be installed only in an UNUSED chimney. A chimney, either single or multiple ue type, is considered UNUSED when none of the ues is being used for any appliance venting. Where one of the multiple ues is being used for an appliance venting, the exible vent installation is not permitted through any of adjacent ues.

NOTICE

Pressure drop for exible polypropylene liner is 20% greater than from rigid pipe. Multiply measured exible polypropylene liner length by

1.2 to obtain equivalent length. Maximum equivalent length of exible polypropylene liner is 48 ft. (14.6 m).

a. Models PHNTM210 and PHNTM285 are listed

for vertical venting by installing exible vent

in an UNUSED masonry chimney/chase and supplying combustion air through a separate wall or roof combustion air terminal.

b. Refer to Figure 15 for details of chimney chase

installation.

c. Flexible polypropylene pipe must be treated

carefully and stored at temperatures higher than 41°F (5°C).

d. Do not bend or attempt to install exible pipe if

it has been stored at lower ambient temperature without allowing the pipe to warm up to a higher

temperature rst.

WARNING

Asphyxiation Hazard. Bending or attempting to install exible pipe if it has been stored at ambient temperature below 41°F (5°C) will cause material to become brittle and lead to cracks, resulting in ue gas leaks.

Do not install exible polypropylene pipe at an angle greater than 45 degrees from vertical plane when used for combustion product venting. Failure to do so will result in improper condensate drainage towards the boiler and possible subsequent vent pipe blockage.

NOTICE

Exterior run to be included in equivalent vent/

combustion air lengths.

e. When exible polypropylene pipe (liner) is used

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

ow back towards the boiler.

f. When exible polypropylene pipe (liner) is used

for combustion air supply to a boiler, the pipe (liner) can be installed in vertical or horizontal position.

g. Follow exible polypropylene pipe (liner)

manufacturer specic installation instructions

regarding application/listing, permits, minimum clearances to combustibles, installation details (proper joint assembly, pipe support and routing,

gasket and tting installation, optional tooling

availability/usage, routing through masonry combination of combustion product venting and combustion air supply).

h. When there is a conict between exible

polypropylene pipe (liner) manufacturer installation instructions and Phantom boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.

Page 28

IV. Venting D. Stainless Steel Venting (continued)

Venting of Other Appliances (or Fireplace)

into Chase or Adjacent Flues Prohibited!

D. Stainless Steel Venting

WARNING

Asphyxiation Hazard. Follow these instructions and the installation instructions included by the original stainless steel venting component manufacturers, Heat Fab, M&G/DuraVent or Z-Flex, whichever applicable. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death. Where a conict arises between Heat Fab, M&G/ DuraVent or Z-Flex instructions and these instructions, the more restrictive instructions shall govern.

Do not mix vent components from listed manufacturers.

Examine all components for possible shipping damage prior to installation.

All condensate that forms in the vent must be able to drain back to the boiler.

Figure 15: Flexible PP Vent in Masonry Chimney with

Separate Combustion Air Intake

NOTICE

Do not exceed maximum vent/combustion air system length. Refer to “2. Vent/ Combustion Air Piping” under “A. General Guidelines” in this section for maximum vent/combustion air system length.

Use only vent and combustion air terminals and terminal locations shown in “3. Vent/ Combustion Air Terminals” under “A. General Guidelines” of this section.

1. Components

a. Acceptable listed stainless steel vent system

manufacturers and components are shown in Table 11.

b. Where the use of “silicone” is called for in the

following instructions, use GE RTV 106 or equivalent for the vent collar. Seal galvanized

Page 29

IV. Venting D. Stainless Steel Venting (continued)

combustion air piping sections with any generalpurpose silicone sealant such as GE RTV102. Seal PVC combustion air piping sections with PVC cement.

c. Do not drill holes in vent pipe.

2. Field Installation of CPVC/PVC Two-Pipe Vent System Connector and PVC to Stainless

Steel Adapter

a. Install CPVC/PVC two-pipe vent system

connector. Follow instructions in “2. Field Installation of CPVC/PVC Two-Pipe Vent System Connector” under “B. CPVC/PVC Venting.” See also Figures 9 and 17.

b. Apply provided dielectric grease (grease pouch

taped to the vent system connector) all around to the vent or air connection inner red silicon gasket.

c. Push and twist PVC to stainless steel adapter

into two-pipe vent system connector vent or combustion air supply port until bottomed out. See Figure 16.

d. Tighten the worm band clamp screw to secure

PVC to stainless steel adapter.

e. Do not install PVC to stainless steel adapter

at the lower combustion air supply port of the two-pipe vent system connector when using PVC pipe for combustion air supply to boiler.

WARNING

Failure to properly secure the vent adapter lower end into the elbow with the clamp could lead to property damage, personal injury or loss of life.

3. System Assembly

a. Plan venting system to avoid possible contact

with plumbing or electrical wires. Start at vent connector at boiler and work towards vent termination.

b. Follow all manufacturer instructions and

warnings when preparing pipe ends for joining and when assembling the vent/combustion air system.

NOTICE

The venting system must be free to expand and contract and supported in accordance with installation instructions included by the original stainless steel venting component manufacturers, Heat Fab, M&G / DuraVent or Z-Flex, whichever applicable.

c. On horizontal pipe sections, orient all welded

seams at the 12:00 position. Do not place longitudinal welded seams at the bottom of horizontal sections of vent pipe.

d. Assemble the combustion air system using either

galvanized or PVC pipe.

i. If PVC piping is used, use PVC cement

to assemble the PVC intake system components. See “B. CPVC/PVC Venting” for combustion air pipe installation instructions.

ii. If galvanized piping is used, use at least two

sheet metal screws per joint. Seal outside of all joints

4. Horizontal Sidewall Vent Termination

a. Standard Two-Pipe Termination

See Figures 5A and 5B.

i. Vent Termination

• Use a stainless steel tee in the upright position.

WARNING

Asphyxiation Hazard. Vent systems made by Heat Fab, M&G / DuraVent and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions:

• Make sure that gasket is in position and undamaged in the female end of the pipe.

• Make sure that both the male and female pipes are free of damage prior to assembly.

• Only cut vent pipe as permitted by the vent manufacturer in accordance with their Instructions. When pipe is cut, cut end must be square and carefully de-burred prior to assembly.

NOTICE

The joint between the terminal and the last piece of pipe must be outside of the building.

• Male end of terminal will t into female

end of any of the listed stainless vent systems.

• Apply a heavy bead of silicone to the male end of the terminal before inserting it into the last piece of pipe. Orient the terminal so that the seam in the terminal is at 12:00.

• Smooth the silicone over the seam between the terminal and the last piece of pipe, applying additional silicone if necessary to ensure a tight seal.

Page 30

IV. Venting D. Stainless Steel Venting (continued)

Table 11: Acceptable Stainless Steel Vent Systems and Vent Components

Manufacturer

M&G/DuraVent FasNseal

Z-Flex

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

supports.

Vent

System

SVE Series III

(“Z-Vent III”)

Nominal Dia.

4 in.

(100 mm)

4 in.

(100 mm)

• Allow the silicone to cure per the silicone manufacturer’s instructions before operating the boiler.

ii. Combustion Air Termination

• Use a tee in the upright position. Tee should protrude the same distance from the wall as the exhaust terminal as shown in Figure 5.

• Install a rodent screen (not supplied) in the inlet terminal. Use a screen having 1/2 in. x 1/2 in. (13 mm x 13 mm) mesh.

b. Optional Two-Pipe Snorkel Termination

See Figures 6A and 6B.

This installation will allow a maximum of 7 ft. (2.1 m) vertical exterior run of the vent/

combustion air piping to be installed on the approved AL29-4C stainless steel horizontal venting application. i. Vent Termination

• After penetrating wall, install the appropriate manufacturer’s 90° elbow so that the elbow leg is in the up direction.

• Install maximum vertical run of 7 ft.

(2.1 m) of appropriate manufacturer’s vent

pipe as shown in Figure 6A.

• At top of vent pipe length install another appropriate manufacturer’s 90° elbow so that the elbow leg is opposite the building’s exterior surface.

• Install horizontal vent terminal.

• Brace exterior piping if required.

PVC to SS

Adapter

810005231 FSWT4 Tee: FSTT4 FSBS4

2SVSTTA04.5 2SVSWTF04 Tee: 2SVSTTX04 2SVSTPX04

Wall Thimbles

Horizontal

Termination

Vertical

Termination

ii. Combustion Air Termination

• After penetrating wall, install a 90° elbow so that the elbow leg is in the up direction.

• Install maximum vertical run of 7 ft.

(2.1 m) of combustion air pipe as shown in

Figure 6B.

• At top of vent pipe length install another 90° elbow so that the elbow leg is opposite the building’s exterior surface.

• Install rodent screen (not supplied) and horizontal vent terminal.

• Brace exterior piping if required.

5. Vertical Vent Termination

a. Standard Two-Pipe Termination

See Figures 7 and 8.

i. Vent Termination

• Use the terminal supplied by the vent system manufacturer shown in Table 11. Follow manufacturer’s instructions to attach terminal to vent system.

ii. Combustion Air Termination

• Install vertical combustion air terminal. Vertical combustion air terminal consists of a 180° bend (comprised of two 90° elbows) as shown in Figure 7.

• Install rodent screen (not supplied) in the combustion air terminal. Use a screen having 1/2 in. x 1/2 in. (13 mm x 13 mm) or larger mesh.

6. Running Flexible Stainless Steel Vent (Liner) Through Unused Chimney or Chase

Figure 16: Field Installation of Two-Pipe Vent

System Adapter for Stainless Steel

WARNING

Asphyxiation Hazard. Flexible stainless steel vent must be installed only in an UNUSED chimney ue. A chimney ue is considered UNUSED when it is not being used for any appliance venting. Where one of the multiple ues is being used for an appliance venting, the exible stainless vent installation is permitted through an adjacent unused ue providing a local authority having jurisdiction approves such installation.

Page 31

IV. Venting D. Stainless Steel Venting, E.. Removing the Existing Boiler (continued)

a. Both models are listed for vertical venting by

installing exible stainless steel vent (M&G/

DuraVent FlexNSeal brand) in an UNUSED masonry chimney/chase and supplying combustion air through a separate wall or roof combustion air terminal. The unused chimney

ue must be structurally sound and in good

repair.

b. Refer to Figure 17 for details of chimney chase

installation.

WARNING

Asphyxiation Hazard. Flexible stainless steel pipe (liner) must be installed at vertical or near vertical plane when used for combustion product venting. Failure to do so will result in improper condensate drainage towards the boiler and possible subsequent vent pipe blockage.

c. 105290-01 (3”), 102219-01 (3”), and 102220-01

(4”) adapters are available from Crown.

d. FSA-HB3 (3”) and FSA-HB4 (4”) adapters as

well as FasNSeal rigid and exible vent pipe are eld supplied and available from M&G/

DuraVent.

e. When exible stainless steel pipe (liner) is used

for combustion product venting, it must be installed at vertical or near vertical plane. This

will insure proper condensate ow back towards

the boiler.

f. Follow exible stainless steel pipe (liner)

manufacturer M&G/DuraVent FlexNSeal

specic installation instructions (DuraVent

publication L1150 - latest edition) regarding application/listing, permits, minimum clearances to combustibles, installation details (proper joint assembly, pipe support and routing, gasket and

tting installation, optional tooling availability/

usage, routing through masonry combination of combustion product venting and combustion air supply).

g. When there is a conict between exible stainless

steel pipe (liner) manufacturer installation instructions and Phantom boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.

E. Removing the Existing Boiler

When an existing boiler is removed from a common

venting system, the common venting system is likely to be too large for proper venting of the remaining appliances. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting

system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

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

2. Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion, and other

deciencies which could cause an unsafe condition.

3. Insofar as is practical, close all building doors and windows and all doors between the space in which the appliances remaining connected to the common 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 maxi mum speed. Do not operate a summer exhaust fan. Close

replace dampers.

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

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

5 minutes of main burner operation. Use the ame

of a match or candle, or smoke from a cigarette, cigar or pipe.

6. After it has been determined that each appliance remain ing connected to the common venting system properly vents when tested as outlined above, return

doors, win dows, exhaust fans, replace dampers and

any other gas burning appliance to their previous conditions of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/CSA B149.1. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part II in the National

Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or the Natural Gas and Propane Installation Code, CAN/

CSA B149.1.

Au moment du retrait d’une chaudière existante, les

mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’evacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas:

1. Sceller toutes les ouvertures non utilisées du système d’évacuation.

Page 32

IV. Venting E.. Removing the Existing Boiler, F. Multiple Boiler Installation Venting (continued)

2. Inspecter de façon visuelle le système d’évcuation pour déterminer la grosseur et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement, de fuite, de corrosion et autres défaillances qui pourraient présenter des risques.

3. Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés au système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinière et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

4. Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

5. Faire fonctionner le brùleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde

à l’ouverture de décharge. Utiliser la amme d’une

allumette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

6. Une fois qu’il a été déterminé, selon la méthode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façon adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

7. Tout mauvais fonctionnement du système d’évacuation commun devrat être corrigé de façon que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CAN/CSA-B149.1. Si la grosseur d’une section du système d’évacuation

doit être modiée, le système devrait être modié

pour respecter les valeurs minimales des tableaux pertinents de l’appendice F du National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) des codes d’installation CAN/CSA-B149.1.

F. Multiple Boiler Installation Venting

1. Vent Piping and Terminations

a. Multiple boiler vent terminations are shown in

Figure 18.

b. Each individual boiler must have its own vent

pipe and vent terminal. Refer to Paragraphs A through E (as applicable) for individual boiler vent guidelines and options.

c. Do not exceed the individual boiler maximum

vent length listed in Table 5.

Asphyxiation Hazard. No common manifold venting (vent piping and vent terminals) is permitted.

d. For horizontal sidewall terminations, maintain

at least 12 in. (300 mm) minimum horizontal distance between any adjacent individual boiler vent terminations. Additional horizontal spacing between any adjacent individual boiler vent terminations as well as extending the distance from building surfaces to vent termination end are recommended to avoid frost damage to building surfaces where vent terminations are placed.

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

e. Individual boiler sidewall vent terminals must be

placed at least 12 in. (300 mm) [18 in. (460 mm) in Canada] above the ground plus the expected snow accumulation.

f. Multiple individual boiler vertical vent pipes

may be piped through a common conduit or chase so that one roof penetration may be made.

g. For vertical roof terminations, maintain at

least 12 in. (300 mm) minimum horizontal distance between adjacent individual boiler vent terminations.

2. Combustion Air Piping

a. Multiple boiler combustion air terminations are

shown in Figure 18.

b. Each individual boiler must have own

combustion air pipe and terminal. Refer to Paragraphs A through E (as applicable) for individual boiler combustion air guidelines and options.

c. Do not exceed the individual boiler maximum

combustion air pipe length listed in Table 5.

d. If possible, locate vent and combustion air

terminals for an individual boiler on the same wall to prevent nuisance shutdowns. If not, an individual boiler may be installed with a roof vent terminal and sidewall combustion air terminal.

WARNING

NOTICE

Page 33

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

Figure 17 : Flexible Stainless Steel Vent in Masonry Chimney with Separate Combustion Air Intake

Figure 18: Multiple Boiler Direct Vent Termination

Page 34

V. Condensate Disposal

A. Condensate Trap and Drain Line

1. All condensate which forms in the boiler or vent system collects in the sump under heat exchanger and leaves the boiler through factory installed condensate trap.

2. The trap allows condensate to drain from sump

while retaining ue gases in the boiler. The trap has factory installed overow switch, which shuts

down the boiler in the event the drain line becomes obstructed, preventing proper condensate removal. Refer to Section XI “Service and Maintenance” for

condensate trap and condensate overow switch

removal and replacement procedure, if required.

3. Note the following when disposing of the condensate:

a. Condensate is slightly acidic, typical pH around

3.5 - 4.5. Do not use metallic pipe or ttings in

the condensate drain line. Do not route the drain line through areas that could be damaged by leaking condensate.

b. Do not route or terminate the condensate drain

line in areas subject to freezing temperatures.

c. If the point of condensate disposal is above the

trap, a condensate pump is required to move the condensate to the drain. Select a condensate pump approved for use with condensing

furnaces. If overow from the pump would

result in property damage, select a pump with an

overow switch. Wire this switch in series with

installer provided external high limit, to shut off the boiler, and, if desired, in series with installersupplied alarm, to trigger an alarm in the event of

overow.

d. Do not attempt to substitute another trap for one

provided with the boiler.

e. In order for boiler to work properly, the boiler

must be leveled during installation.

4. The condensate trap connection is located at boiler left side, below inlet and outlet water pipe connections. Refer to Figures 1A, 1B and19.

5. Condensate trap must be lled up with water,

prior to boiler start-up and before connecting any condensate line to the boiler to insure combustion

products cannot escape from operating boiler. To ll

the trap, inject water in the amount of 1 cup (240ml)

through condensate trap connection. Do not overll

the trap.

6. Install tee for condensate overow and vent as

shown in Figure 19.

WARNING

Asphyxiation Hazard. Failure to ll the condensate trap with water prior to boiler startup could cause ue gas to enter the building, resulting in personal injury or death.

7. If any additional condensate drain line is needed, construct the extension from PVC or CPVC Schedule 40 pipe. The factory supplied ¾ in. x 5-5/8 in. long PVC coupling, located in the miscellaneous parts carton, must be used to connect drain line to the condensate trap. Do not over tighten coupling compression nuts when connecting drain line and condensate trap.

8. Size condensate drain line, pump and neutralizer (if using other than manufacturer neutralizer kit) to

accommodate maximum condensate ow shown in

Table 11C “Maximum Condensate Flow”.

WARNING

Asphyxiation Hazard. Failure to install the condensate drain in accordance with the above instructions could cause ue gas to enter the building, resulting in personal injury or death.

NOTICE

Boiler condensate is corrosive. Route condensate drain line in a manner such that any condensate leakage will not cause property damage.

Some jurisdictions may require that condensate be neutralized prior to disposal.

Use materials approved by the authority having jurisdiction.

B. Condensate Neutralizer Installation

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

2. The limestone chips used in neutralizers will get coated by salts and lose neutralizing effectiveness over time. Therefore, periodic condensate neutralizer maintenance and limestone chip replacement must be performed. A pH test or acid test kits are available from HVAC/plumbing distributors and should be used to measure condensate acidity before/after neutralizer thus indicating a need for service and chip replacement.

Page 35

V. Condensate Disposal (continued)

Table 11C: Maximum Condensate Flow

Boiler

Model

PHNTM210 2.4

PHNTM285 3.2

*Assumes 100% of water in fuel condenses.

*Maximum Condensate Flow,

GPH

Figure 19: Condensate Trap and Drain Line

Page 36

VI. Water Piping and Trim

NOTICE

Failure to properly pipe boiler may result in improper operation and damage to boiler or structure.

Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during appliance operation and service (circulator replacement, etc.).

Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Crown Boiler Company’ s Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.

Do not ll boiler with softened water to prevent chloride contamination.

Installation is not complete unless a safety relief valve is installed into the tapping located on left side of appliance or the supply piping.

A. Installation of Factory Supplied Piping and

Trim Components

Phantom boilers have factory supplied Miscellaneous

Part Carton which includes supply piping components, gas piping components, Temperature & Pressure Gauge, Pressure Relief Valve and Drain Valve. See Figure 20 “Factory Supplied Piping and Trim Installation”.

Install these components prior to connecting boiler to

system piping as follows:

1. Relief Valve Piping, PHNTM210 Boiler

Model

a. Locate and remove ¾ in. NPT x close black

nipple, ¾ in. NPT black tee, ¾ in. MPT x ¾ in. FPT Pressure Relief Valve, ¾ in. NPT Drain Valve.

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾ in. tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Mount ¾ in. MPT x ¾ in. FPT Pressure Relief

Valve into the tee top outlet.

d. Install Drain Valve into the tee bottom outlet.

2. Relief Valve Piping, PHNTM285 Boiler

Model

a. Locate and remove (1) ¾ in. NPT x close black

nipple, (1) ¾ in. NPT x 10 in. black nipple, ¾ in. NPT black tee, ¾ in. FPT x ¾ in. FPT Pressure Relief Valve, ¾ in. NPT Drain Valve.

Notice: Required near boiler piping (“boiler loop piping”) size may be larger than piping/ trim supplied with boiler. See Table 13. If larger piping is required, increase size directly after supplied trim.

Figure 20: Factory Supplied Piping and Trim Installation

Page 37

VI. Water Piping and Trim B. Piping System To Be Employed (continued)

b. Install close nipple into tee branch, then, screw

the assembly into boiler left side front ¾ in. tapping making sure tee run outlets are in vertical plane and parallel to boiler side.

c. Install the ¾ in. NPT x 10 in. black nipple into

tee run top outlet.

d. Mount ¾ in. FPT x ¾ in. FPT Pressure Relief

Valve onto the 10 in. nipple.

e. Install Drain Valve into the tee bottom outlet.

3. Temperature /Pressure Gauge Piping, PHNTM210 Boiler Models

a. Locate and remove 1 in. NPT x 4 in. long black

nipple, 1 in. x 1 in. x 1 in. NPT black tee, 1 in. x ¼ in. NPT black reducing bushing and Temperature & Pressure Gauge.

b. Mount the nipple into 1 in. boiler supply tapping

(see Figure 1A), then, install the tee onto the nipple, making sure 1 in. branch outlet is in horizontal plane and facing the boiler front.

c. Install 1 in. x ¼ in. NPT black reducing bushing

into the tee branch, then, put in Temperature & Pressure Gauge.

4. Temperature /Pressure Gauge Piping, PHNTM285 Boiler Model

a. Locate and remove 1¼ in. NPT x 2 in. long black

nipple, 1¼ in. x 1¼ in. x ¾ in. NPT black tee, ¾ in. x ¼ in. NPT black reducing bushing and Temperature & Pressure Gauge.

b. Mount the nipple into 1¼ in. boiler supply

tapping (see Figure 1B), then, install the tee onto the nipple, making sure ¾ in. branch outlet is in horizontal plane and facing the boiler front.

c. Install ¾ in. x ¼ in. NPT black reducing bushing

into the tee branch, then, put in Temperature & Pressure Gauge.

B. Piping System To Be Employed.

Phantom boilers are designed to operate in a closed

loop pressurized system. Minimum pressure in the boiler must be 14.5 PSI. Proper operation of the

Phantom boiler requires that the water ow through the

boiler remain within the limits shown in Table 14, any

time the boiler is ring.

NOTICE

Failure to maintain the ow through boiler within specied limits could result in erratic operation or premature boiler failure.

1. Near boiler piping must isolate boiler from

system piping via closely spaced tees to insure

specied ow range through boiler any time the boiler is ring:

a. The ow rate through the boiler loop is

maintained by factory supplied boiler circulator.

b. The ow rate through the boiler loop is

completely independent of the ow rate through

the heating system loop(s).

c. The ow rate through the heating system loop(s)

is controlled by installer sized/provided system loop circulator(s).

d. This piping arrangement can be used either for

space heating-only applications or space heating with indirect water heater(s) applications.

i. Space heating only - refer to Table 13 and

Figure 21 “Near Boiler Piping - Heating Only” as applicable.

ii. Space heating plus indirect water

heater(s) - refer to Table 13 and Figure 22

“Near Boiler Piping - Heating Plus Indirect Water Heater” as applicable.

NOTICE

Where it is not possible to install a separate boiler loop, the system circulator must be sized to ensure that the ow through boiler stays within the dened parameters to prevent overheating when the boiler is red at it’s full rated input. Install a ow meter to measure the ow, or re the boiler at full rate and ensure the boiler DT does not exceed 35°F (19°C).

2. Direct connection of Phantom boiler to

heating system, similar to a conventional boiler, is

NOT RECOMMENDED because:

a. The ow rate through system must be the same

as through boiler and fall within limits specied

in Table 12.

b. Pressure drop through entire system must be

known, added to pressure drop through boiler, and, a circulator selected to provide required

ow at total calculated pressure drop.

c. It is often very difcult to accurately calculate

the pressure drop through the system.

d. In replacement installations, it may be nearly

impossible to get an accurate measurement of

piping amount and number of ttings in the system. If system is zoned, the system ow rate

may drop well below recommended minimum

ow when only a single zone is calling for heat.

Page 38

VI. Water Piping and Trim B. Piping System To Be Employed (continued)

Table 12: Flow Range Requirement Through Boiler

Boiler Model

PHNTM210 1 1 11.1 5.4 12.9 7.1 15.5 9.8 19.4 14.4 PHNTM285 1¼ 1¼ 15.1 5.9 17.7 7.8 21.2 10.7 26.5 16.0

Notes: Required Flow (GPM) = ** Output (MBH) x 1000/500 x ΔT

** Output (MBH) - Select Value for specic Boiler Model from Table 2.

Boiler

Supply

Connection,

Inch, FPT

will result in higher uid density and may require larger circulators.

Boiler

Return

Connection,

Inch, FPT

Minimum Required

Flow (GPM)

@ 35°F ΔT

Boiler

Head Loss,

Ft.

@ 35°F ΔT

Required

Flow,

(GPM)

@ 30°F ΔT

Boiler

Head Loss,

Ft.

@ 30°F ΔT

Required

Flow,

(GPM)

@ 25°F ΔT

Boiler

Head Loss,

Ft.

@ 25°F ΔT

Maximum

Required

Flow (GPM)

@ 20°F ΔT

See also Table 13 for near boiler piping sizing. Using boiler antifreeze

Boiler

Head Loss,

Ft.

@ 20°F ΔT

Table 13: Recommended Circulators for 50 ft. Equivalent ft. Near Boiler Piping [Approximately 20 ft. Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]

Boiler Model

Boiler Supply

Connection,

Inch, FPT

PHNTM210 1 1 1¼ 1¼ 15.5 11.7 Taco 0014

PHNTM285 1¼ 1¼ 1½ 1½ 21.5 12.3 Taco 0013

Notes:

(1)

Temperature Differential = 20°F

(2)

Taco Circulators shown are not equipped with internal ow check valve (IFC).

When selecting Circulators other than recommended, contact Circulator Manufacturer for sizing information.

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

Boiler

Return

Connection,

Inch, FPT

Near-Boiler

Piping

Supply Pipe

Size, Inch

Near-Boiler

Piping

Return Pipe

Size, Inch

Flow, GPM

@ 25°F

Temp.

Differential

Combined

Boiler &

Piping Loop

Head Loss, Ft.

Recommended

Circulator

Make & Model

(2)

Page 39

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

Table 14: Fitting and Valve Equivalent Length

(cont’d)

Copper Fitting and Sweat Valve

Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.5 3.0 4.0 5.5

45° Elbow 1.0 1.2 1.5 2.0

Tee (through ow) 0.5 0.6 0.8 1.0

Tee (Branch ow) 4.5 5.5 7.0 9.0

Diverter Tee (typical) 23.5 25.0 23.0 23.0

Gate Valve 0.3 0.4 0.5 0.7

Globe Valve 25.0 36.0 46.0 56.0

Angle Valve 5.3 7.8 9.4 12.5

Ball Valve (standard port) 4.3 7.0 6.6 14.0

Ball Valve (full port) 1.9 1.4 2.2 1.3

Swing Check Valve 4.5 5.5 6.5 9.0

Flow-Check Valve (typical)

Buttery Valve 2.7 2.0 2.7 4.5

NOTE: Table 14 is provided as reference to assist in piping design and species equivalent length of typical piping ttings and

valves.

Copper Pipe or Valve Size

1 1¼ 1½ 2

54.0 74.0 57.0 177.0

3. Phantom boiler models are factory supplied with circulators, which were sized for near-

boiler piping equivalent length of 50 ft. and listed temperature differential. See Table 13 for details.

It is the installer’s responsibility to insure a proper

installation and where applicable, proper circulator

Threaded Fitting and Valve Equivalent Length (Ft)

Fitting or Valve Description

90° Elbow 2.6 3.5 4.0 5.2

Long Radius

Elbow (45° or 90°)

Tee (through ow) 1.8 2.3 2.7 3.5

Tee (Branch ow) 5.3 6.9 8.1 10.0

Close Return Bend 4.4 5.8 6.7 8.6

Gate Valve (full open) 0.7 0.9 1.1 1.4

Globe Valve (full open) 30.0 39.0 46.0 59.0

Angle Valve (full open) 13.0 17.0 20.0 26.0

Swing Check Valve (full open)

Flow-Check Valve (typical)

Black Threaded Pipe or

Valve Size

1 1¼ 1½ 2

1.4 1.8 2.2 2.8

8.7 12.0 13.0 17.0

42.0 60.0 63.0 83.0

if the valve opens. The end of the discharge pipe must terminate in an unthreaded pipe. If the relief valve is not piped to a drain, it must terminate at

least 6” above the oor. Do not run relief valve

discharge piping through an area prone to freezing. The termination of discharge piping must be in an area where it will not become plugged by debris.

speed setting for the boiler circulator to achieve

a required ow rate. Where near-boiler piping

exceeds 50 equivalent feet, alternate circulator selection may be required.

C. Standard Installation Requirements

Observe the following guidelines when making the

actual installation of the boiler piping:

1. Safety Relief Valve (Required) - The relief

valve is packaged loose with boiler and must be installed in the location shown in Figure 20 “Factory Supplied Piping and Trim Installation”. The relief valve must be installed with spindle in vertical position. Installation of the relief valve must comply with ASME Boiler and Pressure Vessel Code, Section IV. The standard factory shipped relief valve is rated for 30 PSI maximum working pressure for PHNTM210 and PHNTM285. Optional 50 PSI, 80 PSI and 100 PSI maximum working pressure rated relief valves are available. If the valve is to be replaced, the replacement valve must have a relief capacity equal or exceeding the minimum relief valve capacity shown on the ASME plate. Pipe the relief valve discharge to a location where hot water or steam will not create hazard or property damage

Burn Hazard. Safety relief valve discharge piping must be piped such that the potential of severe burns is eliminated. DO NOT pipe in any area where freezing could occur. DO NOT install any shut-off valves, plugs or caps. Consult local codes for proper discharge piping arrangement.

2 Circulator (Required) – Usually at least two

circulators will be required to properly install a Phantom Series boiler. See Paragraph B above for information on sizing the circulators.

3. Expansion Tank (Required) – If this boiler is

replacing an existing boiler with no other changes in the system, the old expansion tank can generally be reused. If the expansion tank must be replaced, consult the expansion tank manufacturer’s literature for proper sizing.

4. Fill Valve (Required) – Either manual

(recommended) or automatic ll valve may be used. However, if automatic rell is employed, a water

meter must be added to evaluate the makeup water

CAUTION

Page 40

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 13 for recommended Boiler Loop

Circulator.

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

Figure 21: Near Boiler Piping - Heating Only

Page 41

CAUTION

It is the installers responsibility to select pumps

and boiler piping congurations that provide the

proper ow rates and performance for the boiler

and indirect water heater.

Refer to Table 13 for recommended Boiler Loop

Circulator.

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

Figure 22: Near Boiler Piping - Heating Plus Indirect Water Heater

Page 42

VI. Water Piping and Trim D.Special Situation Installation Requirements, E. Multiple Boiler Installation

(continued)

volume taken after initial ll and eliminate any

water leakage as early as possible.

5. Automatic Air Vent (Required) –At least one

automatic air vent is required. Manual vents will usually be required in other parts of the system to

remove air during initial ll.

6. Manual Reset High Limit (Required by some Codes) – This control is required by ASME CSD-1

and some other codes. Install the high limit in the

boiler supply piping just above the boiler with no intervening valves. Set the manual reset high limit to 200°F. Wire the limit per Figures 26 and 27 in Section VIII Electrical.

7. Flow Control Valve (Strongly Recommended) –

The ow control valve prevents ow through the

system unless the circulator is operating. Flow control valves are used to prevent gravity circulation

or “ghost ows” in circulator zone systems through

zones that are not calling for heat.

8. Y-strainer (Recommended) – A Y-strainer or

equivalent strainer removes heating system debris from hydronic systems and protects boiler heat exchanger from fouling up. Install the strainer downstream of full port isolation valve, at the inlet side of the circulator, for easy service.

9. Isolation Valves (Strongly recommended) –

Isolation valves are useful when the boiler must be drained, as they will eliminate having to drain and

rell the entire system.

10. Drain Valve (Required) – Drain valve is

packaged loose with boiler and must be installed in the location shown in Figure 20 “Factory Supplied Piping and Trim Installation” of the Installation, Operating and Service Instructions.

11. Low Water Cutoff (Required by some Codes) –

Optional Automatic Reset LWCO with harness

is available. Order Part Number 450610 when required.

D. Special Situation Installation Requirements

Observe the following guidelines when making the

actual installation of the boiler piping for special situations:

1. Systems containing high level of dissolved oxygen – Many hydronic systems contain enough

dissolved oxygen to cause severe corrosion damage to Phantom boiler heat exchanger. Some examples include but not limited to:

• Radiant systems employing tubing without

oxygen barrier

• Systems with routine additions of fresh water

• Systems open to atmosphere

If the boiler is used in such a system, it must be

separated from oxygenated water being heated with a heat exchanger as shown in Figure 24. Consult the heat exchanger manufacturer for proper heat

exchanger sizing as well as ow and temperature

requirements. All components on the oxygenated side of the heat exchanger, such as the pump and expansion tank, must be designed for use in oxygenated water.

2. Piping with a Chiller - If the boiler is used in

conjunction with a chiller, pipe the boiler and chiller in parallel. Use isolation valves to prevent chilled water from entering the boiler.

3. Boiler Piping with Air Handlers - Where the

boiler is connected to air handlers through which

refrigerated air passes, use ow control valves in the

boiler piping or other automatic means to prevent gravity circulation during the cooling cycle.

E. Multiple Boiler Installation Water Piping –

(See Table 15 and Figures 23A and 23B)

1. Refer to this Section of this manual for:

a. Installation of Factory Supplied Piping and Trim

Components for an individual module (boiler).

b. Regarding an individual module (boiler) piping

system specic details.

c. Selection criteria for individual module (boiler)

space heating and/or DHW circulators.

2. For installations where indirect domestic hot water heater is combined with space heating,

pipe the indirect water heater zone off of the primary loop as shown in Figure 23A.

Table 15: Multiple Boiler Water Manifold Sizing

Number of Boilers

Boiler Model

PHNTM210 2” 2½” 2½” 3” 3½” 3½” 3½” PHNTM285 2” 3” 3” 3½” 4” 4” 5”

2 3 4 5 6 7 8

Recommended Minimum Common Water

Manifold Size (NPT)

Page 43

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

Figure 23A: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 1 of 2)

NOTICE

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by Local Codes.

Page 44

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

Figure 23B: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

NOTICE

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by Local Codes.

Page 45

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

NOTICE

The Phantom boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once lled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.

•

Before connecting the boiler, insure the system is free of impurities, grease, sediment, construction dust, sand, copper dust, ux and any residual boiler water additives. Flush the system thoroughly and repeatedly, if needed, with clear water mixed with concentrated rinse agent to remove these contaminants completely.

•

Iron oxide (red oxide sludge Fe ence in the system, the system must be air free and leak tight. Do not connect the boiler to radiant tubing without an oxygen barrier. Using automatic water rell is not recommended, however, if such rell is employed, a water meter must be added to evaluate the makeup water volume taken after initial ll and eliminate any water leakage as early as possible.

•

Maintain the water pressure in the boiler at a minimum of 14.5 psi (100 kPa).

•

The boiler water pH must be within 7.5 < pH < 9.5. If the system contains any aluminum components, pH must be less than 8.5.

•

Black oxide sludge (magnetite Fe system not protected by an inhibitor.

•

Scale deposit is made up of lime scale contained in most distributed water and settles over the warmest surfaces of boiler heat exchanger causing subsequent overheating and eventual failure. Water hardness must be maintained within 3 to 9 grain/gal range.

•

Refer to Section XI “Service and Maintenance” for recommended heating system water treatment products (corrosion/scale inhibitors, cleaners etc) and their suppliers.

) is produced during oxygenation. To minimize any oxygen pres-

2O3

) forms as the result of continuous electrolytic corrosion in any

3O4

Figure 24: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

Page 46

VII. Gas Piping

WARNING

Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation and damage to the boiler or structure. Always assure gas piping is absolutely leak free and of the proper size and type for the connected load.

An additional gas pressure regulator may be needed. Consult gas supplier.

NOTICE

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

A. Size gas piping. Design system to provide adequate

gas supply to boiler. Consider these factors:

1. Allowable pressure drop from point of delivery to boiler. Maximum allowable system

pressure is ½ psig (3.4 kPa). Actual point of delivery pressure may be less; contact gas supplier for additional information. Minimum gas valve inlet pressure is printed on the rating label located in the boiler’s vestibule compartment.

2. Maximum gas demand. Refer to the boiler’s

input as printed on its rating label. Also consider existing and expected future gas utilization equipment (i.e. water heater, cooking equipment).

3. Length of piping and number of ttings.

Refer to Tables 17A (natural gas) or 17B (LP gas) for maximum capacity of Schedule 40 pipe. Table

15 lists equivalent pipe length for standard ttings.

4. Specic gravity of gas. Gas piping systems for

gas with a specic gravity of 0.60 can be sized directly from Table 14 and gas with a specic

gravity of 1.5 can be sized from Table 16B, unless

authority having jurisdiction species a gravity factor be applied. For other specic gravity, apply gravity factor from Table 16. If exact specic

gravity is not shown choose next higher value.

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, ANSI Z223.1/ NFPA 54 or Natural Gas and Propane Installation Code, CAN/CSA B149.1, or size system using standard engineering methods acceptable to authority having jurisdiction.

B. Connect boiler gas valve to gas supply

system.

Table 17A: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 0.5 PSI or less; 0.3 Inch W.C. Pressure Drop

Nominal Pipe

Size, In.

½ 0.622 131 90 72 62 55 50 46 42 40 38 ¾ 0.824 273 188 151 129 11 4 104 95 89 83 79

1 1.049 514 353 284 243 215 195 179 167 157 148 1¼ 1.380 1056 726 583 499 442 400 368 343 322 304 1½ 1.610 1582 1087 873 747 662 600 552 514 482 455

2 2.067 3046 2094 1681 1439 1275 1156 1063 989 928 877 2½ 2.469 4856 3337 2680 2294 2033 1842 1695 1576 1479 1397

3 3.068 8584 5900 4738 4055 3594 3256 2996 2787 2615 2470

Nominal Pipe

Size, In.

½ 0.622 172 118 95 81 72 65 60 56 52 50 ¾ 0.824 360 247 199 170 151 137 126 117 11 0 104

1 1.049 678 466 374 320 284 257 237 220 207 195 1¼ 1.380 1392 957 768 657 583 528 486 452 424 400 1½ 1.610 2085 1433 1151 985 873 791 728 677 635 600

2 2.067 4016 2760 2217 1897 1681 1523 1402 1304 1223 1156 2½ 2.469 6401 4400 3533 3024 2680 2428 2234 2078 1950 1842

3 3.068 11316 7778 6246 5345 4738 4293 3949 3674 3447 3256

Inside

Diameter, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 0.5 PSI or less; 0.5 Inch W.C. Pressure Drop

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

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

Page 47

VII. Gas Piping (continued)

Table 17B: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 0.5 psig or Less

Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop

Nominal

Pipe Size, In.

½ 0.622 88 60 48 41 37 33 31 29 27 25

¾ 0.824 184 126 101 87 77 70 64 60 56 53

1 1.049 346 238 191 163 145 131 121 112 105 100

1¼ 1.380 710 488 392 336 297 269 248 231 216 204

1½ 1.610 1064 732 588 503 446 404 371 346 324 306

2 2.067 2050 1409 1131 968 858 778 715 666 624 590

2½ 2.469 3267 2246 1803 1543 1368 1239 1140 1061 995 940

3 3.068 5776 3970 3188 2729 2418 2191 2016 1875 1760 1662

Nominal

Pipe Size, In.

½ 0.622 11 6 80 64 55 48 44 40 38 35 33

¾ 0.824 242 166 134 114 101 92 85 79 74 70

1 1.049 456 314 252 215 191 173 159 148 139 131

1¼ 1.380 937 644 517 442 392 355 327 304 285 269

1½ 1.610 1403 964 775 663 588 532 490 456 427 404

2 2.067 2703 1858 1492 1277 1131 1025 943 877 823 778

2½ 2.469 4308 2961 2377 2035 1803 1634 1503 1399 1312 1239

3 3.068 7615 5234 4203 3597 3188 2889 2658 2472 2320 2191

Inside

Diameter, In.

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 11.0 Inch W.C.; 0.5 Inch W.C. Pressure Drop

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

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

Table 18: Equivalent Lengths of Standard Pipe Fittings & Valves

Nominal

Pipe Size,

Inc.

½ 0.622 0.4 17.3 8.7 4.3 0.7 1.6 3.5 1.6 3.1

¾ 0.824 0.5 22.9 11.4 5.7 1.0 2.1 4.6 2.1 4.1

1 1.049 0.6 29.1 14.6 7.3 1.2 2.6 5.8 2.6 5.2

1¼ 1.38 0.8 38.3 19.1 9.6 1.6 3.5 7.7 3.5 6.9

1½ 1.61 0.9 44.7 22.4 11.2 1.9 4.0 9.0 4.0 8.0

2 2.067 1.2 57.4 28.7 14.4 2.4 5.2 11.5 5.2 10.3

2½ 2.469 1.4 68.5 34.3 17.1 2.9 6.2 13.7 6.2 12.3

3 3.068 1.8 85.2 42.6 21.3 3.6 7.7 17.1 7.7 15.3

Inside

Diameter,

In.

Valves (Screwed) - Fully Open Screwed Fittings

180 Close

Return

Bend

90 Tee Flow

Through Run

Gate Globe Angle

Swing Check

45°

Elbow

90°

Elbow

90 Tee, Flow

Through

Branch

Page 48

VII. Gas Piping (continued)

Table 19: Specic Gravity Correction Factors

Specic

Gravity

0.60 1.00 0.90 0.82

0.65 0.96 1.00 0.78

0.70 0.93 1.10 0.74

0.75 0.90 1.20 0.71

0.80 0.87 1.30 0.68

0.85 0.81 1.40 0.66

Correction

Factor

Specic

Gravity

Correction

Factor

WARNING

Explosion Hazard. Failure to use proper thread compounds on all gas connectors may result in leaks of ammable gas.

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

1. Use methods and materials in accordance

with local plumbing codes and requirements of gas supplier. In absence of such requirements, follow National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1.

2. Use thread (joint) compounds (pipe dope)

resistant to action of liqueed petroleum gas.

3. Phantom boilers have factory supplied

Miscellaneous Part Carton which includes gas piping components to connect boiler gas valve to gas supply system. Install these components prior to connecting boiler to gas supply system piping as follows:

a. Locate and remove either ½ in. NPT x 6 in. long

black nipple and ½ in. NPT external gas shutoff valve (PHNTM210), or ¾ in. NPT x 6 in. long black nipple and ¾ in. NPT external gas shutoff valve (PHNTM285 only).

b. Feed the appropriate nipple through factory

installed jacket left side panel grommet (refer to Figure 1A or 1B for gas supply connection

identication) and screw the nipple into boiler

gas valve inlet port.

c. Mount the appropriate external gas shutoff valve

onto the threaded nipple end outside of the jacket left side panel.

d. Install sediment trap, ground-joint union and

manual shut-off valve upstream of mounted factory supplied manual shut-off valve. See Figure 25.

4. All above ground gas pipin

g upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do not use gas piping as grounding electrode. Refer to National Electrical Code, NFPA 70.

C. Pressure test. See Table 20 for Phantom Min./Max.

Pressure Ratings. The boiler and its gas connection must be leak tested before placing boiler in operation.

1. Protect boiler gas control valve. For all testing

over ½ psig, boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig or less, isolate boiler from gas supply piping by closing boiler’s individual manual shutoff valve.

2. Locate leaks using approved combustible gas

non-corrosive leak detector solution.

Table 20: Min./Max. Pressure Ratings

Natural Gas

Min. Pressure

Inlet to Gas

Valve

(in. w.c.)

Boiler

Model No.

PHNTM210

PHNTM285

Natural/LP

Gas Max. Pressure

(in. w.c.)

14 4.0 11.0

Figure 25: Recommended Gas Piping

LP Gas

Min.

Pressure

Inlet to Gas

Valve

(in. w.c.)

DANGER

Explosion Hazard. Do not use matches, candles, open ames or other ignition source to check for leaks.

Page 49

VII. Gas Piping (continued)

E. Gas Piping for Multiple Boiler Installation

1. Individual module (boiler) gas pipe sizing specic details - see Paragraph A.

2. Individual module (boiler) recommended gas

piping detail - see Figure 25.

3. An additional gas pressure regulator(s) may need

to be installed to properly regulate inlet gas pressure at the smallest individual module (boiler).

CAUTION

If gas pressure in the building is above ½ psig (3.4 kPa), an additional gas pressure regulator is required. Using one additional regulator for multiple boilers may result in unsafe boiler operation. The additional regulator must be able to properly regulate gas pressure at the input of the smallest boiler. If the regulator cannot do this, two or more additional regulators are required. Consult regulator manufacturer and/or local gas supplier for instructions and equipment ratings.

Page 50

VIII. Electrical

DANGER

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

WARNING

Electrical Shock Hazard. Failure to properly wire electrical connections to the boiler may result in serious physical harm.

Electrical power may be from more than one source. Make sure all power is off before attempting any electrical work.

Each boiler must be protected with a properly sized over-current device.

Never jump out or make inoperative any safety or operating controls.

The wiring diagrams contained in this manual are for reference purposes only. Each boiler is shipped with a wiring diagram attached to the front door. Refer to this diagram and the wiring diagram of any controls used with the boiler. Read, understand and follow all wiring instructions supplied with the controls.

IMPORTANT

This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

• An external energy management system is installed that reduces the boiler water temperature as the heating load decreases.

• This boiler is not used for any space heating.

• This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr or greater.

• This boiler is equipped with a tankless coil.

NOTICE

This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control. Certain local codes require an additional water temperature limit. In addition, certain types of systems may operate at temperatures below the minimum set point of the limit contained in the boiler.

If this occurs, install an additional water temperature limit (Honeywell L4006 Aquastat). Wire as indicated in the Electrical Section of this manual.

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

A. General. Install wiring and electrically ground boiler

in accordance with authority having jurisdiction or, in the absence of such requirements, follow the National

Electrical Code, NFPA 70, and/or Canadian Electrical Code Part 1, CSA C22.1 Electrical Code.

B. A separate electrical circuit must be run

from the main electrical service with an over-current device/disconnect in the circuit. A service switch is

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

Page 51

VIII. Electrical (continued)

C. Refer to Figures 26 and 27 for details on the

internal boiler wiring.

Line Voltage (120 VAC) Connections - see Figure 26.

1. The line voltage connections are located in the

junction box on the left side of the vestibule. The terminal block TB-1 in conjunction with terminal

screw identication label is attached to the junction

box combination cover/inside high voltage bracket.

2. The conductor insulation colors are:

a. Black – L1 line voltage “Hot” b. White – L2 line voltage “Neutral” for boiler and

circulators

c. Red – Line voltage “Hot” for “Heating”

circulator, “System” circulator and “DHW” circulator

d. Green – Ground connection

Low Voltage (24 VAC) Connections - see Figure 26.

3. The terminal block TB-2 in conjunction with

terminal screw identication label is attached to the

junction box front and located inside R7910 Control compartment on the left side.

4. The connections are (listed identication label top to bottom):

• 1 – “Heating Thermostat”

• 2 – “Heating Thermostat”

• 3 – “DHW Temperature Switch”

• 4 – “DHW Temperature Switch”

• 5 – “Outdoor Sensor”

• 6 – “Outdoor Sensor”

• 7 – “Header Sensor”

• 8 – “Header Sensor”

• 9 – “Remote Firing Rate -”

• 10 – “Remote Firing Rate +”

• 11 – “External Limit”

• 12 – “External Limit”

5. If the outdoor sensor is connected to

terminals 5 and 6 “Outdoor Sensor”, the boiler will adjust the target space heating set point supply water temperature downwards as the outdoor air temperature increases. If used, this sensor should be located on the outside of the structure in an area where it will sense the average air temperature around the house. Avoid placing this sensor in areas where it may be covered with ice or snow. Locations where the sensor will pick up direct radiation from the sun should also be avoided. Avoid placing the sensor near potential sources of electrical noise

such as transformers, power lines, and uorescent

lighting. Wire the sensor to the boiler using 22 gauge or larger wire. As with the sensor, the sensor

wiring should be routed away from sources of electrical noise. Where it is impossible to avoid such noise sources, wire the sensor using a 2 conductor, UL Type CM, AWM Style 2092, 300 Volt 60°C shielded cable. Connect one end of the shielding on this cable to ground.

NOTICE

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

D. Power Requirements

Nominal boiler current draw is provided in Table

21. These values are for planning purposes only and represent only the boiler’s power consumption. To obtain total system power consumption add any selected circulator and component current draws.

Table 21: Boiler Current Draw

Model Number

PHNTM210 <3

PHNTM285 <5

E. Multiple Boiler Wiring

Install over-current protection in accordance with

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

F. External Multiple Boiler Control System

This boiler is equipped with a Honeywell R7910 Control

which has a built-in sequencer for multiple boiler operation.

The R7910 control also accepts a 4-20 mA input from an

external sequencer. Follow multiple boiler control system manufacturer (Honeywell, Tekmar, etc.) instructions to properly apply a multiple boiler control system.

Nominal Current

(amps)

Page 52

VIII. Electrical (continued)

Page 53

VIII. Electrical (continued)

Figure 26: Wiring Connections Diagram

Page 54

VIII. Electrical (continued)

Figure 27: Ladder Diagram

Page 55

VIII. Electrical (continued)

Figure 28A: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater

Page 56

VIII. Electrical (continued)

Heating (with Central Heating Zone Valves) Plus Alternately Piped Indirect Water Heater

Figure 28B: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

Page 57

VIII. Electrical (continued)

CROWN PN 3501505

Figure 28C: DHW Priority/Circulators (with Crown PN 3501505 Zone Panel) Piped Off

System Header Wiring Schematic for Heating Zone Circulators

Page 58

VIII. Electrical (continued)

Figure 29A: Multiple Boiler Wiring Diagram

Internal R7910 Multiple Boiler Control Sequencer

(Three Boilers Shown, Typical Connections for up to Eight Boilers)

Page 59

VIII. Electrical (continued)

Figure 29B: Boiler-to-Boiler Communication (with Crown Zone Panel PN 3501505)

Page 60

VIII. Electrical (continued)

G. Multiple Boiler Operating Information

1. Required Equipment and Setup

a. Header Sensor (Honeywell 32003971-003)

A header sensor must be installed and wired

to the Master Sequencer “enabled” R7910 Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master. Refer to piping diagram Figure 23A for installation location and Figure 30 for installation detail.

b. Ethernet Cables

Ethernet cables are used to connect the boiler

network together. These are standard “straight through” cables that can be purchased at electrical distributors.

Alternately, the network can be wired together

by simply wiring terminal J3, Modbus 2, terminals A, B and V- between each boiler. Refer to Figures 26 and 27 terminal J3 for wiring location.

c. RJ45 Splitters

When Ethernet cables are used to connect three

or more boilers together, RJ45 Splitters are required. When two boilers are connected the splitter is not required.

Figure 30: Recommended “Immersion”

Type Header Sensor Installation Detail

Figure 31: RJ45 Splitter Installation Detail

Page 61

VIII. Electrical (continued)

d. Multiple Boiler Setup

Step Description Comments

Wire the header sensor to low voltage terminal strip terminals “Header sensor”.

Install and wire the Header

Sensor

Install Ethernet Cables

between boilers

3 Apply Power to All Boilers

Set Unique Boiler

Addresses

5 Enable 1 Boiler Master

6 Power Down All Boilers

Power Up Master

Sequencer

“Enabled” Boiler First

This step can not be skipped. The Sequence Master can not be “enabled”unless a Header

Sensor is installed.

Standard Ethernet type cables with RJ45 connectors are “plugged in” to the Boiler-to-Boiler Communication Network connection located on the side of the boiler. When more than two boilers are connected an RJ45 splitter may be used to connect the boilers. Refer to Figure

31.

Assign all boilers a unique Boiler Address using any number from 1 through 8.

When two boiler’s addresses are the same undesirable simultaneous operation occurs.

Enable only one Control’s Sequencer Master.

When more than one Sequencer Master is enable erratic behavior will result.

NOTE

WARNING

8 Power Up Other Boilers

9 Conrm Communication

From the Home Screen of the Control with the Master Sequencer “enabled”, select the Status button. The Sequencer display shows the boiler address of the communicating boilers. Additionally, from the “Home” screen select the “Detail” button and then the “Networked Boilers” buttons to view boiler communication status.

If a boiler is not shown, check Ethernet cable connections and conrm all boilers have unique

addresses.

Page 62

IX. System Start-up

WARNING

Explosion Hazard. Asphyxiation Hazard. Electrical Shock Hazard. Start-up of this boiler should be undertaken only by trained and skilled personnel from a qualied service agency. Follow these instructions exactly. Improper installation adjustment, service or maintenance can cause property damage, personal injury or loss of life.

A. Verify that the venting, water piping, gas

piping and electrical system are installed properly.

in this manual.

Refer to installation instructions contained

B. Conrm all electrical, water and gas

supplies are turned off at the source

vent is clear of obstructions.

and that

C. Conrm that all manual shut-off gas valves

between the boiler and gas source are closed.

D. If not already done, ush the system to remove

sediment, ux and traces of boiler additives. This must

be done with the boiler isolated from the system. Fill entire heating system with water meeting the following requirements:

NOTICE

pH between 7.5 and 9.5. If system contains aluminum components, pH

must be less than 8.5 Chlorides< 50 ppm Total Dissolved Solids - less than 2500 PPM Hardness - 3 to 9 grains/gallon.

F. Prepare to check operation.

1. Obtain gas heating value (in Btu per cubic foot)

from gas supplier.

2. Phantom gas valves have inlet and outlet

pressure taps with built-in shut off screw. Turn

each screw from fully closed position three to four turns counterclockwise to open taps. Connect manometers to pressure taps on gas valve.

NOTICE

If it is required to perform a long term pressure test of the hydronic system, the boiler should rst be isolated to avoid a pressure loss due to the escape of air trapped in the boiler.

To perform a long term pressure test including the boiler, ALL trapped air must rst be removed from the boiler.

A loss of pressure during such a test, with no visible water leakage, is an indication that the boiler contained trapped air.

3. Temporarily turn off all other gas-red

appliances.

4. Turn on gas supply to the boiler gas piping.

5. Open the eld installed manual gas shut-off valve

located upstream of the gas valve on the boiler.

6. Conrm that the supply pressure to the gas valve

is 13.5 in wc (3.4 kPa) or less. Refer to Table 20 for minimum supply pressure.

7. Using soap solution, or similar non-combustible

solution, electronic leak detector or other approved method, check that boiler gas piping valves, and all other components are leak free. Eliminate any leaks.

Pressurize the system to at least 20 psi (140 kPa).

Purge air from the system.

WARNING

Burn Hazard. The maximum operating pressure of this boiler is 30 psig (210 kPa), 50 psig (340 kPa), 80 psig (550 kPa) or 100 psig (689 kPa) depending on the model and safety relief valve option selected. Never exceed the maximum allowable working pressure on the heat exchanger ASME plate.

E. Conrm that the boiler and system have no

water leaks.

DANGER

Explosion Hazard. Do not use matches, candles, open ames or other ignition source to check for leaks.

8. Purge gas line of air.

G. Operating Instructions

Start the boiler using the Operating Instructions, see

Figure 32. After the boiler is powered up, it should go through sequence of operation shown in Table 28.

H. Purge Air From Gas Train

Upon initial start-up, the gas train will be lled with air.

Even if the gas line has been completely purged of air,

it may take several tries for ignition before a ame is

Page 63

IX. System Start-up (continued)

Phantom Series Lighting and Operating Instructions

Figure 32: Operating Instructions

Page 64

IX. System Start-up (continued)

Status Control Action

Initiate Power-up

This state is entered when a delay is

Standby Delay

Standby

Safe Startup

Drive Purge

Prepurge

Drive Light-off

Pre-ignition

Test

Pre-ignition

Direct

Ignition

Running

Postpurge

Lockout

needed before allowing the burner control to be available and for sensor errors.

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

Tests ame circuit then checks for ame

signal.

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

Purges the combustion chamber for the

10 second purge time.

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

Tests the safety relay and veries that

downstream contacts are off.

Energizes the igniter and checks for ame.

Opens main fuel valve and attempts

to ignite the main fuel directly from the

ignition source.

Normal boiler operation. Modulation rate

depends on temperature and setpoint selections and modulating control action.

Purges the combustion chamber for the

30 second purge time.

Prevents system from running due to a

detected problem and records fault in

Lockout History.

established. If more than 2 tries for ignition are needed, it will be necessary to press the reset button to restart

the boiler. Once a ame has been established for the rst time, subsequent calls for burner operation should result in a ame on the rst try.

I. Check Burner Flame

Inspect the ame visible through the window. On high

re the ame should be stable and mostly blue (Figure

33). No yellow tipping should be present; however,

intermittent ecks of yellow and orange in the ame are

normal.

J. Check Gas Inlet Pressure

Check the inlet pressure and adjust if necessary. Verify

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

WARNING

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

K. For LP Gas, perform procedure as described

in Paragraph Q “Field Conversion From Natural Gas to LP Gas”.

L. Perform Combustion Test

WARNING

Asphyxiation Hazard. Each Phantom Series boiler is tested at the factory and adjustments to the air fuel mixture are normally not necessary. Improper gas valve or mixture adjustments could result in property damage, personal injury or loss of life.

Any gas valve adjustments (throttle and/ or offset) specied herein and subsequent combustion data (%O collection must be performed using a calibrated combustion analyzer. Failure to use combustion analyzer could result in property damage, personal injury or loss of life.

1. Remove ue temperature sensor from vent

connector (see Figure 9) and insert combustion

analyzer probe through ue temperature sensor cap opening. If required, also remove the ue

temperature sensor silicon cap and insert the

analyzer probe directly into ue sensor port.

Reinstall the sensor and the cap upon combustion testing completion.

2. Verify O2 (or CO2) and CO are within limits

specied in Table 22 (natural gas) or Table 23 (LP gas) at both high and low re as described in the

following steps.

, %CO2, CO ppm)

Figure 33: Burner Flame

Page 65

IX. System Start-up (continued)

a. Lock boiler in high re and allow boiler to

operate for approximately 5 minutes before taking combustion readings. To lock boiler in

high re, from the home screen, press “Adjust”,

Table 22: Typical Combustion Settings, Natural Gas

Boiler Model

PHNTM210

PHNTM285

% CO

9.9 - 8.2

(High Fire)

9.9 - 7.9

(Low Fire)

Altitude Range

0 - 7000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire)

Less than

100 PPM

Table 23: Typical Combustion Settings, LP Gas

Boiler

Model

PHNTM210

PHNTM285

% CO

11.4 - 9.5

(High Fire)

11.4 - 9.1

(Low Fire)

Altitude Range

0 - 7000 Ft.

% O2 Range CO, PPM

3.5 - 6.5

(High Fire)

3.5 - 7.0

(Low Fire)

Less than

100 PPM

“Adjust”, “Login”, “000”. Enter the password “086” and press return arrow to close the keypad. Press “Save”, “Adjust”, “High” to lock boiler in

high re.

WARNING

Make sure that all adjustments at high re are made with the throttle, not offset screw (see Figure 34). The offset screw has been factory set using precision instruments and must never be adjusted in the eld unnecessarily. Attempting to adjust the offset screw unnecessarily could result in damage to the gas valve and may cause property damage, personal injury or loss of life.

to both gas valves equally and simultaneously. Refer to Figure 34 for location of throttle screw. Verify CO is less than 100 ppm.

d. Lock boiler in low re and allow boiler to

operate for approximately 5 minutes before taking combustion readings. Press “Low” to

lock boiler in low re.

WARNING

Asphyxiation Hazard. Offset screw is adjusted at the factory to the specication. DO NOT touch the offset screw if measured low re O2 (or CO2) is within limits specied in Table 22 or 23.

e. If low re O

is too low (CO2 is too high),

increase O2 (decrease CO2) by turning offset screw counterclockwise in less than 1/8 turn increments and checking the O

(or CO2) after

each adjustment. If boiler is equipped with 2 gas valves, offset screw adjustments must be done to both gas valves equally and simultaneously. Refer to Figure 34 for location of offset screw. Verify CO is less than 100 ppm.

f. If low re O2 is too high (CO2 is too low),

decrease O2 (increase CO2) by turning offset screw clockwise in less than 1/8 turn increments and checking the O2 (or CO2) after each adjustment. If boiler is equipped with 2 gas valves, offset screw adjustments must be done to both gas valves equally and simultaneously. Refer to Figure 34 for location of offset screw. Verify CO is less than 100 ppm.

WARNING

Asphyxiation Hazard. Install ue temperature sensor and sensor cap into two-pipe vent connector port upon completion of combustion test. Failure to properly secure the ue temperature sensor into the port could lead to property damage, personal injury or loss of life.

b. If high re O

is too low (CO2 is too high),

increase O2 (decrease CO2) by turning the throttle screw clockwise in 1/4 turn increments and checking the O2 (or CO2) after each adjustment. Refer to Figure 34 for location of throttle screw. Verify CO is less than 100 ppm.

c. If high re O2 is too high (CO2 is too low),

decrease O2 (increase CO2) by turning the throttle screw counter-clockwise in 1/4 turn increments and checking the O2 (or CO2) after each adjustment. If boiler is equipped with 2 gas valves, throttle screw adjustments must be done

3. Reinstall ue temperature sensor with sensor

cap at two-pipe vent adapter.

a. Inspect ue temperature sensor cap for

degradation. Replace if needed.

b. Use Molykote 111 grease to lubricate outer

surface of two-pipe vent adapter stub where ue

temperature sensor is inserted. Also lubricate

tip of ue temperature sensor. Reinstall ue

temperature sensor with cap into two-pipe vent adapter.

4. Return boiler to normal operating mode by

pressing “Auto”.

Page 66

IX. System Start-up (continued)

M. Test Safety Limits Controls

1. Test the ignition system safety shut-off by

disconnecting the ame sensor connector (black plug with orange wire) from the ame ionization

electrode. See Figure 26. The boiler must shut

down and must not start with the ame sensor

disconnected.

2. Test any other external limits or other controls

in accordance with the manufacturer’s instructions.

N. Check Thermostat Operation

Verify that the boiler starts and stops in response to

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

WARNING

Explosion Hazard. Asphyxiation Hazard. This conversion should be performed by a qualied service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a re, an explosion or production of carbon monoxide may result causing property damage, personal injury, or loss of life. The qualied service agency is responsible for proper conversion of these boilers. The conversion is not proper and complete until the operation of the converted appliance is checked as specied in this manual.

O. Adjust Supply Water Temperature

As shipped, the heating set point supply temperature

is set to 180°F (82.2°C) and, indirect water heater set point supply temperature is set to 170°F (76.7°C). If necessary, adjust these to the appropriate settings for the type of system to which this boiler is connected. See Section X “Operation” (Parameter Table 29) of this manual for information on how to adjust supply setpoint.

P. Adjust Thermostats

Adjust the heating and indirect water heater thermostats

to their nal set points.

Q. Field Conversion From Natural Gas to LP

Gas

Phantom models PHNTM210 and PHNTM285

are factory shipped as natural gas builds. Models

congured for use at altitudes below 7000ft can be eld converted to LP gas. Follow steps below for eld

conversion from natural gas to LP Gas.

1. Conversion of Phantom models PHNTM210

and PHNTM285 from one fuel to another is accomplished using the throttle screw on the gas valve. Figure 34 “Gas Valve Detail” shows the location of the throttle screw on the valve. Locate the throttle screw on the boiler being converted.

2. If conversion is being made on a new installation, install the boiler in accordance

with the installation instructions supplied with the boiler. If an installed boiler is being converted, connect the new gas supply to the boiler, check for gas leaks, and purge the gas line up to the boiler in accordance with the National Fuel Gas Code, ANSI Z223.1/NFPA 54 and/or Natural Gas and Propane Installation Code, CAN/CSA B149.1 or the requirements of the authority having jurisdiction.

3. Before attempting to start the boiler, make the

number of turns to the throttle screw called for in Table 24.

4. Attempt to start the boiler using the Operating

Instructions located inside the lower front cover of

the boiler. If the boiler does not light on the rst

try for ignition, allow to boiler to make at least four more attempts to light. If boiler still does not light, turn the throttle counter clockwise in 1/4 turn increments, allowing the boiler to make at least three tries for ignition at each setting, until the boiler lights.

WARNING

Asphyxiation Hazard. The throttle adjustments shown in Table 24 are approximate. The nal throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO level in excess of the value shown in Table 23 could result in injury or death from carbon monoxide poisoning.

5. After the burner lights, complete all steps

outlined in Paragraph L “Perform Combustion Test” before proceeding.

Page 67

IX. System Start-up (continued)

6. Verify that the gas inlet pressure is between the

upper and lower limits shown in Table 20 with all gas appliances (including the converted boiler) both on and off.

WARNING

Asphyxiation Hazard. These instructions include a procedure for adjusting the air-fuel mixture on this boiler. This procedure requires a combustion analyzer to measure the O2 (or CO2) and Carbon Monoxide (CO) levels in ue gas. Adjusting the air-fuel mixture without a proper combustion analyzer could result in unreliable boiler operation, personal injury, or death due to carbon monoxide poisoning.

7. A label sheet is provided with the boiler for

conversions from natural gas to LP gas. Once conversion is completed, apply labels as follows:

a. Apply the “Rating Plate Label” adjacent to the

rating plate.

b. Apply the “Gas Valve Label” to a conspicuous

area on the gas valve.

c. Apply the “Boiler Conversion Label” to a

conspicuous surface on, or adjacent to, the outer boiler jacket. Fill in the date of the conversion and the name and address of the company making the conversion with a permanent marker.

Table 24: Number of Clockwise Throttle Screw

Turns for LP Conversion

Throttle Screw Turns at

Boiler Model Gas Valve

Dungs

PHNTM210

PHNTM285

GB-055

(½” NPT)

Dungs

GB-057

(¾” NPT)

Altitude Range

0 - 7000 Ft.

2¾

3¼

4½

R. Correcting Throttle Screw Mis-Adjustment

(if required)

Phantom boilers are re tested at factory and gas

valve throttle screws are preset. However, if boiler

does not start when rst turned on, and, the problem

cannot be remedied following “Help” prompts on the boiler control display, it may be necessary to reset and readjust the throttle screw according to the following instructions.

1. Fully close throttle by turning throttle screw

clockwise until it fully stops.

2. Open throttle screw counter-clockwise the

number of full (360 degrees) and partial turns listed in Table 25A for natural gas or Table 25B for LP gas.

3. Follow instructions in Section L “Perform

Combustion Test” to verify O2 (or CO2) is within the

range specied in Table 22 for natural gas or Table 23 for LP gas at both high re and low re.

Figure 34: Dungs Gas Valve Detail

WARNING

The throttle adjustment values shown in Table 25A and Table 25B are approximate. The nal throttle setting must be found using a combustion analyzer.

Page 68

IX. System Start-up (continued)

Table 25A: Approximate Throttle Screw Adjustment Values from Fully Closed Position, Natural Gas

Boiler

Model

PHNTM210 9 &1/2

PHNTM285 9

(Number of Counter-clockwise Turns

Throttle Position

from Fully Closed Position

Table 25B: Approximate Throttle Screw Adjustment Values from Fully Closed Position, LP Gas

Boiler

Model

PHNTM210 5 & 1/2

PHNTM285 4 & 1/2

Throttle Position (Number of Counter-

clockwise Turns from Fully Closed

Position

WARNING

Asphyxiation Hazard. If the throttle is very far out of adjustment on the “rich” (counter-clockwise) side, the boiler burner may be running at 0% excess air or even with air deciency. Operating the boiler in this condition may cause property damage, personal injury or loss of life.

Under these conditions most combustion analyzers used in the eld will show 0% O2 and a very high (well over 1000 ppm) CO. Combustion readings will also appear to be unresponsive to throttle adjustment.

If the boiler appears to operate under these conditions, shut down the boiler and follow instructions in Paragraph S “Correcting Throttle Screws Mis-Adjustment. Then, use a combustion analyzer to verify and adjust O2 (or CO2) and CO to values shown in Table 22 for natural gas or Table 23 for LP gas.

Page 69

IX. System Start-up (continued)

S. Controls Startup Check List

The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked

and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.

No. Title Terminal Description

1 & 2

2 & 3 Is an Indirect Water Heater (IWH) providing a boiler heat demand?

5 & 6

From the Home Screen press the Adjust button and login to access the adjust mode screens (if required, refer to X. Operation Section, “Entering Adjustment Mode” Paragraph G, 1 for login instructions). The following parameters should be reviewed:

No. Menu Parameter Description

8 DHW

10 Sequencer Master Slave

Check

Wiring

System

Setup

Modulation

Setup

Pump Setup

Contractor

Setup

Manual Control

Central

Heat

Remote 4-20mA

7 & 8 Is a header sensor used? If yes, refer to step 10 below to activate this feature.

9 & 10

11 & 12 Is an External Limit used? Remember to remove factory-installed jumper.

LWCO Plug Is a LWCO required? Check installation of the LWCO.

Warm Weather

Shutdown

Warm Weather

Shutdown Setpoint

Boiler Type

System Pump

Boiler Pump

Domestic Pump

Contractor Name

Address

Phone

Manual Speed

Control

Setpoint Ensure Setpoint, (ring rate target temperature) is correct for your type of radiation.

Setback

Setpoint

Setpoint Ensure Setpoint, (ring rate target temperature) is suitable for the IWH requirements.

Setback

Setpoint

Modulation Source

Setpoint Source Set to 4-20mA when a Energy Management system is sending a “remote” setpoint.

Is the heating thermostat connected? Insure this is “dry”, non-powered input.

Is an Outdoor Air sensor used? If no, select outdoor sensor type “not installed” under

system menu.

Is a Remote 4-20mA required for a Energy Management System or external multiple boiler control? If used see step 9 below to activate this input.

Selecting “Enable” will restrict boiler start during warm weather (only if an outdoor air temperature sensor is installed).

Use this setting to adjust the temperature that the WWSD function will shut boiler off.

WARNING

Conrm that the correct boiler model is shown. Stop installation and contact factory if the wrong boiler model is shown.

Ensure that the pump parameter selections are correct for your heating system. Refer to Paragraph G. Adjusting Parameters, Pump Setup Menu for additional information.

Enter your contact information, name, address, and phone number on this screen. In the event of a fault or the need to adjust a setting the display will direct the homeowner to you.

Use the “High and “Low” options to force the boiler to high re and low re for combustion testing.

Check the setting for the central heat setpoint when the T-Stat “Sleep” or “Away” Setback mode is entered (if EnviraCOM Setback thermostat is used).

Check the setting for the DHW setpoint when the T-Stat “Sleep” or “Away” Setback mode is entered (if EnviraCOM Setback thermostat is used).

Set to 4-20mA when an external multiple boiler controller is connected to the system.

Refer to Sequencer Master Setup Section X, G if multiple boilers are installed at this

site.

Page 70

X. Operation

A. Overview

1. R7910 Controller

The R7910 Controller (Control) contains features and

capabilities which help improve heating system operation,

and efciency. By including unique capabilities, the Control can do more, with less eld wiring, and fewer aftermarket

controls and components – improving the operation of both new and replacement boiler installations.

2. Advanced Touch Screen Display

Home Screen

Boiler status and setup selections are available from an

easy to use, dual color, LCD Touch Screen Display. Over one hundred helpful information screens are provided to explain status information and setup functions. In the event of a fault condition the user is guided by “blinking” touch buttons to Help screens that explain the problem cause and corrective action. Operation evaluation and problem-solving is enhanced by historical capability including graphic trends, lockout history records as well as boiler and circulator cycle counts and run time hours.

3. Advanced Modulating Control

The Control modulates the boiler input by varying the fan

speed. As the fan speed increases, so does the amount of fuel gas drawn into the blower. As a result, a fairly constant air-fuel ratio is maintained across all inputs. The Control determines the input needed by looking at both current and recent differences between the measured temperature and the setpoint temperature. As the measured temperature approaches the setpoint temperature, the fan will slow down and the input will drop. The Control also utilizes boiler

return water and ue gas temperatures to adjust fan speed.

4. HeatMatchTM Software

When the boiler is installed with a Crown 3501505 Zone

Control Panel (Zone Control) into a multiple zone home the Control uses a patent pending HeatMatch Software to improve home comfort, increase component life and save energy. The R7910 Controller with the Zone Control detects active (turned “on”) zones, totals btu/hrs expected and limits

the boiler ring rate to “match” actual home demand. Instead of simply ring to 100% in response to a cold supply water

temperature the Control combines heat matching with supply water temperature control. The result is longer run times, dramatic reduction in boiler excessive cycling and higher

operating efciency. Avoiding extra cycling saves customer

fuel dollars (pre and post purge sends heat up stack) and saves wear and tear on the boiler. Lowering the boiler’s

ring rate saves fuel dollars by increasing the amount of ue gas condensation, always the goal of condensing boiler

installations.

5. Built-in Safety Control

The Control includes safety controls designed to ensure

safe and reliable operation. In addition to ame safety

controls the Control includes supply water temperature, differential water temperature, and stack temperature safety limits and stepped modulation responses. Boiler modulation is adjusted when required to help avoid loss of boiler operation due to exceeding limits. Additionally, the

Control accepts the eld installation of optional auxiliary

safety limits.

6. Outdoor Air Reset

When selected the modulation rate setpoint is automatically

adjusted based on outside air temperature, time of day and length of demand (boost) settings. Outdoor air “reset” setpoint saves fuel by adjusting the water temperature of a heating boiler lower as the outside air temperature increases.

7. Warm Weather Shutdown (WWSD)

Some boilers are used primarily for heating buildings,

and the boilers can be automatically shutdown when the outdoor air temperature is warm. When outside air temperature is above the WWSD setpoint, this function will shut down the boiler and system pump.

8. Energy Management System (EMS) Interface

The control accepts a 4-20mAdc input from the EMS

system for either direct modulation rate or setpoint.

A factory congured RS485 Modbus interface is available

for Energy Management System (EMS)monitoring when not used for Multiple Boiler Sequencer Peer-To-Peer Network. Consult factory if this interface must be used in addition to the boiler Peer-to-Peer Network.

9. Circulator Control

The Control may be used to sequence the domestic hot

water, boiler and system circulators. Service rated relay outputs are wired to a line voltage terminal block for

easy eld connection. Simple parameter selections allow

all three pumps to respond properly to various hydronic piping arrangements including either a boiler or primary piped indirect water heater. Circulators are automatically run for a 20 second exercise period after not being used for longer than 7 days. Circulator exercise helps prevent pump rotor seizing.

10. Multiple Boiler Sequencer Peer-To-Peer Network

The Control includes state-of-the-art modulating lead-lag

sequencer for up to eight (8) boilers capable of auto rotation, outdoor reset and peer-to-peer communication. The peerpeer network is truly “plug and play”. Communication is activated by simply connecting a RJ45 ethernet cable between boilers. The Control provides precise boiler coordination by sequencing boilers based on both header water temperature and boiler modulation rate. For example,

the lead boiler can be congured to start a lag boiler after operating at 50% modulation rate for longer than an

adjustable time. The boilers are modulated in “unison” (parallel) modulation rate to ensure even heat distribution.

Page 71

X. Operation

B. Supply Water Temperature Regulation

1. Priority Demand

The Control accepts a call for heat (demand) from multiple

places and responds according to it’s “Priority”. When more than 1 demand is present the higher priority demand is used to determine active boiler settings. For example, when Domestic Hot Water (DHW) has priority the setpoint, “Diff Above”, “Diff Below” and pump settings are taken from DHW selections. Active “Priority” is displayed on the “Boiler Status” screen.

Table 26: Order of Priority

Priority

Status Screen

Display

1st Sequencer

Control

2nd Domestic Hot

Water

3rd Central Heat Central Heat call for heat is on and there

4th Auxiliary Heat Auxiliary Heat call for heat is on and there is

5th Frost

Protection

6th Warm

Weather

Shutdown

(WWSD)

7th Standby There is no demand detected.

The boiler is connected to the peer-to-peer network. The boiler accepts demand from the Sequencer Master.

DHW call for heat is on and selected as the priority demand. DHW is always higher priority than Central Heat. It also has higher priority than the Sequencer Control when DHW priority is “enabled” and “Boiler Piped”

IWH is selected.

is no DHW demand or DHW priority time

has expired.

no Central Heat or DHW demand. (NOTE: May be user selected to be higher priority than Central Heat.)

Frost Protection is active and there is no other call for heat. Frost protection will be a higher priority than Sequencer Control if the Sequence Master has no active call for heat.

WWSD is active and the boiler will not respond to central heat demands. DHW demand is not blocked by WWSD.

Boiler Responding to:

2. Setpoint Purpose

The Control starts and stops the boiler and modulates the

boiler input from minimum (MBH) to maximum (MBH) in order to heat water up to the active setpoint. The setpoint is determined by the priority (Central Heat or Domestic Hot Water) and as described in the following paragraphs.

3. Central Heat Setpoint

Upon a Central Heat call for heat the setpoint is either the

user entered Central Heat Setpoint, or is automatically adjusted by a thermostat’s “Sleep” or “Away” modes and/ or Outdoor Air Reset or, an Energy Management System (EMS) supplied 4-20mAdc setpoint.

4. Auxiliary Heat Setpoint

Auxiliary Heat is a second heating demand that may be used to serve either lower temperature radiation or warmer heat demands such as fan coils. Upon an Auxiliary Heat call for heat the setpoint is either the user entered Auxiliary Heat Setpoint or is automatically adjusted as a thermostat’s

“sleep” or, Away Modes or, Outdoor Air Reset.

5. Outdoor Air Reset

If an outdoor temperature sensor is connected to the

boiler and Outdoor Reset is enabled, the Central Heat and Auxiliary Heat setpoints will automatically adjusted downwards as the outdoor temperature increases. When the water temperature is properly matched to heating needs there is minimal chance of room air temperature overshoot. Excessive heat is not sent to the room heating elements by “overheated” (supply water temperature maintained too high a setting) water. Reset control saves energy by reducing room over heating, reducing boiler temperature

& increasing combustion efciency and, reducing standby

losses as a boiler and system piping cool down to ambient following room over heating.

6. Boost Time

When the Central Heat Setpoint is decreased by Outdoor

Air Reset settings the Boost function can be enabled to increase the setpoint in the event that central heat demand

is not satised for longer than the Boost Time minutes.

The Boost feature increases the operating temperature

setpoint by 10°F (5.6°C) every 20 minutes (eld adjustable) the central heat demand is not satised. This process will continue until heat demand is satised (indoor air is at desired temperature). Once the heat demand is satised,

the operating setpoint reverts to the value determined by the Outdoor Air Reset settings. If Boost Time is zero, then the boost function is not used.

7. Domestic Hot Water (DHW) Setpoint

Upon a DHW call for heat the setpoint is either the user

entered DHW setpoint or the Thermostat’s “Sleep” or “Away” DHW setpoint. The optimal value of this setpoint is established based on the requirements of the indirect water heater.

8. Domestic Hot Water Priority (DHWP)

Some boilers are used primarily for building space heating,

but also provide heat for the domestic hot water users. When the outdoor temperature is warm, the outdoor reset setpoint may drop lower than a desirable domestic hot water temperature. Also, often it is required to quickly recover the indirect water heater. When DHWP is enabled, heating circulators are stopped, the domestic circulator is started and the domestic hot water setpoint is established in response to a domestic hot water demand. Priority protection is provided to allow the heating loop to be serviced again in the event of an excessively long domestic hot water call for heat.

9. “Setback” Setpoints

User adjustable Thermostat “Sleep” or “Away” Setback

Setpoints are provided for both Central Heat and DHW demands. The Setback setpoint is used when the EnviraCOM thermostat is in “leave” or “sleep” modes. When setback is “on”, the thermostat setback setpoint shifts the reset curve to save energy while the home is in reduced room temperature mode. The Honeywell VisionPro IAQ (part number TH9421C1004) is a “setback” EnviraCOM enabled thermostat.

Page 72

X. Operation

C. Boiler Protection Features

1. Supply Water Temperature High Limit

The boiler is equipped with independent automatic

reset and a manual reset high limit devices. A supply manifold mounted limit device provides the automatic reset high limit. The automatic high limit is set to 200°F (93.3°C). The control monitors a supply water temperature sensor that is also mounted in the supply water manifold and an internal, manual reset high limit If the temperature exceeds 210°F (98.9°C), a manual reset hard lockout results. If the boiler is responding to the internal Multiple Boiler Control Sequencer, Header Sensor or, an External EMS demand, and the supply water temperature increases above 190° F (87.7° C), the control begins to reduce the blower maximum speed setting and the temperature increases to 200° F (93.3° C), a forced recycle results. Additionally, if the supply temperature rises faster than the degrees Fahrenheit per second limit, a soft lockout is activated.

2. High Differential Temperature Limit

The Control monitors the temperature difference

between the return and supply sensors. If this difference exceeds 43°F (23.9°C), the control begins to reduce the maximum blower speed. If temperature difference exceeds 53°F (29.4°C), a forced boiler recycle results. If the temperature difference exceeds 63°F (35°C), the control will shut the unit down. The unit will restart automatically once the temperature difference has decreased and the minimum off time has expired.

3. Return Temperature Higher Than Supply Temperature (Inversion Limit)

The Control monitors the supply and return temperature

sensors. If the return water temperature exceeds the supply water temperature for longer than a limit time delay, the Control shuts down the boiler and delays restart. If the inverted temperature is detected more

than ve times, the boiler manual reset Hard Lockout is

set. This condition is the result of incorrectly attaching the supply and return piping.

4. External Limit

An external limit control can be installed between

terminals 11 and 12 on the low voltage terminal strip. Be sure to remove the jumper when adding an external limit control to the system. If the external limit opens, the boiler will shut down and an open limit indication and error code are provided. If the limit installed is a manual reset type, it will need to be reset before the boiler will operate.

5. Boiler Mounted Limit Devices

The Control monitors individual limit devices:

pressure switch, high limit device, condensate level switch, Thermal Link (ALP285B only), Burner Door Thermostat with manual reset (ALP285B only) and external limit (optional). If any of these limits open, the boiler will shut down and an individual open limit indication is provided.

6. Stack High Limit

The Control monitors the ue gas temperature sensor

located in the vent connector. If the ue temperature

exceeds 184°F (84.4°C), the control begins to reduce

the maximum blower speed. If the ue temperature

exceeds 194°F (90.0°C), a forced boiler recycle results.

If the ue temperature exceeds 204°F (95.6°C), the

control activates a manual reset Hard Lockout.

7. Ignition Failure

The Control monitors ignition using a burner mounted

ame sensor. In the event of an ignition failure, the

control retries (ALP080B through ALP285B) 5 times and then goes into soft lockout for one hour.

8. Central Heating System Frost Protection

When enabled, Frost Protection starts the boiler and

system pump and res the boiler when low outside air

and low supply water temperatures are sensed. The Control provides the following control action when frost protection is enabled:

Table 27: Frost Protection

Device

Started

Boiler & System

Pump

Boiler Supply Water < 38°F (3.3°C) Supply Water > 50°F (10°C)

Outside Air < -22°F (-30°C)

Supply Water < 45°F (7.2°C)

FROST PROTECTION NOTE

The Control helps provide freeze protection for the boiler

water. Boiler ue gas condensate drain is not protected from

freezing. Since the Control only controls the system and boiler circulators individual zones are not protected. It is recommended that the boiler be installed in a location that is not exposed to freezing temperatures.

Start

Temperatures

Stop

Temperatures

Outside Air > -18°F (-28°C)

Supply Water > 50°F (10°C)

Page 73

X. Operation

D. Multiple Boiler Control Sequencer

1. “Plug & Play” Multiple Boiler Control Sequencer

When multiple boilers are installed, the Control’s

Sequencer may be used to coordinate and optimize the operation of up to eight (8) boilers. Boilers are connected into a “network” by simply “plugging in” standard ethernet cables into each boiler’s “Boiler-ToBoiler Communication” RJ45 connection.

2. Sequencer Master

A single Control is parameter selected to be the Sequencer

Master. The call for heat, outdoor and header sensors, and common pumps are wired to the Sequencer Master “enabled” Control.

3. Lead/Slave Sequencing & Equalized Run Time

One boiler is a “Lead” boiler and the remaining networked

boilers are “Slaves”. When demand is increasing, the

Lead boiler is the rst to start and the Slave boilers are

started in sequential order (1,2,3,…) until the demand

is satised. When demand is decreasing, the boilers are

stopped in reverse order with the Lead boiler stopped last (…,3,2,1). To equalize the run time the sequencer automatically rotates the Lead boiler after 24 hours of run time.

4. Improved Availability

The following features help improve the heat availability:

a. Backup Header Sensor: In the event of a header sensor

failure the lead boiler’s supply sensor is used by the

Sequence Master to control ring rate. This feature

allows continued coordinated sequencer control even after a header sensor failure.

b. “Stand Alone” Operation Upon Sequence Master

Failure: If the Sequence Master Control is powered down or disabled or if communication is lost between boilers, individual boilers may be setup to automatically resume control as a “stand alone” boiler.

c. Slave Boiler Rate Adjustment: Each slave boiler

continues to monitor supply, return and ue gas temperatures and modies the Sequence Master’s ring rate demand to help avoid individual boiler

faults, minimize boiler cycling and provide heat to

the building efciently.

d. Slave Boiler Status Monitoring: The Sequence Master

monitors slave boiler lockout status and automatically skip over disabled boilers when starting a new slave boiler.

5. Customized Sequences

Normally, boilers are started and stopped in numerical

order. However, custom sequences may be established to optimize the heat delivery. For example, in order to minimize boiler cycling, a large boiler may be selected

to run rst during winter months and then selected to

run last for the remainder of the year.

6. Multiple Demands

The Sequence Master responds to Central Heat, Auxiliary

Heat DHW and frost protection demands similar to the stand alone boiler. For example, when selected and DHW priority is active, the sequence master uses DHW setpoint, “Diff Above”, “Diff Below” and pump settings.

7. Shared or Isolated DHW Demand

When the Indirect Water Heater (IWH) parameter is set

to “Primary Piped” the Sequence Master sequences all required boilers to satisfy the DHW setpoint (default 180°F (82.2°C). When “Boiler Piped” is selected only the individual slave boiler, with the wired DHW demand and pump, res to satisfy the DHW setpoint.

8. DHW Two boiler Start

When the Indirect Water Heater (IWH) parameter is set to

“Primary Piped” and the DHW Two Boiler Start parameter is set to “Enabled” two boilers are started without delay in response to a DHW call for heat. This feature allows rapid recovery of large IWH’s and multiple IWH’s.

9. Optimized Boiler Modulation

Boiler ring rate is managed to increase smoothly as

boilers are started. For example, when a second boiler is

started the initial ring rate is 100%/2 or 50%, when the third boiler is started the ring rate starts at 200%/3 or 66%. After the initial start, the Sequence Master develops a unison ring rate demand based on it’s setpoint and

sensed header temperature.

10. Modulating Condensing Boiler Control

During low loads, the Sequence Master limits ring rates

to a ‘Base Load Common Rate” to ensure peak modulating

condensing boiler operating efciency. Lower ring rates boost efciency by helping increase the amount of ue

gas water vapor condensation. The Control maintains a “Base Load Common Rate” until the last lag boiler is started. At this point, the “Base Load Common Rate” is released to allow boilers to modulated as required to meet heat load.

11. Advanced Boiler Sequencing

After there is a Call For Heat input, both header water

temperature and boiler ring rate percent are used to start

and stop the networked boilers. The control starts and stops boilers when the water temperature is outside the user selected “Diff Above” and “Diff Below” settings. Also, in order to minimize temperature deviations, the control

adjusts the number of boilers running based on the ring

rate. This combination allows the boilers to anticipate slow load changes before they disrupt water temperature yet still respond quickly to sudden load changes. These special sequencer features help reduce energy wasting system temperature swings and the resulting unnecessary boiler cycling.

12. Stop All Boilers

All boilers are stopped without delay if the Call for Heat

input is removed, or, if the header temperature is higher

than 195°F (90.6°C) (eld adjustable).

Page 74

X. Operation

Boiler 1

E. Boiler Sequence of Operation

1. Normal Operation

Table 28: Boiler Sequence of Operation

Status Screen Display Description

Priority:

Standby

Status:

Standby

Priority:

Central Heat

Status:

(burner Off, circulator(s) Off)

Boiler is not ring and there is no call for heat, priority equals standby. The boiler is ready to respond to a call for heat.

(burner Off, circulator(s) On)

Boiler is not ring. There is a Central Heat call for heat and the Supply temperature is greater than setpoint minus the “Diff Below”.

Standby

When supply temperature drops burner demand continues with following Status

Priority:

Central Heat

Status:

Prepurge

shown:

Safe Startup: Flame circuit is tested.

Drive purge: The blower is driven to the fan purge speed. Prepurge: After the blower reaches the fan purge speed setting the 10 second combustion chamber purge is conducted.

Priority:

Central Heat

Status:

Direct

ignition

Boiler 1

Supply

Setpoint

Rate

Priority:

Status:

132 F 140 F 100%

Central Heat Running

Central Heat

Priority:

Status:

Running

After purge time is complete the following Status is shown: Drive light-off: The blower is driven to light-off rate.

Pre-Ignition Test: After the blower reaches light-off rate a safety relay test is

conducted.

Pre-ignition: Spark is energized and it is conrmed that no ame is present

Direct Ignition: Spark and Main fuel valve are energized.

(burner On, circulator(s) On)

After ame is proven the sequence continues with run stabilization and low re hold time. Once the eld adjustable low re hold time is completed normal boiler operation begins, modulation rate depending on temperature and setpoint

selections.

Priority:

Domestic

Hot Water

Status:

Running

Priority:

Standby

Status:

Post-purge

Priority:

Standby

Status:

Standby

Delay

Priority:

Standby

Status:

Lockout

If the Central Heat call for heat is active and a Domestic Hot Water (DHW) call for heat received the DHW demand becomes the “priority” and the modulation rate, setpoint, “Diff Above” and “Diff Below” are based on DHW settings.

(burner Off, circulator(s) Off)

If there is no call for heat, the main fuel valve is closed and, the blower is driven to the fan post-purge speed. After the blower reaches the fan post-purge speed setting, the 30-second combustion chamber purge is conducted.

Standby delay status is entered when a delay is needed, before allowing the burner control to be available. For example, when Anti-Short Cycle time is selected Standby delay is entered after the Central Heat call for heat ends. Select “Help” button from the “Home Screen” to determine the cause of the Standby

Delay.

A lockout Status is entered to prevent the boiler from running due to a detected problem. Select “Help” button from the “Home Screen” to determine the cause of the Lockout. The last 10 Lockouts are recorded in the Lockout History.

Supply

132 F

Setpoint

Rate

Priority:

Status:

180 F 100%

Domestic Hot Water

Running

Page 75

X. Operation E. Boiler Sequence Of Operation (continued)

2. Using The Display

The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen

navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below. When no selection is made, while viewing any screen, the display reverts to the “Home Screen” after 4 minutes. The “Home Screen” provides

boiler temperature, ring rate in BTU/hr, boiler status, efciency information and page links.

Menu Buttons

The Home Screen Menu Buttons connect the displays four main dis-

play groups:

Information Symbol

“Information” symbol links most screens to screen content explana-

tions. New terminology used in status and adjustment screens are

explained in plain words.

Fault Indication

In the event of a boiler fault the screen color turns red and the user is guided by “blinking” touch buttons to Help screens that explain the prob-

lem cause and corrective action.

Rate Firing rate is displayed as kbtu/hr input.

Demand Status

The reason or cause of the boiler demand is displayed; Central Heat, Auxiliary Heat, Domestic Hot Water, Sequencer Control (peer-to-peer Demand) or Frost Protection. Warm Weather Shutdown status is shown. “Standby’ is shown when no demand is present.

Energy Save On Indication

Outdoor Air Reset, DHW or setback have lowered boiler water setpoint.

High Efciency On Indication

Return temperature is low enough to allow energy saving ue gas condensation.

(see Figure 41)

Status Screen

(see bottom of page 91)

Figure 38: Home Screen Details

Close Symbol

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

Arrow Symbol

The “Arrow” symbol links together all screens in the selected group. For example, repeated pressing the right “Arrow” symbol will rotate the display around all the screens in the Status group. Using this feature the user can review all the boiler status and adjustment mode

screens.

Fault Symbols

“Active Fault” and “Rate Limit”

of a boiler fault or ring rate limit. The rst boiler status screen provides an overview of boiler operation including fault status.

Figure 39: Screen Navigation

(see Figure 48)

symbols provide a link to the cause

(see Figure 43)

Page 76

X. Operation E. Boiler Sequence Of Operation (continued)

3. Status Screens

Boiler Status screens are the primary boiler monitoring screens. The user may simply “walk” though boiler

operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status” button from the “Home” screen.

NOTE

Only visible if Zone Panel is connected. Zone Panel 1 and 2 shown typical for 1 through 4.

Figure 40: Status Screen Overview

Supply:

Measured supply water temperature. This is the temperature being used to start/stop and re boiler when there is a call-for- heat. Header temperature is shown when selected.

Setpoint:

This is the active setpoint. This temperature setpoint determined based on active priority; Central Heat, Auxiliary Heat or Domestic Hot Water. The setpoint may be the result of Outdoor Air Reset and Setback selections.

Rate:

The rate % value is equal to the actual kbtu/hr input divided by the boiler rated input.

Priority:

The selected Priority is shown. Available Priorities are: Standby (no call for heat is present), Sequencer Control, Central Heat, Auxiliary Heat, Domestic Hot Water, Frost Protection or Warm Weather Shutdown.

Status:

Information found at the bottom of the Status screen and on the Home screen. Table 28 shows each status and the action the control takes during the condition.

Active fault:

A hard lockout will cause the active fault indication to appear. When visible the text becomes a screen link to the “Help” Menu.

Rate Limit:

The “6” symbol appears to the right of the Rate % when ring rate is lim-

ited or overridden in any way. During

the start-up and shutdown sequence it is normal for the rate to be overridden by the purge, light-off and low re hold requirements. When a rate limit is the result of boiler protection logic the “6” symbol blinks and becomes a screen link.

Figure 41: Boiler Status Screen Denitions

Page 77

X. Operation E. Boiler Sequence Of Operation (continued)

3. Status Screens (continued)

Bargraph Screen

The bargraph screen presents measured values for easy comparison. Included on this screen is ring rate and when the Zone Panel is connected the measure Heat Loss. Measured heat loss is the heat rate kbtu/hr sum of all active (call for heat) zones. This value represents the maximum required

ring rate.

Trend Screens

Data Logging

Real time graphic trends allow users to observe process changes over time providing valuable diagnostic information. For example, ame current performance over start up periods and varying loads can be an

indication of gas supply issues. Additionally, supply and return tempera-

ture dual pen trends brings a focused look at heat exchanger and pump performance. For example, studying a differential temperature trend may indicate pump speed settings need to be changed.

Burner Status Screen

NOTE

“Boiler Cycle” and “Run Time Hours” are resettable by selecting the “Reset Counts” button located on the information screen. The “Controller Cycles” and “Controller Run Time” data is not resettable and remains for the life of the control.

NOTE

Firing Rate Trend shows fan demand and feedback.

Cycles and Hours

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

Page 78

X. Operation E. Boiler Sequence Of Operation (continued)

Circulator Status Screen

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

Head Demand Screen

This screen provides the status of the boilers ve (5) possible heat demands. When demand is off the Control has not detected the call-for-heat. This screen allows the user to determine which demands are present when more than one

demand is present.

Zone Control Status Screens

NOTE

Only visible if Zone Panel is connected. Zone Panel 1 and 2 shown typical for 1 through 4.

Zone Control Status

Screen provides status and a page links for up to four zone panels. Individual

zone “on” status is shown by a bold zone number with a solid underscore. “Press” the zone control “button” to view individual

zone .

Zone Panel 1 (typical for 2 through 4)

Zone panel screens show individual zone

status, cycle counts and individual zone

heat loss size in kbtu/hr. Individual zone heat loss may be adjusted under the Adjust

NOTE

Zone cycles are resettable by selecting the “Reset Cycle Counts” button located on the information screen.

“Modulation” menu. Also zone descriptions may be modied using the “Zone Control

Description Setup” menu.

4. Detail Screens

Detail screens are accessed by selecting the “Detail” button from the “Home” screen. These screens provide in depth operating parameter status such as “On Point”, “Off Point” and “Setpoint Source” information. Demand-specic details are provided for Central Heat, Auxiliary Heat, Domestic Hot Water and the Sequence Master demands. Detail screens also provide details on outdoor air reset and Sequencer network status. Sequencer screens are only shown when the Sequence Master is enabled and, Auxiliary Heat screen is only shown when a Zone Panel is connected.

Demand Detail Display

(Central Heat shown, Typical for Auxiliary Heat, Domestic Hot Water and Sequencer Master)

Outdoor Reset Display

(Central Heat shown, Typical for Auxiliary Heat)

Page 79

X. Operation E. Boiler Sequence Of Operation (continued)

5. Multiple Boiler Sequencer Screens

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

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

Header:

measured header water temperature. This is the temperature being used to start, stop and re boiler when there is a call-for-heat.

Setpoint:

this is the active setpoint. This temperature is the result of Outdoor Air Reset, Setback and Domestic Hot Water (DHW) selections.

Networked Boiler Status:

Provides connected, start sequence and ring rate status information for all connected boiler addresses. The boiler number is underlined if the boiler is running and blinks if the boiler has the start sequence in progress. For example the status for boiler address

1 is provided as follows:

1 - Boiler 1 is connected to the network 1 - “Blinking underline” - boiler 1 is starting 1 - “Solid underline” - boiler 1 is running

The “Networked Boilers” screen is selected by “pressing” the “Detail” button from the “Home” screens and “pressing” Networked Boilers” from the “Detail” screen.

Rate:

The rate % value is equal to the Sequence Master demand to the individual boiler. Actual boiler ring rate is found on the individual boiler

status pages.

Priority:

The selected Sequencer Priority is shown. Available Priorities are: Standby (no call for heat is present), Central Heat, Auxiliary Heat, Domes-

tic Hot Water, Frost Protection or

Warm Weather Shutdown.

Boiler Number:

Up to eight (8) boiler’s status is shown

Lead Boiler:

Upon power up the lowest numbered boiler becomes the lead boiler. The lead boiler is the rst to start and last to stop. The lead boiler is automatically rotated after 24 hours of run time. Additionally, the lead is rotated if there is a lead boiler fault.

Sequence Status: Slave boiler status is provide as follows:

Available: Add Stage:

Running:

On Leave:

Recovering:

Disabled:

Boiler is ready and waiting to be started by the Sequencer

Master.

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

Boiler is running.

Boiler has left the network to service a DHW demand.

Boiler is in the process of returning to the network. For example, the slave boiler is in the Postpurge state.

Note: The recovery time is normally 30 seconds. However, if the slave boiler fails to start the recovery time increases

from 30 seconds to 5, 10 and 15 minutes.

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

Firing Rate:

Demanded ring rate is

provided.

Page 80

X. Operation

F. Changing Adjustable Parameters

1. Entering Adjust Mode

The Control is factory programmed

to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings:

- Press the “Adjust” button on the “Home”

screen.

- Press the “Adjust” button on the Adjust

Mode screen or Press “Service Contact” for service provider contact information.

- Press “Login” button to access password

screen.

- Press 5-digit display to open a keypad.

Enter the password (Installer Password is 86) and press the return arrow to close the keypad. Press the “Save” button.

- Press the “Adjust” button to enter

Adjustment mode.

Figure 42: Adjust Mode Screens

2. Adjusting Parameters

Editing parameters is accomplished as follows:

Page 81

X. Operation F. Changing Adjustable Parameters (continued)

System

Setup

2. Adjusting Parameters (continued)

The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on

the Control’s Display, from top to bottom and, left to right. From the “Home” screen select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode):

“Press”

Factory

Setting

Fahrenheit

4 0-14

8 0-14

Wired

Not

Connected

Enabled Enable/Disable

0 Secs 0-900 Secs

Disabled Enable/Disable

70°F 0-100°F

tenths of degree

Not Connected

button to access the following parameters:

Range /

Choices

Fahrenheit,

Celsius

Not Installed,

Wired

Wireless

-100 to 100

Connected,

Parameter and Description

Temperature Units

The Temperature Units parameter determines whether temperature is represented in units of Fahrenheit

or Celsius degrees.

Display Brightness

Display brightness is adjustable from 0 to 14.

Display Contrast

Display contrast is adjustable from 0 to 14.

Outdoor Sensor Source

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

Wireless Outdoor sensor is installed and wireless.

Outdoor Air Sensor Calibration

Outdoor Air Sensor Calibration offset allows a single point calibration. Using a reliable source (reference) for outdoor temperature measure outdoor air temperature. Set the offset equal to the difference between the controller reading and the reference. The result will be the Control’s measurement matching the refer-

ence reading.

Zone Control Status Connected

When the Zone Control is connected adjustable settings are automatically shown under the Adjust “Modulation”, “Auxiliary Heat” and “Zone Control Description Setup” menus. This feature allows these adjustments to be made before the zone panel is connected. When the user selects “Show As If Connected” Zone Control related parameters are made visible and may be adjusted.

Frost Protection

Disable Frost Protection is not used. Enable Boiler and system circulators start and boiler res when low outside air, supply and return

temperatures are sensed as follows:

Device Started Start Temperatures Stop Temperatures

Boiler & System Outside Air < -22°F (-30°C) Outside Air > -18°F (-28°C)

Anti-Short Cycle Time

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

Warm Weather Shutdown Enable

Disable Warm Weather Shutdown (WWSD) is not used. Enable The boiler and pumps will not be allowed to start in response to a central heat call for heat if

the outside temperature is greater than the WWSD setpoint. WWSD is initiated as soon as outside air temperature is above WWSD Setpoint. The control does not require call for heat to be satised.

The boiler will still start in response to a Domestic Hot Water call for heat.

Warm Weather Shutdown Setpoint

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

Page 82

X. Operation F. Changing Adjustable Parameters (continued)

Modulation

Setup

WARNING

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

“Press”

Factory

Setting

See Table

Range / Choices Parameter and Description

button to access the following parameters:

Boiler Type

Boiler Size Setup

To verify the boiler size selection, a qualied technician should do the following:

1. Check boiler’s label for actual boiler size.

See Table 29

2. Set “Boiler Type” to match actual boiler size.

3. Select “Conrm”.

The Boiler Type parameter changes the minimum and maximum modulation settings. This parameter is intended to allow a user to set the parameters in a spare part Control to a particular boiler

type.

Table 29: Parameters Changed Using the Boiler Type Parameter Selections:

R7910

Repair Control Kit

Spare Part:

Altitude 0 - 7000 Ft. 7001 - 10,000 Ft.

Boiler Type

Minimum Heat Rate 1370 2400 1450 1800 2400

Maximum Heat Rate 5950 5950 5560 7000 7000

Absolute Maximum Heat Rate

Light-off Heat Rate 4000 3000 2500

NOTE: Maximum Modulation Rates are designed for 100% nameplate rate at 0°F (-18°C) combustion air. Contact factory before attempting to increase the Maximum Modulation Rate.

P/N 106177-01

Maximum

Light-off Heat Rate

= 4000

210

-02

6350 6350 6200 7000 7000

210

-27

285

-07

R7910

Repair Control Kit

P/N 106177-02

Maximum

Light-off Heat Rate

= 3000

210

-70

R7910

Repair Control Kit

P/N 106177-03

Maximum

Light-off Heat Rate

= 2500 rpm

285

-70

Page 83

X. Operation F. Changing Adjustable Parameters (continued)

Expected Heat Rate Adjustment Screens (HeatMatch Software)

The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize

setup.

The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a "call for heat" the Control rst uses the expected heat rate value to set a maximum heat rate. The maximum heat rate is the highest heat rate that the boiler can re to at that moment. The maximum heat rate is the summation of the expected heat rates for the active (turned on) zones. After establishing the maximum heat rate the Control then measures water temperature and res the boiler only as hard as required for the heat demand.

Example “call for heat”

durations for a four zone

house.

Maximum heat rate limits ring rate and prevents the Control from ring to 100% in response to a

smaller zone demands.

Maximum Heat Rate:

Automatically adjusted

by the Control based on the size and number of zones calling for heat.

Actual Heat Rate:

Boiler is free to modulate based on temperature from minimum to

maximum heat rate.

Maximum modulation numbers are shown in both RPM and kbtu/hr to allow for easier understanding of boiler heat

rate.

Figure 43: Four Zone House (with Zone Control Connected)

NOTE

This feature requires Zone Control to be connected.

Refer to Electrical section for Zone Control connection information.

The sum of Zone Expected Heat Rates plus DHW Maximum Expected Heat Rate (if DHW is active) is used to calculate the active maximum

modulation rate.

Figure 44: Expected Heat Rate Adjustment (with Zone Control Connected)

Page 84

X. Operation F. Changing Adjustable Parameters (continued)

Modulation

Setup

“Press”

Factory

Setting

100%

80%

100%

40%

Minutes

See Table

button to access the following parameters:

Range / Choices Parameter and Description

Central Heat Maximum Expected Heat Rate

Minimum to

Maximum

Heat Rate

Minimum to

Maximum

Heat Rate

Minimum to

Maximum

Heat Rate

Minimum to

Maximum

Heat Rate

0 to 60 Minutes

Minimum

- 100 to Maximum

See Table 29

This parameter denes the highest modulation rate the Control will go to during a central heat call for heat. If the rated input of the installed home radiation is less than the maximum output of the boiler, change the Central Heat Maximum Expected Heat Rate (fan speed) setting to limit the boiler output accordingly.

Domestic Hot Water (DHW) Maximum Expected Heat Rate

This parameter denes the highest modulation rate the Control will go to during a Domestic Hot Water call for heat. If the rated input of the indirect water heater is less than the maximum output of the boiler, change the DHW Maximum Expected Heat Rate (fan speed) setting to limit the boiler

output accordingly.

Auxiliary Maximum Expected Heat Rate

This parameter denes the highest modulation rate the Control will go to during the auxiliary heat call for heat. If the rated input of the Auxiliary Heat Zones is less than the maximum output of the boiler, change the Auxiliary Heat Maximum Expected Heat Rate (fan speed) setting to limit the boiler output accordingly.

Zone 1 Expected Heat Rate (typical for zone 1 through 16)

This parameter denes the highest modulation rate the Control will go to during the Zone 1 call for heat. If the rated input of the installed home radiation in zone 1 is less than the maximum output of the boiler, change the Zone 1 Expected Heat Rate (fan speed) setting to limit the boiler output

accordingly.

Zone Release Time

After the Zone Release Time minutes and a zone has not been satised (thermostat opens) the measured heat loss will be released to increase to the Central Heat Maximum Heat Rate.

Minimum Heat Rate

This parameter is the lowest modulation rate the Control will go to during any call for heat.

Lightoff Heat Rate

This is the blower speed during ignition and ame stabilization periods.

Page 85

Pump Setup

X. Operation F. Changing Adjustable Parameters (continued)

“Press”

Factory Setting Range / Choices Parameter and Description

Any Demand

Primary

Loop Pipe

IWH

button to access the following parameters:

System Pump run pump for:

Activates the system pump output according to selected function.

Never,

Any Demand,

Central Heat,

No Priority,

Central Heat,

Optional Priority

Any Demand,

Central Heat, off

DHW demand

Never,

Primary Loop

Piped IWH,

Boiler Piped IWH

Never: Pump is disabled and not shown on status screen. Any Demand: Pump Runs during any call for heat. Central Heat, No Priority: Pump Runs during central heat and frost protection call for

heat. Pump does not start for a DHW call for heat and

continues to run during Domestic Hot Water Priority.

Central heat, Optional Priority: Pump Runs during central heat and frost protection call for heat. Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot

Water Priority is active.

Boiler Pump run pump for:

Activates the boiler pump output according to selected function. Any Demand: Pump Runs during any call for heat.

Central Heat, off DHW

demand: Make sure indirect water heater and DHW circulator are sized to maintain ow through boiler within limits shown in Table 12.

Domestic Pump run pump for:

Activates the Domestic pump output according to selected function. Never: Pump is disabled and not shown on status screen.

Primary Loop Piped IWH: Pump Runs during domestic hot water call for heat. Domestic Hot Water Priority enable/disable

does not affect pump operation. Boiler Piped IWH: Make sure indirect water heater and DHW

circulator are sized to maintain ow through boiler within limits shown in Table 12.

Pump Runs during domestic hot water call for heat. Pump is forced off during a central heat call for heat when Domestic Hot Water Priority “disabled” is selected and when Domestic Hot Water Priority “enable” has been selected and the DHW call for heat has remained on for longer than 1 hour (priority protection time).

Pump Runs during central heat and frost protection call for heat. Pump does not start for a DHW call for heat and will be forced off if there is a DHW call for heat and Domestic Hot

Water Priority is active.

Example Pump Parameter selections:

Single boiler with no Indirect Water Heater

Explanation:

This piping arrangement only services central heat. When there is any demand both boiler and system pumps turn

on.

Page 86

X. Operation F. Changing Adjustable Parameters (continued)

Example Pump Parameter selections (continued):

Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority.

Parameter Selections:

System Pump= “Central Heat ,

Optional Priority”

Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH” DHW Priority Enable is optional

Explanation:

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

for heat.

Multiple Boilers with Boiler Piped IWH, System and DHW Wired to Master

Sequencer Master

(Boiler 1)

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump =

Boiler Pump =

DHW Pump = Boiler Piped IWH Never

Explanation:

Make sure indirect water heater and DHW pump are sized to maintain ow though boiler within limits shown in Table 12. This piping arrangement does not allow both the Slave 1’s boiler and domestic hot water pump to run at the same time. When call for Domestic Hot Water is received the DHW pump is turned on and the boiler pump is turned off. However, the system pumps may run to satisfy a central heat demand that is being satised by a different slave. The central heat demand is ignored by Slave 1 until the domestic hot water demand is ended. If domestic hot water priority is enabled and priority protection time is exceeded the domestic hot water pump turns off to allow the boiler pump to run.

“Boiler Piped”

Central Heat,

No Priority

Central Heat,

Off DHW Priority

Boiler 2

Never

Any

demand

Page 87

X. Operation F. Changing Adjustable Parameters (continued)

Example Pump Parameter selections (continued):

Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority

Sequencer Master

(Boiler 1)

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump =

Boiler Pump = Any demand

DHW Pump =

Explanation:

“Primary Piped”

Central Heat,

Optional Priority

Primary Loop

Piped IWH

Boiler 2

Never

Any

demand

Never

Multiple Boilers, IWH piped to primary, system pump required to run for any call for heat

Sequencer Master

(Boiler 1)

Wiring locations:

Thermostat X

DHW call for heat X

System pump X

DHW pump X

Boiler Pump X X

Sequencer Master Parameter Selections:

Sequencer Master Enabled

Indirect Water Heater

Pump Parameter Selections:

System Pump = Any demand Never

Boiler Pump = Any demand Any demand

DHW Pump =

Explanation:

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

“Primary Piped”

Primary Loop

Piped IWH

Boiler 2

Never

Page 88

Contractor

Setup

X. Operation F. Changing Adjustable Parameters (continued)

Manual Control

“Press”

button to access the following parameters:

Use Up and DOWN Arrows for More

Exit Screen without Saving

Save Field and Exit

Contractor Name

Press box to input contractor information.

Bill Smith

Save

Press SAVE button to store revisions.

Enter Contractor Information

Bill Smith

Clear Entire Field

Backspace

For Service Contact:

Bill Smith

12 Victory Lane

Plainview, New York

516 123-4567

Example Screen

Factory Setting Range / Choices Parameter and Description

Contractor Name User dened Contractor Name

Address Line 1 User dened Contractor Address Line 1

Address Line 2 User dened Contractor Address Line 2

Phone User dened Contractor Phone

“Press”

button to access the following screen:

The Manual Speed Control speed screen allows the technician to set ring rate at low or high speed for combustion testing.

NOTE

Rate % can only be set

when the boiler has heat

demand and is released to

modulate.

Selecting “Low” or “High” locks (manual mode) ring rate at min or max Rate %.

After combustion testing select

“Auto” to return the boiler to

NOTE

normal operation.

“Press” “Low” to select

manual ring rate control

and Minimum ring rate %

“Press” “High” to select

manual ring rate control

and Central Heat Maximum

ring rate %

Press “Auto” to

return ring rate

to Automatic

Mode

Page 89

Central

Heat

X. Operation F. Changing Adjustable Parameters (continued)

“Press”

Factory

Setting

180°F

(82.2°C)

170°F

(76.7°C)

7°F

(3.9°C)

5°F

(2.8°C)

3 1 to 5

120

seconds

Supply

Sensor

Range / Choices Parameter and Description

60°F to 190°F

(16°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

(1.1°C to 5.6°C)

(1.1°C to 14°C)

0 to 300 seconds

Supply Sensor, Header Sensor

button to access the following parameters:

2°F to 10°F

2°F to 25°F

Central Heat Setpoint

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

Central Heat Thermostat “Sleep” or “Away” Setback Setpoint

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

savings.

Central Heat Diff Above

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

Central Heat Diff Below

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

Response Speed

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

Low Fire Hold Time

“Low Fire Hold Time” is the number of seconds the control will wait at low re modulation rate before being released to modulate. After ignition and ame stabilization periods the ring rate is held at low re for “Low Fire Hold Time”. This delay allows heat to travel out to the system and provide system feedback prior to the control modulating ring rate.

Modulation Sensor

Heat Demand may respond to the boiler’s Supply Temperature or Header Temperature sensors. When Header Sensor is selected the boiler is red in response to the sensor wired to Header

Sensor Low Voltage Terminal Block Terminals.

Page 90

X. Operation F. Changing Adjustable Parameters (continued)

“Press” button to access the following parameters:

Factory

Setting

180°F

(82.2°C)

170°F

(76.7°C)

7°F

(3.9°C)

5°F

(2.8°C)

3 1 to 5

Disable Disable, Enable

Zone

Control

Supply

Sensor

Range / Choices Parameter and Description

60°F to 190°F

(16°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

2°F to 10°F

(1.1°C to 5.6°C)

2°F to 25°F

(1.1°C to 14°C)

Zone Control,

DHW Terminal

Supply Sensor, Header Sensor

Auxiliary Heat Setpoint

Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset

function.

Auxiliary Heat Thermostat “Sleep” or “Away” Setback Setpoint

savings.

Auxiliary Heat Diff Above

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

Auxiliary Heat Diff Below

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

Response Speed

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

Auxiliary Priority Over Central Heat

This parameter allows the Auxiliary Heat demand to be higher or lower priority than Central Heat demand. When both demands are active at the same time the Control uses the Setpoint, Diff Above and Diff Below for the demand that has priority.

Disabled Auxiliary Heat is lower priority than Central Heat demand. Enable Auxiliary Heat is higher priority than Central Heat demand.

Auxiliary Heat Demand Source

The Control’s “DHW Temp Switch” input terminal may be used as a Domestic Hot Water (DHW) demand or Auxiliary Heat demand. When the Domestic Hot Water Demand Source is set to Zone Control and the Auxiliary Heat Demand Source is set to “DHW Terminal” an Auxiliary Heat Demand may be wired to the DHW Temp Switch terminals. This feature may be used even if a

Zone Control is not installed.

Zone Control Auxiliary Heat demand may only be wired to the Zone Control DHW Terminal Auxiliary Heat demand may be wired to the Zone Control or DHW Terminal.

Modulation Sensor

Heat Demand may respond to the boiler’s Supply Temperature or Header Temperature sensors. When Header Sensor is selected the boiler is red in response to the sensor wired to Header

Sensor Low Voltage Terminal Block Terminals.

Page 91

X. Operation F. Changing Adjustable Parameters (continued)

Domestic

Hot Water

“Press”

Factory

Setting

170°F

(76.7°C)

160°F

(71.1°C)

7°F

(3.9°C)

5°F

(2.8°C)

3 1 to 5

seconds

Enabled Enable, Disable

60 30 to 120 Minutes

DHW

Terminal

Range / Choices Parameter and Description

(26.7°C to 87.8°C)

(1.1°C to 5.6°C)

(1.1°C to 14°C)

0 to 300 seconds

DHW Terminal,

button to access the following parameters:

60°F (16°C) to

190°F

60°F (16°C) to

190°F

2°F to 10°F

2°F to 25°F

Zone Control

Domestic Hot Water Setpoint

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

ignored.

Domestic Hot Water Thermostat “Sleep” or “Away” Setback Setpoint

Domestic Hot Water Diff Above

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

Domestic Hot Water Diff Below

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

Response Speed

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

Low Fire Hold Time

“Low Fire Hold Time” is the number of seconds the control will wait at low re modulation rate before being released to modulate. After ignition and ame stabilization periods the ring rate is held at low re for “Low Fire Hold Time”. This delay allows heat to travel out to the indirect water heater and provide feedback prior to the control modulating ring rate.

Domestic Hot Water Priority (DHWP)

When Domestic Hot Water Priority is Enabled and Domestic Hot Water (DHW) heat demand is “on” the DHW demand will take “Priority” over home heating demand. When the System and Boiler pumps are congured as “Central Heat (off DHW priority)” or “Central Heat, Optional Priority” then they will be forced “off” during DHW Priority. Priority protection time is provided to end DHWP in the event of a failed or excessive long DHW demand.

Priority Time

When DHWP is Enabled the Priority Time Parameter appears and is adjustable.

Domestic Demand Source

The Control’s “DHW Temp Switch” input terminal may be used as a DHW demand or Auxiliary Heat demand. When “DHW Terminal” is selected the Control will accept a DHW input from either the “DHW Temp Switch” or the Zone Control (zone 4, set to priority). If “Zone Control” is selected the Control can only accept the DHW input from the Zone Control. This allows the Control to be set to accept an Auxiliary heat demand from the “DHW Temp Switch” input terminal. Refer to the Auxiliary heat menu for required selection to use this input.

DHW Terminal DHW demand may be wired to the DHW Switch terminal or Zone Control. Zone Control DHW demand may only be wired to the Zone Control.

Page 92

X. Operation F. Changing Adjustable Parameters (continued)

“Press” button to access the following parameters:

Factory

Setting

Enabled Enable Disable

0°F

(-18°C)

70°F

(21.1°C)

110°F

(43.3°C)

130°F

(54.4°C)

0 Minutes

Range / Choices Parameter and Description

Central Heat Outdoor Reset Enable

If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure

45. The maximum set point is dened by the Central Heat Setpoint [factory set to 180°F (82.2°C)] when the outdoor temperature is 0°F (-18°C) or below. The minimum set point temperature shown is 130°F (54.4°C) [adjustable as low as 80°F (26.7°C)] when the outdoor temperature is 50°F (10°C) or above. As the outdoor temperature falls the supply water target temperature increases. For example, if the outdoor air temperature is 30°F, (-1.1°C) the set point temperature for the supply water is 150°F (65.6°C).

Disable Do Not Calculate setpoint based on outdoor temperature Enable Calculate the temperature setpoint based on outdoor temperature using a reset

curve dened by Low Outdoor Temp, High Outdoor Temp, Low Boiler Water

Temp, Min Boiler Temp and Central Heat Setpoint and Boost Time parameters.

Central Heat Low Outdoor Temperature

-40°F to 100°F

(-40°C to 37.8°C)

32°F to 100°F

(0°C to 37.8°C)

70°F to 190°F

(21.1°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

0-1800 Seconds

(0-30 Minutes)

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

Central Heat High Outdoor Temperature

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

temperature.

Central Heat Low Boiler Water Temperature

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

Minimum Boiler Temperature (Central Heat and Auxiliary Heat)

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

Central Heat Boost Time

When the Central Heat Setpoint is decreased by Outdoor Reset settings, the Boost Time parameter is used to increase the operating setpoint when the home heat demand is not satised after the Boost Time setting is exceeded. When heat demand has been “on” continuously for longer than the Boost Time parameter the operating setpoint is increased by 10°F (5.6°C). The highest operating setpoint from Boost Time is current Central Heat Setpoint minus the Central Heat “Diff Above” setting. A setting of 0 seconds disables this

feature.

Page 93

X. Operation F. Changing Adjustable Parameters (continued)

“Press” button to access the following parameters:

Factory

Setting

Enabled Enable Disable

0°F

(-18°C)

70°F

(21.1°C)

110°F

(43.3°C)

0 Minutes

Range / Choices Parameter and Description

Auxiliary Heat Outdoor Reset Enable

If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure

Disable Do Not Calculate setpoint based on outdoor temperature Enable Calculate the temperature setpoint based on outdoor temperature using a reset

curve dened by Low Outdoor Temp, High Outdoor Temp, Low Boiler Water

Temp, Min Boiler Temp and Central Heat Setpoint and Boost Time parameters.

Auxiliary Heat Low Outdoor Temperature

-40°F to 100°F

(-40°C to 37.8°C)

32°F to 100°F

(0°C to 37.8°C)

70°F to 190°F

(21.1°C to 87.8°C)

0-1800 Seconds

(0-30 Minutes)

Auxiliary Heat High Outdoor Temperature

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

temperature.

Auxiliary Heat Low Boiler Water Temperature

Auxiliary Heat Boost Time

feature.

Page 94

X. Operation F. Changing Adjustable Parameters (continued)

Figure 45: Outdoor Reset Curve - Typical for Central Heat and Auxiliary Heat

Central Heat

Setpoint

180°F to 190°F

(82.2°C to 87.8°C)

160°F to 190°F

(71.1°C to 87.8°C)

130°F to 160°F

(54.4°C to 71.1°C)

Heating Element Type

Fan Coil

Convection

Baseboard

Fin Tube

Convective

Radiant

Baseboard

Central Heat

Setpoint

100°F to 140°F

(37.8°C to 60°C)

130°F to 160°F

(54.4°C to 71.1°C)

140°F to 160°F

(60°C to 71.1°C)

In Slab Radiant High

Staple-up Radiant

Low Mass Radiant

Heating Element Type

Mass Radiant

Radiators

Page 95

X. Operation F. Changing Adjustable Parameters (continued)

“Press” button to access the following parameters:

Factory

Setting

Disable

Boiler Piped

Disabled

180 Secs 120 - 1200 Secs

195°F

(90.6°C)

70% 50% - 100%

Range / Choices Parameter and Description

Enable,

Disable

Boiler Piped,

Primary Piped

Enable,

Disable

Central Heat

Setpoint,

195°F (90.6°C)

3 1-5

Master Enable/Disable

The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! enable ONLY one Sequence Master.

Indirect Water Heater (IWH) Boiler Piped Sequencer to respond to an Isolated DHW demand that is piped to a single boiler. The individual boiler goes on “Leave” from the Sequencer Master and

goes to DHW Service.

Primary Piped The Sequence Master responds to the DHW Call For Heat. This allows one or more boilers to provide heat to the IWH.

DHW Two Boiler Start

The Sequencer to immediately start two boilers for a DHW call for heat. Used when DHW is the largest demand. Only visible when primary piped IWH is selected.

Boiler Start Delay

Slave boiler time delay after header temperature has dropped below the setpoint minus “Diff below” setpoint. Longer time delay will prevent nuisance starts due to short temperature swings.

Stop All Boilers Setpoint

When this temperature is reached all boilers are stopped. This setpoint allows the Sequencer to

respond to rapid load increases.

Base Load Common Rate

To maximize condensing boiler efciency, the ring rate is limited to an adjustable value. Boilers are kept at or below this ring rate as long as the boilers can handle the load. After last available boiler has started, the modulation rate limit is released up to 100%.

Response Speed

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

Page 96

Sequence

Slave

X. Operation F. Changing Adjustable Parameters (continued)

“Press”

Factory Setting

None 1-8

Normal

Range / Choices Parameter and Description

Use Boiler First,

Use Boiler Last

“Press”

NOTE

Zone Control Description Setup shown for 2 panels, typical for up to 4.

button to access the following parameters:

Boiler Address

Each boiler must be given a unique address. When ”Normal” slave selection order is used, the boiler address is used by the Master Sequencer as the boiler start order. The boiler address is also the Modbus Address when a Energy Management System is connected.

Slave Selection Order

Normal,

“Use Boiler First”; places the Slave in the lead permanently. ”Normal”; ring order follows boiler number (1,2,3,..) order. ”Use Boiler Last”; places the slave last in the ring order.

button to access the following parameters:

Use Up and DOWN Arrows for More

Exit Screen without Saving

Clear Entire Field

Backspace

Save Field and Exit

Factory Setting Range / Choices Parameter and Description

Central Heat 1 User dened Zone Control 1 Zone 1

Central Heat 2 User dened Zone Control 1 Zone 2

Central Heat 3 User dened Zone Control 1 Zone 3

Central Heat 4 User dened Zone Control 1 Zone 4

Central Heat 1 User dened Zone Control 2 Zone 1

Central Heat 2 User dened Zone Control 2 Zone 2

Central Heat 3 User dened Zone Control 2 Zone 3

Central Heat 4 User dened Zone Control 2 Zone 4

Central Heat 1 User dened Zone Control 3 Zone 1

Central Heat 2 User dened Zone Control 3 Zone 2

Central Heat 3 User dened Zone Control 3 Zone 3

Central Heat 4 User dened Zone Control 3 Zone 4

Central Heat 1 User dened Zone Control 4 Zone 1

Central Heat 2 User dened Zone Control 4 Zone 2

Central Heat 3 User dened Zone Control 4 Zone 3

Central Heat 4 User dened Zone Control 4 Zone 4

Page 97

X. Operation F. Changing Adjustable Parameters (continued)

“Press”

Factory

Setting

Local

130°F

(54.4°C)

180°F

(82.2°C)

Local

* Only visible when Central Heat Setpoint Source is set to 4-20mA.

80°F (26.7°C) -

Central Heat

80°F (26.7°C) -

Central Heat

button to access the following parameters:

Range /

Choices

Central Heat Modulation Source

This parameter enables the 4-20mA input to control ring rate and the thermostat input to control

Local,

4-20mA

Local,

4-20mA

Setpoint

Local,

Modbus

boiler on/off demand directly without using the internal setpoint. The 4-20mA selection is used to enable a remote multiple boiler controller to control the R7910 Control: Local: 4-20mA Input on Terminal 9 & 10 is ignored. 4-20mA 4-20mA Input on Terminal 9 & 10 is used to control ring Rate % directly. Modbus Modbus input used to control ring Rate % directly.

Central Heat Setpoint Source

Sets the remote (Energy Management System) control mode as follows: Local: Local setpoint and modulation rate is used. 4-20mA input on Terminal 9 & 10 is ignored. 4-20mA 4-20mA Input on Terminal 9 & 10 is used as the temperature setpoint. The following two parameters may be used to adjust the signal range. Modbus Modbus is used as the temperature setpoint.

Central Heat 4-20mAdc Setup, 4 mA Water Temperature*

Sets the Central Heat Temperature Setpoint corresponding to 4mA for signal input on terminal 9 & 10. Current below 4mA is considered invalid, (failed or incorrect wired input).

Central Heat 4-20mAdc Setup, 20 mA Water Temperature*

Sets the Central Heat Temperature Setpoint corresponding to 20mA for signal input on terminal 9 &

10. Current above 20mA is considered invalid, (failed or incorrect wired input).

Central Heat Demand Source

This parameter enables a Modbus input to be take the place of the Heating Thermostat Input: Local Local Heating Thermostat input is used for Central Heat demand. Modbus Modbus input is used for Central Heat demand.

Parameter and Description

Page 98

XI. Service and Maintenance

Important Product Safety Information

Refractory Ceramic Fiber Product

Warning:

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

AVOID Breathing Fiber Particulates and Dust

Precautionary Measures:

Do not remove or replace RCF parts or attempt any service or repair work

involving RCF without wearing the following protective gear:

1. A National Institute for Occupational Safety and Health (NIOSH)

approved respirator

2. Long sleeved, loose fitting clothing

3. Gloves

4. Eye Protection

• Take steps to assure adequate ventilation.

• Wash all exposed body areas gently with soap and water after contact.

• Wash work clothes separately from other laundry and rinse washing

machine after use to avoid contaminating other clothes.

• Discard used RCF components by sealing in an airtight plastic bag. RCF and crystalline silica are not classified as hazardous wastes in the United

States and Canada.

First Aid Procedures:

• If contact with eyes: Flush with water for at least 15 minutes. Seek

immediate medical attention if irritation persists.

• If contact with skin: Wash affected area gently with soap and water.

Seek immediate medical attention if irritation persists.

• If breathing difficulty develops: Leave the area and move to a location

with clean fresh air. Seek immediate medical attention if breathing

difficulties persist.

• Ingestion: Do not induce vomiting. Drink plenty of water. Seek

immediate medical attention.

Page 99

XI. Service and Maintenance (continued)

WARNING

Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual.

Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or loss of life. Read and understand the entire manual before attempting installation, start-up operation, or service. Installation and service must be performed only by an experienced, skilled, and knowledgeable installer or service agency

This boiler must be properly vented.

This boiler needs fresh air for safe operation and must be installed so there are provisions for adequate combustion and ventilation air.

Asphyxiation Hazard. The interior of the venting system must be inspected and cleaned before the start of the heating season and should be inspected periodically throughout the heating season for any obstructions. A clean and unobstructed venting system is necessary to allow noxious fumes that could cause injury or loss of life to vent safely and will contribute toward maintaining the boiler’s efciency.

Installation is not complete unless a safety relief valve is installed into the tapping located on left side of appliance or the supply piping. - See the Water Piping and Trim Section of this manual for details.

This boiler is supplied with safety devices which may cause the boiler to shut down and not re-start without service. If damage due to frozen pipes is a possibility, the heating system should not be left unattended in cold weather; or appropriate safeguards and alarms should be installed on the heating system to prevent damage if the boiler is inoperative.

Burn Hazard. This boiler contains very hot water under high pressure. Do not unscrew any pipe ttings nor attempt to disconnect any components of this boiler without positively assuring the water is cool and has no pressure. Always wear protective clothing and equipment when installing, starting up or servicing this boiler to prevent scald injuries. Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the boiler. This boiler contains components which become very hot when the boiler is operating. Do not touch any components unless they are cool.

Respiratory Hazard. Boiler materials of construction, products of combustion and the fuel contain alumina, silica, heavy metals, carbon monoxide, nitrogen oxides, aldehydes and/or other toxic or harmful substances which can cause death or serious injury and which are known to the state of California to cause cancer, birth defects and other reproductive harm. Always use proper safety clothing, respirators and equipment when servicing or working nearby the appliance.

Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all those contained in component manufacturers manuals which are provided with the boiler before installing, starting up, operating, maintaining or servicing.

All cover plates, enclosures and guards must be in place at all times.

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

NOTICE

Page 100

XI. Service and Maintenance (continued)

DANGER

Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses ammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.

Do not attempt any service work if gas is present in the air in the vicinity of the boiler. Never modify, remove or tamper with any control device.

WARNING

This boiler must only be serviced and repaired by skilled and experienced service technicians.

If any controls are replaced, they must be replaced with identical models.

Read, understand and follow all the instructions and warnings contained in all the sections of this manual.

If any electrical wires are disconnected during service, clearly label the wires and assure that the wires are reconnected properly.

Never jump out or bypass any safety or operating control or component of this boiler.

Read, understand and follow all the instructions and warnings contained in ALL of the component instruction manuals.

Assure that all safety and operating controls and components are operating properly before placing the boiler back in service.

Annually inspect all vent gaskets and replace any exhibiting damage or deterioration.

NOTICE

Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specied.

A. Continuously:

1. Keep the area around the boiler free from

combustible materials, gasoline and other ammable

vapors and liquids.

2. Keep the area around the combustion air inlet terminal free from contaminates.

3. Keep the boiler room ventilation openings

open and unobstructed.

B. Monthly Inspections:

1. Inspect the vent piping and outside air intake piping to verify they are open,

unobstructed and free from leakage or deterioration. Check rodent screens in vent and air intake terminations to verify they are clean and free of debris. Call the service technician to make repairs if needed.

2. Inspect the condensate drain system to verify

it is leak tight, open and unobstructed. Call the service technician if the condensate drain system requires maintenance.

3. Inspect the ue temperature sensor cap to verify that it is free from leakage and deterioration. Call the service technician to make repairs, if needed.

4. Inspect the water and gas lines to verify they

are free from leaks. Call the service technician to make repairs if required.

NOTICE

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

C. Annual Inspections and Service: In addition

to the inspections listed above the following should be performed by a service technician once every year.

1. Follow the procedure for turning the boiler off

per Figure 32 “Operating Instructions”.

2. Inspect the wiring to verify the conductors are in

good condition and attached securely.

100

Crown Boiler Phantom-X PHNTM210, Phantom-X PHNTM285 Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual