Crown Boiler PHANTOM-X SERIES, PHNTM500C, PHNTM399C Installation And Operating Instructions Manual

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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.

Models:

• PHNTM399C

• PHNTM500C

This manual is for use with boilers having a part number ending in “C” (example: PHNTM399HNL2HUC.

Manufacturer of Hydronic Heating Products

106309-01 - 6/16

9700609

WARNING: Improper installation, adjustment, alteration,

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

consult a 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

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 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.

WARNING

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

WARNINGS FOR THE OWNER

FOLLOW ALL INSTRUCTIONS and warnings printed in this manual, the owner’s manual and posted on the boiler.

MAINTAIN THE BOILER. To keep your boiler safe and efficient, have a service technician maintain this boiler as specified in Part XIII of the manual.

CAUTION

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

NOTICE

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

DO NOT BLOCK AIR FLOW into or around the boiler. Insufficient air may cause the boiler to produce carbon monoxide or start a fire.

KEEP FLAMMABLE LIQUIDS AWAY from the boiler, including paint, solvents, and gasoline. The boiler may ignite the vapors from the liquids causing explosion or fire.

IF YOU ARE NOT QUALIFIED to install or service boilers, do not install or service this one.

THE BOILER MAY LEAK WATER at the end of its useful life. Be sure to protect walls, carpets, and valuables from water that could leak from the boiler.

PROTECT YOUR HOME OR BUSINESS IN FREEZING WEATHER. A power outage, safety lockout, or component failure will prevent your boiler from lighting. In winter, your pipes may freeze and cause extensive property damage. Do not leave the heating system unattended during cold weather unless alarms or other safeguards are in place to prevent such damage

KEEP CHILDREN AND PETS away from hot surfaces of the boiler, boiler piping, vent piping and vent terminals.

CARBON MONOXIDE (CO) is an odorless, deadly gas that may be introduced into your home by any malfunctioning fuel-burning product or vent system failure. Consider installing CO alarms near bedrooms in all levels of the building to warn you and your family of potential CO exposure.

DANGER

Explosion Hazard. 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, DO 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.

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.

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.

TABLE OF CONTENTS

I. Product Description, Specications and Dimensional Data...................... 6

II. Unpacking Boiler........................................................................................ 9

III. Pre-Installation and Boiler Mounting.......................................................... 10

IV. Venting...................................................................................................... 15

A. General Guidelines............................................................................... 15

B. CPVC/PVC Venting.............................................................................. 22

C. Polypropylene Venting......................................................................... 27

D. Stainless Steel Venting........................................................................ 32

E. Optional Room Air for Combustion....................................................... 34

F. Removing the Existing Boiler............................................................... 35

G. Multiple Boiler Installation Venting....................................................... 36

V. Condensate Disposal................................................................................. 39

VI. Water Piping and Trim............................................................................... 41

VII. Gas Piping ............................................................................................... 53

VIII. Electrical ................................................................................................... 58

IX. System Start-Up ....................................................................................... 70

X. Operation...................................................................................................... 78

A. Overview.............................................................................................. 78

B. Supply Water Temperature Regulation................................................ 79

C. Boiler Protection Features.................................................................... 80

D. Multiple Boiler Control Sequencer........................................................ 81

E. Boiler Sequence of Operation.............................................................. 83

1. Normal Operation............................................................................ 83

2. Using the Display............................................................................ 84

3. Status Screens............................................................................... 85

4. Detail Screens................................................................................. 87

5. Multiple Boiler Sequencer Screens................................................ 88

F. Changing Adjustable Parameters......................................................... 89

1. Entering Adjust Mode..................................................................... 89

2. Adjusting Parameters...................................................................... 89

XI. Service and Maintenance ........................................................................ 108

XII. Troubleshooting........................................................................................ 114

XIII. Repair Parts ............................................................................................. 120

Appendix A - Instructions for High altitude Installations Above 2000 ft..... 131

I. Product Description, Specications and Dimensional Data

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

in forced hot water space or space heating with indirect domestic hot water heating systems, where supply water temperature does not exceed 210°F. These boilers have special coil type stainless steel heat exchangers, constructed, tested and stamped per Section IV ‘Heating Boilers’ of ASME Boiler and Pressure Vessel Code, which provide a

Table 1: Specications

Specication

Altitude (ft. above sea level)

Fuel

Max. Allowable Water Temperature (°F) 210 210

Max. Allowable Working Pressure (psi) 160 160

Factory Supplied Safety Relief Valve (psi)* 50 50

Boiler Water Volume (gal.) 3.4 4.3 Heat Transfer Area (sq. ft.) 41.8 58.1

Approx. Shipping Weight (lb.) 316 368

Follow Instructions for High Altitude Installations above 2000 ft. (see Appendix A)

PHNTM500C LP cannot be installed above 6,000 ft.

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 “C” (example: PHNTM399CHNL2HUC).

Boiler Model

PHNTM399C PHNTM500C

0-10,100 0-10,100

Shipped for Natural Gas, Field

Converted for LP Gas

Table 2: Dimensions (See Figures 1 and 2)

31-3/16

(792)

5-1/2

(140)

12-3/8

(314)

(584)

15-1/8

(384)

Boiler Model

46-1/2

(1181)

N/A

21-5/16

(541)

34-13/16

(884)

28-5/16

(719)

(100)

Dimension

A - Inch

(mm)

B - Inch

(mm)

C - Inch

(mm)

D - Inch

(mm)

E - Inch

(mm)

Gas Inlet G - Inch 3/4 (FPT)

Return H - Inch 1-1/2 FPT 2 MPT Supply J - Inch 1-1/2 FPT 2 MPT

PP Condensate Drain K - Inch 3/4 PVC Compression Coupling

PVC Combustion Air Connector - Inch 4

CPVC/PP/SS Vent Connector - Inch

(mm)

PHNTM399C PHNTM500C

ACCESS PANEL

LOW VOLTAGE

KNOCKOUTS

(24 VOLTS)

LINE VOLTAGE

KNOCKOUTS

(120 VOLTS)

'G'

GAS VALVE INLET

'J' 1-1/2" FPT

SUPPLY TAPPING

ACCESS PANELACCESS PANEL

'H' 1-1/2" FPT

RETURN TAPPING

3/4" FPT

TAPPING

RELIEF/DRAIN

'K'

CONDENSATE DRAIN

ACCESS PANEL ACCESS PANEL

'B'

'C'

'E'

'D'

Figure 1: Phantom X - Model PHNTM399C

'A'

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

4" PVC COMBUSTION

AIR CONNECTOR

4" CPVC/PP/SS

VENT CONNECTOR

ACCESS PANEL

(24 VOLTS)

KNOCKOUTS

LOW VOLTAGE

(120 VOLTS)

KNOCKOUTS

LINE VOLTAGE

'H' 2" MPT

ACCESS PANEL ACCESS PANEL

RETURN TAPPING

'J' 2" MPT

SUPPLY TAPPING

'G'

GAS VALVE INLET

'K'

ACCESS PANELACCESS PANEL

CONDENSATE DRAIN

'C'

'E'

'D'

'A'

Figure 2: Phantom X - Model PHNTM500C

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

4" PVC COMBUSTION

AIR CONNECTOR

4" CPVC/PP/SS

VENT CONNECTOR

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

Table 3: Ratings

Phantom X Series Gas-Fired Boilers

Model

Number

PHNTM399C 80 399 375 326 94.1 94.5

PHNTM500C 100 500 485 422 97.0 96.0

Ratings shown are for installations at sea level and elevations up to 2000 ft. at minimum vent length. For elevations above 2000 ft., see Appendix A Instructions for High Altitude Installations above 2000 ft.

Net AHRI Water Ratings based on allowance of 1.15. Consult manufacturer before selecting boiler for installations having

unusual piping and pickup requirements, such as intermittent system operation, extensive piping systems, etc.

Input (MBH)

Min. Max.

Gross Output

(MBH)

Net Ratings Water

(MBH)

Thermal

Efciency (%)

Combustion

Efciency (%)

II. Unpacking Boiler

NOTICE

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.

E. Move boiler to its permanent location.

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 Co. 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.

WARNING

Asphyxiation Hazard. Apply supplied dielectric grease to gasket

inside 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 CSD-1.

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 4 for minimum listed clearances from combustible material. Recommended 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.

Table 4: Corrosive Combustion Air Contaminants

and Sources

Contaminants to avoid:

Spray cans containing chloro/uorocarbons (CFC’s)

Permanent wave solutions

Chlorinated waxes/cleaners

Chlorine-based swimming pool chemicals

Calcium chloride used for thawing

Sodium chloride used for water softening

Refrigerant leaks

Paint or varnish removers

Hydrochloric acid/muriatic acid

Cements and glues

Antistatic fabric softeners used in clothes dryers

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

Adhesives used to fasten building products and other similar

products

Excessive dust and dirt

Areas likely to have contaminants:

Dry cleaning/laundry areas and establishments

Swimming pools

Metal fabrication plants

Beauty shops

Refrigeration repair shops

Photo processing plants

Auto body shops

Plastic manufacturing plants

Furniture renishing areas and establishments

New building construction

Remodeling areas

Garages with workshops

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

weight of boiler, water and all additional system components.

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. Locate combustion air pipe termination away from areas that may contaminate combustion air, (see Table 4). 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.

G. General.

1. Phantom X boilers are intended for installations in

an area with a oor drain, or in a suitable drain pan

to prevent any leaks or safety relief valve discharge resulting in property damage.

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

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

4. Boiler Installation:

a. For basement installation provide a solid level

base such as concrete where oor is not level or where water may be encountered on the oor

around boiler. Floor must be able to support

Boiler Clearances to Combustible (and NonCombustible) Material:

Models PHNTM399C and PHNTM500C:

These boilers 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 provided 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:

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.

1. The boiler front is accessible through a door.

2. Access is provided to the condensate trap located on the left side of boiler.

3. Access is provided to thermal link located at the boiler rear.

Table 5: Vent Pipe Clearances to Combustible Material

Listed Direct

Vent System

Standard

Two-Pipe CPVC/PVC Vent and PVC Combustion Air Intake

Optional

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

Optional

Two-Pipe Stainless Steel Vent and Galvanized Steel or PVC Combustion Air Intake

Vent Pipe Material

CPVC/PVC

Rigid Polypropylene (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 or 110 mm)

3 in. (80 mm),

4 in. (100 mm or 110 mm)

3 in. (80 mm),

4 in. (100 mm or 110 mm)

Minimum Clearance to Combustible

Material

1 in. (25 mm)

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

Figure 4: Clearances To Combustible and Non-combustible Material

H. Boiler Stacking

1. For installations with unusually high space heating and/or domestic hot water heating loads, where

employing multiple boilers will offer the benets of greater operational efciency, oor space savings

and boiler redundancy, boilers may be installed stacked maximum one boiler on top of another. Refer to Table 6 “Phantom X Boiler Model Stacking Combinations” for details.

Table 6: Phantom X Boiler Model Stacking Combinations

Bottom

Boiler Model

PHNTM399C

PHNTM500C PHNTM399C or PHNTM500C

PHNTM399C

2. To eld assemble individual Phantom X 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 X boiler is factory packaged

with 2 stacking boiler attachment brackets (P/N 101679-01) and the bracket mounting hardware

Top Boiler Model

[six (6) self-drilling hex washer head plated #8 x ½” long screws, P/N 80860743]. Locate and remove the brackets and the hardware. The stacking boiler attachment bracket has three 7/32” diameter holes punched in a triangular pattern. See Figure 5 “Boiler Stacking”.

c. Phantom X 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 X

boiler model variable depth.

d. Position the upper boiler on 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.

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

• 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 fourth

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 sidewall venting individual model vent

terminals must terminate no closer than 12 in. (300 mm) horizontally and 3 ft. (900 mm)

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 in. (300 mm) horizontally. If vertical terminals cannot end in one plane, they must be spaced no closer than 3 ft. (900 mm) 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 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.

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

Figure 5: Boiler Stacking

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 specied vent and combustion air pipe diameters. 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 X may be installed as a direct vent/

sealed combustion boiler or with optional room air for combustion. Direct vent is recommended for residential applications. For direct vent, pipe combustion air from the outdoors directly to the boiler cabinet. Room air is optional for commercial applications. For room air, provide combustion and ventilation air per the National

Fuel Gas Code, ANSI Z223.1, or, in Canada, Installation Code for Gas Burning Appliances and Equipment, CGA Standard B149.

c. The following combustion air/vent system

options are listed for use with the Phantom X boilers (refer to Table 7):

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.

iv. Room Air for Combustion – CPVC/

PVC, polypropylene, or stainless steel pipe serves to expel products of combustion and combustion air is supplied from the boiler

room. Refer to Part E for specic details.

2. Vent/Combustion Air Piping

a. Do not exceed maximum vent/combustion air

lengths listed in Table 8. 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 9 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 10.

IV. Venting A. General Guidelines (continued)

Table 7: Vent/Combustion Air Intake System Options

Vent & Intake

Materials

Standard CPVC/PVC Two-Pipe,

CPVC/PVC

Vent and PVC Air Intake

Optional Polypropylene

Two-pipe, Rigid PP

Vent or Flexible PP

Vent (Vertical Only) and Rigid PP

or PVC Air Intake

Optional Stainless Steel

Two-pipe, SS Vent and

Galvanized Steel or PVC

Air Intake

Option

Penetration

Through

Termination Figures

Structure

Intake Horizontal Sidewall 90° Elbow w/ Screen

Vent Horizontal Sidewall Coupling w/ Screen

Intake Horizontal Sidewall

Vent Horizontal Sidewall

Intake Horizontal Sidewall 90° Elbow w/ Screen

Vent Vertical Roof Coupling w/ Screen

Intake Vertical Roof (2) 90° Elbows w/ Screen

Vent Vertical Roof Coupling w/ Screen

Intake N/A - Room Air

Vent Horizontal Sidewall 90° Elbow or Tee w/ Screen

Intake N/A - Room Air

Vent Vertical Roof Coupling w/ Screen

Intake Horizontal Sidewall

Vent Horizontal Sidewall

Intake Horizontal Sidewall

Vent Horizontal Sidewall

Intake Horizontal Sidewall

Vent Vertical Roof

Intake Vertical Roof

Vent Vertical Roof

Intake N/A - Room Air

Vent Horizontal Sidewall

Intake N/A - Room Air

Vent Vertical Roof

Intake Horizontal Sidewall 90° Elbow w/Screen

Vent Horizontal Sidewall

Intake Horizontal Sidewall 90° Elbow w/Screen

Vent Vertical Roof

Intake Vertical Roof (2) 90° Elbows w/Screen

Vent Vertical Roof

Intake N/A - Room Air

Vent Horizontal Sidewall 90° Elbow or Tee w/Screen

Intake N/A - Room Air

Vent Vertical Roof 90° Elbow or Tee w/Screen

Ipex Low Prole 9 13

UV Resistant 90° Elbow

w/Screen

UV Resistant Straight Pipe

w/Screen

Ipex Low Prole 9 13, 17, 18

UV Resistant 90° Elbow

w/Screen

UV Resistant Straight Pipe

w/Screen

(2) UV Resistant 90° Elbows

w/Screen

UV Resistant Straight Pipe

w/Screen

UV Resistant 90° Elbow

w/Screen

UV Resistant Straight Pipe

w/Screen

Straight Termination

w/Screen

Straight Termination

w/Screen

Straight Termination

w/Screen

Component

Table

7, 8 11, 12

7, 8, 10 not provided

10 14

7, 8 not provided

10 not provided

7, 8 17, 18

7, 8, 10 17, 18

10 17, 18

7, 8 17, 18

10 17, 18

7, 8 19, 20, 21

7, 8, 10 19, 20, 21

10 19, 20, 21

7, 8 19, 20, 21

10 19, 20, 21

Reference

Section

A, B

A, B, E

A,C

A,C, E

A, D

A, D, E

IV. Venting A. General Guidelines (continued)

Table 8: Vent and Combustion Air Pipe Sizes and Equivalent Lengths (Applies to All Listed Vent/Combustion Air System Options)

Combustion Air Length Vent Length

Boiler Model Option

Standard

PHNTM399C

PHNTM500C

Diameter

Reduced Diameter

Standard Diameter

Reduced Diameter

Pipe Dia., in.

(mm)

4 (100 or 110) 0 100 (30.5) 4 (100 or 110) 2.5 (760) 100 (30.5) 5

3 (80) 0 50 (15.2) 3 (80) 2.5 (760 ) 50 (15.2 ) 5

4 (100 or 110) 0 100 (30.5) 4 (100 or 110) 2.5 (760) 100 (30.5) 11

3 (80) 0 50 (15.2) 3 (80) 2.5 (760) 50 (15.2 ) 12

Min., ft.

(m)

Max., ft.

(m)

Pipe Dia., in.

(mm)

Min., ft.

(m)

Table 9: Vent System and Combustion Air System Component Equivalent Length (Applies to All Listed Vent/Combustion Air System Options)

Component Equivalent Length

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

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

90° Elbow, Long Sweep/Sanitary 4.0 ft. (1.2 m) 9 ft. (2.7 m)

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

Max., ft.

(m)

Approx. Derate at

Max. Length

(%)

Table 10: Vent and Combustion Air Equivalent Length Calculation Worksheet

Combustion Air Vent

Component

Straight Pipe x = A E

90° Elbow,

Short Radius

90° Elbow,

Long Sweep/

Sanitary

45° Elbow x = D H

Notes:

1. Total equivalent length cannot exceed maximum equivalent length shown in Table 8.

2. Use elbow equivalent lengths provided in Table 9.

3. Combustion air and vent terminations do not count towards total equivalent length.

4. 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 Measured length = 35 ft. Equivalent length =35 ft. x 1.2 = 42 ft.

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

Equivalent Length Per

Piece

Combustion Air Total

Equivalent Length

x Quantity =

x = B F

x = C G

Subtotal

Equivalent Length

= A+B+C+D Vent Total

Equivalent Length Per

Piece

Equivalent Length

x Quantity =

Subtotal Equivalent

Length

= E+F+G+H

IV. Venting A. General Guidelines (continued)

Two-Pipe System Vent Terminal (Shown), Two-Pipe System Air Intake Terminal (Not Shown)

Figure 6: Location of Vent Terminal Relative to Windows, Doors, Grades, Overhangs, Meters and Forced Air Inlets -

IV. Venting A. General Guidelines (continued)

b. Maintain minimum clearance to combustible

materials. See Table 5 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.

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

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.

3. Vent/Combustion Air Terminals

Install venting system components on exterior

of building only as specically required by these

instructions (refer to Figure 6).

a. Use only listed vent/combustion air terminals.

i. Horizontal Sidewall Venting: Use coupling

for vent and 90° elbow pointed down for combustion air as shown in Figure 7 or Figure 8. If using room air for combustion, use 90° elbow or tee for vent. Alternate low

prole termination is shown in Figure 9.

Figure 7: Direct Vent - Sidewall Standard Terminations

IV. Venting A. General Guidelines (continued)

Figure 8: Direct Vent - Sidewall Snorkel Terminations

Figure 9: Direct Vent - Sidewall Low Prole Termination

ii. Vertical Roof Venting: Use coupling on vent

and two 90° elbows turned downwards for combustion air as shown in Figure 10 and Figure 11.

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. 36 in. (915 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.

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.

IV. Venting A. General Guidelines (continued)

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.

Figure 10: Direct Vent - Vertical Terminations

j. Do not locate the vent terminal under decks or

similar structures.

k. Top of terminal must be at least 24 in.

(600mm) below ventilated eves, softs, and other overhangs. In no case may the overhang exceed 48 in. (1200 mm). 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 6 for details.

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

spacing between vent terminal and a building corner.

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

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.

Figure 11: Direct Vent - Vertical Terminations

with Sloped Roof

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

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.

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.

1. Components

a. See Table 11 for CPVC/PVC vent and

combustion air components included with boiler.

b. See Table 12 for CPVC/PVC installer provided

vent and combustion air components required for optional horizontal snorkel terminals shown in Figure 8.

c. See Table 13 for installer provided Ipex Low

Prole Vent Termination Kits.

d. See Table 14 for CPVC/PVC installer provided

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

10.

2. Field Installation of CPVC/PP/SS Vent Connector

Refer to Figure 12 and following steps:

a. Position the vent connector and gasket onto

boiler rear panel and insert vent connector into heat exchanger vent outlet.

b. Align vent connector plate and gasket clearance

holes with rear panel engagement holes. Be sure combustion sample port is on left side looking at rear of boiler. Then, secure the connector and

gasket to the panel with four mounting screws.

3. Near-Boiler Vent/Combustion Air Piping

Refer to Figure 13 and the following Steps:

a. Apply supplied dielectric grease to gasket inside

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 clamp.

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. Apply PVC primer and cement and insert

Schedule 40 PVC combustion air pipe (installer provided) into the combustion air connector with a slight twisting motion.

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.

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

WARNING

Asphyxiation Hazard. Apply supplied dielectric grease to gasket inside vent section of 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.

Table 11: CPVC/PVC Vent & Air Intake Components Included With Boiler

Quantity

Vent & Air Intake Components

Schedule 40 PVC Coupling 1 Schedule 40 PVC 90° Elbow 1

Stainless Steel Screen 2

30 in. Schedule 40 CPVC Pipe 1 Schedule 80 CPVC 90° Elbow 1

Table 12: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Horizontal Snorkel Termination

Models PHNTM399C & PHNTM500C

Standard 4 in. Intake/4 in. Vent Kit

includes

Quantity

Vent Components

Schedule 40 PVC Pipe x up to 7 ft. (2.1 m) max. vertical run 2 Schedule 40 PVC 90° Elbow 4 Schedule 40 PVC Pipe x 6 in. (150 mm) min. horizontal run 2 Schedule 40 PVC Pipe x 9 in. (230 mm)min. horizontal run N/A

PHNTM399C & PHNTM500C

Horizontal (Snorkel)

4 in. Intake/4 in. Vent

Table 13: Components Required for Optional Ipex Low Prole Sidewall Termination

Description Ipex Part Number Applicable to Boiler Sizes

3 in. Low Prole Termination Kit 196985

4 in. Low Prole termination Kit 196986

399 (reduced dia.)

500 (reduced dia.) 399 (standard dia.) 500 (standard dia.)

Table 14: CPVC/PVC Vent & Air Intake Components (Installer Provided) required for Optional Vertical Roof Termination

Quantity

Vent Components

Schedule 40 PVC Coupler 1 Schedule 40 PVC 90° Elbow 2

Schedule 40 CPVC Pipe x 6 in. (150 mm) min. horizontal

run

PHNTM399C & PHNTM500C

Vertical (Roof) Termination,

4 in. Intake/4 in. Vent

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

Figure 12: Field Installation CPVC/PP/SS Vent Connector

Figure 13: Near-Boiler Vent/Combustion Air Piping

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 14 and Table 15.

c. All CPVC/PVC vent and combustion air

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.

5. Horizontal Sidewall Termination

a. Standard Two-Pipe Termination

See Figure 7.

i. Vent Piping

Running PVC vent pipe inside Enclosures

and through Walls:

• 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 non-combustible walls.

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

Table 15: Expansion Loop Lengths

Nominal

Pipe

Dia. (In.)

Length of

Straight Run

ft. m in. mm

20 30 40 50 60

20 6.1 60 1520 30 9.1 74 1880 40 12 85 2159 50 15 95 2413 60 18 104 2642

6.1

9.1

Loop Length

“L”

1350

1650

1900

2130

2340

• PVC vent pipe may not be used to penetrate combustible or noncombustible walls unless all following three conditions are met simultaneously (see Figure 15):

- 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 15 is maintained around outside of the vent pipe to provide air circulation

• If above three conditions cannot be met simultaneously when penetrating a combustible wall, use CPVC pipe for wall penetration.

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

Figure 14: CPVC/PVC Expansion Loop and Offset

Figure 15: Wall Penetration Clearances

for PVC Vent Pipe

• Apply sealant between vent pipe and wall opening to provide weather-tight seal. Sealant should not restrain the expansion of the vent pipe.

• Install contractor provided optional trim plate on wall outside surface to cover wall opening (see Figure 15).

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

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

Figure 16: Screen Installation

• Install screen and vent terminal (supplied with boiler). See Figure 16 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 screen and combustion air terminal (supplied with boiler). See

Figure 16 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 Figure 8.

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.

NOTICE

Exterior run to be included in equivalent vent/ combustion air lengths.

• Install screen and vent terminal (supplied with boiler), see Figure 16 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 vent pipe.

See Figure 8.

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

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

Figure 16 for appropriate conguration.

• Brace exterior piping if required.

6. Vertical Roof Termination

a. Standard Two-Pipe Termination

See Figures 10 and 11.

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 10 and

11.

- 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

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 9.

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

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.

- 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.

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

• Install screen and vent terminal (supplied with boiler). See Figure 16 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 screen and combustion air terminal (supplied with boiler). See

Figure 16 for appropriate conguration.

• Brace exterior piping if required.

C. Polypropylene Venting

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.

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 16. 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’.

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 17 for specic M&G Duravent

components.

c. See Table 18 for specic Centrotherm Eco

Systems components.

2. Field Installation of Polypropylene Adapters

a. Vent Connector (see Figure 17)

i. No adapter is required for M&G DuraVent

PolyPro vent pipe unless vent diameter is reduced per Table 8. See Table 17 for M&G DuraVent boiler adapters for reduced vent diameter. An adapter is always required for Centrotherm InnoFlue vent pipe. See Table 18 for Centrotherm InnoFlue boiler adapters.

WARNING

IV. Venting C. Polypropylene Venting (continued)

ii. Install CPVC/PP/SS vent connector. Follow

instructions in “2. Field Installation of CPVC/PP/SS Vent Connector” under “B. CPVC/PVC Venting.”

iii. Apply provided dielectric grease to gasket

inside vent connector that will be in contact with adapter.

iv. Push and twist adapter into vent system

connector until adapter bottoms out.

v. Tighten clamp to secure adapter in CPVC/

PP/SS vent connector.

b. Combustion Air Connector (see Figure 18)

i. No adapter is required if using PVC

combustion air pipe. An adapter is required for both M&G DuraVent PolyPro (see Table

17) and Centrotherm InnoFlue (see Table

18) combustion air pipe.

ii. Insert adapter into combustion air connector.

Adapter has gasket to seal against combustion air connector.

3. System Assembly

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. Terminations

a. For standard horizontal sidewall terminations, see

Figures 7 and 8. For vertical roof terminations, see Figures 10 and 11. Use UV resistant components listed in Tables 17 or 18.

b. Install screens per Figure 16. Remove gasket

inside termination and install screen in place of gasket. If using Centrotherm InnoFlue end pipe,

screen ts onto end of pipe.

c. For low prole sidewall termination, see Figure

9. Use low prole termination listed in Table 13

and adapter kit listed in Table 17 or 18.

5. 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.

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.

See Figure 19 or Figure 20 for locking band clamp installation.

Table 16: Listed Polypropylene Vent System

Manufacturers

Make Model

PolyPro Single Wall Rigid Vent

M&G/DuraVent

Centrotherm Eco

Systems

PolyPro Flex Flexible Vent (PHNTM399C and PHNTM500C)

InnoFlue SW Rigid Vent

Flex Flexible Vent (PHNTM399C and PHNTM500C)

Ipex Low

Adapter Kit:

Prole Termination

Wall Plate

Pipe Adapter &

Ipex Low

Pipe Adapter &

Prole Adapter Kit:

Wall Plate

ISLTK03

ISLTK04

Flex

Chimney

Termination: UV

Sidewall* or Roof

Resistant Straight

3PPS-FKL 3PPS-HLKL

Lining Kit

Pipe w/ Screen

Pipe: 3PPS-12BL

Screen: 3PPS-BG

4PPS-R3L

Boiler Adapter

w/Screen

90° Elbows

(2) UV Resistant

Roof Termination:

Screen: 3PPS-BG

Elbow: 3PPS-E90BL

4PPS-FKL 4PPS-HLKL

Pipe: 4PPS-12BL

Screen: 4PPS-BG

PHNTM399C &

Adapter Required

PHNTM500C: No

Screen: 4PPS-BG

Elbow: 4PPS-E90BL

Flex

Chimney

Termination: UV

Sidewall* or Roof

Resistant Straight

Boiler Adapter

IFCK0325

Lining Kit

IFCK0335

ISEP0339

Pipe: ISEP03 or

Pipe w/Screen

Screen: IASPP03

ISRD0403

ISAAL0404 and

Screen

90° Elbows w/

(2) UV Resistant

Roof Termination:

Screen: IASPP03

Elbow: ISELL0387UV

IFCK0425

IFCK0435

ISEP0439

Pipe: ISEP04 or

Screen: IASPP04

ISAAL0404

Screen: IASPP04

Elbow: ISEL0487UV

Sidewall

Combustion Air Vent

90°Elbow

Termination:

UV Resistant

Boiler

Adapter

Clamp

Pipe Joint

Locking Band

Pipe

Nominal

Diameter

Boiler Model

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

Table 17: M&G DuraVent PolyPro Polypropylene Vent/Combustion Air System Components

w/Screen

Screen: 3PPS-BG

Elbow: 3PPS-E90BL

4PPS-R3L

4PPS-ADL with

3PPS-LBC

3PPS-LB2 or

3 in.

(80 mm)

PHNTM399C (reduced dia.)

PHNTM500C (reduced dia.)

Screen: 4PPS-BG

Elbow: 4PPS-E90BL

4PPS-ADL

4PPS-LBC

4PPS-LB2 or

4 in.

(100 mm)

PHNTM399C (standard dia.)

PHNTM500C (standard dia.)

* Note: When using room air for combustion, use UV resistant 90° elbow or tee for sidewall vent termination. UV resistant 90° elbow part numbers: 3PPS-E90BL(3 in.), 4PPS-E90BL (4 in.).

UV resistant tee part numbers: 3PPS-TBL (3 in.), 4PPS-TBL (4 in.), 6PPS-TTBL (6 in.).

Combustion Air Vent

Sidewall

Termination:

UV Resistant

Boiler

Adapter

Clamp

Pipe Joint

Locking Band

Pipe

Nominal

Diameter

Screen: IASPP03

Elbow: ISELL0387UV

90° Elbow w/Screen

with

ISRD0403

ISAGL0404

IANS03

3 in.

(80 mm)

Screen: IASPP04

Elbow: ISEL0487UV

IANS04 ISAGL0404

4 in.

(110 mm)

Boiler Model

PHNTM399C (reduced dia.)

PHNTM500C (reduced dia.)

PHNTM399C (standard dia.)

Table 18: Listed Polypropylene Pipe, Fittings and Terminations - Centrotherm Eco

PHNTM500C (standard dia.)

* Note: When using room air for combustion, use UV resistant 90° elbow or tee for sidewall vent termination. UV resistant 90° elbow part numbers: ISEL0387UV (3 in.).

UV resistant tee part numbers: ISTT0320 (3 in.).

See Centrotherm InnoFlue literature for other required component part numbers such as straight pipe, elbows, restops, and vent supports.

IV. Venting C. Polypropylene Venting (continued)

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 PHNTM399C and PHNTM500C 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 21 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.

Figure 17: Field Installation of

Polypropylene Vent Adapter

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.

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,

Figure 18: Field Installation of Polypropylene

Combustion Air Adapter

gasket and tting installation, optional tooling

availability/usage, routing through masonry chimney for combustion product venting or, 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 X boiler Installation, Operating and Service Instructions, the more restrictive instructions shall govern.

IV. Venting C. Polypropylene Venting

Figure 19: Locking Band Clamp Installation,

M&G DuraVent or Centrotherm InnoFlue

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

Figure 20: Alternate Locking Band Clamp

Installation, M&G DuraVent

Figure 21: Flexible Vent in Masonry Chimney with Separate Combustion Air Intake

IV. Venting D. Stainless Steel Venting (continued)

D. Stainless Steel Venting

NOTICE

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.

1. Components

a. Acceptable listed stainless steel vent system

manufacturers and components are shown in Tables 19, 20 and 21.

b. Alternate listed stainless steel vent system

manufacturers and components are shown in Tables 20 and 21.

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.

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

following instructions, use GE RTV 106 or equivalent for the vent collar. Seal galvanized combustion air piping sections with any generalpurpose silicone sealant such as GE RTV102. Seal PVC combustion air piping sections with PVC cement.

d. Do not drill holes in vent pipe.

2. Field Installation of Stainless Steel Vent

Adapter (see Figure 22)

a. No adapter is required for stainless steel vent

pipe unless vent diameter is reduced per Table 8. See Table 19, 20, or 21 for adapters for reduced vent diameter.

Table 20: M&G DuraVent FasNSeal Stainless Steel Vent System Components, Single Wall

Boiler Model

PHNTM399C (reduced dia.) PHNTM500C (reduced dia.)

PHNTM399C (standard dia.) PHNTM500C (standard dia.)

Note: When using room air for combustion, use tee for sidewall vent termination. Termination tee part numbers: FSTT3 (3 in.), FSTT4 (4 in.). See M&G DuraVent FasNSeal literature for other required component part numbers such as straight pipe, elbows, restops, and vent supports.

Nominal Pipe

Diameter

3 in. (80 mm) FS0403TR FSBS3 FSWT3

4 in. (100 mm)

Boiler Adapter

PHNTM399C &

PHNTM500C:

No Adapter Required

Sidewall * or Roof Termination:

Straight Termination w/Screen

FSBS4 FSWT4

Wall Thimble

IV. Venting D. Stainless Steel Venting (continued)

Table 21: Z-Flex, Z-Vent (SVE Series III, Z-Vent III) Stainless Steel Vent System Components, Single Wall

Boiler Model Nominal Pipe Diameter Boiler Adapter

PHNTM399C (reduced dia.) PHNTM500C (reduced dia.)

PHNTM399C (standard dia.) PHNTM500C (standard dia.)

* Note: When using room air for combustion, use 90° elbow or tee for sidewall vent termination. Termination elbow part numbers: 2SVSTEX0390 (3 in.), 2SVSTEX0490 (4 in.). Termination tee part numbers: 2SVSTTX03 (3 in.), 2SVSTTX04 (4 in.). See Z-Flex literature for other required component part numbers such as straight pipe, elbows, restops, and vent supports.

3 in. (80 mm) 2SVSR0403 2SVSTPX03 2SVSWTF03

PHNTM399C & PHNT-

4 in. (100 mm)

M500C: No Adapter

Required

Sidewall * or Roof Termination:

Straight Termination w/Screen

2SVSTPX04 2SVSWTF04

Wall Thimble

b. Install CPVC/PP/SS vent connector. Follow

instructions in “2. Field Installation of CPVC/ PP/SS Vent Connector” under “B. CPVC/PVC Venting.”

c. Apply provided dielectric grease to gasket inside

vent connector that will be in contact with adapter.

d. Push and twist adapter into vent system

connector until adapter bottoms out.

e. Tighten clamp to secure adapter in CPVC/PP/SS

vent connector.

3. System Assembly

Figure 22: Field Installation of Stainless

Steel Vent Adapter

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.

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.

IV. Venting D. Stainless Steel Venting - E. Optional Room Air for Combustion (continued)

4. Horizontal Sidewall Vent Termination

a. Standard Two-Pipe Termination

See Figure 7.

i. Vent Termination

• Use components listed in Table 19, 20 or

21.

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.

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

ii. Combustion Air Termination

• Use a 90° elbow directed downward..

• Install a screen 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 Figure 8.

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 8.

• 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.

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 8.

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

• Install screen and horizontal vent terminal.

• Brace exterior piping if required.

5. Vertical Vent Termination

a. Standard Two-Pipe Termination

See Figures 10 and 11.

i. Vent Termination

• Use the terminal supplied by the vent system manufacturer shown in Table 19, 20 or 21. 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 10.

• Install screen in the combustion air terminal. Use a screen having 1/2 in. x 1/2 in. (13 mm x 13 mm) or larger mesh.

E. Optional Room Air for Combustion

1. General Guidelines

a. Room air is optional for commercial applications.

Room air uses one pipe to expel products of combustion directly outdoors with combustion air supplied from boiler room or enclosure. Direct vent is recommended for residential applications. Direct vent uses two pipes, one to expel products of combustion directly outdoors and one to supply combustion air to the boiler directly from outdoors. See preceding sections A through D for direct vent instructions.

b. Avoid combustion air contaminants in the boiler

room. See Table 4. Permanently remove any contaminants found in the boiler room. If contaminants cannot be removed, do not use room air for combustion.

IV. Venting E. Optional Room Air for Combustion - F. Removing the Existing Boiler (continued)

3. Terminations

WARNING

Sources of combustion air contaminants, including chlorines, chlorouorocarbons (CFC’s), petroleum distillates, detergents, volatile vapors or other chemicals must not be present in the boiler room. If any of these contaminants is present, severe boiler corrosion and failure will result.

a. For standard horizontal sidewall terminations,

see Figures 7 and 8. When using room air for combustion, use 90° elbow or tee for sidewall vent termination.

NOTICE

Use 90° elbow or tee for horizontal sidewall vent termination when using room air for combustion.

2. Outdoor Openings to Boiler Room

a. Provide combustion and ventilation air to the

boiler room or enclosure. Follow the National

fuel Gas Code, ANSI Z223.1, or, in Canada, Installation Code for Gas Burning Appliances and Equipment, CGA Standard B149 Code as

well as all applicable local codes. Use one of the following two methods.

b. Two Permanent Openings Method: Provide

two permanent openings, once within 12 in. (300 mm) of the top of the enclosure and one within 12 in. (300 mm) of the bottom of the enclosure. Openings must communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

i. Direct communication or through vertical

ducts: minimum free area of each opening shall be 1 in.2/4000 Btu/hr (550 mm2/kW) of total input rating of all appliances within the enclosure.

ii. Horizontal ducts: minimum free area of

each opening shall be 1 in.2/2000 Btu/hr (1100 mm2/kW) of total input rating of all appliances within the enclosure.

c. One Permanent Opening Method: Provide

one permanent opening, commencing within 12 in. (300 mm) of the top of the enclosure. The opening shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of the following:

i. 1 in.2/3000 Btu/hr (700 mm2/kW) of total

input rating of all appliances located within the enclosure.

ii. Not less than the sum of the areas of all vent

connectors in the space.

d. Motorized Louvers or Dampers: Motorized

louvers or dampers must be interlocked with the

boiler to allow ignition and ring of the burner

only when louvers are in the fully-open position. Wire the interlock to the Auto Reset External

Limit connections. See Section VIII. Electrical.

b. For vertical roof terminations, see Figures 10 and

11.

F. 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.

IV. Venting F. Removing the Existing Boiler - G. Multiple Boiler Installation Venting (continued)

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.

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.

G. Multiple Boiler Installation Venting

1. Vent Piping and Terminations

a. Multiple boiler vent terminations are shown in

Figure 23.

b. Each individual boiler must have its own vent

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

WARNING

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

c. Do not exceed the individual boiler maximum

vent length listed in Table 8.

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.

NOTICE

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.

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

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 23.

b. Each individual boiler must have own

combustion air pipe and terminal. Refer to Paragraphs A through F (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 8.

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.

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

Figure 23: Multiple Boiler Direct Vent Termination

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 1, 2, 3 and 24.

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 24.

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 22 “Maximum Condensate Flow”.

Table 22: Maximum Condensate Flow

Boiler Model

PHNTM399C 4.5

PHNTM500C 5.6

*Assumes 100% of water in fuel condenses.

*Maximum Condensate Flow,

GPH

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.

V. Condensate Disposal (continued)

Figure 24: Condensate Trap and Drain Line

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. Limestone chips will get coated by neutral salts (product of chemical reaction between limestone and acidic condensate) and lose neutralizing effectiveness over time. Therefore, periodic condensate neutralizer maintenance and limestone chip replacement must be performed. A pH test or acid test kits are available from HVAC/plumbing distributors and should be used to measure condensate acidity before/after neutralizer thus indicating a need for service and chip replacement.

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 Co.’ 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

1. Install provided components per Figure

25 for PHNTM399C or Figure 26 for the PHNTM500C. Rear tapping is return/inlet. Front tapping (middle on PHNTM399C) is supply/outlet. Piping and trim components are located in miscellaneous parts carton shipped with the boiler.

a. Safety Relief Valve – Install on tee off 3/4 in.

NPT tapping on PHNTM399C or on tee off supply tapping on the PHNTM500C. Use

provided 10 in. long nipple to locate valve above heat exchanger top.

b. Drain Valve – Install on tee off 3/4” NPT

tapping on PHNTM399C or on tee off supply tapping on PHNTM500C.

c. Temperature and Pressure Gauge – Install on

supply piping.

d. Flow Switch – Install on supply piping. Use

provided tee with 1 in. NPT outlet. Use correct paddle per Table 23. Refer to Section VIII

“Electrical” for ow switch wiring.

e. Install drain valve into tee bottom outlet.

Figure 25: Factory Supplied Piping and Trim Installation - PHNTM399C

VI. Water Piping and Trim (continued)

Table 23: Flow Switch Paddle Application

Boiler Flow Switch

Paddle Marking

PHNTM399C 1

PHNTM500C E

B. Piping System To Be Employed.

Phantom X boilers are designed to operate in a closed

loop pressurized system. Minimum pressure in the boiler must be 14.5 psi (100 kPa). Proper operation

of the Phantom X boiler requires that the water ow

through the boiler remain within the limits shown in

Table 24 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 Phantom X

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 isolated near-boiler

loop is maintained by installer supplied boiler circulator. See Tables 25 and 26 for recommended circulators.

b. The ow rate through the isolated near-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.

Table 24: Flow Range Requirement Through Boiler

i. Space heating only - refer to Tables 25 and

26 and Figure 28 “Near Boiler Piping Heating Only” as applicable.

ii. Space heating plus indirect water heater(s)

– refer to Tables 25 and 26 and Figure 29 “Near Boiler Piping - Heating Plus Indirect Water Heater” as applicable.

iii. If piping indirect water heater off boiler (see

Figure 30), be sure that indirect water heater and domestic hot water circulator are sized

to maintain ow through boiler within limits

shown in Table 24.

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 X 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 24.

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.

Supply

Boiler Model

PHNTM399C 1-1/2 1-1/2 21.5 6.1 25.1 7.9 30.2 10.8 37.7 15.9 PHNTM500C 2 2 27.7 5.2 32.3 6.8 38.8 9.3 48.5 13.6

Notes: Required Flow = Output*1000/(500*ΔT), where ow rate is in GPM, output is in MBH, and ΔT is in °F

Outputs for specic boiler models are provided in Table 3. See also Tables 25 and 26 for near boiler piping sizing. Using boiler antifreeze will result in increased uid density and may require larger circulators.

Connection

(in.)

Return

Connection

(in.)

Flow (GPM)

DT= 35°F DT = 30°F DT = 25°F ΔT = 20°F

Minimum Required

Boiler

Head Loss

(ft.)

Required

Flow

(GPM)

Boiler

Head

Loss

(ft.)

Required

Flow

(GPM)

Boiler

Head Loss

(ft.)

Maximum

Required

Flow (GPM)

Boiler

Head Loss

(ft.)

Model

Circulator

Model

Circulator

UPS43-100F,

Spd. 3

UP50-60F,

Spd. 3

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

(ft.)

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

(ft.)

UPS43-100F,

37.7 16.9

Spd. 2

48.5 15.2

Spd. 2

UPS43-100F,

VI. Water Piping and Trim (continued)

Table 25: Recommended Taco Circulators for 50 ft. Equivalent ft. Near Boiler Piping [Approximately 20 ft.

DT=35°F DT=30°F DT=25°F DT=20°F

Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]

Flow

(GPM)

Model

Circulator

Piping

Boiler &

Head Loss

Flow

(GPM)

(in.)

Pipe Size

Near Boiler

(in.)

Supply

& Return

Connection

Boiler Model

(ft.)

PHNTM399C 1½ 2 21.4 6.4 0014 25.0 8.3 0013 30.0 11.4 2400-60 37.5 16.8 2400-70

PHNTM500C 2 2 27.7 5.8 0012 32.3 7.5 2400-60 38.8 10.3 2400-60 48.5 15.2 2400-65

PHNTM399C 1½ 2 21.5 6.4 UP26-64F 25.1 8.4 UP26-99F 30.2 11.5

32.3 7.5 UPS43-44F 38.8 10.3

Spd. 2

UPS43-44FC,

PHNTM500C 2 2 27.7 5.8

Flow

(GPM)

Model

Circulator

DT=35°F DT=30°F DT=25°F DT=20°F

Near

Supply

Table 26: Recommended Grundfos Circulators for 50 Equivalent ft. Near Boiler Piping [Approximately 20 ft.

Straight Pipe, (4) 90° Elbows, and (2) Full Port Ball Valves]

(ft.)

Piping

Boiler &

Head Loss

Flow

(GPM)

(in.)

Boiler

Pipe Size

(in.)

& Return

Connection

Boiler Model

VI. Water Piping and Trim (continued)

Figure 26: Factory Supplied Piping and Trim Installation - PHNTM500C

C. Standard Installation Requirements.

Observe the following guidelines when making the

actual installation of the boiler piping:

1. Safety Relief Valve (Required) – The safety

relief valve is packaged loose with boiler and must be installed in the location shown in Figure 25 or 26 “Factory Supplied Piping and Trim Installation”. The safety relief valve must be installed with spindle in vertical position. Installation of the safety relief valve must comply with ASME Boiler and Pressure Vessel Code, Section IV. The standard factory shipped safety relief valve is set at 50 psi (340 kPa) on PHNTM399C and PHNTM500C. If the safety relief valve is to be replaced, the replacement valve must have a relief capacity equal or exceeding the minimum relief valve capacity shown on the heat exchanger ASME plate. Also, when replacing the safety relief valve, verify the temperature and pressure gage meets ASME requirements for the replacement safety relief valve. Pipe the safety relief valve discharge to a location where hot water or steam will not create hazard or property damage if the valve opens.

The end of the discharge pipe must terminate in an

unthreaded pipe. If the safety relief valve is not

piped to a drain, it must terminate at least 6 in. (150

mm) above the oor. Do not run safety 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.

CAUTION

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. Flow Switch (Required) – A ow switch is

required in lieu of manual reset low water cutoff (LWCO) for forced circulation coil-type water boilers to prevent overheating and heat exchanger failure in accordance with requirements of ASME Boiler and Pressure Vessel Code, Section IV, and ANSI/ASME CSD-1 – latest edition, “Controls and Safety Devices for Automatically Fired Boilers”.

VI. Water Piping and Trim (continued)

Figure 27: Boiler Head Loss

The ow switch is factory provided. Follow Section

VI, Paragraph A and Section VIII ‘Electrical’ of

these instructions to install and wire the ow switch.

3. Circulator (Required) – Usually at least two

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

4. 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.

5. 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

volume taken after initial ll and eliminate any

water leakage as early as possible.

6. 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.

7. Manual Reset High Limit - Phantom X

boilers have factory provided UL353 listed boiler control and UL1434 listed manual reset high limit. An optional manual reset external high limit is available from Crown Boiler Co. to meet local code requirements.

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

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

9. 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.

10. 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.

11. Drain Valve (Required) – Drain valve is

packaged loose with boiler and must be installed in the location shown in Figure 25, 26 or 27 “Factory Supplied Piping and Trim Installation”.

12. An optional LWCO with manual reset is

available from Crown Boiler Co. to meet local code requirements.

VI. Water Piping and Trim (continued)

Table 27: 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) 54.0 74.0 57.0 177.0 Buttery Valve 2.7 2.0 2.7 4.5

NOTE: Table 27 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

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

NOTICE

The Phantom X 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 Fe2O3) is produced during oxygenation. To minimize any oxygen presence in the system, the system must be air free and leak tight. Do not connect the boiler to radiant tubing without an oxygen barrier. Using automatic water 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 14.50 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 Fe3O4) forms as the result of continuous electrolytic corrosion in any 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.

VI. Water Piping and Trim (continued)

Figure 28: Near Boiler Piping - Heating Only

NOTICE

For single boiler servicing indirect water heater

(IWH), install DHW heat source sensor in boiler

supply connection to IWH. Header Sensor

cannot be used to control modulation for DHW

demand on a single boiler installation.

VI. Water Piping and Trim (continued)

DHW Heat Source Sensor

(When Used See Page 101)

Figure 29: Near Boiler Piping - Heating Plus Indirect Water Heater

VI. Water Piping and Trim (continued)

D. Special Situation Piping Installation

Requirements

Observe the following guidelines when making the actual installation of the boiler piping for special situations:

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

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

• Radiant systems employing tubing without

oxygen barrier

• Systems with routine additions of fresh water

• Systems open to atmosphere

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

separated from oxygenated water being heated with a heat exchanger as shown in Figures 30 and

31. 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.

Table 28: Multiple Boiler Water Manifold Sizing

Number of Units

Boiler Model

PHNTM399C 2½” 3” 3” 4” 5” 5” 5” PHNTM500C 3” 4” 4” 5” 5” 6” 6”

2 3 4 5 6 7 8

Recommended Minimum Common

Water Manifold Size (NPT)

Figure 30: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

(IWH Piped as Part of Boiler Piping)

VI. Water Piping and Trim (continued)

Figure 31: Isolation of the Boiler From Oxygenated Water with A Plate Heat Exchanger

E. Multiple Boiler Water Piping

1. See Figure 34 for example multiple boiler piping.

2. Install one header sensor in system piping

downstream of the boiler supply connection. See Figure 34 for header sensor location and Figures 32 and 33 for installation detail. Wire header sensor to Sequencer Master boiler. See also Section VIII. Electrical and Section X. Operation.

(IWH Piped Off System Header)

3. For installations where indirect domestic hot water heater is combined with space heating, the indirect water heater (IWH) must be piped

as a separate heating zone off the system header.

The circulator must be sized based on the IWH ow

requirement and the pressure drop through the IWH zone. Refer to Indirect Water Heater literature for

specic model coil ow and pressure drop. Refer to

Figure 34.

Figure 32: Recommended Direct Immersion Header Sensor or DHW Heat Source Sensor Installation Detail

Figure 33: Alternate “Immersion” Type Header Sensor or DHW Heat Source Sensor Installation Detail

VI. Water Piping and Trim (continued)

Figure 34: 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.

NOTICE

Figure 34, continued: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2)

VI. Water Piping and Trim (continued)

Installing a low water cutoff in the system piping

of multiple boilers is strongly recommended and

may be required by local codes.

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 29 (natural gas) or 30 (LP gas) for maximum capacity of Schedule 40 pipe. Table 31

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 29 and gas with a specic

gravity of 1.5 can be sized from Table 30, unless

authority having jurisdiction species a gravity factor be applied. For other specic gravity, apply gravity factor from Table 32. If exact specic

gravity is not shown choose next higher value.

Table 29: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Natural Gas) For Gas Pressures of 1/2 psi (3.4 kPa) or Less

Inlet Pressure 14.0 in wc (3.4 kPa)or less; 0.3 in wc (0.07 kPa) Pressure Drop

Nominal Pipe

Size, In.

½ 0.622 131 90 72 62 55 50 46 42 40 38

¾ 0.824 273 188 151 129 114 104 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

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 14.0 in wc (3.4 kPa) or less; 0.5 in wc (0.12 kPa) Pressure Drop

Nominal Pipe

Size, In.

½ 0.622 172 118 95 81 72 65 60 56 52 50

¾ 0.824 360 247 199 170 151 137 126 117 110 104

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

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

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

VII. Gas Piping (continued)

For materials or conditions other than those listed

above, refer to National Fuel Gas Code, ANSI Z223.1/

B. Connect boiler gas valve to gas supply

system.

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.

Table 30: Maximum Capacity of Schedule 40 Black Pipe in CFH* (LP Gas) For Gas Pressures of 1/2 psi (3.4 kPa) or Less

Inlet Pressure 11.0 in wc (2.7 kPa); 0.3 in wc (0.07 kPa) 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

Inside

Diameter, In.

Length of Pipe, Ft.

10 20 30 40 50 60 70 80 90 100

Inlet Pressure 11.0 in wc (2.7 kPa); 0.5 in wc (0.12 kPa) Pressure Drop

Nominal Pipe

Size, In.

½ 0.622 116 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.

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 31: Equivalent Lengths of Standard Pipe Fittings & Valves (ft)

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

Gate Globe Angle

Swing

Check

45°

Elbow

90°

Elbow

180 Close

Return Bend

90 Tee Flow

Through

Run

90 Tee, Flow

Through

Branch

VII. Gas Piping (continued)

Table 32: 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 X boilers have factory supplied

miscellaneous parts cartons, which include gaspiping components to connect boiler gas valve(s) to gas supply system. Install these components prior to connecting boiler to gas supply system piping as follows:

Figure 35: Recommended Gas Piping

4. All above ground gas piping

upstream from manual shut-off valve must be electrically continuous and bonded to a grounding electrode. Do

not use gas piping as grounding electrode. Refer to

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

Table 33: Min./Max. Inlet Gas Pressure Ratings

Boiler Model

PHNTM399C

PHNTM500C

Natural/LP

Gas Max,

in. wc (kPa)

14.0

(3.49)

Natural Gas

Min,

in. wc (kPa)

4.0

(1.00)

LP Gas

Min,

in. wc (kPa)

8.0

(1.99)

Boiler Model Miscellaneous

Parts Carton

PHNTM399C 106315-01 PHNTM500C 106316-01

Models PHNTM399C and PHNTM500C

a. Locate and remove the ¾ in. NPT x 6 in. long

black nipple and ¾ in. NPT external gas shutoff valve (required).

b. Insert nipple though grommet in left side panel.

Apply pipe dope and thread nipple into gas valve (PHNTM399C) or gas inlet tee (PHNTM500C).

c. Mount the ¾ in. NPT external gas shutoff valve

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

d. Install sediment trap, ground-joint union and

manual shut-off valve upstream of mounted factory supplied manual shut-off valve. See Figure 35 “ Recommended Gas Piping ”.

VII. Gas Piping (continued)

C. Pressure test. See Table 33 for Phantom X 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 (3.4 kPa), boiler and its individual shutoff valve must be disconnected from gas supply piping. For testing at ½ psig (3.4 kPa) 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.

DANGER

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

D. Phantom X Model PHNTM500C (if equipped

with optional low and high gas pressure switches)

1. Use a lock-up type gas pressure regulator.

Some examples of lock-up regulators are listed below:

• Sensus Model 143-80

• Pietro Fiorentini Governor, Standard Model

• Dungs FRS Series

NOTICE

Use a lock-up type gas pressure regulator when low and high gas pressure switches are installed. Older or non-lock-up type regulators may result in nuisance lockouts on gas pressure droops or spikes.

2. Verify low and high gas pressure switch settings are within the range shown in Table 33.

The switches are preset for natural gas. For LP gas, the low gas pressure switch setting must be adjusted.

3. The low gas pressure switch must be reset after

the boiler is piped to the gas supply and before it is

red.

4. For the low and high gas pressure switches

proper operation, the boiler inlet gas pressure must be within the range shown in Table 33.

5. The gas pressure can be measured at the gas

valve inlet pressure port. Refer to Figure 36 “Gas Inlet Pressure Tap and Pressure Switch Location “.

6. If either pressure switch is tripped, it must be

manually reset before the boiler can be restarted.

Figure 36: Gas Inlet Pressure Tap and Pressure Switch Location

PHNTM500

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 35.

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.

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.

NOTICE

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

A. General. Install wiring and electrically ground boiler

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

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

current protection not greater than 15A.

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.

C. Power Requirements

Nominal boiler current draw is provided in Table

34. 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.

D. Boiler wiring. Refer to Figures 40 and 41.

Table 34: Boiler Current Draw

Model Number

PHNTM399C < 7

PHNTM500C < 6

1.Connecttoeldwiringinside the junction box,

located on the upper left side of the boiler as shown in Figure 37. Inside the junction box are two printed circuit boards (PCB’s), 120 VAC Connections on the

left and Low Voltage Connections on the right.

2. 120VAC connections (line voltage) are located

on left PCB and are shown in Figure 38. Do not exceed 5.6A total pump current draw (system + DHW + boiler pumps). One 6.3A slow-blow pump fuse and spare are provided.

Nominal Current

(amps)

VIII. Electrical (continued)

Figure 37: PCB Locations for Field Wiring

Figure 38: 120 VAC Field Wiring

VIII. Electrical (continued)

3. 24VAC low voltage connections are located on

left side of right PCB and are shown in Figure 39. One 24V fuse and spare are provided. PHNTM399C and PHNTM500C use 1.6A slow-blow fuse.

4. 5VDC low voltage connections are located on

right side of right PCB and are shown in Figure 38.

5. If the outdoor sensor is connected, 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.

E. Flow Switch Wiring

Phantom X boilers require a ow switch to prevent boiler

overheating. See Section VI, Water Piping and Trim, and

ow switch instruction sheet for piping details. The ow switch and ow switch wire harness are factory provided.

1.Wireowswitchharnesstoboiler. Connect

Molex on harness to boiler low voltage connector P11, labeled “Flow Switch”.

2.Wireowswitchharnesstoowswitch.

Connect fork terminals on harness to ow switch

NO (normally open) and COM (common) terminal screws.

WARNING

Scald Hazard. The DHW sensor connection on this boiler is intended for use in modulating the boiler supply temperature at the indirect water heater. It is not intended for direct control of DHW temperature. Attempting to use this sensor for direct control of DHW temperature could result in injury or death due to scalding.

NOTICE

Disable boiler internal sequencer when connecting to an energy managment system.

SIZE 399-525: 1.6A SLOW BLOW SIZE 600-825: 2.0A FAST ACTING

SIZE 399-500: 1.6A SLOW BLOW

OPTIONAL AUTO RESET EXTERNAL LIMIT(S)

SPACE HEATING THERMOSTAT

OPTIONAL DOMESTIC HOT WATER THERMOSTAT (IF USED)

DAMPER PROVING SWITCH (IF USING

ROOM AIR)

OPTIONAL MANUAL RESET EXTERNAL LIMIT(S)

ALARM CONTACTS

OPTIONAL ENVIRACOM THERMOSTAT OR ZONE PANEL

5mm X 20mm FUSE

(+)

(-)

OPTIONAL

ENERGY

MANAGEMENT

SYSTEM

OPTIONAL OUTDOOR SENSOR

OPTIONAL HEADER SENSOR

OPTIONAL DOMESTIC HOT

DHW HEAT SOURCE

WATER SENSOR

SENSOR*

OPTIONAL MULTIPLE BOILER COMMUNICATION

FLOW

OPTIONAL

SWITCH

24V LWCO

Figure 39: Low Voltage Field Wiring

* NOT for direct measurement of DHW

temperature. (See page 101)

VIII. Electrical (continued)

Size 399-500: 1.6A Slow Blow

(Size 500 Only)

Figure 40: Ladder Diagram

VIII. Electrical (continued)

SIZE 500 ONLY:

Figure 41: Wiring Connections Diagram

Size 399-500: 1.6A Slow Blow

VIII. Electrical (continued)

Figure 42a: 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

POWER

120/60/1

SUPPLY

GND

DISCONNECT

PROTECTION/

OVERCURRENT

ITEMS SUPPLIED BY INSTALLER

BOILERS

ADDITIONAL

120V

GND

BOILER

CIRCULATOR

SERVICE

HEATING THERMOSTATS

RJ45

CONNECTOR

SWITCH

(OPTIONAL)

THERMOSTATS24 VAC PRIORITY

EXPANSION ZONE 1 ZONE 2 ZONE 3 ZONE 4 NET

A B C CWR R R R 1W W WC C C 2

MAIN PRIORITY

X X X X

END SWITCH

OFF

MASTER

NORMAL

SLAVE

RESET

PRIORITY ON

NOTE:

LED

ZONE 1

ZONE 2

ZONE 3

ZONE 4

POWER

INDICATORS

6 AMP FUSE

ZONE CONTROL

CROWN PN 3501505

CIRCULATOR PANEL

6 AMP FUSE

4 MIN/24 HR

OFF

6 AMP FUSE

30 SEC/2 WK

POST PURGE ON

LOW LIMIT (ZC) ON

PRIMARY PUMP ON

PUMP EXERCISE ON

PRIOR. PROTECT ON

OFF

ZC1 ZC2 ZC3

ZC4 BT LT

AMPERES (BECAUSE OF THE NUMBER OF BOILERS PROVIDED) USE SEPARATE CIRCUITS AND OVER-CURRENT PROTECTION

SUCH REQUIREMENTS, FOLLOW THE NATIONAL ELECTRIC CODE, NFPA 70, AND/OR CSA C22.1 ELECTRCAL CODE. DO NOT

PROVIDE OVER-CURRENT PROTECTION GREATER THAN 15 AMPERES. IF IT BECOMES NECESSARY TO PROVIDE GREATER

FOR ADDITIONAL BOILER.

1. INSTALL OVER-CURRENT PROTECTION IN ACCORDANCE WITH AUTHORITY HAVING JURISDICTION OR, IN THE ABSENCE OF

N N

H H H H

N N N N

PRIMARY ZONE 1 ZONE 2 ZONE 3 ZONE 4 ZONE 4

ZC ZR N H

TERMINALS A, B, AND C LABELED 'BOILER-TO-BOILER' MAY BE USED TO CONNECT AN ENERGY MANAGEMENT SYSTEM

'BOILER-TO-BOILER'.

ONLY IF INTERNAL SEQUENCER IS DISABLED.

USING SCREW TERMINALS A, B, AND C LABELED 'EMS (DELTA ONLY)'.

4. BOILERS WITH PANASONIC DISPLAY: SCREW TERMINALS A, B, AND C LABELED 'EMS (DELTA ONLY)' ARE NOT USED. SCREW

2. BOILER-TO-BOILER WIRING CAN BE DONE WITH RJ45 PLUGS (SHOWN) OR USING SCREW TERMINALS A, B, AND C LABELED

3. BOILERS WITH DELTA DISPLAY: ENERGY MANAGEMENT SYSTEM WIRING CAN BE DONE WITH RJ45 PLUGS (SHOWN) OR

DHW

BOILER

CIRCULATOR

INPUT

120 VAC

CLOSED

NORMALLY

PRIORITY

120 VOLT CIRCULATORS

REMOVE JUMPER

BOILER 2

IN SEQUENCE

(IF REQUIRED)

TO NEXT BOILER

REMOVE JUMPER(S) TO CONNECT

EXTERNAL LIMIT(S).

BOILER 1 (WITH SEQUENCER MASTER ENABLED)

NOTES 3 AND 4)

SYSTEM (IF USED, SEE

TO ENERGY MANAGEMENT

System Header Wiring Schematic for Heating Zone Circulators

Figure 42b: DHW Priority/Circulators (with Crown PN 3501505 Zone Panel) Piped Off

VIII. Electrical (continued)

DHW

AQUASTAT

REMOVE JUMPER(S) TO CONNECT

EXTERNAL LIMIT(S).

VIII. Electrical (continued)

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

Figure 43: Modied Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header -

VIII. Electrical (continued)

Figure 44: Multiple Boiler Wiring Diagram

Internal Multiple Boiler Control Sequencer

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

VIII. Electrical (continued)

Sequence of Operation

Tekmar 265 Based Control System (or equal)

Figure 45: Multiple Boiler Wiring Diagram w/Tekmar 265 Control

The Tekmar 265 Control (or equal) can control up to three (3) boilers and an Indirect Water Heater. When a call for heat is received by the Tekmar 265 Control, the control

will re either one or more boilers in either parallel or sequential ring mode to establish a required reset water temperature in the system supply main based on outdoor

temperature. The boilers will modulate based on an Analog communication signal established between the Tekmar 265 Control and each boiler’s control. The boiler(s) and

system supply water temperature will be reset together to maintain the input that is needed to the system. When a call for Indirect Hot Water is generated to the Tekmar 265,

the control will de-energize the zone pump control (ZC terminal), energize the Indirect pump and modulate the boiler ring to establish a setpoint temperature in the main for the

Indirect Heater using Priority. The Tekmar 265 also controls each boiler’s pump and a post purge of leftover temperature in the boilers will occur at the end of the call for Indirect

Hot Water.

Sequence of Operation

Tekmar 264 Based Control System (or equal)

Figure 46: Multiple Boiler Wiring Diagram w/Tekmar 264 Control

VIII. Electrical (continued)

The Tekmar 264 Control (or equal) can control up to four (4) boilers and an Indirect Water Heater by utilizing stage ring. When a call for heat is received by the Tekmar 264

Control, the control will re either one or more boilers in sequential ring mode to establish a required reset water temperature in the system supply main based on outdoor

temperature. The boilers will modulate on their own based on each boiler’s control and will target a setpoint temperature to supply enough input to the system main to satisfy

the desired reset water temperature in the main established by the Tekmar 264 Control. When a call for Indirect Hot Water is generated to the Tekmar 264, the control will de-

energize the zone pump control (ZC terminal), energize the Indirect pump and sequentially re the boilers to establish a setpoint temperature in the main for the Indirect Heater

using Priority. The Tekmar 264 Control will disable the stage ring and post purge the Indirect Pump to reduce the temperature in the Supply Main near the end of the Indirect

Mode to a point where it will need to be when it changes back to Space Heating Mode. The Tekmar 264 Control also has the ability to rotate the lead-lag ring of the boilers to

establish equal operating time for each boiler stage.

VIII. Electrical (continued)

F. Multiple Boiler Wiring

1. 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.

2. Required Equipment and Setup

a. Header Sensor (P/N 101935-01 or 103104-01)

A header sensor must be installed and wired to

the Sequencer Master boiler. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master. Refer to Figure 34 for installation location and Figure 32 or 33 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 Modbus Boiler-to-Boiler terminals A, B, and C between each boiler. Refer to Figures 40, 41 and 44 for wiring location.

G. External Multiple Boiler Control System

As an alternate to the control internal sequencer, the control

also accepts an input from an external sequencer. Follow multiple boiler control system manufacturer (Honeywell, Tekmar, etc.) instructions to properly apply a multiple boiler control system. The Tekmar Model 264 and Model 265 based control wiring diagrams (Figures 45 and 46) are provided as examples of typical multiple boiler control systems.

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.

B. Conrmallelectrical,waterandgas

supplies are turned off at the source

vent is clear of obstructions.

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

between the boiler and gas source are closed.

Refer to installation instructions contained

and that

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

water leaks.

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.

F. Check all gas piping for leaks and purge piping

sections that are lled with air. Refer to National Fuel Gas Code, ANSI Z223.1/NFPA 54 or, in Canada, Natural Gas and Propane Installation Code, CAN/CSA

B149.1.

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.

Pressurize the system to at least 14.5 psi (100 kPa).

Purge air from the system. A manual air vent is located on the right side of the heat exchanger inside the cabinet.

WARNING

Burn Hazard. The maximum operating pressure of this boiler is 30 psig (210 kPa), 50 psig (340 kPa), 60 psig (410 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.

DANGER

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

Make sure that the area around the boiler is clear and free from combustible materials, gasoline and other ammable vapors and liquids.

G.Conrmventsystemiscomplete and free of

obstructions before attempting to re boiler.

H. Inspect all wiring for loose, uninsulated, or

miswired connections.

I. If boiler is to be converted to LP gas

(propane), convert as described in Part T of this

section of the manual. Only models PHNTM399C and PHNTM500C can be converted to LP gas.

J. If boiler is operating at elevations above

2000 ft, see Appendix A for setup instructions.

K. Start the boiler using operating instructions

in Figure 47. After the boiler is powered up with a call for heat, the boiler should go through the sequence of operation shown in Table 44.

IX. System Start-up (continued)

Figure 47: Operating Instructions

IX. System Start-up (continued)

L. 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 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.

M. Check Burner Flame

Inspect the ame visible through the window. On high

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

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

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

normal.

N. 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.

O. Perform Combustion Test

WARNING

Asphyxiation Hazard. Each Phantom X 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.

WARNING

Any gas valve adjustments (throttle and/ or offset) specied herein and subsequent combustion data (%O2, %CO2, CO air free ppm) 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. Use a combustion analyzer to sample boiler

ue gas and measure O2 (or CO2) and CO air

free. Boilers are equipped with a screw cap in the vent connector. Be sure to replace this cap when

combustion testing complete.

2. Verify O2 (or CO2) and CO air free are within limits specied in Table 35 for natural gas

or Table 36 for LP gas (propane). Note: Tables 35 and 36 are for sea level only. For altitudes above 2000 ft, see Appendix A.

a. Lock boiler in high re and allow fan speed and

combustion analyzer reading to stabilize before taking combustion readings. To lock boiler in

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

“Adjust”, “Login”, “000”. Enter the password “086” and press return arrow to close the key pad. Press “Save”, “Adjust”, “High”.

Table 35: Natural Gas Typical Combustion Readings (Sea level Only)

Boiler Model CO2 % O2 %

PHNTM399C 8.6 - 9.2 4.7 - 5.8 PHNTM500C 8.7 - 9.2 4.7 - 5.6

Table 36: LP Gas (Propane) Typical Combustion Readings (Sea Level Only)

Boiler Model CO2 % O2 %

PHNTM399C 9.4 - 10.2 5.4 - 6.6 PHNTM500C 9.8 - 10.2 5.4 - 6.0

CO air free

(PPM)

Less than

200 PPM

CO air free

(PPM)

Less than

200 PPM

IX. System Start-up (continued)

Figure 48: Burner Flame

WARNING

Make sure that all adjustments at high re are made with the throttle, not offset screw (see Figure 49). 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 unnecessary could result in damage to the gas valve and may cause property damage, personal injury or loss of life.

b. If high re O

increase O2 (decrease CO2) by turning the throttle screw 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 to both gas valves equally and simultaneously. Refer to Figure 49 for location of throttle screw. Verify CO air free is less than 200 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 to both gas valves equally and simultaneously. Refer to Figure 49 for location of throttle screw. Verify CO air free is less than 200 ppm.

d. Lock boiler in low re and allow fan speed and

combustion analyzer reading to stabilize before taking combustion readings. Press “Low” to

lock boiler in low re.

is too low (CO2 is too high),

e. If low re O2 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 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 49 for location of offset screw. Verify CO air free is less than 200 ppm.

f. If low re O

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 49 for location of offset screw. Verify CO air free is less than 200 ppm.

Figure 49: Gas Valve Detail

is too high (CO2 is too low),

3. Remove analyzer probe and replace cap on

boiler vent connector.

4. Return boiler to Automatic Mode. Press

“Auto”.

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 35 or

36.

WARNING

P. 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 40. The boiler must shut

down and must not start with the ame sensor

disconnected.

IX. System Start-up (continued)

2. Testtheowswitch by disabling the primary

loop circulator. The boiler must not start if ow is

not present.

3. Test any other external limits or other controls

in accordance with the manufacturer’s instructions.

Q. 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.

R. 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) of this manual for information on how to adjust supply setpoint.

S. Adjust Thermostats

Adjust the heating and indirect water heater thermostats

to their nal set points.

T. Field Conversion From Natural Gas to LP

Gas (Propane)

Phantom X models PHNTM399C and PHNTM500C

are factory shipped as natural gas builds and can be

eld converted to LP gas. Follow steps below for eld

conversion from natural gas to LP Gas.

1. Conversion of Phantom X models PHNTM399C

and PHNTM500C from one fuel to another is accomplished using the throttle screw on the gas valve. Figure 49 “Gas Valve Detail” shows the location of the throttle screw on the valve. Locate

the throttle screw on the boiler being converted.

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.

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 37.

4. Start the boiler using operating instructions

in Figure 47. After the boiler is powered up with a call for heat, the boiler should go through the sequence of operation shown in Table 44. Even if the gas line has been completely purged of air, it

may take several tries for ignition before a ame

is established. If more than 2 tries for ignition are needed, it will be necessary to press the reset button to restart the boiler. If boiler does not light, turn the throttle screw 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.

Table 37: Approximate Clockwise Throttle Screw Turns for LP Gas (Propane) Conversion

Boiler Model

PHNTM399C 2¾ PHNTM500C 3

Approximate

Throttle Screw Turns

IX. System Start-up (continued)

WARNING

Asphyxiation Hazard. The throttle adjustments shown in Table 37 are approximate. The nal throttle setting must be found using a combustion analyzer. Leaving the boiler in operation with a CO air free level in excess of 200 ppm could result in injury or death from carbon monoxide poisoning.

5. After the burner lights, complete all steps outlined

in Paragraph O “Perform Combustion Test” before proceeding.

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 air free) 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.

6. Verify that the gas inlet pressure is between the

upper and lower limits shown in Table 33 with all gas appliances (including the converted boiler) both

on and off.

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.

U. Correcting Throttle Screw Mis-Adjustment

(if required)

Phantom X 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 38 for natural gas or Table 39 for LP gas.

3. Follow instructions in Paragraph O “Perform

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

range specied in Table 35 for natural gas or Table 36 for LP gas at both high re and low re.

WARNING

The throttle adjustment values shown in Table 38 and Table 39 are approximate. The nal throttle setting must be found using a combustion analyzer.

Table 38: Approximate Counter-Clockwise Throttle Screw Turns from Fully Closed Position, Natural Gas

Boiler Model

PHNTM399C 5¾

PHNTM500C 6½

Table 39: Approximate Counter-Clockwise Throttle Screw Turns from Fully Closed Position, LP Gas (Propane)

Boiler Model

PHNTM399C 3

PHNTM500C 3½

Approximate

Throttle Screw Turns

Approximate

Throttle Screw Turns

IX. System Start-up (continued)

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.

At 0% excess air the CO2 readings will be either 11.9% CO2 for natural gas or 13.8% CO2 for LP gas (O2 will be 0%) and CO air free level will be extremely high (well over 1000 PPM).

If the burner operates with air deciency, the following phenomena may be observed:

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

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

If the boiler appears to operate with air deciency, shut down the boiler and follow instructions in Paragraph U “Correcting Throttle Screws Mis-Adjustment. Then, use a combustion analyzer to verify and adjust O2 (or CO2) and CO air free to values shown in Table 35 for natural gas or Table 36 for LP gas.

V. Controls Start-up Check List

Check eld wiring and control parameters per below Table 40 and Table 41. The control is factory programmed with default

parameters. Review parameters and adjust as necessary to conform to specic site requirements. From Home Screen, select

ADJUST to access below listed parameters. Login as needed to make changes. For detailed login instructions, refer to Section X. Operation, Paragraph F “Changing Adjustable Parameters”.

Table 40: Field Wiring Checklist

Step Wiring Location Parameter Description

120V Line Is line voltage connected with overcurrent protection?

1 120V PCB

Low Voltage

Connections PCB

Boiler, System, and

DHW Pumps

Enable/Disable

DHW Demand Is an indirect water heater (IWH) providing a heat demand?

Auto Reset and Man

Reset External Limit

Lockout Alarm Are alarm contacts connected?

EnviraCOM Are any EnviraCOM devices used?

Outdoor Sensor Is an outdoor sensor used? Refer to Steps 1 & 7 in Table 41.

Header Sensor

DHW Sensor

Remote 4-20mA

Boiler-to-Boiler

EMS

Flow Switch Is ow switch installed in piping and plugged in?

LWCO Is a 24V LWCO used? Check installation.

Conrm pumps are connected. If using room air for combustion, conrm combustion air damper is connected.

Is the space heating thermostat connected. Ensure thermostat is

a “dry”, non-powered input.

Are external limits used? If so, ensure jumper is removed and limits properly connected. Also check that external limits are

closed and any manual reset devices are reset.

Is a header sensor used? A header sensor is required for the master boiler in a multiple boiler installation. Refer to Step 8 in Table 41 to activate this input.

For single boiler servicing indirect water heater (IWH), install DHW Sensor at boiler-side inlet to IWH. Refer to Step 6 in Table 41 to activate this input.

Is a 4-20mA input required for: 1) modulation input from an energy management system, or 2) Central Heat setpoint input from external multiple boiler control? If yes, refer to Step 11 in Table 41.

Are multiple boilers connected? If yes, refer to Steps 8 & 9 in Table 41 to activate boiler-to-boiler communication.

Is the boiler connected to an energy management system? If yes, refer to Step 10 in Table 41.

IX. System Start-up (continued)

Table 41: Control Parameter Checklist

Step

Parameter

Location

Adjust >>

System Setup

Adjust >>

Modulation Setup

Adjust >>

Pump Setup

Adjust >>

Contractor Setup

Adjust >>

Central Heat

Adjust >>

Domestic Hot Water

Adjust >>

Outdoor Reset

Central Heat

Adjust >>

Sequencer Master

Adjust >>

Sequencer Slave

Adjust>>

Energy

Management

Adjust>>

Energy

Management

Parameter Description

Outdoor Sensor Source Select appropriate source: Not Installed, Wired or Wireless.

Warm Weather Shutdown

Enable/Disable

Boiler Type

Boiler Circulator

Domestic Circulator

Contractor Name

Contractor Address

Contractor Phone

Setpoint

DHW Modulation Sensor If using DHW Sensor, select DHW Sensor.

Enable/Disable If not using an outdoor sensor, select Disable.

Sequencer Master

Boiler Address

Demand Source

Modulation Source If using an external multiple boiler controller, set to 4-20 mA.

Central Heat Boiler

Setpoint Source

Selecting Enable will restrict boiler start during warm weather, but

only if an outdoor sensor is installed.

WARNING

Conrm correct boiler model is shown. Stop installation and contact factory if incorrect boiler model is shown.

Ensure pump parameter selections are correct for your application.System Circulator

Enter contact information. In the event of a fault, or the need to adjust a setting, the display will direct the user to the entered

contact.

Ensure target space heating water temperature (Setpoint) is correct

for your type of radiation.

Ensure target domestic hot water water temperature (Setpoint) is

correct.

If boiler is the master boiler in a multiple boiler installation, select Enable.

If boiler is a slave boiler in a multiple boiler installation, assign a unique boiler address.

If boiler is connected to an energy management system, select Enable. NOTE: Disable boiler internal sequencer when connecting

to an energy management system.

If an Energy Management System is sending a remote setpoint to

the boiler, set to 4-20 mA.

X. Operation

A. Overview

1. R7910 Controller The R7910 Controller (Control) contains features

and capabilities which help improve heating system operation, and efficiency. By including unique

capabilities, the Control can do more, with less 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 PN 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.

X. Operation B. Supply Water Temperature Regulation (continued)

The peer-peer network is truly “plug and play”. Communication is activated by simply connecting a RJ45 ethernet cable between boilers. The Control provides precise boiler coordination by sequencing boilers based on both header water temperature and boiler modulation rate. For example, the lead boiler

can be 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.

11. Modbus Communication Interface

A factory congured RS485 Modbus interface is

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 42: Order of Priority

Status

Priority

1st Sequencer

2nd Domestic

3rd Central

4th Auxiliary Heat Auxiliary Heat call for heat is on and there is no

5th Frost

6th Warm

7th Standby There is no demand detected.

Screen

Display

Control

Hot Water

Heat

Protection

Weather

Shutdown

(WWSD)

Boiler Responding to:

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.

Central Heat call for heat is on and there is no DHW demand or DHW priority time has expired.

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.

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.

X. Operation C. Boiler Protection Features (continued)

7. Domestic Hot Water (DHW) Setpoint

This is the boiler supply water setpoint upon a DHW call for heat. Unless an Enviracom thermostat is connected

to the boiler, this set point will always be the xed

“DHW set point” value entered in the boiler control. If an Enviracom thermostat is connected, this may also be the thermostat’s “sleep” or “away” DHW set point. 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.

C. Boiler Protection Features

1. Supply Water Temperature High Limit

The boiler is equipped with a UL 353 listed boiler

control and UL 1434 listed high limit sensor. Response to supply temperature is as follows:

• Supply exceeds 190°F (87.7°C) – output (fan speed) reduced

• Supply exceeds 200°F (93.3°C) – recycle

• Supply exceeds 210°F (98.9°C) – manual reset hard lockout

Additionally, a soft lockout occurs if the supply

temperature rises to fast (i.e. faster than the degrees Fahrenheit per second limit).

2. High Limit Differential Temperature Limit

The control monitors temperature difference

between return and supply sensors. Response to temperature difference is as follows.

• Differential exceeds 43°F (23.9°C) – output (fan speed) reduced

• Differential exceeds 53°F (29.4°C) – recycle

• Differential exceeds 63°F (35°C) – shutdown; automatic restart after temperature difference has decreased and minimum off time has expired

3. Flue Temperature High Limit

The control monitors ue gas temperature sensor

located in vent outlet at rear of heat exchanger.

Response to ue temperature is as follows:

• Flue exceeds 184°F (84.4°C) – output (fan speed) is reduced

• Flue exceeds 194°F (90.0°C) – recycle

• Flue exceeds 204°F (95.6°C) – manual reset hard lockout

4. Flow Switch

The ow switch shuts down the boiler when there

is insufcient water ow in the boiler primary loop. When water ow is restored to a boiler-specic minimum value (see Table 24), the ow switch detects ow and automatically restarts the boiler. The ow switch is required and is factory provided.

5. Return Temperature Higher Than Supply Temperature (Inversion Limit)

If return water temperature exceeds 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 shuts down with a hard lockout. Condition is caused by incorrect supply and return piping connections.

6. Ignition Failure

The control monitors ignition using a burner mounted

ame sensor. Response on ignition failure is as

follows:

• Size 399: retries ve times, then soft lockout for

one hour

• Size 500: retries one time, then manual reset hard lockout

7. Automatic Reset Limit Devices

If any below listed limit opens, the boiler shuts

down and provides an open limit indication. The boiler will automatically restart once the limit closes. An external limit control with its own manual reset button requires pressing external limit reset button after limit closes even when connected to Auto Reset External Limit terminals.

• Sump pressure switch – opens if inadequate air

ow is detected during operation

• Condensate oat switch – opens if condensate

drain is blocked

• 24V LWCO (if used) – opens if low water

condition is detected

• Device(s) connected to Auto Reset External

Limit terminals

X. Operation D. Multiple Boiler Control Sequencer (continued)

8. Manual Reset Limit Devices

If any below listed limit opens, the boiler will restart

only after the limit closes and the boiler control manual reset button is depressed. During boiler start sequence, air proving switch must prove open before blower starts and closed after blower starts. If air proving switch is not in the required position, the control waits for a preset time period and then shuts down with a manual reset hard lockout.

• Thermal link – opens if rear of combustion chamber overheats; one time use device

• Burner door thermostat – opens if burner door overheats, manual reset button on thermostat

• High and low gas pressure switches (if used, size 500 only) – open if gas pressure is outside of preset limits, manual reset button on each switch

• Air proving switch – opens if inadequate air ow

is detected prior to ignition

• Device(s) connected to Man Reset External Limit terminals

9. 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 43: 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)

Start

Temperatures

Stop

Temperatures

Outside Air > -18°F (-28°C)

Supply Water > 50°F (10°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.

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.

X. Operation D. Multiple Boiler Control Sequencer (continued)

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).

X. Operation E. Boiler Sequence Of Operation (continued)

Boiler 1

E. Boiler Sequence of Operation

1. Normal Operation

Table 44: 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

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 display

groups:

Information Symbol

“Information” symbol links most

screens to screen content

explanations. 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 problem

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.

Status Screen

Figure 50: 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”

symbols provide a link to the cause of a boiler fault or ring rate limit. The rst boiler status screen provides an overview of boiler operation including fault status.

Figure 51: Screen Navigation

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 Crown Boiler Co. 3501505 Zone Panel is connected. Zone Panel 1 and 2 shown typical for 1 through 4.

Figure 52: 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 44 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 limited or overridden in any way.

During the start-up and shutdown sequence it is normal for the rate to be overridden by the purge, lightoff 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 53: Boiler Status Screen Denitions

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.

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 Crown Boiler Co.

3501505 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)

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, Domestic 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.

X. Operation (continued)

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 54: Adjust Mode Screens

2. Adjusting Parameters

Editing parameters is accomplished as follows:

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

tenths of degree (-45.6 to 10°C)

Not

Connected

Enabled Enable/Disable

0 min. 0-20 min.

Disabled Enable/Disable

70°F

(21.1°C)

Not Connected

(-6.7 to 37.8°C)

button to access the following parameters:

Range /

Choices

Fahrenheit,

Celsius

Not Installed,

Wired

Wireless

-50 to +50°F

Connected,

20 to 100°F

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 and wired to boiler low voltage PCB.

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

reference reading.

Crown Boiler Co. 3501505 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 circulator starts and boiler res when low outside air, supply and return

temperatures are sensed as follows:

Device Started

Boiler Pump

Boiler Supply Water < 38°F (3.3°C) Supply Water > 50°F (10°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.

Outside Air < -0°F (-18°C)

or Supply Water < 45°F (7.2°C)

Start

Temperatures

Stop

Temperatures

Outside Air > -4°F (-16°C)

Supply Water > 50°F (10°C)

X. Operation F. Changing Adjustable Parameters (continued)

Modulation

Setup

500C‐02

  

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

Varies by

Model

button to access the following parameters:

Range /

Choices

Boiler Type

Boiler Size Setup To verify the boiler size selection, a qualied technician should do the following:

1. Check boiler’s rating plate for the model size. For example, if the model number shown on the rating plate is “PHNTM500C”, the model size is “500”.

See Figure 55

2. Verify the altitude at which the boiler is installed.

3. Set “Boiler Type” to match the model size and altitude as shown in Figure 55.

4. 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 for altitudes above 2000 ft or in a spare part control to a particular boiler model. See Figure 55.

Parameter and Description

NOTICE

If boiler is being installed at elevation above 2000 ft, refer to Appendix A: Instructions for High Altitude Installations Above 2000 ft.

modelsize

 altitude

 02=0–2000ft (0–609m)

24=2,001–4,500ft (610–1371m) 46=4,501–6,000ft (1372–1828m) 67=6,001–7,800ft (1829–2377m) 70=7,801–10,100ft(2378–3078m)

Figure 55: Selecting Boiler Type

X. Operation F. Changing Adjustable Parameters (continued)

Expected Heat Rate Adjustment Screens (Zone Panels with HeatMatch Software Only)

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 56: 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 57: Expected Heat Rate Adjustment (with Zone Control Connected)

X. Operation F. Changing Adjustable Parameters (continued)

Modulation

Setup

“Press”

Factory

Setting

100%

80%

of CH

Maximum Heat

Rate

100%

40%

Minutes

Varies by

Model

Varies by

Model

button to access the following parameters:

Range /

Choices

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

Varies by

Model

399: 3,500 -

4,000 rpm 500 - 800:

non-adjustable

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.

Parameter and Description

X. Operation F. Changing Adjustable Parameters (continued)

Pump Setup

“Press”

Factory Setting Range / Choices Parameter and Description

Any Demand

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: Pump is disabled and not shown on status screen.

Any Demand: Pump Runs during any call for heat.

Central Heat: Pump Runs during central heat and frost protection call for No Priority: heat. Pump does not start for a DHW call for heat and continues to run during Domestic Hot Water Priority.

Central Heat: Pump Runs during central heat and frost protection call for Optional Priority: 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 and combustion air damper (if using room air) output according

to selected function.

Any Demand: Pump Runs /damper opens during any call for heat.

Make sure indirect water heater and DHW circulator are sized to maintain ow through boiler within limits shown in Table 24.

Central Heat: Pump runs during central heat and frost protection call for Off DHW demand: 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.

Primary

Loop Pipe

IWH

Header Sensor

Demand/

Combustion Air

Damper

Never,

Primary Loop

Piped IWH,

Boiler Piped IWH

Fresh Air Damper

Header SensorDemand/ Pump runs when boiler is ring to satisfy any call for heat. Combustion Air Damper: Used when header sensor is enabled to prevent unnecessary operation of boiler pump. Also used when combustion air

damper is wired to Boiler Pump output.

NOTE: Header Sensor must be used when combustion air

damper output is required.

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 24.

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).

X. Operation F. Changing Adjustable Parameters (continued)

Example Pump Parameter selections (continued):

Single boiler Primary Piped Indirect Water Heater, Optional DHW Priority.

Domestic Heat Source Sensor

(When Used See Page 101)

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.

Single boiler with no Indirect Water Heater

Parameter Selections:

System Pump= “any demand” Boiler Pump = “any demand”

DHW Pump = “never”

Explanation:

This piping arrangement only services central heat. When there is any demand both boiler and system

pumps turn on.

X. Operation F. Changing Adjustable Parameters (continued)

Example Pump Parameter selections (continued):

Multiple Boilers with Boiler Piped Indirect Water Heater

Sequencer Master

(Boiler 1)

Wiring locations:

Enable/Disable X

DHW Demand 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

X. Operation F. Changing Adjustable Parameters (continued)

Example Pump Parameter selections (continued):

Multiple Boilers, Primary Piped Indirect Water Heater, Optional DHW Priority

Sequencer Master

(Boiler 1)

Wiring locations:

Enable/Disable X

DHW Demand 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, Primary Piped Indirect Water Heater, System Pump Run for Any Demand

Sequencer Master

(Boiler 1)

Wiring locations:

Enable/Disable X

DHW Demand 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

X. Operation F. Changing Adjustable Parameters (continued)

Contractor

Setup

Manual Control

“Press”

button to access the following parameters:

Contractor Name

Press box to input contractor information.

Bill Smith

Save

Press SAVE button to store revisions.

For Service Contact:

12 Victory Lane

Plainview, New York

Example Screen

Enter Contractor Information

Bill Smith

Use Up and DOWN Arrows for More

Exit Screen without Saving

Clear Entire Field

Backspace

Save Field and Exit

Factory Setting Range / Choices Parameter and Description

Contractor Name User 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

Bill Smith

516 123-4567

“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.

“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 %

NOTE

Selecting “Low” or “High”

locks (manual mode) ring

rate at min or max Rate %.

After combustion testing select

“Auto” to return the boiler to

normal operation.

Press “Auto” to

return ring rate

to Automatic

Mode

X. Operation F. Changing Adjustable Parameters (continued)

Central

Heat

“Press”

Factory

Setting

180°F

(82.2°C)

170°F

(76.7°C)

10°F

(-12.2°C)

5°F

(-15.0°C)

3 1 to 5

120

seconds

Supply

Sensor

Range / Choices Parameter and Description

(10°C to 87.8°C)

(-16.7°C to 3.9°C)

0 to 1800 seconds

button to access the following parameters:

50°F to 190°F

2°F to 25°F

Supply Sensor,

Header Sensor

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 terminals.

NOTE: When Header Sensor is selected, also set Boiler Pump parameter to Header Sensor Demand/Combustion Air Damper.

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

(-13.7°C)

5°F

(-15.0°C)

3 1 to 5

Disable Disable, Enable

Zone

Control

Supply

Sensor

Range / Choices Parameter and Description

60°F to 190°F

(15.6°C to 87.8°C)

80°F to 190°F

(26.7°C to 87.8°C)

2°F to 10°F

(-16.7°C to -12.2°C)

2°F to 25°F

(-16.7°C to -3.9°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

cost 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 terminals.

NOTE: When Header Sensor is selected, also set Boiler Pump parameter to Header Sensor Demand/Combustion Air Damper.

100

Crown Boiler PHANTOM-X SERIES, PHNTM500C, PHNTM399C Installation And Operating Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual