EI onex Installation And Maintenance Manual

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Installation and maintenance

instructions for gas-ﬁ red condensing

hot water boiler

OXIOM-3

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.

ASME

certiﬁ ed

62403535.R00 9/02/2010

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SAFETY INSTRUCTIONS

WARNING: If the information in these instructions is not followed exactly, a ﬁ re or explosion may result causing property damage, personal injury or death.

- Do not store or use gasoline or other ﬂ ammable vapors and liquids in the vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier from

a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier,

call the ﬁ re department.

- Installation and service must be performed by a qualiﬁ ed installer, service agency or the gas supplier.

AVERTISSMENT: Assurez vous de bien suivre les instructions données dans cette notice pour réduire au minimum le risque d’incendie ou d’explosion ou pour éviter tout dommage matériel, toute blessure ou la mort

- Ne pas entreposer ni utiliser d’essence ou ni d’autres vapeurs ou liquides inﬂ ammables à proximité de cette appareil ou de tout autre appareil.

- QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer l’appareil.

• Ne touchez à aucun interrupteur, ne

pas vous servir des téléphones se trouvant dans le bâtiment

• Appelez immédiatement votre

fournisseur de gas de puis un voisin. Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le

fournisseur, appelez le service des incendies

- L’installation et l’entretien doivent être assurés par un installateur ou un service d’entretien qualiﬁ é ou par le fournisseur de gaz.

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SAFETY INSTRUCTIONS

62403535.R00

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SAFETY INSTRUCTIONS

WARNING!!! These instructions must be read prior to installation. If the information in these instructions is not followed exactly, a ﬁ re or explosion may result, causing property damage, personal injury, or death.

 Liability

The manufacturer declines all liability, contractual or otherwise, for damages resulting from the incorrect installation of this boiler. This includes the failure to comply with the instructions provided by the manufacturer or from a failure to comply with the applicable local and national regulations in force. The manufacturer declines all liability, contractual or otherwise, for any damage to people, animals or property caused by the incorrect use of this boiler or inadequate or incorrect service or maintenance.

 Hazards and Your Safety - Hot Water Can Scald!

Water temperature over 125°F (52°C) can cause severe burns instantly, or death from scalds. Children, the disabled, and the elderly are at highest risk of being scalded; see instruction manual before setting temperature at boiler! Feel water before bathing or showering.

 If there is a smell of combustion products, turn the

unit off, air out the room and call a licensed authorized technician. Failure to take proper precautions can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

 Qualiﬁ ed Technicians:

Qualiﬁ ed technicians are individuals with speciﬁ c, technical training in space heating systems, domestic hot water systems, fuel gas systems and electrical systems. These individuals must have the legally required qualiﬁ cations.

 Installation and Alterations:

Licensed, authorized personnel must carry out the installation and calibration of the boiler. Never modify the boiler or its ﬂ ue gas carrying components in any way. This boiler must be properly vented. Failure to follow these instructions could result in personal injury or death!

 In the event of a breakdown and/or malfunction

of the boiler, turn off the unit and do not make any

attempt to repair it. The boiler must be serviced exclusively by a qualiﬁ ed technician using original spare parts. Failure to comply with this requirement may compromise the safety of the unit and void its warranty.

 Use the service switch to disconnect the boiler

from the electrical circuit before carrying out any

service or maintenance operations.

 Electrical

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper and dangerous operation. Verify proper operation after servicing.

 ATTENTION: Au moment de l’entretien des

commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

 Correct Use:

This boiler must only be used for the purpose for which it has been expressly designed: heating of water for closed circuit systems for central heating and the production of domestic hot water.

 Should overheating occur or the gas supply fail

to shut off, do not turn off or disconnect the electrical

supply to the pump. Instead, shut off the gas supply at a location external to the appliance.

 En cas de surchauffe ou si l’alimentation de gaz

ne peut être coupée, ne pas couper ni débranch

l’alimentation électrique de la ponpe. Fermer plutôt le robinet d’admission de gaz à l’extérieur de l’appareil

 Do not use this appliance if any part has been

under water. Immediately call a qualiﬁ ed service

technician to inspect the appliance and to replace any part of the control system and any gas control, which has been under water.

 For safety and environmental reasons, the packing

materials must be properly disposed of. Any replaced part or packaging should never be left within the reach of children. Failure to follow these instructions could result in severe personal injury

 Maintenance:

at least once a year the user must call in a licensed authorized technician for routine maintenance.

 N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter l’appareil

par un tecnicien qualiﬁ é et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

 Do not obstruct the air intake or vent pipe

terminals. Failure to take proper precautions can

result in excessive levels of carbon monoxide which can cause severe personal injury or death!

 Any optional extras or kit ﬁ tted subsequently

must be original manufacturer parts.

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TABLE OF CONTENTS

SAFETY INSTRUCTIONS .....................................................................................................................................................................2

TABLE OF CONTENTS .........................................................................................................................................................................5

1 - INSTALLATION - CODE REQUIREMENTS .....................................................................................................................................7

1.1 - National installation legislation .................................................................................................................................................7

2 - GENERAL INFORMATION ...............................................................................................................................................................7

2.1 - Key to symbols used ................................................................................................................................................................7

2.2 - Description of models: ..............................................................................................................................................................7

3 - MAIN COMPONENTS ......................................................................................................................................................................8

4 - FUNCTION OVERVIEW .................................................................................................................................................................10

4.1 - Intended use and functions of the boiler ................................................................................................................................12

4.2 - Setting of the boiler .................................................................................................................................................................12

4.3 - Efﬁ ciency up to 98% ...............................................................................................................................................................13

4.4 - Characteristic curves of heating system’s residual head ........................................................................................................14

4.5 - Boiler head loss curve ............................................................................................................................................................14

4.6 - Characteristic curve of the domestic side ...............................................................................................................................14

5 - INSTALLATION - Mounting & gas and water connections ........................................................................................................ 15

5.1 - Clearances for installation and servicing for models ..............................................................................................................15

5.2 - Clearances from combustible material ...................................................................................................................................15

5.3 - Choosing the installation location ........................................................................................................................................... 15

5.4 - Mounting the boiler ................................................................................................................................................................. 16

5.5 - Gas and water connections .................................................................................................................................................... 16

5.6 - Condensate disposal .............................................................................................................................................................. 17

5.7 - Relief valve ............................................................................................................................................................................. 17

5.8 - Supply and return piping .........................................................................................................................................................18

5.8.1 - Converting a combi boiler into a heating only boiler.................................................................................................18

5.9 - Low temperature heating systems ..........................................................................................................................................18

5.10 - Use of glycol and other chemicals ........................................................................................................................................18

5.11 - Domestic hot and cold water (only for 160C model) .............................................................................................................18

5.12 - Gas supply piping ................................................................................................................................................................. 19

5.13 - Operating at high altitudes ....................................................................................................................................................19

5.14 - Suggested piping and wiring connections for the 160C and 160OC versions Boiler ...........................................................20

5.15 - Suggested piping and wiring connections for the 160B and 160OB versions Boiler ............................................................21

6 - INSTALLATION - Electrical connections .....................................................................................................................................22

6.1 - Electrical connections: overview .............................................................................................................................................22

6.2 - Connecting the power supply cable ........................................................................................................................................23

6.3 - Choosing the room thermostat ...............................................................................................................................................23

6.4 - Thermostat wiring ................................................................................................................................................................... 23

6.5 - Installing the outdoor temperature sensor (optional) .............................................................................................................. 24

6.6 - Wiring the circulator pump for 160B and 160OB models .......................................................................................................24

6.7 - Alarm output ...........................................................................................................................................................................24

7 - INSTALLATION - Indirect storage tank connections .................................................................................................................. 25

7.1 - Connecting the boiler to an indirect storage tank ..................................................................................................................25

8 - INSTALLATION - Vent & combustion air .....................................................................................................................................27

8.1 - Removing of a boiler from a common venting system ............................................................................................................27

8.2 - Venting systems .....................................................................................................................................................................28

8.3 - Design of the venting system .................................................................................................................................................28

8.4 - Flue terminal location in compliance with CAN/CSA B149 .....................................................................................................29

9 - INSTALLATION - Split venting system ........................................................................................................................................ 30

9.1 - Split system (polypropylene) or AL29-4C (UL 1738/UL C 636) system .................................................................................. 30

9.2 - Split system components .................................................................................................

9.3 - Split system components ........................................................................................................................................................33

9.4 - Split system: installation examples .........................................................................................................................................33

10 - INSTALLATION - Coaxial venting system ................................................................................................................................. 34

10.1 - Coaxial system ....................................................................................................................................................................34

10.2 - Coaxial system components .................................................................................................................................................35

10.3 - Coaxial system components .................................................................................................................................................36

10.4 - Coaxial system: installation examples ..................................................................................................................................36

11 - OPERATING .................................................................................................................................................................................37

11.1 - Operating ..............................................................................................................................................................................37

11.1.1 - User instructions .....................................................................................................................................................37

11.1.2 - Filling the condensate trap .....................................................................................................................................37

11.1.3 - Filling the heating system .......................................................................................................................................37

11.1.4 - Filling the domestic hot water heat exchanger (160C and 160OC models only) ....................................................38

11.1.5 - Auto-purging the heating system ............................................................................................................................ 38

.......................................................32

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TABLE OF CONTENTS

11.2 - General warnings concerning gas supply .............................................................................................................................38

11.3 - Conﬁ rming the boiler’s gas type ...........................................................................................................................................38

11.4 - Gas type conversion .............................................................................................................................................................38

11.5 - Start-up .................................................................................................................................................................................38

11.6 - Ignition control testing ...........................................................................................................................................................39

11.7 - Gas supply pressure checking and adjustment ....................................................................................................................39

11.8 - Check the combustion air pressure .....................................................................................................................................40

11.9 - Checking and adjusting CO2 levels ......................................................................................................................................41

11.9.1 - Checking and adjusting CO2 levels without CO2 meter .........................................................................................42

11.10 - Adjusting the heating capacity ............................................................................................................................................42

11.11 - Domestic hot water ﬂ ow rate adjustment (160C and 160OC models only) ......................................................................... 42

11.12 - Cold start boiler ................................................................................................................................................................... 42

12 - USE ...............................................................................................................................................................................................43

12.1 - Check heating system pressure ...........................................................................................................................................43

12.2 - Overview ...............................................................................................................................................................................43

12.3 - Displays ................................................................................................................................................................................ 43

12.4 - Start-up procedure ................................................................................................................................................................44

12.5 - Summer mode ...................................................................................................................................................................... 44

12.6 - Winter mode .........................................................................................................................................................................44

12.7 - Adjusting the domestic hot water temperature .....................................................................................................................44

12.8 - Heating system temperature adjustment ..............................................................................................................................44

12.9 - Heating system type selection ..............................................................................................................................................45

12.10 - Outdoor reset adjustment ................................................................................................................................................... 45

12.10.1 - Outdoor reset applications ...................................................................................................................................45

12.10.2 - Outdoor reset adjustment precautions ................................................................................................................. 45

12.10.3 - Outdoor reset: setting parameters........................................................................................................................46

12.10.4 - Outdoor reset: zone adjustments ......................................................................................................................... 46

12.10.5 - Outdoor reset activation ....................................................................................................................................... 46

12.10.6 - Outdoor reset with room compensation ...............................................................................................................46

12.11 - Boiler switch settings ..........................................................................................................................................................48

12.12 - Delays, alarms and protective actions ................................................................................................................................48

12.13 - Circulator pump and three way valve protection ................................................................................................................48

12.14 - Freeze protection ................................................................................................................................................................48

12.15 - Display in energy saving mode ..........................................................................................................................................48

12.16 - “Users’ menu” ..................................................................................................................................................................... 49

12.17 - “Installer’s menu” ................................................................................................................................................................ 50

12.18 - Diagnostics ......................................................................................................................................................................... 52

12.18.1 - Diagnostics: “L” lock-outs .....................................................................................................................................53

12.18.2 - Diagnostics: “E” blocking errors ...........................................................................................................................55

13 - MAINTENANCE ............................................................................................................................................................................ 57

13.1 - General precaution ............................................................................................................................................................... 57

13.2 - Removing the casing .............................................................................................................................................................57

13.3 - Cleaning the burner and primary heat exchanger, ﬂ ue gas side ..........................................................................................58

13.4 - Correct positioning of the ignition and ﬂ ame detection electrodes ......................................................................................59

13.5 - Domestic hot water heat exchanger (only for 160C and 160OC model) .............................................................................. 59

13.6 - Condensate trap cleaning .....................................................................................................................................................60

13.7 - Circulator pump motor replacement (only for 160C and 160OC models) .....................................................

13.8 - Expansion tank pressure (only for 160C and 160OC models) .............................................................................................61

13.9 - 3-way valve removal (only for 160C and 160OC models) .................................................................................................... 62

13.10 - Draining the heating side of the boiler ................................................................................................................................ 64

13.11 - Draining the domestic hot water side of the boiler ..............................................................................................................64

13.12 - Overrides ............................................................................................................................................................................ 64

13.12.1 - Auto-purging .........................................................................................................................................................64

13.12.2 - Fan ......................................................................................................................................................................64

13.12.3 - Minimum and maximum output ............................................................................................................................ 64

13.12.4 - Checking the ﬂ ame current ..................................................................................................................................65

13.13 - Water and ﬂ ue temperature sensor ....................................................................................................................................65

13.14 - Outdoor temperature sensor (optional) ..............................................................................................................................65

13.15 - Functional wiring diagram ...................................................................................................................................................66

13.16 - Multiwire wiring diagram ..................................................................................................................................................... 67

14 - TECHNICAL DATA ......................................................................................................................................................................68

15 - SPARE PARTS ............................................................................................................................................................................. 69

16 - READ OUT FLOW CHART ..........................................................................................................................................................74

17 - WARRANTY ..................................................................................................................................................................................76

.......................61

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1 - INSTALLATION - CODE REQUIREMENTS

1.1 - National installation legislation

- The installation must conform to the requirements of the authority having jurisdiction or, in the absence of such requirements, to the latest edition of the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 and or CAN/CSA B149.1, Natural Gas and Propane Installation Code.

- 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

2 - GENERAL INFORMATION

2.1 - Key to

2.2 - Description of

symbols used

WARNING!!! Failure to follow these indications can causing an explosion, extensive property damage, severe personal injury or death!

CAUTION!!!

Electrical caution! Risk of electric shock: failure to observe this warning may compromise the smooth running of the appliance or cause serious damage to individuals, animals or property.

CAUTION!!! General caution. Failure to observe this warning may compromise the smooth running of the appliance or cause serious damage to individuals, animals or property.

NOTE:

models:

160

B = heating only version, for inside

installation C = combi version (space heating and

instantaneous D.H.W. production), for inside installation. OB = heating only version, for outdoor installation OC =

combi version (space heating instantaneous D.H.W. production), for outdoor installation.

Modulating gas-ﬁ red, condensing hot water boiler, with sealed combustion chamber and pre-mix burner, with maximum power input of 160,000 Btu/hr (47 kW) and minimum of 30,000 Btu/hr (9 kW)

and

 Operation symbol

 Important indication symbol

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3 - MAIN COMPONENTS

1 - P/N 61206001 - Automatic air vent 2 - P/N 61405160 - Air intake and ﬂ ue gas discharge ﬁ tting

(venting system) 3 - P/N 62111015 - U7 ﬂ ue gas temp. sensor and ﬂ ue safety switch 4 - P/N 62201005 - Expansion tank

(not present on 160B and 160OB models) 5 - P/N 62651016 - Inlet air plenum 6 - Air/gas mixer device (For P/N see Section 15) 7 - P/N 62111017 - U2 d.h.w. temp. sensor

(not present on 160B and 160OB models) 8 - P/N 62113035 - Heating pressure switch (low water cut-off) 9 - Heating supply connection 10 - DHW connection (not present on 160B and 160OB models) 11 - Gas inlet connection

Figure 1 - Main components

12 - Cold water connection (not present on 160B and 160OB models) 13 - Heating return connection 14 - P/N 62110076 - Power Control Board 15 - P/N 62118015 - Openterm interface board (optional) 16 - P/N 60507056 - Connection board 17 - P/N 62649004 - Primary heat exchanger 18 - P/N 60504206 - Spark cable 19 - External jacket (For P/N see Section 15) 20 - Combustion chamber door 21 - Instrument panel door

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3 - MAIN COMPONENTS

22 - Combustion analysis tap

(For P/N see Section 15)

23 - P/N 62111016 - U1 supply temperature

sensor 24 - Burner window (For P/N see Section 15) 25 - Air/gas manifold (For P/N see Section 15) 26 - P/N 62111017 - U6 high temperature limit

sensor 27 - Flue gases back ﬂ ow preventer

(For P/N see Section 15) 28 - P/N 61901029 - Fan 29 - P/N 61201040 - Gas valve 30 - P/N 62102009 - Heating pressure gauge 31 - Display 32 - Domestic hot water temperature control 33 - Heating temperature control 34 - P/N 60506019 - On/off power switch 35 - Three way valve (not present on 160B and

160OB models) (For P/N see Section 15) 36 - P/N 62110052 - U3 domestic cold water

temp. sensor (not present on 160B and

160OB models) 37 - P/N 61101001 - Cable clamp 38 - P/N 61205010 - ASME Safety relief valve 39 - P/N 62111016 - U8 return temperature

sensor 40 - P/N 60305073 - By-pass pipe (not present

on 160B and 160OB models) 41 - P/N 60322010 - Condensation discharge

pipe 42 - Secondary heat exchanger for domestic

hot water production (not present on 160B

and 160OB models) (For P/N see Section

15)

43 - P/N 62625064 - Expansion tank

connection pipe (not present on 160B and

160OB models) 44 - Circulator pump screw (not present on

160B and 160OB models) 45 - P/N 62301031 - Circulator pump (not

present on 160B and 160OB models) 46 - P/N 62630136 - Condensation discharge

trap 47 - P/N 60505024 - Flame-proving electrode 48 - Burner (For P/N see Section 15) 49 - P/N 60505023 - Right ignition electrode 50 - P/N 60505022 - Left ignition electrode 51 - P/N 60510022 - Spark generator 52 - P/N 62113041 - Flue pressure switch

Figure 1 - Main components

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4 - FUNCTION OVERVIEW

Key to ﬁ gure 2: 1 = boiler model 160C or 160OC 2 = automatic air vent 3 = air intake 4 = ﬂ ue gases discharge 5 = sealed combustion chamber 6 = expansion tank 7 = burner 8 = fan 9 = gas valve 10 = condensate discharge trap 11 = circulator pump 12 = 3-way valve 13 = secondary heat exchanger for d.h.w. 14 = pressure gauge 15 = by-pass valve 17 = safety relief valve 21 = condensate discharge pipe 22 = heating supply pipe 23 = domestic hot water outlet 24 = gas inlet 25 = cold water inlet 26 = heating return pipe 45 = U7 = ﬂ ue gas temperature sensor 46 = U1 = boiler temperature sensor 47 = U6 = high limit temperature sensor 48 = U3 = domestic cold water sensor/storage tank

sensor 49 = U2 = domestic hot water temperature sensor 50 = U8 = return temperature sensor 51 = ﬂ ue pressure switch

Figure 2 - 160C and 160OC Hydronic functional schematic

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4 - FUNCTION OVERVIEW

Key to ﬁ gure 3: 1 = boiler model 160B and 160OB 2 = automatic air vent 3 = air intake 4 = ﬂ ue gases discharge 5 = sealed combustion chamber 7 = burner 8 = fan 9 = gas valve 10 = condensate discharge trap 14 = pressure gauge 17 = safety relief valve 20 = safety relief valve discharge 21 = condensation discharge pipe 22 = heating supply pipe 24 = gas inlet 26 = heating return pipe 45 = U7 = ﬂ ue gas temperature sensor and high limit

safety switch 46 = U1 = boiler temperature sensor 47 = U6 = high limit temperature sensor 50 = U8 = return temperature sensor 51 = ﬂ ue pressure switch

Figure 3 - 160B and 160OB Hydronic functional schematic

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4 - FUNCTION OVERVIEW

4.1 - Intended use and functions of the boiler

This gas-ﬁ red condensing boiler, is designed to be used for central heating and producing domestic hot water. The maximum output heat is always guaranteed for the production of domestic hot water since it is given priority over space heating demands. Follow the speciﬁ c procedure in section 12.1 for the adjustment of the domestic hot water temperature. Depending on the model choosen, the following system types can be created:

- 160C. Using this boiler model, a system can be created for the production of instantaneous domestic hot water and a heating system with heating elements functioning at temperatures ranging between 68°F (20°C) and 189°F (87°C). The boiler can also function directly with a radiant ﬂ oor panel, see section

5.9. When connecting the boiler to the heating system the installer must consider the head loss of the heating system to verify that the boiler pump is adequate. Pump curve is shown in ﬁ gure 5. The same veriﬁ cation must be done for the domestic installation, see ﬁ gure 7.

- 160B. Using this boiler model, a heating system with heating elements functioning at temperatures ranging between 68°F (20°C) and 187°F (87°C) can be conﬁ gured. The boiler can also function directly with a radiant ﬂ oor panel, see section

5.9. The 160B model is not equipped with the components required for the production of domestic hot water. Also not included is the expansion tank and circulator pump, see ﬁ gure 3. To connect the boiler to the heating system, the installer must consider the loss of pressure generated by the boiler (see ﬁ gure 6), and choose a pump capable of overcoming the head loss of both the boiler and the heating system.

- 160OC. This boiler is equal to the 160C model, but is intended for outdoor installation.

- 160OB. This boiler is equal to the 160B model, but is intended for outdoor installation.

All models can be connected to an indirect storage tank for the production of domestic hot water, section 7.

All models can be connected to a room thermostat, section 6.3 and 6.4.

Because boiler models 160OC and 160OB are usually installed outside the building, they need to be connected to a Remote Command, section 6.8.

An outdoor air temperature sensor can also be connected to the boiler for an outdoor reset supply temperature control for maximum fuel efﬁ ciency and comfort (see section 6.5). In this conﬁ guration the room thermostat will compensate by adjusting the room temperature. The room temperature compensation can be of an ON / OFF type or two-stage. For further information on the outdoor-air reset, refer to section 12.4.

 The boiler must be connected to

a heating system and a domestic hot water supply with compatible speciﬁ cations, performance and power rating.

 Before installation, thoroughly

ﬂ ush the heating and plumbing systems of any residue or impurities which might compromise the smooth running of the boiler.

 Only boilers model 160OC and

160OB are designed for outdoor installation. However also for these boilers you need to choose a sheltered place where it is protected from atmospheric elements including frost.

 Refer to ﬁ gure 8 for minimum

clearance distances for installation and future maintenance.

 Refer to section 5.2 for minimum

clearance distances from combustible material.

4.2 - Setting of the boiler

Section 16 details the setting changes that should be made to best match the boiler’s operation to the needs of each application.

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4 - FUNCTION OVERVIEW

4.3 - Efﬁ ciency up to 98%

When the outdoor reset is activated (an outside sensor is connected), this boiler is designed to always work at the maximum efﬁ ciency . It will automatically change the supply temperature in relation with the outdoor temperature (Outdoor reset). The graph in ﬁ gure 4 shows an example on how it can work. This graph represents an installation where the supply and return temperatures are 139°F and 115°F respectively, and the outside temperature is 23°F. The outdoor reset drives the boiler, to progressively reduce the supply temperature and thereby optimize the efﬁ ciency. It changes from 87% when outside is -10°F, to 94.8% when outside is 23°F and up to 98% when the outside temperature rises up to 67°F.

Figure 4 - Outdoor reset control to optimize the efﬁ ciency

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4 - FUNCTION OVERVIEW

Figure 5 - Available Head for heating circuit for models “160C” and “160OC”

4.4 - Characteristic curves of heating system’s residual head

160C and 160OC boilers are ﬁ tted with a Grundfos circulator pump. The head available to supply ﬂ ow through the heating system at the boiler connections is shown in graph form in ﬁ gure 5.

4.5 - Boiler head loss curve

160B and 160OB boilers are not ﬁ tted with an internal pump. The installer needs to install an external pump as illustrated in ﬁ gure 17, item “6”. Use the graph in ﬁ gure 6 to choose the correct pump.

Figure 6 - Internal Boiler Head Loss for models “160B” and “160OB”

Figure 7 - Domestic Water Coil Head Loss for models “160C” and “160OC”

4.6 - Characteristic curve of the domestic side

160C and 160OC boilers, offers resistance to the passage of domestic water (see graph ﬂ ow/ pressure of ﬁ gure 7). The installer or the engineer must take account of this in order to ensure the correct domestic water ﬂ ow to the utilities.

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5 - INSTALLATION - Mounting & gas and water connections

5.1 - Clearances for installation and servicing for models

Figure 8 shows the clearances required for installation and servicing.

NOTE: Service clearances are not mandatory, but are recommended to ensure ease of service should it be required.

5.2 - Clearances from combustible material

This boiler may be installed directly onto a wall of combustible material with the following clearance: Ceiling: 2 inches (51 mm) Front: 2 inches (51 mm)

Figure 8 - Recommended minimum clearance distances for proper installation and servicing

Rear: 0 inches (0 mm) Sides: 2 inches (51 mm) Floor: 2 inches (51 mm) Concentric vent: 0 inches (0 mm) Split vent (ﬁ rst 12" from the boiler): 1 inch (25 mm) Split vent (after 12" from the boiler): 0 inches (0 mm)

1 = Area for power supply cable 2 = Heating supply connection (3/4") 3 = Domestic hot water connection (3/4") (absent in 160B model) 4 = Gas connection (3/4") 5 = Domestic cold water connection (3/4") (absent in 160B model) 6 = heating return connection (3/4") 7 = positions for boiler support 8 = Flue discharge/air intake connection

Figure 9

- Dimensions

5.3 - Choosing the installation location

CAUTION!!! The boiler must be installed on a

vertical wall constructed to bear its weight or the boiler and building may be damaged. NOTE: The boiler must never be installed on carpeting.

CAUTION!!! This boiler is not designed for direct

outdoor installation. However a kit P/N 62610069 to convert the boiler for outdoor installation is available. If installed outside of the structure it must be sheltered so it is protected from rain, wind, sun and frost. NEVER place this boiler in a location that would subject it to temperatures at or near freezing. Failure to properly locate this boiler can result in premature failure voiding the warranty .

When locating the boiler the following factors must be considered:

• the location of vent/air intake terminals;

• connection to the gas supply;

• connection to the water supply;

• connection to the heating system;

• connection to the domestic hot water system;

• connection to the electrical supply;

• disposal of the condensation produced by the boiler;

• connection to the room thermostat;

• piping of the safety relief valve discharge;

• possible connection of the outdoor temperature sensor;

• possible connection of an indirect storage tank, see section 7.

Page 16

5 - INSTALLATION - Mounting & gas and water connections

5.4 - Mounting the boiler

Refer to ﬁ gure 10:

1. place the cardboard template, provided with the boiler, against the wall;

2. ensure that the template is plumb and the screw holes line up with the wall studs;

CAUTION!!! The wall bracket screws must be screwed into the buildings framing or other material capable of supporting the weight of the boiler or the boiler and building may be damaged.

3. mark the screw holes for the wall bracket, “A”;

4. remove the cardboard template;

5. install the wall bracket “A”, using the screws

“E”, provided;

6. hang the boiler on the wall bracket, “A”, by

hanging connections “B” and “C” on tabs “D”.

5.5 - Gas and water

Figure 10 - Wall bracket installation

connections

The boiler comes with the ﬁ ttings shown in ﬁ gure 11.

A = heating system supply (3/4") B = domestic hot water supply (3/4") (Absent on 160B and 160OB models) C = Inlet gas connection (3/4") D = domestic cold water (3/4") (Absent on 160B and 160OB models) E = heating system return (3/4")

Figure 11 - Fittings supplied with the boiler

Page 17

5 - INSTALLATION - Mounting & gas and water connections

5.6 - Condensate disposal

WARNING! The condensate trap must be connected to the boiler per the following instructions or combustion gases will enter the room. This can result in excessive levels of carbon monoxide which can cause severe personal injury or death!

This boiler produces water as a byproduct of combustion. The boiler is equipped with a condensate trap, ﬁ gure 1, item 46, for the evacuation of condensate and to prevent the leakage of combustion products. The condensate trap drains through pipe “C” shown in ﬁ gure 12. The condensation disposal system must:

be connected to the domestic

waste disposal system by means of an appropriate trap capable of preventing the pressurization of the condensate system and the return of sewer gases (see ﬁ gure 13);

comply with national and/or local

codes for condensate neutralizer between pipe “C” of ﬁ gure 12 and the waste disposal system;

be carried out with a pipe with

an internal diameter equal to or greater than 1/2 in, 13 mm;

be installed in such a way so as to

avoid the freezing of the liquid;

never discharge into gutters or rain

collectors;

be properly pitched towards the

point of discharge avoiding high points, which could place the condensate system under pressure.

CAUTION!!! The condensate drainage system is designed to empty all the condensate produced by one boiler only. Each boiler must be equipped with its own condensate drainage system or the drainage system may malfunction.

5.7 - Relief valve

Each boiler is equipped with a safety relief valve set at 30 psi (2 bar) which must be piped in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, to prevent scalding in the event of a discharge, see Figures 1, item “38” and ﬁ gure 12.

WARNING!!! Failure to properly pipe the relief valve discharge can result in scalding of individuals and animals. Never install any type of valve between the boiler and the relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

A = 3/4" pipe extension (not provided) B = Discharge device open to the atmosphere (not provided) C = Condensate discharge pipe

Figure 12 - Relief valve connection

Figure 13 - Condensate trap and drain

Page 18

5 - INSTALLATION - Mounting & gas and water connections

5.8 - Supply and return piping

CAUTION!!! All heating system piping must be installed in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV. All applicable local codes and ordinances must also be followed. If the boiler is installed above any radiation elements it must be ﬁ tted with a low water cutoff device installed above the normal boiler water level! Failure to do this can result in damage the unit and void the warranty!

CAUTION!!! This boiler must have adequate water ﬂ owing through it whenever the burner is on. Failure to do this will damage the unit and void the warranty!

CAUTION!!! Before connecting the boiler to the heating system the heating system must be thoroughly ﬂ ushed to remove sediment, ﬂ ux, ﬁ lings and other foreign matter. An approved inhibitor should be added to the heating system water to prevent limestone and magnetite deposits from forming and to protect the boiler from galvanic corrosion.

CAUTION!!! This boiler is equipped with an ASME safety relief valve set at 30 psi (2 bar). The heating system must be designed so that no piping or radiation elements are higher than 65 ft (20 m) or else the hydraulic head of the system will cause the relief valve to open.

CAUTION!!! The manufacturer cannot be held responsible for any damage caused by incorrect use of additives in the heating system.

Figure 11 illustrates the position of

the supply and return pipes.

Install a metallic mesh ﬁ lter on the

return pipe to prevent any residue from the system returning to the boiler.

Do not use the appliance for

adding any type of additive to the system.

5.8.1 - Converting a combi boiler into a heating only boiler

If you are in possession of a combi boiler (160C or 160OC) you can use it as a heating system only without using the domestic hot water circuit. To do so, simply plug the two ﬁ ttings, items 3 and 5 of ﬁ gures 9 and 10, and move switch No. 5 (see ﬁ gure

21) from OFF position to ON position. Now knob 32 of ﬁ gure 1 is disabled.

5.9 - Low temperature heating systems

CAUTION!!! When the boiler

is installed in a low temperature system, the switch “6” in ﬁ gure 21 must be placed in the ON position to prevent the supply water temperature from exceeding 113°F (45°C) or damage to the low temperature system components could occur (see section 5.9).

With switch “6” in ﬁ gure 21, in the ON position, the boiler will maintain the supply water temperature between 68°F (20°C) and 113°F (45°C). No setting changes made from the control panel will cause the supply water temperature to exceed 113°F (45°C).

CAUTION!!! If the boiler

is installed in a radiant panel heating system using plastic piping, precautions must be taken against corrosion caused by water oxygenation. If the piping does not incorporate an oxygen barrier, the radiant panel circuit must be isolated from the boiler using a titanium plate heat exchanger.

5.10 - Use of glycol and other chemicals

WARNING!!! Never use nonapproved additives or toxic boiler treatment chemicals in the heating system as they can cause serious health problems or possibly death. Any additives introduced into the heating system must be recognized as safe by the United States Food and Drug Administration.

If glycol is used, it must be used in accordance with the instructions supplied with the product.

CAUTION!!! Any additives added to the heating system must not be added directly inside the boiler but through the heating system piping to prevent damage to the boiler.

5.11 - Domestic hot and cold water (only for 160C and 160OC models)

CAUTION!!! If the water hardness is greater than 9 gr/gal (150 mg/l) we recommend installing a water softener with ﬁ lter.

Figure 11 illustrates the positioning

of the domestic hot and cold water pipes.

For servicing purposes, install an

isolation valve upstream from the cold water inlet.

To correctly set the domestic water

ﬂ ow, install an adjustable ﬂ ow restrictor upstream the cold water inlet (see ﬁ gure 15 item “12”)

160C and 160OC boilers can be

used as heating only boilers. No connection is needed to the domestic pipes “B” and “D” of ﬁ gure 11.

Page 19

5 - INSTALLATION - Mounting & gas and water connections

5.12 - Gas supply piping

WARNING!!! Check that the type and the pressure of the gas supplied correspond with those required for the boiler as stated on the rating plate. Never use a gas different than that stated on the boiler rating plate. Failure to comply with this warning can result in a ﬁ re or explosion causing extensive property damage, severe personal injury or death!

If the gas type and/or the supply

pressure do not match those stated on the boiler rating plate the boiler must be converted to the type of gas and/or supply pressure available. A conversion kit is supplied together with the boiler.

The boiler comes from the factory

ready to be piped to the gas supply. The National Fuel Gas Code, ANSI Z223.1/NFPA 54 and local codes for gas piping requirements and sizing must be followed.

Install a manual gas shutoff valve

and drip leg as shown in ﬁ gure 14.

Before installation a thorough

internal cleaning of the gas supply line should be performed. Figure 11 shows the positioning of the gas connection on the heater.

The boiler and its gas connection

must be leak tested before placing the boiler in operation.

To avoid damaging the gas control,

perform a leak test at a pressure of no greater than 20 in W.C. (50 mbar).

WARNING!!! Never use an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this WARNING could result in an explosion!

The boiler and its individual shutoff

valve must be disconnected from the gas supply piping during any pressure testing at test pressures in excess of 1/2 psi (3.5 kPa).

The boiler must be isolated from

the gas supply piping by closing its individual manual shutoff valve during any pressure testing at test pressures equal to or less than 1/2 psi (3.5 kPa).

The gas supply piping to the boiler must be properly sized to guarantee that the gas supply meets the maximum requirements. If more than one appliance is supplied by the same gas supply pipe, the gas supply piping must be sized based on the maximum possible demand. Do not neglect the pressure drop due to pipe ﬁ ttings. Table 1 below, should be used in conjunction with table 2 below, to ensure that the gas supply piping is sized properly. See section

Figure 14 - Gas supply piping

14 for values of “maximum gas supply pressure” and “minimum gas supply pressure” and also section 11.7.

Table 1 - Gas Pipe Capacity

Nominal Iron

Pipe Size

3/4"

1" 1 1/4" 1 1/2"

Note: Maximum pipe capacity in ft at a pressure of 0.5 psig and a 0.3" WC pressure drop.

10'

278

520 1050 1600

20'

190 350 730

1100

30'

152 285 590 890

Pipe Length

40'

50'

60'

Gas Pipe Capacity (ft

130

115

105

245

215

195

500

440

400

760

670

/hr is based on a 0.60 speciﬁ c gravity gas

610

/hr)

80'

90 170 350 530

100'

79 150 305 460

150'

64 120 250 380

5.13 - Operating at high altitudes

For installations in the United States, the boiler is rated for operation at altitudes up to 2,000 ft (609 m). For installations at higher altitudes in the United States, follow local codes or, in the absence of local codes, follow ANSI Z223.1/NFPA No. 54, The National Fuel Gas Code. For installations in Canada, the boiler is rated for installations up to 2,000 ft (609 m). For installations above this altitude, follow local/provincial codes.

Table 2 - Equivalent Pipe Length Chart

Type of Pipe Fitting

Nominal Iron

Pipe Size

3/4"

1" 1 1/4" 1 1/2"

90° Gas Cocks

Equivalent length of pipe ﬁ ttings in feet

2.06

2.62

3.45

4.02

Tee

(brach ﬂ ow)

4.12

5.24

6.90

8.04

Gas Valve

(full port)

0.48

0.61

0.81

0.94

1.25

1.60

2.15

2.50

Page 20

5 - INSTALLATION - Mounting & gas and water connections

5.14 - Suggested piping and wiring connections for the 160C and 160OC versions Boiler

Figure 15 shows the suggested piping and wiring connection for boiler models 160C and 160OC. All component listed below, except the ﬂ ue terminal must be ﬁ eld supplied.

1 = ball valve 2 = drain valve 3 = Manual gas shut-off valve 4 = sediment trap 5 = ground joint union 8 = Relief valve drain 9 = Condensate drain 10 = Domestic mixing valve 12 = Flow restrictor 13 = Fill valve 14 = Heating supply 15 = Domestic Hot Water 16 = Cold water 17 = Heating return 18 = Gas supply 19 = Concentric vent/air intake terminal OS = Outdoor sensor (optional) RC = Remote command (only for 160OC model) RT = Room thermostat 120 Vac = Electrical supply

Figure 15 - Typical piping and wiring connections for a boiler models 160C and 160OC

Page 21

5 - INSTALLATION - Mounting & gas and water connections

5.15 - Suggested piping and wiring connections for the 160B and 160OB versions Boiler

Figure 16 shows the suggested piping and wiring connections for boiler models 160B and 160OB. All components listed below, except the ﬂ ue terminal must be ﬁ eld supplied.

1 = ball valve 2 = drain valve 3 = Manual gas shut-off valve 4 = sediment trap 5 = ground joint union 6 = Circulator pump 7 = By pass valve 8 = Relief valve drain 9 = Condensate drain 10 = Domestic mixing valve 11 = Expansion tank 12 = Flow restrictor 13 = Fill valve 14 = Heating supply 15 = Domestic Hot Water 16 = Cold water 17 = Heating return 18 = Gas supply 19 = Concentric vent/air intake terminal OS = Outdoor sensor (optional) RC = Remote command (only for 160OB model) RT = Room thermostat 120 Vac = Electrical supply

Figure 16 - Typical piping and wiring of a boiler models 160B and 160OB

Page 22

6 - INSTALLATION - Electrical connections

6.1 - Electrical connections: overview

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

A TTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonction-nement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretirn terminé.

WARNING!!! The boiler must be electrically wired to ground in accordance with the requirements of the authority having jurisdiction or, in the absence of such requirements, with the National Electrical

Code, ANSI/NFP A 70 and/or the Canadian Electrical Code Part I, CSA C22.1, Electrical Code.

This is an essential safety requirement which must be checked.

Check that the electrical system is adequate

for the power consumption indicated on the rating plate.

Line voltage ﬁ eld wiring of any controls or

other devices must conform to the temperature limitation of type T wire at 95°F (35°C), above room temperature. Use copper conductors with a minimum size of #14 AWG. Low voltage wiring must not be less than #18 AWG with a neoprene, thermoplastic or other equivalent insulation having a minimum insulation thickness of 0.012 in, (3 mm).

 A properly rated shut-off switch shall be

located at the boiler.

Ensure that the polarity between live and

neutral wires is maintained when connecting the boiler.

CAUTION!!! Ensure that heating and water piping is not used as a ground connections for the electric and telephone systems. This piping is completely unsuitable for this purpose and, could rapidly lead to serious corrosion damage to the boiler, piping and radiators, voiding the warranty

CAUTION!!! The boiler is not provided with any protection against lightening strikes.

A = Junction box B = Plastic spring C = Opening direction D = Screws for junction box cover E = Junction box cover F = Junction box cover opening direction G = Electrical supply cable H = Room thermostat cable (optional) L = Outside temperature sensor cable (optional) M = Storage tank temperature sensor N = Remote command cable (optional)

Figure 17 - Junction box

Page 23

6 - INSTALLATION - Electrical connections

Indirect water heater sensor

Outdoor sensor

Room thermostat

120Vac Line central heating Neutral 120Vac Line domestic hot water

120Vac LINE (HOT) NEUTRAL GROUND

Figure 18 - Electrical connections

6.2 - Connecting

10. connect the 120 volt neutral wire

the power supply

NOTICE! If the 120 volt power wires

cable

To connect the electrical power supply cable, follow the steps below while referring to ﬁ gure 17 and 18:

1. remove the boiler casing following

the instructions given in section

13.2;

2. press the two plastic springs tabs

labeled “B” on the bottom side;

3. open panel “A” in the “C” direction;

4. remove the three screws labeled

“D”;

5. open door “E” in the “F” direction;

6. install the power supply wires, “G”

as shown;

7. strip the power supply wires being

careful to leave the ground wire 1 in (25 mm) longer than the other two;

8. connect the ground wire to the

ground terminal;

9. connect the 120 volt hot wire to

terminal “L1”;

are inverted, the boiler will block, displaying error code E21.

NOTICE! If the boiler is not properly grounded, the boiler will block, displaying error code E23

6.3 - Choosing the room thermostat

This boiler is designed to function with any type of room thermostat which has an electrical contact with the following speciﬁ cations:

- open (end call for heat); closed (call for heat);

- clean dry contact (not powered);

- electrical capacity of 24Vac, 1A.

to terminal “N”.

External three way valve for indirect water heater

6.4 - Thermostat wiring

Install the room thermostat in a part of the house where the temperature is as near to average as possible. Avoid areas subject to sudden temperature changes such as outside windows or doors, above radiation elements, near lamps, etc., (see ﬁ gure 19).

Connect the room thermostat to the boiler by following the steps below:

1. remove the boiler casing according to the instructions given in section

13.2 and open the junction box per section 6.2;

2. use a two conductor cable with a minimum cross section of # 18 AWG between the boiler and the room thermostat;

3. route the cable through an empty cable clamp in the junction box

4. connect the cable leads to the “RT” terminals as shown in ﬁ gure 18.

Page 24

6 - INSTALLATION - Electrical connections

NOTICE! the maximum room thermostat cable length permitted is 65 ft (20 m). For longer lengths, up to 300 ft (100 m) a shielded cable, with the shield connected to the ground, must be used.

WARNING!!! Since the room thermostat wires conduct 24 Vac, they must never be run through conduits containing 120Vac power wires or an electrical shock hazard will exist

6.5 - Installing the outdoor temperature sensor (optional)

Install the outdoor temperature sensor, on an exterior wall of the building facing NORTH or NORTH-EAST, at a height of between 4 ft (1.2 m) and 6 ft (1.8 m) from the ground level. On multi story buildings, install the sensor near the upper half of the second ﬂ oor. Do not install the sensor above doors, windows or ventilation outlets nor directly under balconies or gutter pipes. Do not shield the outdoor temperature sensor. Do not install the sensor on walls without overhangs, or not protected from rain. T o connect the outdoor temperature sensor to the boiler proceed as follows:

1. remove the boiler casing according to the instructions given in section

13.2 and open the junction box per section 6.2;

2. use a two conductor cable with a minimum cross section of # 18 AWG. between the boiler and the outdoor temperature sensor.

NOTICE! the maximum outdoor temperature sensor cable length permitted is 65 ft (20 m). For longer lengths, up to 300 ft (100 m) a shielded cable, with the shield connected to the ground, must be used;

WARNING!!! Since the outdoor temperature sensor wires conduct 24 Vac, they must never be run through conduits containing 120 Vac power wires or an electrical shock hazard will exist.

3. connect the outdoor temperature sensor cable leads to terminals OS as shown in ﬁ gure 18;

4. connect the outdoor temperature sensor cable leads to the ends of the external temperature sensor.

Set the boiler so that it detects the outdoor temperature sensor, as follows:

1. press down the button for 12

seconds until the display starts blinking and shows ;

2. then press and release the button several times until the following parameter appears;

3. using the and keys, change the parameter value from 00 to 01 or 02 in relation to the type of climatic heat adjustment desired as explained in section 12.10;

press the button repeatedly

until exiting the menu; the display will no longer ﬂ ash.

6.6 - Wiring the

circulator pump for 160B and 160OB models

Install the circulator pump as per ﬁ gure 16 item “6”. Wire the pump to the boiler following the steps below while refering to ﬁ gure 18:

1. remove the boiler casing according to the instructions given in section

13.2 and open the junction box per section 6.2;

2. use a three wire cable with a minimum cross section of # 18 AWG between the boiler and the circulator pump;

3. route the circulator cable through an empty cable clamp in the junction box;

4. connect the Line and Neutral cable wires respectively to the “4 and 5” terminals in the junction box;

5. connect the Ground wire to an empty “Ground” connection inside the junction box.

NOTICE! If the 120 volt power wires are inverted, the boiler will lockout, displaying error code L05.

Figure 19 - Room thermostat location

6ft ( )

6.7 - Alarm output

Inside the electrical box (see 13.15 and 13.16) there is an electrical connection for a 120Vac output that is energized each time the boiler goes into a lock-out or error condition. The Installer can use this output to activate any kind of external signalization devices such an audible alarm, phone, or other devices.

Page 25

7 - INSTALLATION - Indirect storage tank connections

7.1 - Connecting the boiler to an indirect storage tank

All boilers listed in this manual, can be connected to an indirect storage tank as follows (the water and electrical connections must be made per ﬁ gure 20): T o make the electrical connections, follow the steps below while refering also to ﬁ gure 20:

1. disconnect the boiler from the electrical supply;

2. remove the boiler casing according to the instructions given in section 13.2;

3. push the plastic spring tabs “B” shown in ﬁ gure 21;

4. open the front half of the electrical box in the “C” direction as shown in ﬁ gure 21;

5. move switch #1, item “D” in ﬁ gure 21, to its “ON” position as marked on the control board;

6. ensure that switch #5 is in the OFF position;

7. on the rear side of the electrical junction box board, if present, disconnect the plug with two wires (see ﬁ gure 21, item “E”), corresponding to wires #44 and #45.

on the rear side of the electrical box, disconnect the plug from the diverter valve (see ﬁ gure 1, item “35”). When you disconnect the plug you must be sure the boiler is doing heating. If you are not sure light the boiler ON, wait the display show “F” and then light-off the boiler . Now you can disconnect the plug from the diverter valve.

9. use a # 18 AWG two wire cable to connect the indirect storage tank temperature sensor to terminals “TS”, item “M”, as per ﬁ gure 18;

1 Outdoor temperature sensor (optional) 2 120Vac electrical supply 3 Heating system supply circuit 4 Room thermostat (ﬁ eld supplied) 5 Heating circuit drain valve (ﬁ eld supplied) 6 Boiler 7 By-pass valve (ﬁ eld supplied on models 160B and 160OB) 8 Three way valve (ﬁ eld supplied) 9 Gas supply 10 Manual gas shutoff valve (ﬁ eld supplied) 11 Circulator pump (ﬁ eld supplied on models 160B and 160OB) 12 Expansion tank (ﬁ eld supplied on models 160B and 160OB) 13 Automatic ﬁ ll valve (ﬁ eld supplied ) 14 Cold water inlet connection 15 Indirect storage tank (ﬁ eld supplied) 16 Domestic hot water outlet 17 Domestic cold water inlet

Figure 20 - Indirect storage tank connections

10. insert the probe of the tank temperature

sensor into the socket of the storage tank.

11. use a #18 AWG four wire cable to connect the three way valve to terminals “1”, “2”, “3” and Ground as per ﬁ gure 18 where:

“1” = 120Vac Line for domestic side ”2” = Neutral “3” = 120Vac Line for heating side

WARNING!!! Since the indirect storage tank temperature sensor wires conduct 24 Vac, they must never be run through conduits containing 120 Vac power wires or an electrical shock hazard will exist.

WARNING!!! Once the boiler is connected to an indirect storage tank, it will perform a weekly antilegionella cycle. This cycle raises the storage tank temperature to 140°F one time per week.

Page 26

7 - INSTALLATION - Indirect storage tank connections

A = Front cover of the electrical box B = Plastic spring to open the electrical box C = Direction to open the electrical box D = Switches for the functional setting of the boiler

Figure 21 - Control board and junction box board details

Page 27

8 - INSTALLATION - Vent & combustion air

8.1 - Removing of a boiler from a common venting system

WARNING!!! DO NOT connect this boiler or any other appliance using a positive pressure, in a common vent system! Failure to comply with this WARNING could result in the accumulation of carbon monoxide gas which can cause severe personal injury or death!

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 appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the

common venting system.

(b) Visually inspect the venting system

for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deﬁ ciencies which could cause an unsafe condition.

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

(d) Place in operation the appliance

being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

(e)

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

(f) After it has been determined

that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, ﬁ replace dampers and any other gasburning appliance to their previous condition of use.

(g) Any improper operation of the

common venting system should be corrected so the installation conforms with the National Fuel Gas Code, ANSI Z223.1 /NFPA 54 and/or CAN/CSA B149.1, Natural Gas and Propane Instal-lation Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code, ANSI Z223.1 /NFPA 54 and/or CAN/CSA B149. 1, Natural Gas and Propane Installation Code.

Au moment du retrait d’une chaudière existante, les mesures suivantes doivent être prises pour chaque appareil toujours raccordé au système d’évacuation commun et qui fonctionne alors que d’autres appareils toujours raccordés au système d’évacuation ne fonctionnent pas: système d’évacuation

(a) Sceller toutes les ouvertures non

utilisées du système d’évacuation.

(b) Inspecter de façon visuelle le

système d’évacuation pour déterminer la grosser et l’inclinaison horizontale qui conviennent et s’assurer que le système est exempt d’obstruction, d’étranglement de fruite, de corrosion et autres défaillances qui pourraient présenter des risques.

fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés du 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 cuisinère 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.

(d) Mettre l’appareil inspecté en

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

(e) Faire fonctionner le brûleur

principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge. Utiliser la ﬂ amme d’une allunette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

(f) Une fois qu’il a été déterminé,

selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis à l’air libre de façor adéquate. Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz à leur position originale.

(g) Tout mauvais fonctionnement

du systéme d’évacution commun devrait étré corrigé de façon que l’installation soit conforme au National Fuel Gas Code, ANSI Z223.1/NFPA 54 et (ou) aux codes d’installation CSA-B149. Si la grosseur d’une section du système d’ évacuation doit étré modiﬁ ée, le système devrait étré modiﬁ 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 CSA-B149.

Page 28

8 - INSTALLATION - Vent & combustion air

8.2 - Venting systems

WARNING!!! The vent installation must be in accordance with Part 7, Venting of Equipment, of the latest edition of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 or section 7, Venting Systems and Air Supply for Appliances, of the CAN/CSA B149.1, Natural Gas and Propane Installation code or applicable provisions of the local building codes. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!! Under certain operating conditions the temperature of the boiler’s ﬂ ue gases may reach 230°F, (110°C). Use only the polypropylene vent piping supplied with the boiler or a vent system listed by a nationally recognized testing agency for the application. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

Horizontal vent runs must be

sloped upwards not less than 1/4 in/ft (21 mm/m), from the boiler to the vent terminal.

The vent system shall be installed

so as to prevent the accumulation of condensate. When horizontal vent runs exceed 5 ft (1.5m), they must be supported at 3 ft (0.98 m), intervals with overhead hangers.

Horizontal vent systems shall

terminate at least 4 ft (1.22 m) below, 4 ft (1.22 m) horizontally from any door, window or gravity air inlet into any building. It must not terminate less than 4 ft (1.22 m) horizontally from, and in no case above or below, unless a 4 ft (1.22 m), horizontal distance is maintained, from electric meters, gas meters, regulators and relief equipment and not less than 7 ft (2.3 m) from any adjacent public walkway. The bottom of the vent terminal(s) shall be located at least 5 ft (1.5 m) above the air intake terminal(s). Avoid terminal locations likely to be affected by winds, snowdrifts, people and pets. Item

unique to CANADA: vent system shall terminate at least 6 ft from electrical and gas meters.

Due to the high efﬁ ciency of the

boiler it may discharge what looks like white smoke especially when the outside air temperature is cold. This is a simply water vapor, a purely natural phenomenon and not a reason for concern.

The minimum clearance

measurement between two vent end terminations of this kind of boilers shall be not less than 18" (1 m).

WARNING!!! The exhaust vent and the air inlet lines (also in the coaxial version) must be supported to prevent sagging. To do this, use a suitable pipe clamp to support the lines. Pipe clamps shall support the line every 3 ft (1 m). Pipe clamp shall be ﬁ xed in correspondance of a wall stud. Improper supporting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

8.3 - Design of the venting system

This boiler can be ﬁ tted with a very long venting system. However there is a relationship between the length of the venting system and the power input of the boiler. Figure 22 shows this relation which and installer must consider when in the designing stage of the venting.

The maximum length of the Split 80/80PP vent system is 300 ft (Air intake plus ﬂ ue exhuast).

The maximum length of the concentric 60/100PP system is 70 ft.

Figure 22 - Relation between Power input and Vent system length

Each 45° elbow inserted in the concentric or split venting system, has a loss of pressure equivalent to 2.5 ft of linear pipe.

Each 90° elbow inserted in the concentric or split venting system, has a loss of pressure equivalent to 5 ft of linear pipe.

Boilers model 160OC and 160OB can be ﬁ tted only with coaxial venting system (see section 10.1)

Page 29

8 - INSTALLATION - Vent & combustion air

8.4 - Flue terminal location in compliance with CAN/CSA B149

Vent Termination Minimum Clearances

A = 12” clearances above grade, veranda, porch, deck or balcony B = 12” clearances to window or door that may be opened D = 18” vertical clearance to ventilated sofﬁ t located above the terminal within a horizontal distance of 2 feet (0.6 m) from the centre line of the terminal E = 18” clearance to unventilated sofﬁ t F = 9” clearance to outside corner G = 6” clearance to inside corner H = 4 ft (USA) not to be installed above a gas meter/regulator assembly within H horizontally from the centre line of the regulator H = 3 ft (CANADA) not to be installed above a gas meter/regulator assembly within H horizontally from the centre line of the regulator I = 3 ft (USA) clearance to service regulator vent outlet I = 6 ft (CANADA) clearance to service regulator vent outlet J = 9” (USA) clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance J = 12” (CANADA) clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other appliance K = 3 ft (USA) clearance to a mechanical air supply inlet K = 6 ft (CANADA) clearance to a mechanical air supply inlet L = 7 ft directly above a side-walk or paved driveway which is located between two single family dwellings and serves both dwellings unless terminated 7ft above sidewalk) M = 18” clearance under veranda, porch, deck or balcony (only permitted if veranda, porch, deck or balcony is fully open on a minimum of 2 sides beneath the ﬂ oor

clearance above paved side-walk or a paved driveway located on public property (a vent shall not terminate

Page 30

9 - INSTALLATION - Split venting system

9.1 - Split system (polypropylene) or AL29-4C (UL 1738/UL C 636) system

NOTE:This vent system is not available for 160OC and 160OB models

The boiler is not supplied with the ﬁ ttings needed for separate vent and combustion air systems. A special kit must be ordered to connect the boiler to separate vent and combustion air systems. Figure 23 shows ﬁ tting “A” that can freely turn 360 degrees for optimum installation versatility.

WARNING! Under certain operating conditions the temperature of the boiler’s ﬂ ue gases may reach 230°F , (110°C). Use only the polypropylene vent piping supplied with the boiler or a vent system listed by a nationally

Figure 23 - Installation of Split ﬁ tting system

recognized testing agency for the application. Improper venting can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

Pipes or elbows connected directly to the boiler, must be mechanically secure. Follow these instructions (make reference to ﬁ gure 24):

1. prepare the two collars “G” with springs “E” and “F”;

2. insert the collars “L” in hole “M”;

3. insert pipe “N” inside ﬁ tting “A”

4. tight the two collars “O” in a manner to mechanically secure pipe “N” to ﬁ tting “A”.

Horizontal vent sections must always

be pitched by at least 1/4 in/ft (21 mm/m) towards the boiler. Horizontal combustion air sections must always be pitched away from the boiler by at least 1/4 in/ft (21 mm/m) to prevent rain from entering the boiler. The vent and combustion air intake systems can be extended up to 300 ft. Each 90° elbow has is equivalent to 5 ft (1,5 m), of straight pipe. Each 45° elbow has is equivalent to 2.5 ft (0.75 m), of straight pipe.

Figure 24 - Connecting the pipes to the boiler

Page 31

9 - INSTALLATION - Split venting system

Horizontal vent systems should be

as short and straight as possible. The vent system must be both gas tight and watertight. All seams and joints must be joined and sealed in accordance with the vent system manufacturer’s instructions.

WARNING!!! Carefully follow the installation steps below for the assembling the split pipe venting system (elbows and extensions), as illustrated in ﬁ gure 25. it is necessary to properly insert the male side onto the female side and mechanically secure them by using the proper clamps. Improper venting can result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Figure 25 - Connecting extensions and elbows

Mechanically secure each joint with

the supplied clamps as shown in ﬁ gure 25. Follow this procedure:

1. insert the Male side “B” into the Female side “A”;

2. use clamp “C” to keep the two pipes together;

3. use screws “E” to tighten the clamp onto both pipes; DO NOT force.

CAUTION!!! If vent and air intake terminals are located on the same wall,maintain the distances given in ﬁ gure 26, between the vent and air intake, or ﬂ ue gas recirculation may occur, causing improper boiler operation!

CAUTION!!! The air intake terminal must be protected from wind by a 90° elbow, see ﬁ gure 26.

Figure 26 - Clearances of Split system

Page 32

9 - INSTALLATION - Split venting system

61302003

62617286

62617306

62617240

62617244

62617241

62617249

62617236

62617246

61302004

9.2 - Split system components

Some of the most commonly used components for installing the Split polypropylene vent and combustion air systems are listed below: 62617286 - No. 1 - Split adaptor 80/80 PP 62617236 - No. 2 - 3ft PP M/F extension 62617240 - 60 ft PP ﬂ exible extension 62617241 - Spacer for PP ﬂ exible extension 62617244 - No. 3 - 90° PP M/F in line elbow 62617246 - 45° PP M/F in line elbow 62617249 - No. 4 - Secure clamp for PP extensions 62617306 - No. 5 - Split vertical terminal 61302003 - No. 6 - Air intake grid 61302004 - No. 7 - Flue exhaust grid

Figure 27 - Interaxes of Split system

Note: the numbers after the codes correspond to the numbers in ﬁ gure 28

Page 33

9 - INSTALLATION - Split venting system

9.3 - Split system components

Some of the most commonly used components for installing the Split stainless steel vent and combustion air systems are listed here:

9.4 - Split system: installation examples

Three installation examples can be seen in ﬁ gure 28:

1. the ﬁ rst example shows the vent system directly penetrating the roof with the collection of condensation inside the boiler itself. The combustion air system must be pitched outward 1/4 in/ft (21 mm/m) to prevent rainwater from entering the boiler.

WARNING!!! Roof penetrations must be made according to the vent manufacturer’s instructions and prevailing codes. Failure to comply with this warning can result in a ﬁ re causing severe personal injury or death!

Terminal Type

Elbow Termination w/ Screen 9314TERM n/a 2SVSTEX0390

Tee Termination w/ Screen 9330TEE FSTT3 2SVSTTF-3

Mitered Termination w/ Screen 9390 n/a n/a

Screen Termination 9392 FSBS3 2SVSTPF-3

Air Intake Tee SC03TAD3 n/a n/a

3. the third example shows the vent system run through a dormant chimney but the vent is done by the ﬂ exible polypropylene pipe. Condensation is collected inside the boiler itself. The horizontal section of the vent system must be pitched 1/4 in/ft (21 mm/m) towards the boiler. The intake combustion air system must be pitched outward 1/4 in/ft (21 mm/m) to prevent rainwater from entering the boiler.

Heatfab

Saf T Vent

Part Number

WARNING!!! Under no conditions, shall this boiler vent gases directly into a masonry chimney , nor can an active chimney be used as a chase. Failure to comply with this warning can result in chimney or vent system failure causing excessive levels of carbon monoxide which can cause severe personal injury or death!

Pro Tech

FasNSeal

Part Number

Z FLex

Part Number

2. the second example shows the vent system run through a dormant chimney. Condensation is collected inside the boiler itself. The horizontal section of the vent system must be pitched 1/4 in/ft (21 mm/m) towards the boiler. The intake combustion air system must be pitched outward 1/4 in/ft (21 mm/m) to prevent rainwater from entering the boiler.

Figure 28 - Installation examples of the Split system (see section 9.2 for the reference of the numbers)

Page 34

10 - INSTALLATION - Coaxial venting system

10.1 - Coaxial system

The boiler is not supplied with the ﬁ ttings needed for connecting a coaxial vent/combustion air system. A special kit must be ordered to connect the boiler with the Coaxial polypropylene vent. Figure 30 shows how to install the Coaxial ﬁ tting above the boiler:

WARNING!!! Carefully follow installation steps below, for the coaxial pipe assembly (elbows and extensions), as illustrated in ﬁ gure 31. it is necessary to properly insert the internal and

B = Connection ﬂ ange C = Fixing feet D = Fixing screw F = Coaxial vertical adaptor

Figure 29 - Installation of the coaxial ﬁ tting

external pipe and mechanically secure them by using a stainless steel self tapping screw. Improper venting can result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

In particular:

1. slip-ﬁ t the extension “1” and “2” (see ﬁ gure 30) together;

2. drill a suitable hole “3” with a drill “4” (see ﬁ gure 30) in a position where the two pipes “1” and “2” are overlapped;

3. insert a suitable stainless steel self tapping screw “5” and tight it with a screwdriver “6”

It is recommended that wall sleeve

be used when installing the coaxial system through an exterior wall. This will allow the system to be easily slipped out for access during routine maintenance.

Horizontal coaxial systems must

always be pitched by at least 1/4 in/ft, (21 mm/m) towards the boiler.

The Coaxial system should extend

out of the wall to the dimensions shown in ﬁ gure 32.

Figure 30 - Secure ﬁ xing extensions and elbows together

Page 35

10 - INSTALLATION - Coaxial venting system

62617224

62617304

62617232

62617234

62617231

62617252

10.2 - Coaxial system components

The following coaxial polypropylene vent and combustion air system components are available, on request, for installing the Coaxial system

62617234 - No. 1 - In line 90° PP coaxial M/F elbow 62617252 - No. 6 - In line 45° PP coaxial M/F elbow 62617231 - No. 7 - 3ft (1m) PP coaxial extension 62617304 - No. 3 - PP coaxial roof end piece 62617232 - No. 5 - PP coaxial wall end piece 62617224 - No. 8 - PP straight coaxial adaptor

Note: the numbers after the codes correspond to the numbers in ﬁ gure 31.

Page 36

10 - INSTALLATION - Coaxial venting system

10.3 - Coaxial system components

Some of the most commonly used components for installing the coaxial stainless steel vent and combustion air system are listed here.

Terminal Type

Elbow Termination w/ Screen 9314TERM n/a 2SVSTEX0390

Tee Termination w/ Screen 9390TEE FSTT3 2SVSTTF-3

Mitered Termination w/ Screen 9390 n/a n/a

Screen Termination 9392 FSBS3 2SVSTPF-3

Horizontal Termination Adapter SC03HT n/a n/a

Heatfab

Saf T Vent

Part Number

Pro Tech

FasNSeal

Part Number

Z FLex

Part Number

10.4 - Coaxial system: installation examples

When a coaxial vent and combustion air system is installed, ﬁ gure 31, whether vertical or horizontal, it must be sloped 1/4 in/ft, (21 mm/m) towards the boiler.

the distances given in ﬁ gure 32, between the vent terminal and the wall and also between the vent terminal and the ground level (snow line). Maintain 3 ft distance also between the vent terminals of two or multiple boilers (see ﬁ gure 32).

CAUTION!!! Maintain

Figure 31 - Installation examples for the coaxial pipe (see section 10.2 for the reference of the numbers)

Figure 32 - Clearances for the coaxial vent terminal

Page 37

11 - OPERATING

11.1 - Operating

Before starting the boiler, the following must be done.

11.1.1 - User instructions

The user must be correctly instructed by the installer, on how to operate the boiler, in particular:

Make sure that the user keeps this

manual and all other documentation included with the boiler.

Make sure that the user

understands never to tamper with gas control settings and the risk of CO poisoning should an unauthorized individual do so

Make sure that the user is informed

of all the special measures to be taken for combustion air inlet and discharging ﬂ ue gases, and that these must not be modiﬁ ed.

Make sure that the user knows

how to adjust temperatures, controls and the room thermostats for maximum efﬁ ciency .

11.1.2 - Filling the condensate trap

The condensate trap is positioned inside the boiler as shown in ﬁ gure 1, item “46”. It must be ﬁ lled with water to prevent the leakage of ﬂ ue gases from the condensate drainpipe, item “41” in ﬁ gure 1. T o ﬁ ll the condensate trap proceed as follows:

1. unscrew “E” screw (Figure 33);

2. remove ﬂ ange “D” and O-Rings “C” (Figure 33)

3. With a rubber tube and a funnel, slowly pour approximately 4 oz. (100 ml), of water into the “B” opening - DO NOT put water into the “A” opening (Figure 33);

4. re-install ﬂ ange “D” and O-Rings “C” and reinstall screw “E” (Figure

33).

WARNING!!! If boiler stays off for more than 3 months, repeat the above operation to again ﬁ ll the condensate trap.

11.1.3 - Filling the heating system

To ﬁ ll the heating system, proceed as follows:

CAUTION! The heating system must be ﬁ lled with clean water from the domestic water system. Contaminated water can damage the boiler voiding its warranty.

CAUTION!!! The addition of any chemical substances, such as anti-freeze, must be carried out according to the product instructions. Read and follow instructions in sections 13.10 and

13.11 to prevent problems.

Figure 33 - Filling the condensate trap

1. open the automatic air vent, shown

as item “1” in ﬁ gure 1, two turns;

2. open the ﬁ ll valve located under

the boiler and proceed to ﬁ ll the heating system and boiler until the pressure gauge, item “30” in ﬁ gure 1, reads 20 psi (1.5 bar) and “FILL” disappears from the display;

3. check that there is no water leaking

from the ﬁ ttings. If there is the leaks must be eliminated;

4. close the ﬁ ll valve;

5. check the pressure gauge during

the purging process. If the pressure has dropped, re-open the ﬁ ll valve to bring the pressure back up to 20 psi (1.5 bar).

Figure 34 - Purge screw for the domestic hot water heat exchanger

Page 38

11 - OPERATING

11.1.4 - Filling the domestic hot water heat exchanger (160C and 160OC models only)

Once the heating system has been ﬁ lled and purged, the domestic hot water heat exchanger must be ﬁ lled as follows:

1. connect a rubber tube to the pressure coupling “A” shown in ﬁ gure 34 and place the end in an empty bucket or sink;

2. loosen screw “A” as shown in ﬁ gure 34 until air can be heard escaping;

3. once the water runs clear of air bubbles tighten screw “A”;

4. remove the tube and check that there are no water leaks.

11.1.5 – Auto-

purging the heating system

Each time the on/off power switch, item “34” in ﬁ gure 1, is switched on, an auto-purging cycle lasting 3 minutes begins. The auto-purging process involves the turning the pump on and off in order to remove any air trapped in the heating system. Before starting the auto-purging cycle the automatic air vent, item “1” shown in ﬁ gure 1 must be opened.

11.2 - General

warnings concerning gas supply

When starting up the boiler for the ﬁ rst time the following must be checked:

That the boiler is supplied with the

type of fuel that it is conﬁ gured to use. Read sections 11.3 and 11.4

That the gas supply pressure is

within the maximum and minimum values given in listed on the boiler rating plate. The gas supply pressure must be checked with boiler on and the boiler off.

That the gas supply system is

provided with all the safety devices and controls required under current national and local codes.

That the vent and combustion

air terminals are free from any blockages.

That the condensate drain tube is

properly connected.

WARNING!!! If you smell gas:

•

Do not try to light any appliance.

• Do not touch any electrical switch. Do not use any phone in your building.

•

Immediately call your gas supplier from a neighbor’s phone. Follow the gas supplier’s instructions.

• If you cannot reach your gas supplier, call the ﬁ re department. Failure to follow the above steps can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

11.3 - Conﬁ rming the boiler’s gas type

The type of gas and the gas supply pressure that the boiler is set up for is listed on the rating label.

The boiler can operate using one of the following two gases:

NATURAL GAS

Maximum supply pressure = 11 in.W.C. (27.5 mbar). Minimum supply pressure = 1.5 in.W.C. (3.8 mbar).

LP Gas

Maximum supply pressure = 13 in.W.C. (32.5 mbar). Minimum supply pressure = 8 in.W.C. (20 mbar).

11.4 - Gas type conversion

If the gas available at the installation site is not the type the boiler is conﬁ gured to use, the boiler must be converted. Special conversion kits

are available for this purpose. The instruction inside the conversion kit must be followed.

WARNING!!! Conversion of the boiler to use another type of gas must be carried out by a qualiﬁ ed technician. Improper conversion of the gas valve could result in a ﬁ re or an explosion causing severe personal injury or death!

11.5 - Start-up

1. Open the manual gas shut off valve, ﬁ gure 15 and 16, item “3”.

2. Switch the on/off power switch, item “34” in ﬁ gure 1, to “on”.

3. If the display shows code E 21, it means that the polarity has not been observed between the hot and neutral wires. If this happens the wires must be switched.

Upon start-up, an is shown for 2-3 minutes while the boiler goes through its heating system purge cycle as described in section 11.1.5. To by-pass stage, press the and keys together until a blinking appears. Then press the button.

5. Rotate knobs “32” and “33” shown in ﬁ gure 1 to the desired temperature.

6. The boiler will ﬁ re only when the room thermostat calls for heat. If an external temperature sensor is connected, check that the temperature calculated is higher than the minimum running temperature as explained in section 12.10.

7. If the pump indicator is illuminated, item “6” in ﬁ gure 40, but the pump is not running, item “45” in ﬁ gure 1, it may be stuck. If this is the case it can be released by removing screw “44” shown in ﬁ gure 1 and turning the screw underneath.

8. If the pump indicator is illuminated but the heating system does not heat up, repeat the air purging operations on both the boiler and the heating system.

this

Page 39

11 - OPERATING

11.6 - Ignition control testing

After placing the boiler in operation, the ignition control’s safety shutoff function must be tested as follow:

1. turn the power switch (item “34” in ﬁ gure 1) to on;

2. close the room thermostat to create a call for heat;

3. turn knobs “32” and “33” in ﬁ gure 1 to their maximum position;

4. wait a few minutes for the burner to light-up as indicated when light “3” shown in ﬁ gure 40 stays illuminated.

5. close the manual gas shutoff valve, see ﬁ gure 15 and 16, item “3”;

6. after 40 seconds, the display must show L01;

7. open the manual gas shutoff valve, see ﬁ gure 15 and 16, item “3”;

8. verify your gas meter, gas ﬂ ow must be zero.

WARNING!!! If gas ﬂ ow occurs, close the manual gas shutoff valve and troubleshoot the system to determine why there is gas ﬂ ow when the gas valve should be deenergized. Do not operate the boiler until the problem is resolved or a ﬁ re or explosion causing property damage, personal injury or loss of life may occur!

11.7 - Gas supply

pressure checking and adjustment

The gas supply pressure must match that listed on the boiler rating label. Check the gas supply pressure by following the steps below:

1. close the manual gas shut off valve, ﬁ gure 15 and 16, item “3”;

2. follow the steps in section 13.2 to remove the front cover;

3. turn the screw in pressure port “D” shown in ﬁ gure 35 three turns counterclockwise;

4. connect a manometer with graduations of at least 0.1 in.W.C. (0.25 mbar) to the inlet gas port “D” shown in ﬁ gure 35;

5. open the manual gas shut off valve, ﬁ gure 15 and 16, item “3”;

6. check that the gas supply pressure does not exceed the “maximum gas supply pressure” as stated in section 14;

7. turn the power switch to on and generate a heat demand by turning knob “33” shown in ﬁ gure 1 to its maximum setting. Also ensure that the room thermostat is calling for heat;

8. press the and keys at the same time for more than 10 seconds, the display will show

press the

9. key until the display shows . Now the boiler will run for 10 minutes at maximum input;

10. check the manometer to make sure the gas supply pressure does not drop below the “minimum gas supply pressure” as stated on section 14. If the gas supply pressure does not fall within the above values, adjust the upstream gas pressure regulator to bring the gas supply pressure within the maximum and minimum range listed on section 14.

After verifying the correct gas pressures disconnect the manometer, turn the screw in pressure connection “D” in ﬁ gure 35, clockwise until snug and check for any gas leaks.

CAUTION!!! Never force the pressure connection screw or the gas valve will be damaged!

WARNING!!! Never use an open ﬂ ame to check for gas leaks, a ﬁ re or an explosion could result causing severe personal injury or death!

;

C - Service pressure port D - Inlet gas pressure port E - High ﬁ re, CO2 adjusting screw F - Low ﬁ re, CO2 adjusting screw

Figure 35 - Gas valve

Page 40

11 - OPERATING

Figure 36 - Combustion air pressure probes

11.8 - Check the combustion air pressure

The boiler has a factory-set air/gas ratio. The pressure of the gas at the burner is indirectly controlled by the blower. The combustion air pressure must be checked as follows while refering to ﬁ gures 36 and 37:

1. use a differential manometer with a precision of at least 0.1 in.W.C. (0.25 mbar);

2. close the manual gas shut off valve, ﬁ gure 15 and 16 item “3”;

open the boiler casing following section 13.2;

4. press the two plastic spring tabs labeled “B” shown in ﬁ gure 21 and rotate the electrical box;

5. remove plug “B”;

6. turn pressure probe screw “C” one turn counterclockwise;

insert tube “F”, from the negative side of the manometer, through the opening of plug “B”, and connect it to pressure probe “C” as shown in ﬁ gure 36;

8. remove plug “A” from the pressure probe and connect the differential positive side of the manometer to it;

9. the manometer connections must be made as shown in ﬁ gure 37, to get the correct pressure reading;

10. replace panel “H” of ﬁ gure 44 and latch it closed. If panel “H” is not properly in place the manometer reading will not be accurate;

11. turn the power switch to on, item “34” in ﬁ gure 1;

12. press the and keys together for more than 10 seconds, until a blinking is displayed;

13. the combustion blower will run at maximum speed for 10 minutes. During this time the burner will not light;

14. compare the pressure on the manometer with the table in section 14 TECHNICAL DATA, “Combustion air pressure”. The combustion air pressure reading should be within ± 0.3 in.W.C. (0.75 mbar);

15. if the combustion air pressure is too low, check that there are no obstructions in the combustion air and vent systems. Also make sure that panel “H” is properly sealed;

16. if the combustion air pressure is within tolerance press the button to return the boiler to its normal running mode;

17. once the combustion air pressure check has been performed, disconnect the manometer, close pressure probe screw “C”, close the boiler casing, turn the manual gas shut off valve on and proceed with the check and adjustment of CO2, section 11.9.

Figure 37 - Checking the combustion air pressure

Page 41

11 - OPERATING

11.9 - Checking and adjusting CO2 levels

Section 14 lists the correct CO2 ranges for a boiler running at normal operating conditions at an altitude below 3000 ft (1000m). CO2 values outside of the ranges given in section 14 may lead to malfunctioning of the boiler and cause it to prematurely fail. To check the CO2 value, carry out a combustion analysis as follows while referencing ﬁ gure 38:

1. carefully remove items “E”, “D” and “C” from the combustion air/ vent ﬁ tting:

2. generate a call for heat or, if this is not possible, fully open a hot water faucet;

A = air probe B = ﬂ ue gases probe C = O-ring gaskets D = probes cap E = ﬁ xing screw

Figure 38 - Combustion analysis probes

3. press the for more than 10 seconds, the display will show a blinking

4. press the key until the display shows if a call for heat has been generated or until is displayed if a domestic hot water demand has been generated. The boiler will now run for 10 minutes at low ﬁ re input.

5. wait 2 to 3 minutes for the CO2 to stabilize;

6. insert the probe of a calibrated combustion analyzer into port “B” and take a ﬂ ue gas sample;

7. compare the CO2 reading with the low ﬁ re range given in section 14 making sure to use the range for the gas type in use. If the CO2 reading is outside the speciﬁ ed range, it must be adjusted.

To adjust the low ﬁ re CO2 proceed as follows:

1. use a screwdriver to remove the gas valve cap, item “F” in ﬁ gure 35;

2. turn the regulator screw found under cap “F” clockwise to increase the CO2, counter-clockwise to decrease the CO2;

3. turn the regulator screw in small increments and wait for the CO2 to stabilize to prevent overshooting the desired value:

4. replace the gas valve cap, item “F” in ﬁ gure 35;

5. seal screw “F” with red paint or nail polish to discourage tampering.

WARNING!!! Compare also CO (carbon monoxide) reading, with the value given in section 14. If this is higher STOP the boiler and call the service department (see phone number on the last cover page)

and keys

;

Now check and, if necessary, adjust high ﬁ re CO2:

6. press the until the display shows if a call for heat has been generated or until is displayed if a domestic hot water demand has been generated. The boiler will now run for 10 minutes at high ﬁ re input;

7. wait 2 to 3 minutes for the CO2 to stabilize;

8. insert the probe of a calibrated combustion analyzer into port “B” and take a ﬂ ue gas sample;

9. compare the CO2 reading with the high ﬁ re range given in section 14 making sure to use the range for the gas type in use. If the CO2 reading is outside the speciﬁ ed range, it must be adjusted.

To adjust the CO2 proceed as follows:

1. use a screwdriver to turn screw “E” shown in ﬁ gure 35;

2. turn screw “E” clockwise to reduce the CO2, counter-clockwise to increase the CO2;

3. turn screw “E” in small increments and wait for the CO2 to stabilize to prevent overshooting the desired value:

4. seal screw “E” with red paint or nail polish to discourage tampering;

5. press the button to return the boiler to its normal operating mode.

WARNING!!! Compare also CO (carbon monoxide) reading, with the value given in section 14. If this is higher STOP the boiler and call the service department (see phone number on the last cover page

NOTE: During the 10 minutes override mode, if the demand on the boiler is low causing the ﬂ ue gas temperature to increase rapidly. Boiler will go into lock out code L06. To reactivate it, press button.

key

Page 42

11 - OPERATING

11.9.1 - Checking and adjusting CO2 levels without CO2 meter

WARNING!!! This is an emergency procedure: after the sequent procedure you must back, as soon as possible, on the boiler, with a combustion analyzer, to compare the CO (carbon monoxide) content with the reading on section 14. If CO (carbon monoxide) is higher STOP the boiler and call the service department (see phone number on the last cover page).

The ionisation current value is directly related to the CO2 value. Therefore,If you are not in possession of a CO2 meter, you can use the ionisation current value to correctly adjust the CO2 value.

To do so, follow section 11.9 and instead of comparing the CO2 value, compare the right side of the display (ionisation current value) with the corrisponding “ionisation current” value in section 14.

Because the reading of the ionisation current is not a ﬁ xed value but can vary ± 3, you must compare the average value of the ﬂ uctuation, with the value in section 14 (see also section 13.12.4).

11.10 - Adjusting the heating capacity

This boiler has been engineered with an “intelligent” micro-processor control that will adjust the heating output to match the system demand. To maximize the effectiveness of the system, the parameters found in the “Installers menu”, in section 12.17, can be adjusted set the maximum heating output to the effective maximum load necessary for the system. The parameter can be adjusted from 100 (factory set value), to 1. The correspondence between value and heating output is given by table in ﬁ gure 39.

NOTE: This setting, adjusts the heating input only. The domestic output is always 160,000 btu/hr for every value.

11.11 - Domestic

hot water ﬂ ow rate adjustment (160C and 160OC models only)

The volume of domestic hot water that the boiler can produce, depends on the ﬂ ow rate of the domestic water system. If the ﬂ ow rate is too high, the water will move through the heat exchanger without being adequately heated. It is therefore advisable to carry out the following adjustments:

1. switch the on/off power switch, item 34 in ﬁ gure 1, to “on”;

2. adjust control “32” as shown in ﬁ gure 1, to 130 °F (50 °C);

3. fully open a hot water faucet. If a mixing type faucet with single lever is opened, the position must be fully to HOT;

4. set the mixing valve (item “10” of ﬁ gure 15 to its maximum values)

5. wait 5 minutes for the temperature to stabilize;

6. if the water temperature is too low, reduce the water ﬂ ow using a ﬂ ow restrictor (item “12” of ﬁ gure

15) until reaching the desired temperature (turn the ﬂ ow restrictor in small increments and wait for the temperature to stabilize to prevent overshooting the desired value).

NOTE: Water ﬂ ow should generally be regulated according to the values given in section 14, under the heading “instantaneous d.h.w. production (rise 75 °F (42 °C))”.

*Factory set heat input, to adjust see section

11.10.

Figure 39 - Correspondence table to set space heating input

11.12 - Cold start

boiler

The boiler has a “cold start” mode. Any time the room thermostat opens, (no call for heat) the burner stops immediately. However even with the room thermostat contact open, the boiler will still run for freeze protection as described in section 12.14.

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1 - Display of the parameters 2 - Display of the paramenters value. 3 - Light indicates the burner state:

Light-on = Burner ON; Blinking = Burner OFF.

4 - Light indicating DHW service:

Light-on = DHW service ON;

Light-off = DHW service OFF. 5 - Light indicates the decimal. 6 - Light indicates CH service:

Light-on = CH service in function;

Light-off = CH service not function. 7 - Heating temperature control. 8 - Key for decreasing

parameter values. 9 - Key for resetting shutdowns and

for scrolling the list of parameters. 10 - Key for increasing

parameter values. 11 - Domestic hot water

temperature control. 12 - On/off power switch. 13 - Heating circuit pressure gauge.

Figure 40 - Instrument panel

12.1 - Check Heating system pressure

If the pressure inside the heating circuit falls below 7psi (0,5 bar), the appliance switches off and the display “1” as per ﬁ gure 40, shows

to indicate that it is necessary to restore the correct pressure. Proceed as follows:

1. open the ﬁ lling cock;

2. check the pressure on the pressure

gauge “13” of ﬁ gure 40, it must reach a pressure of 20 psi (1,5 bar) and the indication must disappear;

3. close the ﬁ lling cock.

CAUTION!!! During normal operations, the ﬁ lling cock must always remain in the closed position.

If, with time, the pressure drops, restore the correct value. This operation may have to be repeated several times during the ﬁ rst month of operations to remove any gas bubbles present.

12.2 - Overview

The boiler is pre-set with standard parameters. However, it is possible to make a number of changes or consult the parameters by means of using the “Users’ Menu” (see section 12.16). During functioning display “1” of ﬁ gure “40” displays the status of the boiler and display “2” (see ﬁ gure 40) shows the value of the parameter. The various operating statuses are shown in section 12.18.

Within the “Users’ Menu” (see section

12.16) it is possible to check the last lock-out or error which have occurred. In addition to the operating modes, the instrument panel provides important information on the current functioning of the boiler, via theindicators “3”, “4”, “5” and “6” of ﬁ gure 40. In particular:

- the indicator “3” displays whether the burner is functioning (on) or whether it is off (blinking);

- the indicator “4” displays whether the domestic hot water service is on or off;

- the indicator “6” displays whether a heating service request is active (on) or nor (off).

12.3 - Displays

During normal operations, the parameters’ display “1” and the values’ display “2” (see ﬁ gure 40) remain permanently on, if the ”Energy Saving” mode has not be activated (See section 12.15).

The parameters which can be displayed are shown with their meaning in table shown in section

12.18.

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12.4 - Start-up procedure

1. Open the manual shutoff gas valve;

2. switch on electric power to the boiler;

3. If the display shows code E21, it means that the polarity has not been observed between phase

and neutral;

4. on initial start-up, the appliance carries out an auto-purging cycle

lasting two minutes. This is indicated by the appearance of on the display;

5. wait two minutes until the end of

the auto-purging cycle;

6. turn knob “7” of ﬁ gure 40 until it reaches the heating temperature desired. Turn knob “11” of ﬁ gure 40 until it reaches the domestic water temperature desired.

The ﬂ ame control appliance will startup the burner.

If the burner fails to ignite within 15 seconds, the boiler will automatically attempt ignition another three times, after which if it fails to start-up, it will shut down and the display will show 01.

Press the button in order to re-set normal operating conditions. The boiler will automatically attempt another start-up.

CAUTION!!! If the appliance frequently shuts down, contact a qualiﬁ ed technician to restore

normal running conditions.

Now the boiler will continue to operate in relation to the service requested and will indicate the following on display “1”:

if a domestic water request is

active;

if a heating request is active;

- if there is no domestic water or

heating request active.

12.5 - Summer mode

To disable the heating functions for a prolonged period, leaving only the domestic hot water function, switch OFF the heating temperature, until the wording OFF appears, by turning knob “7” of ﬁ gure 40 to the minimum.

12.6 - Winter mode

In Winter mode, by means of the pump, the boiler sends the water to the system at the temperature set using knob “7” of ﬁ gure 40. When the temperature inside the boiler reaches the temperature set, the burner starts to modulate the ﬂ ame so as to reduce the output to a minimum. If the temperature rises further, the burner shuts down. Simultaneously, the pump which sends the water to the system is switched on and off by the room thermostat. This can be noted, because indicator “6” of ﬁ gure 40 switches on and off in correspondence with the on and off of the pump. At ﬁ rst the pump may make a noise. This is due to the presence of residual air in the hydraulic system which will soon disappear on its own. We recommend keeping the temperature set using knob “7” at the point shown by the symbols on the panel for a rational use of the boiler. If it is a particularly cold Winter and it is difﬁ cult to maintain the desired temperature, turn knob “7” to gradually higher values.

12.7 - Adjusting the domestic hot water temperature

The domestic hot water temperature is adjusted by turning knob “11” shown in ﬁ gure 40. When the knob is turned, the display, item “1” in ﬁ gure 40, shows a ﬂ ashing and the temperature being selected. The range within which the domestic hot water can be set is 104°F (40°C) to 140°F (60°C) or from 104°F (40°C) to 158°F (70°C) when an indirect storage tank is used.

12.8 - Heating system temperature adjustment

The boiler provides hot water to the heating system at the temperature set by adjusting knob “7” as shown in ﬁ gure 40. The room thermostat turns the boiler’s circulator pump on in order to satisfy the heat demand of the rooms controlled by the thermostat. T o maximize the boilers’ performance, temperature knob “7” should be set at a value that is just sufﬁ cient to maintain the desired temperature of the rooms. As the weather gets colder , progressively increase the water temperature by adjusting knob “33” When the weather gets milder turn the water temperature down. This extremely simple method is suitable for the following types of systems: A - small systems with radiators where

the thermostat is installed in a room whose temperature is characteristic of all the other rooms;

B - large systems with radiators,

where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisﬁ ed.

C - large systems with low tempera-

ture radiant panels, where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisﬁ ed.

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CAUTION!!! If the boiler is installed in a low temperature system follow the settings speciﬁ ed in section 5.9 or the heating system may be damaged.

12.9 - Heating system type selection

The boiler is factory set for wall stat control as per section 12.8. The heating system type can be changed by going to the “Installers’ Menu” in section

12.17 and changing the parameter. One of the three following heating modes can be selected:

-CH = 00 “Wall stat control”: follow section 12.8;

-CH = 01 “Outdoor reset control”: follow section 12.10 (an outdoor temperature sensor is required);

-CH = 02 “Outdoor reset control with room compensation control”: follow section 12.10 to 12.10.6 (an outdoor temperature sensor is required):

12.10 - Outdoor reset adjustment

While in the “Installers’ Menu”, set the

parameter to 01. In this mode the heating supply water temperature, calculated temperature in ﬁ gures 41 and 42, will be adjusted automatically based on the input from the outdoor temperature sensor. The relationship between the outdoor temperature and the supply water temperature, corresponds with the graphs shown in ﬁ gures 41 and 42. In order to change the relationship between the supply water temperature and the outdoor temperature, all the parameters listed in the sections below must be set.-

12.10.1 - Outdoor reset applications

Outdoor reset is a sophisticated way to maximize comfort and boiler efﬁ ciency. It is suitable for the following system types: A - small systems, with radiators

where the thermostat is installed in a room whose temperature is characteristic of all the other rooms. The room thermostat is used to turn the boiler on and off.

B - Iarge systems, with radiators,

where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisﬁ ed (see to an appropriate electrical system).

C - small systems, with low temper-

ature radiant panels where the thermostat is installed in a room whose temperature is characteristic of all the other rooms. The room thermostat is used to turn the boiler on and off. In this type of system it is necessary to consider that the radiant panel systems sometimes have long lag times. It may be necessary to adapt the heating system and use the “Reaction”

parameter in order to

compensate.

D - Iarge systems with low temper-

ature radiant where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisﬁ ed.

CAUTION! If the boiler is installed in a low temperature system, follow the settings speciﬁ ed in section 5.9 or the heating system may be damaged.

12.10.2 - Outdoor reset adjustment precautions

When making adjustments to change the supply temperature, it is advisable to ﬁ rst set the suggested default values for the desired curves shown in ﬁ gures 41 and 42. If these default values do not produce a satisfactory result, then proceed to make the appropriate adjustments bearing in mind that: A - each parameter must be very

gradually;

B - after each parameter change, wait

at least 24 hours in order to see the result;

C - the closer the adjustment curve

matches the actual load of the building, the greater the comfort and the energy savings will be;

D - knob “37” in ﬁ gure 40 can be used

to make the small line shifts, “b”, shown in ﬁ gures 41 and 42. These shifts will change the supply water temperature up to 18°F (10°C).

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12.10.3 - Outdoor reset: setting parameters

Refer to section 12.16 and set:

- = “The angle of the curve”, which can be adjusted

between 0.1 and 5.0. Suggested starting values are: 0.6 for “low temperature” systems; 1.6 for “high temperature” systems;

- = “Minimum heating

temperature”. When the calculated temperature drops below this value the heating service stops. The range of adjustment is between 68°F (20°C) and 140°F (60°C). The suggested starting values are: 86°F (30°C) for “low temperature” systems; 104°F (40°C) for “high temperature” systems;

- = “Maximum heating

temperature”. This parameter is the limit of the supply heating temperature. Its range of adjustment is between 86°F (30°C) and 194°F (90°C). The suggested starting values are: 113°F (45°C) for “low temperature” systems; 176°F (80°C) for “high temperature” systems.

Refer to section 12.17 and set:

- = “Reaction” of the

calculated temperature with respect to the outdoor temperature input. The range of adjustment is between 1°F (1°C ) and 18°F (10°C). A low “Reaction” value results in a constant dwelling temperature but extended time in reaching full running conditions and responding to outdoor temperature changes. A high “Reaction” value results in reaching full running conditions quickly, but may cause oscillations in the dwelling temperature. It is advised to maintain a “Reaction” value between 1 and 2;

- = “Fix point” is the heating

calculated temperature, when the outdoor temperature is 68°F (20 °C). It is called “Fix Point” because it is also the angle fulcrum of the curve. The suggested starting values are: 92°F (33°C) for “low temperature” systems 122 °F (50°C) for “high temperature” systems.

12.10.4 - Outdoor reset: zone adjustments

The default values previously suggested are for boilers using an outdoor temperature sensor installed in dwellings with average heat loss in areas where the outside temperature for the calculation of the heat requirement is 23°F (-5°C). In the event that the climatic zone is different, adjust the gradient of the curve, parameter , to obtain a calculated temperature of 176°F (80°C) for high temperature systems, see Figure 41. For “Low Temperature” systems adjust the gradient of the curve, parameter , to obtain a calculated temperature of 113°F (45°C), see Figure 42.

12.10.5 - Outdoor reset activation

Once selected, reset adjustment is completely automatic and will switch off at the end of the heating season and switch back on at the beginning of the heating season. When the “Calculated temperature” is lower than the “Minimum heating temperature”, parameter , the heating service switches off. When the “Calculated temperature” exceeds the “Minimum heating temperature”, parameter , the heating service switches back on. If for some reason the heating service doesn’t match the load, use knob “7” in ﬁ gure 40, to raise or lower the calculated temperature and match the “Minimum heating temperature” on an advanced or delayed basis.

12.10.6 – Outdoor reset with room compensation

While in the “Installers’ Menu” (Section 12.17) set the parameter to 02. The system will function exactly as described in the previous “Outdoor reset adjustment” sections except that now the boiler pump will stay on permanently. The opening of the room thermostat contacts will translate into a parallel downward movement of the curve in ﬁ gure 41 or 42. The value by which the curve moves downwards can be adjusted by the parameter present in the “Installers’ Menu”, see section 12.17. The parameter can range from 1°F (1°C) to 36°F, (20°C). The suggested values for this parameter are:

- 18°F (10°C) for high temperature radiator systems;

- 6°F (3°C) for low temperature radiant panel systems

V alues of this parameter that are too high may translate into room temperature instability . V alues that are too low may make the action of the room thermostat ineffective. Climatic adjustment with room compensation can be used in all the systems described in section

12.10.1. The advantage being that the constant running of the pump will stabilize and standardize the room temperatures. This is especially true when some loops in the heating system have considerably greater volume than others.

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Calculated temperature (°F)

Calculated temperature (°C)

Calculated temperature (°F)

Calculated temperature (°C)

Outside temperature (°C)

Outside temperature (°F)

OA = Slope of the line Ob = Minimum heating temperature Oc = Maximum heating temperature br = “Fix point” of the angle fulcrum of the line b = parallel shift of the line (adjusted by the heating knob, item “7” of ﬁ gure 40)

Outside temperature (°C)

Outside temperature (°F)

Figure 41 - Graphs of the outdoor reset adjustment for “high temperature” systems

Calculated temperature (°C)

Calculated temperature (°F)

OA = Slope of the line

Outside temperature (°C)

Ob = Minimum heating temperature

Outside temperature (°F)

Oc = Maximum heating temperature br = “Set point” of the angle fulcrum of the line b = parallel shift of the line (adjusted by the heating

Calculated temperature (°F)

Calculated temperature (°C)

knob, item “7” of ﬁ gure 40)

Outside temperature (°C)

Outside temperature (°F)

Figure 42 - Graphs of the outdoor reset adjustment for “low temperature” systems

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12.11 - Boiler switch settings

The control board shown in ﬁ gure 1, item “14”, and ﬁ gure 22, contains a series of switches that allow the boiler to be conﬁ gured to match the application. The table below lists each switch and its corresponding funtions.

SWITCH Position Description

1 OFF Boiler with production of instantaneous D.H.W. ON Boiler with production of D.H.W. via storage tank 2 OFF Boiler with production of instantaneous D.H.W. ON Position not available for this serie of boilers 3 OFF Heating pressure switch, Low Water Cut Off, disabled ON Heating pressure switch, Low Water Cut Off, enabled 4 OFF EBM PAPST brand fan ON Position not available for this serie of boilers 5 OFF Combination boiler for heating and D.H.W. ON Boiler for heating only 6 OFF High temperature heating service, 86°F (30°C) and 176°F (80°C) ON Low temperature heating service, 68°F (20°C) and 113°F (45°C) 7 OFF Boiler conﬁ guration change, disabled ON Boiler conﬁ guration change, enabled 8 OFF Maximum heating supply water temperature of 176°F (80°C) ON Maximum heating supply water temperature of 189°F (87°C)

12.12 - Delays,

of these switches could cause the boiler to malfunction resulting in improper system performance. Only a qualiﬁ ed technician, with an in-depth knowledge of the boilers’ control system, should change them.

e - Time delay in restarting the burner:

alarms and protective actions

To protect the life of the appliance, improve comfort, and maximize energy savings, the following timings have been incorporated into the control logic: a - Pump delay: each time the room

thermostat is satisﬁ ed, the circulator pump continues to run for 1 minute;

b - DHW delay: each time the

domestic hot water demand is satisﬁ ed, a 2 minutes delay must pass before the heating service is allowed to restart;

c - Protection against legionnaires

bacteria: if the boiler is connected to a DHW storage tank the boiler will increase the tank temperature to 140°F (60°C) every seven days, prevent the formation of legionnaires bacteria. This function is displayed by .

d - DHW alarm: if the call for

domestic hot water lasts for longer than two hours, an 01 alarm is generated. This function is only for boilers set up to provide instantaneous DHW.

12.13 - Circulator pump and three way valve protection

During the summer months, the circulator is run once a day for around 15 seconds to prevent it from seizing. At the same time, the three way valve (if present) is activated for the same reason.

12.14 - Freeze protection

protection function to work, the boiler must remain connected to the electrical and gas supplies with knobs “7” and “11” in ﬁ gure 40, in the OFF position.

CAUTION!!! Improper setting

in its normal functing state, except when providing domestic water, every time the burner stops, there is a delay time of 3 minutes before the boiler restarts again.

CAUTION!!! For the freeze

Once the boiler has reached a temperature of 45 °F (7°C), the heating pump will automatically comes on. Boiler is built in with its own by-pass valve (see ﬁ gure 2, item “15”, against any closed zone vale). If the temperature falls below 35°F (2°C), the burner will light to prevent the boiler from freezing. If the boiler will not be used for more than a year it should be drained per sections 13.10 and 13.11.

12.15 - Display in energy saving mode

If desired, the display, items “1” and “2” in ﬁ gure 40, can be switched permanently off, with the exception of when it displays errors or settings. To switch the display off, access the “Installers’ Menu”, in section 12.17 and set the parameter at a value other than zero. Keep in mind that each value will correspond to a delay in minutes until the display goes into Energy Saving mode.

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12.16 - “Users’ menu”

When entering the “Users’ menu”, the display, item “1” in ﬁ gure 40, will start blinking indicating that a change of mode has taken place. To access the “Users’ menu” (see also section 16 to better understand the several menus):

1. press the button for 2

seconds until the display starts blinking;

2. press and release the button

several times until the desired parameter is displayed;

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” of ﬁ gure 40

Adjustment of the curve angel as shown in ﬁ gures 41 and 42 when outdoor reset is active per section 12.9.

3. use the change the value of the selected parameter.

4. press change before going to the next parameter.

When the last parameter has been reached and the button pressed, the display will stop blinking indicating exit from the menu.

or keys, to

to save the parameter

Setting range: 0,1 to 5,0

NOTE: If no key is pressed for more than 60 seconds, the control automatically exits the “Users’ menu”. Any parameter change not saved using the button, will be lost.

The table below lists each “Users’ menu” parameter, what it affects and its adjustment range.

Adjustment of the “Minimum heating temperature” as shown in ﬁ gures 41 and 42 when outdoor reset is active per section 12.9.

Adjustment of the “Maximum heating temperature” as shown in ﬁ gures 41 and 42 when outdoor reset is active per section 12.9.

Adjustment of the parallel shift of the curve as shown in ﬁ gures 41 and 42 when outdoor reset is active per section 12.9.

Display of the calculated heating temperature when outdoor reset is active per section 12.9, or display of the temperature set by knob “7” shown in ﬁ gure 40.

Display of the domestic hot water temperature when set by knob “11” shown in ﬁ gure 40.

Display of last error code registered, section

12.18.2

Setting range: see section 12.10.3

The adjustment is made by turning knob “7” shown in ﬁ gure 40. The selected curve can be shifted up or down by 18°F (10°C).

Temperature display only with a range between 68°F (20°C) and 189°F (87°C).

Temperature display only with a range between 104 °F (40°C) and 158°F (70°C), see section 12.7

Error code display per section 12.18.2

Display of last lockout occurred, section 12.18.1

Fault code per section 12.18.1

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12.17 - “Installer’s menu”

CAUTION!!! Changing these parameters could cause the boiler and therefore the system to malfunction. For this reason, only a qualiﬁ ed technician who has in-depth knowledge of the boiler should change them.

The boiler’s micro-processor makes this menu of parameters available to the qualiﬁ ed technician for the analysis of the functioning and adjustment of the appliance to the system. When entering the “Installers’ Menu”, the display item “1” in ﬁ gure 40, will start to blink indicating that a change of mode has taken place. To access the “Installers’ Menu” just (see also section 16):

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” of ﬁ gure 40

1. press the button down for 12 seconds until the parameter is displayed;

2. press and release the button to scroll through the list of the parameters;

3. once the parameter has been displayed, it can be changed using the or keys;

4. press and release the button to conﬁ rm the amended data before moving to the next parameter.

When the last parameter has been reached and the button pressed, the display will stop blinking indicating an exit from the menu.

NOTE: If no key is pressed for more than 60 seconds, the control automatically exits the “Installers’ menu”. Any parameter change not saved using the button, will be lost.

The next table lists each “Installers’ menu” parameter, what it affects and its adjustment range.

Boiler and heating supply temperature, measured by U1 sensor

Domestic hot water temperature, measured by U2 sensor

Domestic cold water (or storage tank) temperature, measured by U3 sensor

Outdoor temperature, measured by U4 sensor

Ionization current value

High limit temperature, measured by U6 sensor

Flue gas temperature, measured by U7 sensor

Heating return temperature, measured by U8 sensor

Type of basic setting of control board

Value in °F (cannot be changed)

Value in °F (cannot be changed) (displayed only if outdoor reset is active, as per section 12.9)

Value from 0 to 99 (cannot be changed) (30 corresponds to a current of 1uA) (99 corresponds to a current of 5.5 uA)

Value in °F (cannot be changed)

Can be changed in accordance with the instructions indicated in the gas conversion kit

Status of room thermostat contact

Measurement of fan speed rotation

00 = contact open (heating service off) 01 = contact closed (heating service on)

Value in g/1’/100 (rpm/100) (cannot be changed)

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Continued

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” of ﬁ gure 40

BTU input for heating service

Heating service funtioning mode

Reaction to external temperature

Angle fulcrum of climatic adjustment

Reduction of temperature generated by the opening of the room thermostat

Boiler knobs’ status

Display “1” and “2” as per ﬁ gure 40 energy saver

Adjustable according to the instructions of section 11.10

Can be changed: 00 = thermostatic adjustment (sse section 12.8); 01 = outdoor reset (see section 12.10); 02 = outdoor reset with room compensation

(see section 12.10.6);

Can be changed from 1 to 10 (active only with outdoor reset). See section 12.10.1 for its adjustment.

Can be changed for 16°F (-9°C) to 149°F (65°C) (active only with outdoor reset). See section

12.10.3 fort its adjustment. Can be changed from 1°F (1°C) to 36°F (20°C) (active

only with outdoor reset featuring room compensation) See section 12.10.6 for its adjustment

Can be changed 01 = knobs present; 00 = knobs absent.

Can be changed: 00 = display always on; any other value, corresponds to a delay in the switching off of the display , expressed in minutes (see also section 12.15)

Parameter disable for this kind of boiler

Domestic sensitivity setting

Minimum domestic setpoint during sleep mode

Proportional band of the heating PID modulation

Integral of the heating PID modulation

Burner Anticycling: minimum delay from a burner light-off to the sequent light-on. Value expressed in sec x 10

Can be changed between 1 and 10°F. Default value is 4°F. To increase sensitivity set it to 2°F

Can be changed between 104 and 122°F. Default value is 104°F. Never set domestic setpoint (see section 12.7) at a value lower than this parameter).

Can be changed between 1 and 99. Default value is 15. Can be modiﬁ ed only in conjunction with factory technicians.

Can be changed between 1 and 99. Default value is 30. Can be modiﬁ ed only in conjunction with factory technicians.

Can be changed between 1 and 54. Default value is 18 (180 sec). Can be modiﬁ ed only in conjunction with factory technicians.

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12.18 - Diagnostics

During the normal operation of the boiler, the display, of ﬁ gure 40, continually shows the operating status of the boiler as shown below (see also section 16):

PARAMETER DISPLAY (ITEM “1”, FIGURE 40)

PARAMETER REFERENCE DISPLAY READ OUT (ITEM “2”, FIGURE 40)

Boiler in stand-by mode or pause (no request for heating or domestic hot water)

Anti-freeze function active

Boiler not in lock-out mode but in Attention mode.

System pressure too low, system must be ﬁ lled. See section 12.1.

Domestic hot water service on

Heating service on

Boiler in lock-out mode. To reset it, press the button. If the lock-out occurs frequently, contact a professionally qualiﬁ ed technician.

Boiler temperature (°F)

01 = Boiler temperature (°F) Domestic hot water service active for more than 120 minutes. Turn domestic hot water to OFF position to reinstate heating. 02 = Connection interrupted between boilers in a module

No display

Domestic hot water temperature (°F)

Heating temperature (°F)

Lock-out code (see section 12.18.1 for decodiﬁ cation).

Blocking error. Contact a professionally qualiﬁ ed technician. Blocking errors automatically reset if the condition causing the block disappears

Auto-purging procedure that last 3 minutes in progress (see section 12.4).

Boiler in Anti-legionella functioning (see section 12.12)

Error code (see section 12.18.2 for decodiﬁ cation).

Boiler temperature (°F)

Storage tank temperature (°F)

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12.18.1 - Diagnostics: “L” lock-outs

“L” Code

L01

L02

L03 L04

L05 L06

Lock-out description

No ﬂ ame detected after three ignition attempts.

Flame extinguishes three times.

Boiler temperature is over 203°F (95°C).

Gas valve command relay Safety relay

Flue gas sensor over 230°F (110°C)

Checks to make

Check: a-correct gas supply pressure (see

section 11.7); b-ignition spark (see section 13.4); c-correct combustion air pressure (see

section 11.8); d-120Vac at the gas valve; e-resistance of the two gas valve coils

should be 0.18 kohm and 1.1 kohm; f- If the burner lights, but goes out at the

end of the ignition attempt, check: that

the ionization current is set at a value

greater than 60 (follow procedure in

section 13.12.4)

Check: a-that the ionization current is set

at a value greater than 60 (follow

procedure in section 13.12.4); b-check that vent terminal is not being

adversely affected by wind;

Check that the circulator pump is working

Check for correct polarity of the wires to the pump. Try to switch the wires.

Check: a - that the electrical resistance of the ﬂ ue gas sensor complies with the graph in section 13.13; b - that the efﬁ ciency of the boiler is over 86%

Solutions

a-If the gas supply pressure is incorrect, it must be adjusted to

the correct pressure;

b-If spark is not present, check for correct ignition ectrode

position and gap as per section 13.4; If position is correct, check for 120Vac at the supply of the spark generator.

c-if the combustion air pressure is incorrect, inspect the vent

system and eliminate any obstructions;

d-if the voltage to the gas valve is not 120Vac the power control

board must be replaced;

e-if the resitance of the gas valve coils is not 0.18 kohm and/or

1.10 kohm, the gas valve must be replaced.

f-If the ionization current is not greater than 60, conﬁ rm that

the the CO2 content is adjusted properly (see section

11.9). Check the ﬂ ame detection electrode (section 13.4) and if necessary replace it, check the integrity of the ﬂ ame detection electrode electrical wires.

a-If the ionization current is not greater than 60, conﬁ rm that

the the CO2 content is adjusted properly (see section

11.9). Check the ﬂ ame detection electrode (section 13.4) and if necessary replace it, check the integrity of the ﬂ ame detection electrode electrical wires.

b-If vent terminal is being adversely affected by wind it must be

relocated.

If the circulator pump is bad, replace it, if is good, replace the power control board

Replace the power control board If the pump won’t run replace it. If the pump is good try to

replace the power control board. a-If the ﬂ

ue gas sensor resistance does not correspond with the

correct values, replace it;

b-if the boiler efﬁ ciency is less than 86% and the CO2 content

is correct, the primary heat exchanger has to be replaced and proper water treatment methods employed to prevent mineral build up on the water side

L07

L08 L09

L10 L12

L13 L14 L15 L16 L17

Electrical circuit of ﬂ ue gas sensor is interrupted

Spark generator relay RAM memory

E2prom memory damaged E2prom memory damaged Program error Program error Program error Program error The temperature

difference between the U1 and U6 sensors is too great

Check that the electrical resistance of the ﬂ ue gas sensor corresponds with the

graph in section 13.13;

Check that: a - the electrical resistance of the two sensors corresponds with the graph in section 13.13; b -check that the heating water ﬂ ow is not too low.

If the sensor resistance does not correspond with the correct values, replace it;

Replace the power control board Replace the power control board

Replace the power control board Replace the power control board Replace the power control board Replace the power control board Replace the power control board Replace the power control board a-If one or both sensors does not have the correct resistance

value, it must be replaced;

b-If temperature difference between U1 and U8 is higher than

55°F at maximum input, the heating water ﬂ ow rate is too low. The heating water ﬂ ow rate must be corrected.

Page 54

12 - USE

12.18.1 - Diagnostics: “L” lock-outs (continued)

“L” Code

L18

L19

L20

L25

L32 L33

L45

L46

L47

Lock-out description

Program error

Flame sensed for 10 seconds, after the closure of the gas valve

Flame sensed before opening of the gas valve.

U1 or U6 sensor increase its temperature too fast

Program error Fan rotation error

Heating circuit ﬁ lling time longer than 10 minutes.

Filling of heating circuit repeated 16 times in 24 hours

Flue pressure switch open time longer than 60 minutes

Controls

Check: a - that the heating water ﬂ ow is not too

low;

b - that the circulator pump is working

Check that the voltage to the fan is 163(±10)Vdc.

Check: a - that the heating pressure switch

setting pressure, FILL appears when the pressure drops below 8.7 psi (0,6 bar), and disappears when the pressure rises above 22 psi (1.5 bar);

b - check that there are no water leaks

in the heating system.

Check: a - that no obstructions are in the ﬂ ue

discharge/air intake line

b - check the ﬂ ue pressure switch

setting point, setting is 4.5 in.W.C

c - check that the electrical resistance of

the ﬂ ue gas sensor corresponds with the graph in section 13.14;

d - check that the electrical connection

cables between the ﬂ ue pressure switch, the ﬂ ue sensor and the power control board.

Solutions

Replace the power control board

Call technical service

a - If temperature difference between U1 and U8 is higher than

55°F (13°C), at maximum input, the heating water ﬂ ow rate is too low. The heating water ﬂ ow rate must be corrected.

b - If the pump works, replace the power control board.

Replace the power control board

If the fan is powered with 163Vdc, replace the fan. If the voltage to the fan is not 163 Vdc, replace the board.

a -If the heating pressure switch is not correctly set, it must be

replaced;

b - if the system has a leak, it must be ﬁ xed.

a -If ther’is an obstruction, it must be removed; b - If the ﬂ ue pressure switch is not correctly set, it must be

replaced;

c - If the ﬂ ue sensor resistance does not correspond, it must be

replaced;

d - if the electrical circuit is damaged, it must be repaired; if the previous four cases do not apply, replace the power

control board

Page 55

12 - USE

12.18.2 - Diagnostics: “E” blocking errors

“E” Code

E01

E02

E04

E07

Blocking description

U1 boiler temperature sensor circuit interrupted.

U2 domestic hot water temperature sensor circuit interrupted.

U8 return temperature sensor circuit interrupted

U3 cold water temperature or storage tank sensor circuit interrupted

Checks to make

Solutions

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

E08

E11

E12

E13

U6 boiler temperature sensor circuit interrupted.

U1boiler temperature sensor circuit shortcircuited.

U2 domestic hot water temperature sensor circuit short-circuited

Erroneous temperature reading.

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the power control board

Page 56

12 - USE

12.18.2 - Diagnostics: “E” blocking errors (continued)

“E” Code

E14

E15

E16

E17

E18

E19

Blocking description

U8 return temperature sensor short-circuited

U4 outside sensor shortcircuited

Erroneous temperature reading.

U3 cold water temperature or storage tank sensor circuit shorted

U6 boiler temperature sensor circuit shorted

E2prom memory damaged

Checks to make

Check that the electrical resistance of the sensor corresponds with the graph in section 13.14; check that the electrical connection cables between the sensor and the power control board have continuity and carry current Check that the electrical resistance of the sensor corresponds with the graph in section 13.15; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

Solutions

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the power control board If the sensor resistance does not correspond, it must be

replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the command and control board

E20 E21

E22

E23 E30

E31

E32

E33

E42

E50

Flame presence with gas valve closed

Phase and neutral inverted

Electrical supply frequency other than 60Hz

Ground connection is absent

Erroneous temperature reading.

Program error

Error in the boiler TYPE selection

Invert phase and neutral

Check the electrical frequency of the system. Check if CS parameter is at 03

Check if the boiler is properly grounded

Push ON switches 7 an set again the correct TYPE.

Replace the gas valve

If phase and neutral are correctly wired, replace the power and control board

If the electrical supply frequency is other than 60Hz, contact the electric company; if the mains frequency is 60Hz, replace the command and control board. Make sure that the CS parameter is at 03.

if the boiler is properly grounded, replace the power control board

Replace the power control board

If TYPE value is correct, change the power control board

E51

Reset button pressed too often in a short period time

Page 57

13 - MAINTENANCE

13.1 - General precaution

WARNING!!! Never store combustible materials, gasoline or any product containing ﬂ ammable vapors and liquids in the vicinity of the boiler. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

WARNING!!! Never obstruct the ﬂ ow of combustion and ventilation air. Failure to provide adequate combustion air for this boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

CAUTION!!! Before performing any maintenance operations, shut the boiler off, close the manual gas shut-off valve, ﬁ gures 15 and 16 item “3”, and shut off electrical power to the boiler. Follow the Operating Instructions outlined in the section “SAFETY INSTRUCTION”.

13.2 - Removing the casing

In order to remove the casing, follow the steps below while refering to ﬁ gure 43:

1. remove screws “A”;

2. raise latch “C”;

3. remove the front cover;

4. press the two plastic springs, item “L”, down;

5. lower the electrical box;

6. lift latch “G”;

7. pull the bottom of cover “H” out by around 4 in (10 cm);

8. lift cover “H” up by around 1in (2 cm) and remove it.

WARNING!!! If maintenance is performed on the vent-air intake system it must be properly reassembled and sealed. Failure to properly maintain the vent-air system can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!! Servicing, inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage the boiler! Failure to comply with this warning can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

Figure 43 - Removing the casing on models 160C and 160B

Page 58

13 - MAINTENANCE

13.3 - Cleaning the burner and primary heat exchanger, ﬂ ue gas side

The burner and primary heat exchanger must be cleaned every year. To correctly clean the burner and the ﬂ ue gas side of the heat exchanger follow the steps below:

1. follow the steps in section 13.2 to gain access the internal components;

2. unscrew nut “D” from the gas valve (taking care not to loose gasket “E” in ﬁ gure 46);

3. disconnect the wires from the ignition electrodes and the wire from the ﬂ ame detection electrode, ﬁ gure 1, details “18” and “47”;

4. disconnect the wire from safety sensor “F” in ﬁ gure 44;

5. unscrew the four nuts “C” in ﬁ gure 44;

6. prepare a suitable cover for the gas valve outlet under nut “D” so that no dirt, water, or other foreign objects can fall into the gas valve during cleaning;

7. remove the entire fan - burner assembly, detail “A” in ﬁ gure 44;

8. use a cylindrical brush with plastic bristles to clean the inside of the combustion chamber, detail “H” in ﬁ gure 44;

9. use a vacuum cleaner to remove any unburned residue from the combustion chamber, detail “H” in ﬁ gure 44;

10. using the same vacuum cleaner, clean the surfaces of the burner and around the electrodes;

WARNING!!! Before proceeding to the next step, verify that the electrical supply to the boiler, and any other electrical supply near the boiler, is off. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

WARNING!!! while performing the next step, carefully wash only the inside of the combustion chamber “H” of ﬁ gure 44, and do not get water on the outside of the combustion chamber opening. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

11. using only water, wash the inside of the combustion chamber, detail “H” in ﬁ gure 44. The water, will drain into the condensate drain. Clean the condensate trap (see section 13.6) before reassembling components;

12. reassemble the components by proceeding in reverse order;

13. open the manual gas shutoff valve;

14. restore electrical power to the boiler;

15. check that there are no gas leaks.

WARNING!!! Never use an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Figure 44 - Remove the fan-burner assembly unit

Page 59

13 - MAINTENANCE

13.4 - Correct positioning of the ignition and ﬂ ame detection electrodes

For the boiler to work properly the electrodes must be positioned as shown in ﬁ gure 45:

the distance between the ignition

electrodes “A” and “B”, must be between 0.08 in (2 mm), and 0.10 in (2.5 mm);

the distance of the ignition

electrodes to the burner surface must be between 0.20 in (5.0 mm), and 0.22 in (5.5 mm);

the distance of the ﬂ ame detection

electrode to the burner surface must be between 0.23 in (6.0 mm), and 0.27 in (7.0 mm).

For a correct functioning of the boiler the below distances shall be veriﬁ ed with an hand caliper.

13.5 - Domestic hot water heat exchanger (only for 160C and 160OC model)

The production of DHW takes place in the secondary heat exchanger, detail “42” in ﬁ gure 1. If this heat exchanger looses efﬁ ciency over time, it may be necessary to clean or replace it.

A = Left ignition electrode B = Right ignition electrode C = Flame detection electrode

Figure 45 - Positioning electrodes on burner (Use an hand caliper to veriﬁ e the distances of the electrodes)

Page 60

13 - MAINTENANCE

13.6 - Condensate

trap cleaning

The condensate trap must be cleaned every year. Follow the steps below to properly clean the condensate trap and its associated components while refering to ﬁ gure 46:

1. run the fan as described in section

13.12.2, to minimize the amount of liquid present in the trap, item “A”;

2. follow the steps in section 13.2 to gain access the internal components;

3. carefully cover the electrical panel with a waterproof material, “B”, to prevent water from entering the electrical system;

4. grip spring clamp “G” with a pair of pliers and slide it downwards;

5. pull the condensation trap hose “H” off the trap;

6. remove the fan-burner assembly unit, follow steps of section 13.3;

7. protect the gas valve outlet, from entering any object or condensing water;

8. unscrew nut “I” from the bottom of the trap, “A”, and pull it upwards, taking care not to spill the condensation;

9. open the condensate trap taking care not to loose o-ring “L” and clean the inside “M”;

10. re-assemble everything in reverse order, taking care that o-ring “L” is placed in the proper location;

11. reﬁ ll the condensate trap per section 11.1.2.

Figure 46 - Removing the condensing trap

Page 61

13 - MAINTENANCE

Figure 47 - Replacing the pump motor (only for 160C and 160OC models)

13.7 - Circulator

pump motor replacement (only for 160C and 160OC models)

To replace the circulator pump follow the steps below while, refering to ﬁ gure 47:

1. follow the steps in section 13.10 to isolate and drain the water from the boiler;

2. follow the steps in section 13.2 to gain access the internal components;

3. remove screws “B”;

4. remove the circulator pump motor “A”;

5. label the electrical wires of the circulator pump motor, phase and neutral must be respected;

6. disconnect the electrical wires from the circulator pump motor

7. install the new circulator pump motor and reassemble the boiler

8. open the heating system isolation valves and heating system ﬁ ll valve

9. follow the steps in section 11.1.3 to bleed the air from the heating system.

NOTE: If display shows L05 reverse polarity (phase and neutral) to the pump

13.8 - Expansion

tank pressure (only for 160C and 160OC models)

To check the expansion tank pressure follow the steps below:

1. follow the steps in section 13.10 to isolate and drain the water from the boiler

2. follow the steps in section 13.2 to gain access the internal components;

3. check the pressure of the expansion tank, item “4” of ﬁ gure 1 (The air inlet probe is on the top of the expansion tank). It must be 14 psi (1 bar). If the pressure is lower recharge the expansion tank while letting the water run out of the heating system drain valve.

Page 62

13 - MAINTENANCE

Figure 48 - Supply ﬁ ttings removal (only for 160-C model)

13.9 - 3-way valve

removal (only for 160-C and 160OC models)

The 3-way valve, details “M” and “Q” in ﬁ gures 48 and 49, directs hot water produced by the primary heat exchanger to the heating circuit or to the secondary heat exchanger for the production of D.H.W. T o replace or clean it, follow the steps below while referring to ﬁ gures 48 and 49:

1. follow the steps in section 13.10 to isolate and drain the water from the boiler;

2. follow the steps in section 13.2, to gain access the internal components;

3. disconnect ﬁ ttings “A”;

4. remove screws “C”;

5. rotate “D” ﬂ ange in the sense of the black arrow (See particular ﬁ g. 1);

6. remove the bracket “E”;

7. remove ﬁ tting “F”;

8. remove ﬁ tting “L”;

9. remove ﬁ tting “M” and check its state.

10. remove spring “N”;

11. remove servomotor “O”;

12. remove the ﬁ tting “P”

13. remove the spring “Q” and check for any dirt.

Figure 49 - 3-way valve servomotor removal

Page 63

13 - MAINTENANCE

13.10 - Draining the heating side of the boiler

To drain the heating side of the boiler follow the steps below:

1. allow the water inside to cool by switching off the room thermostat and turning knob “7” in ﬁ gure 40 to minimum. Wait until the display, item “1” in ﬁ gure 40, shows a temperature less than 104°F (40°C);

2. turn off the boiler;

3. shut off electrical power to the boiler;

4. close the manual gas shutoff valve, ﬁ gures 16 and 17 item “3”;

5. close the boiler isolation valves in the heating system. If isolation valves haven’t been installed, the entire heating system will have to be drained.

6. close the heating system ﬁ ll valve;

7. follow the steps in section 13.2 or

13.3, to gain access the internal components;

8. connect a hose to the boiler drain valve and place the other end in a sink or some other suitable drain;

9. open the boiler drain valve and drain the boiler;

10. if boiler isolation valves have not been installed in the heating system open any bleed valves at the highest point of the system;

11. after draining out all the water, close the bleed valves and the boiler drain valve.

WARNING!!! Do not recover and/ or re-use water drained from the heating circuit for any purpose as it could be contaminated. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

13.11 - Draining the domestic hot water side of the boiler

To drain the domestic hot water side of the boiler follow the steps below:

1. turn off the boiler;

2. close the valve in the water main supplying the DHW system;

3. open all the hot and cold faucets in the building;

4. if there isn’t a faucet or drain valve below the boiler level, disconnect DHW connections 10 and 12 in ﬁ gure 1.

13.12 – Overrides

To carry out speciﬁ c checks covered in the manual, it is possible to override the control logic of the boiler. See the next:

13.12.1 - Auto-

purging

To reset the auto-purging procedure press the and keys together for 10 seconds. When the blinking

appears on the display,

press .

13.12.2 - Fan

To run just the fan at full speed press the and keys together for 10 seconds, until the blinking

appears on the display. The fan will run at full speed for 10 minutes. To shut the fan off before the 10 minutes is up press the key.

13.12.3 – Minimum and maximum output

The boiler can be run at its minimum or maximum output in both the heating and domestic hot water modes by following the steps below:

1. generate a demand for the mode to be overridden:

- for heating turn up the room thermostat and turn knob “37” in ﬁ gure 40 to its maximum;

- for domestic hot water turn knob “11” in ﬁ gure 40 to its maximum and fully open a hot water faucet;

press the and keys together for more than 10 seconds, until a blinking appears on the display;

3. press the key until the display shows:

- for minimum heating output;

- for maximum heating output adjusted by P parameter, see section

11.10;

- for maximum heating output;

- for minimum DHW output;

- for maximum DHW output;

4. press the key in order to restore the boiler to normal running conditions.

Page 64

13 - MAINTENANCE

13.12.4 – Checking the ﬂ ame current

While running at the minimum and maximum output described in section

13.12.3, the display will show the letter of the mode checked. In the second part of the display the value of the ionization current will be shown. 30 corresponds to a current of 1 uA, 99 to a current of 5.5 uA. The ﬂ ame current must always be at the correspondent value as shown in section 14, header “ionisation current”. If the value is not within the above values, check: a - positioning of the ﬂ ame sensor

electrod as per section 13.4; b - CO2 content as per section 11.9; c - combustion air pressure as per

section 11.8.

13.13 - Water and ﬂ ue temperature sensor

The boiler has a number of sensors that measure temperature. The electrical resistance between the sensor wires must correspond with the values shown in ﬁ gure 50.

The temperature sensors are: U1; U2, U3, U5, U6, U7 and U8. The location of each sensor can be found in ﬁ gures 1 and section 13.15 and 13.16.

13.14 - Outdoor temperature sensor (optional)

An outdoor temperature sensor can be connected to the boiler (see section 6.5). The electrical resistance existing between the sensor wires must correspond with the values shown in ﬁ gure 51.

Figure 50 - Water temperature sensors’ curve

Figure 51 - Outdoor temperature sensor curve

Page 65

13 - MAINTENANCE

13.15 - Functional wiring diagram

WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les ﬁ ls avant de les débrancher. Des erreurs de câblage peuvent entraîner un fonctionnement inadéquat et dangereux. S’assurer que l’appareil fonctionne adéquatement une fois l’entretien est terminé.

LEGEND: ALA - Alarm output

CM - Power control board CR - Remote command (only for 160OB

and 160OC models) EA - Ignition electrode ER - Flame detection electrode EPO - External pump (REQUIRED FOR

MODELS 160B and 160OB) EV3V - External three way valve (optional) F1 - Fuse 2Amps FPR - Flue pressure switch GS - Spark generator IG - Main electrical switch J1 - Six poles connector J2 - Four poles connector J3 - Twelve poles connector J4 - Four poles connector J5 - Sixteen poles connector J10 - Ten poles connector J18 - Height poles connector U1 - Supply temperature sensor

U2 - Domestic hot water temperature

sensor

U3 - Domestic cold water temperature

sensor

U3 TANK - Storage tank temperature

sensor (optional) U4 - Outside temperature sensor U6 - Heating Safety high limit temperature

sensor U7 - Flue gases temperature sensor with

integrated safety high limit switch U8 - Return temperature sensor PO1 - Heating pump PR - Heating pressure switch SDC - Electrical connection board RT1 - Room thermostat connection RT2 - Room thermostat connection on

remote control “CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

Page 66

13 - MAINTENANCE

13.16 - Multiwire wiring diagram

LEGEND: ALA - Alarm output

CM - Power control board CR - Remote command (only for 160OB

and 160OC models) EA - Ignition electrode ER - Flame detection electrode EPO - External pump (REQUIRED FOR

160B and 160OB models) EV3V - External three way valve (optional) F1 - Fuse 2Amps FPR - Flue pressure switch GS - Spark generator IG - Main electrical switch J1 - Six poles connector J2 - Four poles connector J3 - Twelve poles connector J4 - Four poles connector J5 - Sixteen poles connector J10 - Ten poles connector J18 - Height poles connector U1 - Supply temperature sensor

U2 - Domestic hot water temperature

sensor

U3 - Domestic cold water temperature

sensor

U3 TANK - Storage tank temperature

sensor (optional) U4 - Outside temperature sensor U6 - Heating Safety high limit temperature

sensor U7 - Flue gases temperature sensor with

remote control “CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

Page 67

14 - TECHNICAL DATA

MODEL GC-160-B; GC-160-C, OX-160-B; OX-160-C SS-160-C;

Country of destination USA and Canada Type of boiler Direct Vent boiler Category of discharge chimney IV CSA certiﬁ cate N° 2045300 (114696) Maximum Heat input Btu/hr 160,000 Minimum heat input Btu/hr 30,000 Efﬁ ciency at maximum heat input (160°F/140°F) % 93 Maximum Heat output (160°F/140°F) Btu/hr 148,800 Efﬁ ciency at minimum heat input (122°F/86°F) % 97 Minimum heat output (122°F/86°F) Btu/hr 29,100 Gas ﬂ ow rate Natural gas cu. ft./hr 156 LP Gas gal/hr 1.75 Gas supply pressure Natural gas In.W.C. 7 LP Gas In.W.C. 11 Minimum gas supply pressure Natural gas In.W.C. 1.5 LP Gas In.W.C. 8 Maximum gas supply pressure Natural gas In.W.C. 11 LP Gas In.W.C. 13 Combustion air pressure with min. length Natural gas In.W.C. 2.5 to 3.1 LP Gas In.W.C. 2.1 to 2.7 Combustion air pressure with max. length Natural gas In.W.C. 2.1 to 2.7 LP Gas In.W.C. 1.8 to 2.4 Instantaneous d.h.w production (rise 75°F) gal/min 4.32 Maximum heating temperature °F 189 Minimum heating temperature °F 68 Maximum heating pressure PSI 30 Minimum heating pressure PSI 8 Maximum pressure of domestic hot water circuit PSI 150 Minimum pressure of domestic hot water circuit PSI 1 Capacity of expansion tank gal 2.64 Supply voltage 120Vac - 60Hz Absorbed electric power W 170 Flue gas pipes diameter (split) “ (mm) 3.15 (80) Max. length ﬂ ue gas pipes (split) ft 300 Flue gas pipes diameter (coaxial) “ (mm) 2.36/3.94 (60/100) Max. length ﬂ ue gas pipes (coaxial) ft 70 Equivalent length of one elbow ft 45° elbow = 3ft, 90° elbow = 5ft CO (Carbon monoxide) with natural gas ppm <150 CO (Carbon monoxide) with LP gas ppm <250 NOx (0% O2 with natural gas) ppm <30 CO2 (Carbon dioxide) for Natural gas at high ﬁ re % 8.6 to 9.2 CO2 (Carbon dioxide) for Natural gas at low ﬁ re % 8.2 to 8.6 CO2 (Carbon dioxide) for LP gas at high ﬁ re % 9.7 to 10.6 CO2 (Carbon dioxide) for LP gas at low ﬁ re % 9.2 to 9.8 Ionisation current for Natural gas at high ﬁ re 74 to 80 Ionisation current for Natural gas at low ﬁ re 81 to 87 Ionisation current for LP gas at high ﬁ re 71 to 77 Ionisation current for LP gas at low ﬁ re 83 to 89 Maximum ﬂ ue gas temperature °F 230 Flue gas ﬂ ow-mass lb/hr 160 Head pressure available for ﬂ ue vent/air intake line In.W.C. 3.6 Maximum condensation ﬂ ow rate gal/hr 1.32 Average acidity of condensation PH 4 Boiler weight (160C and 160OC models) lb 100 Boiler weight (160B and 160OB models) lb 90

Page 68

15 - SPARE PARTS

1 - 60504206 CABLE UL IGNITOR CONN 90° L155 2 - 60802005 NUT ZINC COATED 6MA 3 - 60320001 SILICONE PIPE D 4X8 4 - 61405036 TEE FOR DRY WATER CONDENSATION 5 - 60510022 SPARK GENERATOR NO CABLE UL 6 - 62111016 SENSOR NTC 10 KOHM A KLIP DIAM.22 7 - 62622011 COPPER PIPE D22 M/F 3/4”G-1”G 8 - 60802018 3/4” RING NUT 9 - 60702030 O-RING NBR 2,62 X 20,63 10 - 62649004 PRIMARY HEAT EXCHANGER C.R.R ASME 11 - 60702047 GASKET EPDM X OSSIDO D84 H7 12 - 62111017 SENSOR NTC 10 KOHM 1/8” 13 - 60803027 GASKET COPPER 1/8” SP.1,5 14 - 61405025 SILICONE TAP 15 - 60801116 SCREW 6X35 ZINC TC-CR 16 - 60803011 WASHER 6X18X1,5 PIA-ZIN-LAR UNI6593 17 - 60406074 BRACKET SIPHON L84 H130 P32 18 - 60702055 O-RING 134 EPDM 3,53 X 25,8

19 - 60801043 SCREW SELFTAPPING 3.9 X 9.5 CROSS HEAD 20 - 62630136 SIPHON 21 - 60801100 SCREW SELFTAPPING 2.9 X 6.5 CROSS HEAD 22 - 60806020 SPRING 28,7 23 - 62113041 PRESSURE SWITCH ON 4,5 INWC 24 - 60406092 BRACKET PRESSURE SWITCH 25 - 60322012 POLIETYLENE PIPE L=1000 26 - 60402037 SEALING CHAMBER DOOR 27 - 60701001 1”G GASKET 28 - 62301031 PUMP GRUNDFOS UP 15/58U BRUTE USA 29 - 62622012 COPPER PIPE D22 RETURN SEALING CHAMBER 30 - 62111015 SENSOR NTC 10K BAIO 31 - XXX #N/D 32 - 60801132 SCREW 4,8X19 ZINC AF TC-CR UNI6954 33 - 61405164 PLUG FOR FLUE AIR FITTING 34 - 60702052 O-RING 2050 EPDM 1,78 X 12,42 35 - 61405160 DISCHARGE RACCORD PP 36 - 60702035 GASKET ROUND SPONGE D.3,5 MM IP44 S3

Page 69

15 - SPARE PARTS

37 - 61206001 AUTOMATIC AIR VENT 38 - 60101119 3/8G MALE to 1/8NPT FEMALE BUSHING 39 - 60703033 GASKET EPDM D38 F20 SP6 40 - 60411085 45xx WALL MOUNTING BRACKET 41 - 60801097 SCREW SELFTAPPING 5X50 WOOD 42 - 62201005 EXP TANK LT. 8 561X203X80 RETT. 43 - 60815012 GLASS WINDOW WITH GASKET 44 - 60701005 3/8” G GASKET 45 - 61102006 FAIRLEAD 6 POLES SILICONE 46 - 62625064 EXP TANK PIPE 47 - 61405219 PLASTIC CAP TPP 8.5 48 - 62110071 TANK SENSOR 49 - 62610067 EXTERNAL JACKET 500X840X245 50 - 61405167 DOOR SUPPORT 51 - 62610065 DOOR ABS 52 - 62630152 LP TO NATURAL CONVERSION KIT FOR 45 SERIES 53 - 62630151 NATURAL TO LP CONVERSION KIT FOR 45 SERIES 54 - 62417004 45XX USER’S INSTRUCTIONS 55 - 62403466 45XX INSTALLER’S INSTRUCTIONS 56 - 62629036 BURNER HEAD 57 - 61504029 EXTRUSION L.25MM 58 - 60909008 THERM. INSULATION VERMICULITE D117 F74 SP21,5 59 - 60703032 GASKET. SIL. D157 F145 H6,7 60 - 61404108 BASE MANIFOLD AIR ALUMINUM 61 - 60703030 GASKET SIL.MANIFOLD FAN D83 SP3,5 62 - 60801136 SCREW SELFTAPPING 4X12 TC S-TT UNI-8112 63 - 62651016 MANIFOLD AIR CUTTED 64 - 61404114 MIXER AIR/GAS “COSMOMIX” 65 - 60702049 O-RING 3350 NBR 2,62 X 88,57 66 - 60702048 O-RING 3200 NBR 2,62 X 50,47 67 - 60408261 DIAPHRAGM COSMOMIX 9 HOLES D.10

68 - 60702056 O-RING 165 NBR 3,53 X 61,91 69 - 61901029 FAN 45 KW USA 70 - 61405174 BACK FLUE-GASES PREVENTER 71 - 60702051 O-RING 3825 SIL 2,62 X 209,22 72 - 61404109 COVER MANIFOLD AIR ALUMINUM 73 - 60801080 SCREW SELFTAPPING 4X10 TC S-TT UNI8112 74 - 60801111 SELFTAPPING BOLT 6.3X38 75 - 60701013 GASKET FRIZITE D15,5 F11,5 SP1,5 76 - 60815011 GLASS PIREX D15,5 SP3,3 77 - 60404253 FLANGE L21,2 H34 78 - 60801081 SCREW SELFTAPPING 4X8 TC S-TT NI-8112 79 - 60505022 LEFT IGNITION ELECTRODE 80 - 60505023 RIGHT IGNITION ELECTRODE 81 - 60505024 DETECTION ELECTRODE 82 - 60801102 SCREW 5X12 EXAGONAL HEAD 83 - 60406069 SPRING MIXER 84 - 60702050 O-RING 3056 NBR (118) 2,62X13,95 85 - 62624125 GAS PIPE (SIT) USA 86 - 60701006 GASKET 3/4P 24X15X2 KLINSIL 87 - 60801014 SCREW 4X10 ZINC TC-CR 88 - 60101224 FLANGE GAS 32X32 3/4P 89 - 60702029 O-RING 130 2,62 X 22,22 90 - 61201040 GAS VALVE SIGMA848 120V 91 - 60801021 BOLT 5X12 CROSS HEAD 92 - 62623249 PIPE D18 F/F 3/4P-3/4P SIT USA 93 - 62103009 CONTROL KNOB S3 94 - 60702041 O-RING NBR 1,6 X 11,1 95 - 61405203 FRONT INTERFACE 96 - 61405151 TREE POTMETER-KNOB 97 - 61405190 KEYS RUBBER 3 POSITIONS

Page 70

15 - SPARE PARTS

Bottom of the boiler for 160C and 160OC models

98 - 62102009 PRESSURE GAUGE DIAM.38 - 1/4” PSI 99 - 60506019 GAS VALVE SERVICE SWITCH 100 - 61405184 BASE ELECTRICAL BOX 101 - 61405186 FAIRLEAD SX 102 - 61405188 FAIRLEAD DX 103 - 62110076 POWER CONTROL BOARD PHC 120V 104 - 60801138 SCREW 4X8 ZINC TC-CR DIN4042 105 - 60507056 JUNCTION BOARD 45 106 - 62118015 INTERFACE OPENTERM 107 - 61405185 COVER ELECTRICAL BOX 108 - 61103011 FAIRLEAD 7 EXIT 109 - 61405189 COVER JUNCTION BOX 110 - 62623246 PIPE SUPPLY SEALING CHAMBER 111 - 61203015 3 WAY VALVE MOTOR 120V 112 - 61202024 PLUG PISTON BODY OT. 113 - 60808002 SPRING FORCK 3V 114 - 61202027 UPPER PISTON 115 - 61408005 HYDRONIC SUPPLY GROUP. 116 - 62113034 HEATING PRESSURE SWITCH 117 - 60704003 GASKET COPPER 1/4P 118 - 60801134 SCREW 5X18 ZINC TC-ES-INC UNI5931 119 - 61205010 ASME SAFETY RELIEF VALVE 120 - 60101247 ELBOW BRASS 3/4P F 1/2P M WITH RING NUT AND O-RING 121 - 61202025 COVER PISTON HEATING 122 - 61202028 PISTON HEATING SIDE 123 - 60107005 PLUG BRASS 1/4P M WITH O-RING 124 - 60110028 NIPPLE OT 1”-22X1,5 MM 125 - 60702036 O-RING 2075 EPDM 1,78 X 18,77 126 - 61408007 HYDRONIC RETURN GROUP 127 - 61202026 BY-PASS VALVE 128 - 60701006 3/8” MALE CAP 129 - 62653003 DOMESTIC HEAT EXCHANGER “ACQUAJET” 130 - 62110052 SENSOR NTC 10 KOHM KLIP WITH SCREW 131 - 60802008 NUT ZINC COATED 4MA 132 - 60702053 O-RING 3037 EPDM 2,62 X 9,19 133 - 62628001 PURGING PIPE 134 - 61206011 PURGING VALVE M10X1 135 - 60808003 FORCK BY-PASS PIPE 136 - 60305073 BY-PASS PIPE 137 - 60702054 O-RING 4075 EPDM 3,53 X 18,64 138 - 60901022 FRONT THERM. INSULATION “ACQUAJET” 139 - 60901023 REAR THERM. INSULATION “ACQUAJET” 140 - 60440008 BRACKET EXAGONAL HOLES SHORT 141 - 60440009 BRACKET EXAGONAL HOLES LONG 142 - 60110025 NIPPLE OTT 3/4NPT-3/4P USA 143 - 60411117 BRACKET EXAGONAL HOLE SMALL 144 - 60701004 1/2” G GASKET 145 - 61101001 FAIRLEAD PA 107 SCREW HILO 3,5X14,5 146 - 60101011 CONNECTION BRASS 3/4P TO 1P

Page 71

15 - SPARE PARTS

Bottom side of the 160-B model

147 - 60101225 CONNECTION BRASS 1/2P TO 1P 148 - 60802018 3/4" NUT 149 - 60801135 SCREW 6X8 ZINC TC-CR DIN7985 150 - 60310002 COPPER PIPE 1"GAS TO 3/4" 151 - 62623248 SUPPLY PIPE FOR ONLY HEATING 152 - 61408008 HYDRONIC SUPPLY GROUP ONLY HEATING 153 - 60101124 1/2P CAP 154 - 60101193 1/2"-1/4" FF BRASS FITTING 155 - 60107014 PLUG BRASS 3/4P F 156 - 60101190 FITTING D12 1/4 1/4M 157 - 60101217 FITTING 1/4M CH17 158 - 60107015 PLUG BRASS 3/8P F 159 - 61408009 HYDRONIC RETURN GROUP ONLY HEATING

Page 72

15 - SPARE PARTS

External jacket for 160OB and 160OC models

Page 73

16 - READ OUT FLOW CHART

Read out in normal operating condition (see section 12.12 )

Boiler in stand-by

Domestic hot water

Overrides menu (see section 13.13)

Installer’s menu (see section 12.11)

User’s menu, with outdoor reset, CH settings to 01 or 02 (see section 12.10)

User’s menu, with thermostatic CH settings to 00 (see section 12.10)

Push and hold the RESET key for a time, in seconds, indicated by the number

Push and release the RESET key

Central heating temp. setting

D.H.W. temp. setting

Last blocking error

Last lock out error

Curve angle

Min. heat. temp.

Max. heat. temp.

Parallel shift

Calculated heat. temp.

D.H.W. temp. setting

Push and hold together the + and keys, for a time, in seconds, indicated by the number

Push and release the - key Push and release the + key

Supply temp.

D.H.W. temp.

D.C.W. temp./ tank temp.

Outdoor temp.

Ionisation current

High limit temp.

Flue temp.

Return temp.

Basic setting

Only fan in run

Heating at low ﬁ re

Heating at regul. ﬁ re

Heating at high ﬁ re

Domestic at low ﬁ re

Domestic at high ﬁ re

Central heating

Anti Freeze protection

Lock-out

Blocking error

D.H.W. active more than 120 min.

Anti legionella protection

Last blocking error

Last lock out error

Room therm. state

Fan speed rpm/100

Setting output for heating

Heating service mode

Reaction to outdoor temp.

Angle fulcrum

Heat. temp. reduction by open RT

State of the knobs

Energy saver display

Disabled parameter

Page 74

16 - READ OUT FLOW CHART

To enter this menu you must:

1. turn the main electrical supply Off;

2. move the switch No. 7 (see ﬁ gure 22, item “D”) to the ON position;

3. turn the main electrical supply On. Now “ty” is displayed. Use plus and minus keys to change the value; use RESET key to save the value and swap to the next parameter.

The boiler’s micro-processor makes this menu of parameters available to the qualiﬁ ed technician for the setting of the appliance.

To exit this menu you must:

1. turn the main electrical supply Off;

2. move the switch No. 7 (see ﬁ gure 22, item “D”) to the Off position.

Basic functionalities selection and Speed blower selection (see below for more explications).

Main electrical supply and temperature unit selection (see below for more explication).

Domestic functionalities selection. Must be always at 00

Master or slave selection in a module conﬁ guration. Must be always at 00.

Rotating selection in a module conﬁ guration. Must be always at 00.

can assume the follow values: 61 - for 160xx at NATURAL gas; 62 - for 160xx at LP gas;

can assume the follow values: 00 - 230Vac, 50Hz, °C; 01 - 230Vac, 50Hz, °F; 02 - 120Vac, 60Hz, °C; 03 - 120Vac, 60Hz, °F

can assume the follow values:

00, 01 and 02. Must be always at 00.

If readable, can assume the follow values: 00, 01, 02, 03, 04, 05, 06, 07 and 08. Must be always at 00.

Page 75

Page 76

17 - LIMITED CONDENSING WATER HEATER WARRANTY

WHAT DOES THIS LIMITED WARRANTY COVER?

This limited warranty covers the Heat Exchanger for leakage, thermal shock or other malfunction caused by defects in materials and/or workmanship. It extends to the ﬁ rst buyer and to any subsequent owner(s) as long as the water heater remains installed at its original place of installation. This limited warranty shall constitute buyer/owner’s exclusive remedy with respect to the Heat Exchanger. As such, the manufacturer disclaims all other warranties, express or implied, including warranties of merchantability and ﬁ tness for a particular purpose. The manufacturer shall not be liable for any special, direct, indirect, consequential, punitive or incidental damages of any kind, or labor, expenses, lost proﬁ ts lost opportunities, or similar damages of any kind related to the Heat Exchanger.

FIVE YEARS OF COVERAGE!

Model number and serial number are found on the rating plate afﬁ xed to the water heater. Heat exchangers are warranted against leakage and thermal shock for 5 years. Parts are warranted for 1 year. Any replacement heat exchanger under this warranty shall remain in warranty only for the unexpired portion of the original warranty.

WHAT DOES THIS LIMITED WARRANTY NOT COVER?

1. this limited warranty does not cover leakage or other malfunction caused by:

a. Defective installation and speciﬁ cally, any installation which is made: I) in violation of applicable state or local plumbing, housing or building codes, or II) without a certiﬁ ed American Gas Association, ASME, or comparable Temperature Pressure Relief Valve, or III) contrary to the written instructions furnished with the unit. b. Adverse local conditions and speciﬁ cally, sediment or lime precipitate in the tubes and/or headers or corrosive elements in the atmosphere. c. Misuse and speciﬁ cally, operation and maintenance contrary to the written instruction furnished with the unit, disconnection, alteration or addition of non-approved components or apparatus, operation with fuels or at settings other than those set forth on the rating plate, or accidental or other exterior damage.

2. This warranty also does not cover:

a. Production of noise, odors, discoloration or rusty water. b. Damage to surrounding area or property caused by leakage or malfunction. c. All labor costs associated with the replacement and/or repair of the unit, including:

I) examination and replacement of parts claimed to be defective II) any freight, shipping or delivery charges; III) any removal, installation or reinstallation charges; IV) any material and/or permits required for installation, reinstallation or repair; V) charges to return the water heater and/or components to the manufacturer.

d. Any failed component of the water heater system not manufactured as part of the water heater. e. Any water heater altered without prior written approval from the manufacturer. f. Any damage or failure due to contaminated air, including, but not limited to, sheetrock particles, plasterboard particles, lint, dirt or dust, entering the water heater or any of its components. g. Any damage or failure due to chemically contaminated combustion air, including, but not limited to, chlorine gas, halogenated hydrocarbons, Freon, entering the water heater or any of its components. h. Any water heater that has been damaged as a result of natural disasters, including, but not limited to, lightning,

ﬁ re, earthquake, hurricanes, tornadoes or

ﬂ oods.

WHAT WILL WE DO TO CORRECT PROBLEMS?

If a defect occurs within the warranty period we will:

1. Provide a comparable replacement manufacture, or at our option, repair any unit which develops a leak in the heat exchanger within the warranty period.

2. Provide a replacement part, or at our option, repair any part which fails to function within the parts warranty period. To obtain a replacement, you must return the defective part to our manufacturing facility. We reserve the right to verify any claims of defect by inspection.

CONDITIONS

We will not:

1. Repair or replace any water heater, or part, subject to conditions outlined in "What Does This Limited Warranty Not Cover?"

2. Reimburse any costs associated with repair and/or replacement.

3. Replace and/or repair any water heater without complete model number/serial number.

4. Replace any water heater without prior receipt of actual rating plate from the appliance.

HOW TO KEEP YOUR WARRANTY IN EFFECT?

To facilitate warranty service, you should:

1. Retain all bills of sale or receipts for proof of installation, etc.

2. Contact your installer or dealer as soon as any problem or defect is noticed.

3. When necessary, allow our representative to inspect the unit.

4. For your reference, ﬁ ll in the Model and Serial Number found on the unit's Rating Plate:

Model Number

Serial Number _________________________________

Date of Installation ______________________________

_________________________________

315 Oser Avenue • Hauppauge, NY 11788 tel. (631) 694-1800 • fax (631) 694-1832 www.embassyind.com