FLOWMAX 90 Instruction Manual

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Instruction Manual

for model

FLOWMAX – 90

Nordgas Version

Condensing water heater

85,000 BTU

WARNING

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

-Do not store or use gasoline or other flammable vapours 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 elect rica l switc h; do not use any phone in your building.

●Immediately call yo ur gas supplier fro m a neighbour’s pho ne. Fo llow the gas s upplier’s instructions.

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

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

Installation, operating, commissioning and maintenance instructions.

Water heaters for other than recreational vehicle installation

CONTENTS

Pages

General information

1.1 General warnings 1

1.2 Product conformity 9

2. Technical characteristics

2.1 Technical data 10

2.2 Dimensions 11

2.3 Internal parts of the water heater 12

2.4 Water circuit 13

2.5 Circulation pump head/flow graph 14

2.6 Printed circuit board – Technical characteristics 15

2.7 Control panel 16

3. Installation (authorized personnel)

3.1 Reference standard 18

3.2 Unpacking 19

3.3 Installing the water heater 20

3.4 Water connections 21

3.5 Domestic Hot Water Circuit/Hard Water Warning/ Condensate Drain 22

3.6 Schematic of Piping Installation 24

3.7 Gas connection 26

3.8 Electrical connections

3.9 Venting connections 29

4. Commissioning the appliance (authorized personnel)

4.1 General warnings 36

4.2 Filling the system 37

4.3 Flushing the system 38

4.4 Filling the condensate trap 38

4.5 Starting up the water heater 39

5. Regulating the appliance (authorized personnel)

5.1 Parameters table 40

5.2 Setting the parameters 42

5.3 Gas Data 51

CONTENTS

6. Maintenance (authorized personnel)

6.1 General warnings 52

6.2 Maintenance 52

6.3 Water heater inspection 52

6.4 Accessing the water heater 54

6.5 Flushing out the primary side 54

6.6 Draining the central heating and domestic hot water system 55

6.7 Maintenance operations 56

6.8 Wiring diagrams 63

6.9 D.H.W Sensor Connection 66

6.10 Troubleshooting 67

6.11 Diagnostics 68

6.12 Parts list 82

7. Warranty

Pages

7.1 Terms and Condition of Sale 84

7.2 Warranty Registration Form 86

7.3 Warranty Part Request Form 87

GENERAL INFORMATION

1. GENERAL INFORMATION

1.1 General warnings – Installation

Read all safety warnings in the “Instruction Manual”. The additional safety issues outlined below must also be

followed completely when installing this FLOWMAX Combination Water heater.

Failure to remove or maintain the area free of combustible material, gasoline and other flammable liquids or vapours

can result in severe personal injury, death or substantial property damage.

All applicable local, state, national and provincial codes, ordinances, regulations and laws must be observed.

For installations in Massachusetts – code requires the units to be installed by a licensed plumbing or gas fitter.

The appliance cannot operate without the correct amount of air for combustion. Please make sure there is sufficient

inflow and outflow of air for ventilation, never obstruct the flow of ventilation air. Failure to provide the proper amount of combustion air can result in a fire or explosion and cause death, serious bodily injury or property damage.

If an external electrical source is utilized, the appliance, when installed, must be electrically grounded in accordance

with local codes or, in the absence of local codes, with the National Electrical Codes ANSI/NFPA 70 and or the CSA C22.1 Canadian Electrical Code.

Follow all local codes and/or the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the

USA or the Natural Gas and Propane Installation Code in Canada (CAN/CSA B149.1).

This unit is designed for indoor installations. DO NOT operate this unit without the vent piping connected. Exhaust

gases must be completely expelled out of the building.

Do not use this appliance if any part has been underwater. Immediately call a qualified service technician to inspect

the appliance and replace any part of the control system and any gas control which has been underwater.

Be sure not to reverse the water and gas connections as this may damage the gas valves.

Water temperatures over 125⁰F can cause severe burns instantly or death from scalding. If the proposed water

heater outlet temperature is above 125⁰F, a thermostatically controlled mixing valve (or a temperature limiting valve) for reducing point of use water temperature is recommended to reduce the risk of scald injury. Contact a licensed plumber or the local plumbing authority for further information.

The appliance should be located in an area where leakage within the unit or at its connections will not result in

damage to the area adjacent to the appliance or to lower floors of the structure. FLOWMAX will not be responsible for any damage resulting from leaking if adequate drainage is not provided. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the appliance.

Do not use this combination water heater for any purpose other than water heating and space heating.

The flow of combustion air and ventilation to the water heater must not be obstructed. The water heater area must

be kept clear and free from combustible materials, gasoline and other flammable vapours and liquids.

If the water quality is known to be highly acidic and/or extremely hard, water treatments (ie water softeners and

filtration) are recommended to maintain full warranty. Consult the local water authority.

DO NOT over-tighten fittings, as pipe and/or fitting damage may occur causing leakage.

DO NOT install water heater where subject to vibrations.

For other than a direct vent appliance, the appliance must be located as close as possible to a chimney or gas vent.

Should overheating occur or the gas supply fails to shut off, turn the manual gas control valve to the appliance.

Contact a Service Technician immediately.

Clearance must be in accordance with the local installation codes and the requirements of the gas supplier.

GENERAL INFORMATION

Never operate the heater unless it is vented to the outdoors and has adequate air supply to avoid risks of improper

operation, fire, explosion or asphyxiation.

DO NOT install this water heater directly on a carpeted floor. A fire hazard may result. The water heater shall be

installed on a metal or wood panel extending beyond the full width and depth of the water heater by at least 3 inches (76.2mm) in any direction or, if the water heater is installed in an alcove or closet, the entire floor shall be covered by the panel.

For safe operation, an ample supply of air must be provided for proper combustion and ventilation in accordance

with the National Fuel Gas Code ANSI Z223.1/NFPA 54 National Fuel Gas Code CSA/B149.1 Natural Gas and Propane Installation Codes or applicable provisions of the local building codes. An insufficient supply of air may result in a yellow, luminous burner flame, carboning or sooting of the heat exchanger, or create a risk of asphyxiation. Do not obstruct the flow of combustion and ventilation air.

This unit is not intended to operate at gas supply pressures other than those shown on the rating plate. Exposure to

higher gas supply pressure may cause damage to gas valves, which can result in fire or explosion. If over-pressure has occurred, such as through improper testing of gas lines or emergency malfunction of the supply system, the gas valves must be checked for safe operation.

A thermostatic mixing valve must be added to this system to prevent scalding, if regulated by local codes and

authorities.

Check the Rating Plate

FLOWMAX units come from the factory configured for use with natural gas. Prior to installation, check the rating

plate of the water heater to ensure the unit matches gas type, gas pressure, water pressure and electrical supply. If the unit does not match the requirements, do not install.

Be sure the gas type and electricity voltage match the rating plate.

There is a risk in using fuel burning appliances in rooms or areas where gasoline, other flammable liquids or engine-

driven equipment or vehicles are stored, operate or are repaired. Flammable vapours are heavy and travel along the floor and may be ignited by the igniter or main burner flames causing fire or explosion. Some local codes permit operation of gas appliances if installed 18 inches or more above the floor. This may reduce the risk if location in such an area cannot be avoided. Flammable items, pressurized containers or any other potential fire hazardous articles must never be placed on or adjacent to the water heater. Open containers of flammable materials should not be stored or used in the same room with the water heater.

Do not install the FLOWMAX water heater in areas with excessive high humidity.

Do not install the unit in location where there is excessive humidity, such as a bathroom, damp crawl space, and

other areas with high levels of humidity. This may cause the unit to malfunction.

To avoid possible electrical shock, DO NOT touch the internal components of the water heater or the power cord

with wet hands.

DO NOT splash excessive water on the water heater when cleaning, as they are water resistant, not water proof.

Professionally qualified personnel in accordance with current laws and standards and in line with the manufacturer’s

instructions must install the appliance.

The commissioning of the water heater and any subsequent works carried out on the appliance must be effected by

an appropriately qualified technician.

The appliance must be used solely for the purpose for which it has been designed and manufactured: central

heating and domestic hot water production. Any other use is deemed as improper and as such dangerous. Under no circumstances will the manufacturer be held responsible for damage or injury to persons or animals caused by errors in the installation and/or use of the appliance, or through non-compliance with current local and national standards and/or the manufacturer’s instructions.

The installation, operation and maintenance manual forms are an integral and essential part of the product and must

be kept with the appliance always.

GENERAL INFORMATION

The warnings contained in this chapter have been written for the appliance user, the installer and the service

technician.

The “operating instructions” chapter of this manual must be read carefully as it provides information on the operation

and the operating limits of the appliance.

• After the removal of all the packaging, check that the appliance has not been damaged. In case of doubt, do not attempt to use the product but refer to the supplier. Packing materials (cardboard box, wooden crate, nails, staples, plastic bags, polystyrene, etc.) must not be left within reach of children in that these items represent a potential hazard and must be disposed of in a responsible manner.

• Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains electricity supply by switching off at the main switch and/or any other isolating device.

• In the case of a fault and/or malfunction in the appliance, shut down the system. Do not interfere with or attempt any repairs. Call for professionally qualified technical assistance only.

• Any warranty repairs to the appliance must be carried out exclusively by the manufacturer’s authorized service dealers using original spare parts. Non-compliance with the above requirements may compromise the safety of the appliance and invalidate the warranty. In order to guarantee the efficiency of the appliance and its correct operation, it must be serviced regularly by professionally qualified personnel in line with the manufacturer’s instructions.

• Only original accessories or optional extras (including electrical parts) must be used with the appliance.

• Should there be a smell of gas present in the room where the appliance is installed, DO NOT attempt to activate any

electric switches, telephones or any other equipment that may cause sparks. Open doors and windows immediately to create a current of air and ventilate the room. Shut-off the main gas supply valve (at the meter), or on the cylinder in the case of bottled gas, and call an authorized service centre.

• Do not attempt to interfere with the appliance in any way.

• As dictated by current legislation, this appliance must be installed exclusively by qualified personnel. Before starting

the water heater for the first time, make sure that it is connected to a water supply and central heating system compatible with its performance characteristics.

• Prior to start-up, the central heating pipes should be flushed to remove any residues that could compromise the operation of the appliance.

• The domestic power supply must be checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the appliance rating plate (positioned on the casing). In particular, make sure that the cable ratings are adequate for the power absorbed.

• Do not use adapters; multiple sockets or extension leads to connect the appliance to the power supply.

• The appliance must be connected to the mains power supply through an appropriate electrical isolator in accordance with

the current wiring regulations.

• If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified technician.

• When the appliance is no longer required for use, switch off the main power supply, to switch all electrical components off (circulating pump, burner etc.).

GENERAL INFORMATION

Important: Carbon Monoxide Detectors

Many jurisdictions require the installation of carbon monoxide detectors in building where a side wall vented fuel burning appliance is installed. Installers must abide by local code requirements regarding the installation of CO detectors. The use of a certified carbon monoxide detector is recommended but not required by FLOWMAX.

“In the State of Massachusetts only”

(a)For all horizontally vented gas fuelled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned and operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal

vented gas fuelled equipment, the installing plumber or gas fitter shall observe that a hard wired carbon

monoxide detector

is to be installed and on each additional level of the dwelling, building or structure served by the equipment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fuelled equipment is installed in a crawl space or

an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision cannot be met at the time of completion of

installation, the owner shall have a period of 30 days to comply with the above requirements; provided,

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE. A metal or plastic identification plate shall be permanently mounted to the exterior of the building at a minimum height of eight (8) feet above grade directly in line with the exhaust vent terminal for the horizontally vented gas fuelled heating appliance or equipment. The sign shall read, in print size no less than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

however, that during said 30 day period a battery operated carbon monoxide detector with alarm shall be installed.

with an alarm and battery back-up is installed on the floor level where the gas equipment

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fuelled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a) 1 through 4.

GENERAL INFORMATION

1.2 Product conformity

All FLOWMAX water heaters are ETL certified and possess technical and functional characteristics that comply with the following standards:

Gas fired water heaters also comply with the following standards:

American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage Water Heaters with input Ratings above 75,000 Btu per Hour, Circulating and Instantaneous. Conforms to ANSI STD Z21.10.3, certified to CSA STD 4.3.

The materials used such as copper, brass, stainless steel, etc. form a compact, uniform, highly functional unit that is easy to install and simple to operate. In its simplicity, the wall-mounted appliance is equipped with all the appropriate accessories required to make it a fully independent water heater capable of satisfying domestic hot water production and central heating needs. All water heaters are fully inspected and are accompanied by a quality certificate, signed by the inspector, and a guarantee certificate. This manual must be kept in a safe place and must accompany the water

heater at all times.

FLOWMAX will not be held responsible for any misinterpretation of this manual resulting from the inaccurate translation of same.

FLOWMAX will not be held responsible for the consequences in the case of non-observance of the instructions contained in this manual or in the case where actions not specifically described herein are undertaken.

GENERAL INFORMATION

Model FLOWMAX - 90

Heat Input max

kW - BTU/hr

25 – 90 000

Heat Input min

kW - BTU/hr

9 – 35 000

Heat Output max - 122/86°F

kW - BTU/hr

26.7 – 91 019

Heat Output max - 167/140°F

kW - BTU/hr

24.6 – 83 939

Heat Output min - 167/140°F

kW - BTU/hr

8.73 – 29 788

Efficiency 100% (full load 167/140°F)

98.4

Central Heating circuit

Central Heating water temperature setting (min-max)

°C – °F

25–40 / 30-75 - 77–104 / 86-167

Max. heating working temperature

°C – °F

75/167

Expansion vessel capacity

ltrs - gal

6 - 1.58

Max. working pressure (heating)

bar - psi

2.1 - 30

Min. working pressure (heating)

bar - psi

0.3 - 4.29

Domestic Hot Water circuit

D.H.W. temperature setting (min-max)

°C – °F

35-72 – 95-160

Max. Hot water working pressure

bar - psi

6 - 86

Min. Hot water working pressure

bar - psi

0.5 - 7.16

D.H.W. flow rate at ∆T 45°F (25°C)

l/min - gal/min

14.10 - 3.72

D.H.W. flow rate at ∆T 72°F (40°C)

l/min - gal/min

8.7 - 2.30

Dimensions (Water heater casing size)

Width

16.1

Height

28.7

Depth

11.2

Weight (net)

Hydraulic connections

Central Heating Flow connection

BSPP

3/4"

Central heating Return connection

BSPP

3/4"

Cold water mains connection

BSPP

1/2"

D. Hot water connection

BSPP

1/2"

Gas connection

NPT

1/2"

Gas Supply

Natural Gas (Ng)

Inlet pressure

mbar – in wc

20 - 7

Gas consumption

m3/h - ft3/h

2.65 - 93.58

Liquid Propane (Lp)

Inlet pressure

mbar – in wc

37 – 14

Gas Consumption

m3/h - ft3/h

1.01 – 35.67

Electrical specifications

Power supply

V/Hz

120/60

Electrical power consumption

180

2. TECHNICAL CHARACTERISTICS

2.1 Technical data

4.3

5.4

6.4

11.2

5.2

28.7

CWI

HWO

1.9 3.1

1.2

11.2

28.7

4.4

7.3

4.4

1.9

12.3

1.9

4.1

2.7

3.2

LEGEND

HEATING INLET

3/4" BSPP

HEATING OUTLET

3/4" BSPP

GAS

1/2" BSPP

CWI

COLD WATER INLET

1/2" BSPP

HWO

HOT WATER OUTLET

1/2" BSPP

CONDENSATE DRAIN

0.98 in

2.2 Dimensions

GENERAL INFORMATION

2.3 Internal parts of the water heater

LEGEND

1. PRIMARY CONDENSING HEAT EXCHANGER

2. PREMIX BURNER UNIT (GAS MANIFOLD + BURNER)

3. CONDENSATE DRAIN PIPE

4. IONIZATION ELECTRODE

5. IGNITION ELECTRODE

6. FAN

7. VENTURI

8. IGNITION TRANSFORMER

9. ELECTRONIC GAS VALVE

10. PRESSURE RELIEF VALVE

11. AUTOMATIC AIR VENT VALVE

12. HEATING SAFETY THERMOSTAT

13. HEATING SENSOR

14. PUMP WITH AIR VENT

15. WATER PRESSURE SWITCH

16. EXHAUST HOOD

17. SAFETY THERMOFUSE

18. EXPANSION TANK

19. D.H.W. SENSOR

20. CONDENSATE TRAP

21. WATER PRESSURE GAUGE

22. AUTOMATIC BY-PASS

23. AIR PRESSURE SWITCH

24. SYSTEM DRAIN VALVE

25. ROOM SEAL CHAMBER BACK SIDE

26. DIVERTER ACTUATOR VALVE

27. ELECTRONIC FLOWSWITCH

28. DHW EXCHANGER

29. HEATING LOOP FILL TAP

30. NO-RETURN VALVE

LEGEND

HEATING INLET

HEATING OUTLET

GAS

CWI

COLD WATER INLET

HWO

HOT WATER OUTLET

CONDENSATE DRAIN

HWO CWIG

HI HO

GENERAL INFORMATION

2.4 Water circuit

LEGEND

1. PRIMARY CONDENSING HEAT EXCHANGER

2. PREMIX BURNER UNIT (GAS

MANIFOLD+BURNER)

3. CONDENSATE DRAIN PIPE

4. IONIZATION ELECTRODE

5. IGNITION ELECTRODE

6. FAN

7. VENTURI

8. IGNITION TRANSFORMER

9. ELECTRONIC GAS VALVE

10. PRESSURE RELIEF VALVE

11. AUTOMATIC AIR VENT VALVE

12. HEATING SAFETY THERMOSTAT

13. HEATING SENSOR

14. PUMP WITH AIR VENT

15. WATER PRESSURE SWITCH

16. EXHAUST HOOD

17. SAFETY THERMO FUSE

18. EXPANSION TANK

19. D.H.W. SENSOR

20. CONDENSATE TRAP

21. WATER PRESSURE GAUGE

22. AUTOMATIC BY-PASS

23. CONDENSATE DRAIN PIPE

24. SYSTEM DRAIN VALVE

25. ROOM SEAL CHAMBER BACK SIDE

26. FLOW LIMITER

27. ELECTRONIC FLOWSWITCH

28. DHW EXCHANGER

29. DIVERTER ACTUATOR VALVE

30. HEATING LOOP FILL TAP

31. AIR PRESSURE SWITCH

32. NO-RETURN VALVE

GENERAL INFORMATION

Pump head

I, II, III

Pump speed

Water heater losses

III

0 2

4 6 8

Water flow (US gpm )

Head (ft)

2.5 Circulation pump head/flow graph

GENERAL INFORMATION

2.6

DIGITECH CS MIAH4 COD.40-0007

MAIN NEWS

The new electronic board Digitech CS is now installed on all condensing boiler models, from the 13kW output model to the 100kw output model. At the first ignition of the boiler, the function F33 (System purging function) is enable for a period of 5 minutes; pump is enabled while the burner ignition is disable. This cycle eliminates any residual air contained in the system. The same function is automatically enabled every time the E04 error (no water in the system) appears display, activated by the water pressure switch, in this case for a period of 2 minutes.

Other news:

•

Here below a list of possible settings to be performed, according to the specific need, by the authorized personnel:

•

With boiler in ON position, through the INFO button “i” (Info), it is now possible to display the following information:

•

The chimney-sweeper function (or test function) is enabled by keeping the button "R" (Reset) pressed for 7 seconds.

on the

White backlit LCD Display; Improved icons graphic for an easy reading and setting of the electronic board

The electronic board manages the zone control PCB from the boiler control panel (only with zone PCB in

stalled)

The flame presence signal is completed by the power level expressed in 3 steps. Through the INFO button “i”, with boiler in OFF position, it is possible to display the last 5 errors (to reset press "R " button).

technical

Central heating temperature minimum and maximum set point adjustment from min 25°C to max 88°C (factory set as 30-80°C).

Domestic Hot water temperature minimum and maximum set point adjustment from a min. 35°C to a max 75°C (factory set at 35-60°C) ;

∆t set point flow I return (only if a modulating pump and sensor on the return circuit are installed);

Minimum and maximum speed of modulating pump (if installed);

Outdoor temperature (if the outdoor temperature sensor is installed); Kd value of outdoor temperature sensor (if installed); Low temperature circuit temperature (if optional CRAD board for the 2 temperature circuits is connected); Solar panel sensor temperature (if installed); Solar storage cylinder sensor temperature (if installed); Fan speed.

the

GENERAL INFORMATION

>33% >33%<66% >66%<100%

120v 60Hz

2.7 Control panel

Control panel Key

HEATING TEMPERATURE SETTING BUTTONS

INFO BUTTON: PRESS ONCE TO DISPLAY

TEMPERATURES AND INFO (see 2.8 INFO menu display). KEEP INFO BUTTON PRESSED FOR 5 SECONDS (in OFF MODE) TO DISPLAY LAST 5 ERRORS.

MODE SELECTION BUTTON

WINTER ONLY I SUMMER-WINTER I OFF.

RESET BUTTON:

FUNCTION ACTIVATION (CHIMNEY-SWEEPER

- KEEP IT PRESSED FOR 7 SECONDS).

DOMESTIC HOT WATER TEMPERATURE

SETTING BUTTONS.

PRESSED FOR 5 SECONDS TO ACTIVATE DISPLAY BACKLIT MODE FOR A PERIOD OF 10 MINUTES.

6. TERMINAL BLOCK FOR EXTERNAL WIRING.

LCD DISPLAY.

THE

SUMMER ONLY I

ERROR RESET - FLUE TEST

KEEP BUTTONS

'+'

AND '-'

CONTINUOUS

THE

LCD DISPLAY ICONS' KEY

1. PARAMETER NUMBER INFORMATION

PARAMETERS PROGRAMMING MODE ON

SOLAR PCB CONNECTION INFORMATION I

SOLAR PANEL TEMPERATURE DISPLAY (d6)

SOLAR PUMP ON

STORAGE CYLINDER LOW LEVEL TEMPERATURE VISUALIZATION (d7) CYLINDER HIGH LEVEL TEMPERATURE VISUALIZATION (dB)

6. OUTDOOR TEMPERATURE SENSOR CONNECTED I OUTDOOR SENSOR TEMPERATURE DISPLAY (d2)

TEMPERATURE I SET POINT I PARAMETER

VALUE INFORMATION

OPEN THERM COMPONENTS COMMUNICATION CONNECTED (REMOTE MANAGEMENT CONTROL BOX)

9. W ATER LOW PRESSURE INFORMATION

10.

(*) FLAME PRESENCE ON (3 POWER STEPS)

11.

D.H.W. MODE ENABLED

12.

RESETTABLE ERROR DISPLAY

13.

OFF MODE

14.

NOT RESETTABLE ERROR DISPLAY

15.

HEATING MODE ENABLED

(*) -

10 can show 3 different power levels according to the flame modulation icon/power % images

During the boiler operation the display

I STORAGE

CONTROL I ZONE

of the boiler. (See flame

GENERAL INFORMATION

d00

DHW sensor temperature

d01

d02

d03

d04

d05

d06

d07

d08

INFO Menu display

Press the

Once pressed, the parameter number will appear on the left side of the display and the associated parameter value will appear on the center of the display . Use “ temperature setting to scroll the list of available data.

“ ”

INFO button to display the boiler data.

”

and “ ” buttons of the heating

Press the

The list of available display data is the following:

Parameter Icon

“ ”

INFO button to exit the display mode.

Outdoor sensor temperature

Thermoregulation value

Fan speed

Low temperature circuit sensor (only with Zone PCB connected)

Heating return sensor temperature

Solar panel sensor temperature (only with Solar PCB connected)

Solar storage cylinder temperature (

Description

low level

high level

)

(only with Solar PCB

) (only w ith Solar PCB

GENERAL INFORMATION

3. INSTALLATION (authorized personnel)

3.1 Reference standard

Install in accordance with local building and electrical codes.

This appliance meets the requirements of:

American National Standard/CSA Standard for Gas Water Heaters Volume III, Storage Water Heaters with input Ratings above 75,000 Btu per Hour, Circulating and Instantaneous Conforms to ANSI STD Z21.10.3, certified to CSA STD 4.3.

Failure to install a gas appliance correctly and in accordance with the above norms could lead to prosecution. It is in the interest of the installer and safety that the codes are complied with.

The manufacturer’s instructions form an integral part of the installation and should be left with the appliance but do not over ride in anyway statutory obligations.

Installation requirements

Please refer to local and national standards in force with the Country of destination of the product.

Fig. 1

GENERAL INFORMATION

3.2 Unpacking

■ The materials (cardboard) used for packing the appliance are fully recyclable.

■ It is recommended that the packing material is only removed prior to installing the water heater. The

manufacturer will not be held responsible for damage caused by incorrect storage of the product.

■ Packing materials (plastic bags, polystyrene, nails, etc.) must not be left within reach of children, in that

these items represent a potential hazard.

A. Place the packed appliance on the

floor (see fig. 1) making sure that the "up” arrow is facing down. Remove the staples and open out the four flaps of the box.

B. Rotate the water heater 180° while manually supporting it from underneath

C. Lift the box and remove the protections. Lift the water heater by grasping the rear part and proceed with the installation.

STORAGE & HANDLING

Please note that prior to installation the FLOWMAX water heaters should be stored in the horizontal position with no more than three water heaters to a stack; Ensure that the water heaters are stored in dry conditions and be aware that the carton is a two-man lift;

GENERAL INFORMATION

MINIMUM DISTANCES [INCHES]

X Y L H

A B

18 12

FLOWMAX - 90

Model

Fig. 2

Fig. 1

3.3 Installing the water heater

■ The appliance must be installed

exclusively on a flat vertical solid wall capable of supporting its weight.

■ The water heater should be fitted within the building unless otherwise protected by a suitable enclosure i.e. garage or outhouse. (the water heater may be fitted inside a cupboard).

■ If the water heater is sited in an unheated enclosure then it is recommended to leave the power on to give frost protection (frost protection is active even with On/Off switch in Off position).

■ If a water heater is installed in a closed water supply system, such as one having a back flow preventer in the cold water supply line, means shall be provided to control thermal expansion. Contact the water supplier or local plumbing inspector on how to control this situation.

In order to allow access to the interior of the water heater for maintenance purposes, it is important that the necessary clearances indicated in figure 1 are respected. To make the installation easier, the water heater is supplied with a template to enable the pipe connections to be positioned prior to fixing the appliance to the wall.

To install the water heater, proceed as follows (see fig. 2): a. Use a spirit level (of not less than 1” long) to

mark a horizontal line on the wall where the water heater is to be fitted.

b. Position the top of the template along the line

drawn with the level, respecting the distances indicated. Then mark the centres of the positions of the two wall-plugs or anchors. Finally, mark the positions of the water and gas pipes.

c. Remove the template and install the supplied

bracket securely to the wall. Once the heater is securely installed, connect the domestic hot and cold water pipes, the gas supply pipe and the central heating pipes using the fittings supplied with the water heater.

d. Clearance to Combustibles

- Front : 0 inches

- Sides : 0 inches

- Rear : 0 inches

- Top : 0 inches from the jacket cover

1.9

3.1

1.2

HWO G

CWI HO

4.9

2.7

3.2

LEGEND

HEATING INLET

3/4" BSPP

HEATING OUTLET

3/4" BSPP

GAS

1/2" NPT

CWI

COLD WATER INLET

1/2" BSPP

HWO

HOT WATER OUTLET

1/2" BSPP

Fig. 1

3.4 Water connections

In order to safeguard the heat exchanger

and circulation pump, especially in case of water heater replacement, it is recommended that the system is hotflushed to remove any impurities (especially oil and grease) from the pipes and radiators.

Make sure that the domestic water and

central heating pipes are not used to ground the electrical system. The pipes are totally unsuitable for this purpose.

Isolation Valves must be installed on the

heating and D.H.W circuits. This will facilitate all maintenance and service operations where the hot water needs to be drained.

Water connection tail pieces / unions are

supplied with every unit and must be used. These are the only fittings that must be installed on to the unit. They are designed to be tightened on to the appropriate male thread along with the fiber washer.

GENERAL INFORMATION

Failure to use these tail pieces will cause the unit to leak and will VOID the warranty.

 To prevent vibration and noise coming from the system the system, do not use pipes of reduced diameter,

short radius elbows or severe reductions in the cross sections of the water passages.

 In order to guarantee the reliability of the water heater and prevent permanent damage in areas with high water

inlet pressure too, a 30 psi (2 bar) pressure reducing valve should be fitted.

The water flowing out of the pressure/relief valve during its operation may be extremely hot. Before operating relief valve, make sure drain line is installed to direct discharge to a safe location such as an open drain. Avoid scalding and/or water damage. A pressure relief valve is installed in this dual purpose water heater that is rated in accordance with and complying with either The Standard for relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22 CSA

4.4 Code.

The relief valve must be installed such that the discharge will be conducted to a suitable place for disposal when relief occurs and that no reducing coupling or other restriction be installed in the discharge line. The discharge line must be installed to allow complete drainage of both the valve and the line. If this unit is installed with a separate storage vessel, the separate vessel must have its own temperature and pressure relief valve. No valve is to be placed between the relief valve and the tank. This valve must also comply with The Standard for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems. ANSI Z21.22 or CSA 4.4. If a relief valve discharges periodically, this may be due to thermal expansion in a closed water system. Contact the water supplier or local plumbing inspector on how to correct this situation. Do not unplug relief valve.

GENERAL INFORMATION

3.5 Domestic hot water circuit/Condensate Drain

Warning/ Hard Water

 If this water heater is installed in an application where the supply water is hard, it must be treated with either a

water softener and filtration, which removes the hardness or by using sequestering agents that reduce the amount of scale deposits.

 Damage to the water heater as a result of water in excess of 14.5 gpg (250mg/L) of hardness is not covered by

FLOWMAX Limited warranty. If there a problem with the water quality, contact your local water conditioning company for equipment to condition the water supply to this appliance

The cold water supply pressure at the inlet to the water heater must be between 7.25 psi (0.5 bar) and 87 psi (6 bar).

In areas with higher water inlet pressure a pressure reducing valve must be fitted before the water heater.

The frequency of the heat exchanger coil cleaning depends on the hardness of the mains water supply and the presence of residual solids or impurities, which are often present in the case of a new installation. If the characteristics of the mains water supply are such that require it to be treated, then the appropriate treatment devices must be installed, while in the case of residues, an in-line filter should be sufficient.

Central heating circuit

In order to prevent scaling or deposits in the primary heat exchanger, the mains supply water to the heating circuit must be treated according to the requirements of local standards. This treatment is indispensable in the case where the circuit is frequently topped-up or when the system is often either partially or fully drained.

Condensate Drain

■ FLOWMAX water heater is a high efficient gas appliance that creates condensation when it operates. A condensate trap and flexible drain pipe comes factory installed inside each water tank.

The condensate trap must be primed before operation to prevent exhaust gases from entering the building.

■ Follow your local code with regards to the disposal of condensation

■ Here are several options for disposal of condensate

o From combination water heater direct to drain

o From combination water heater to neutralizer to drain

o From combination water heater to laundry tub (bottom of water heater must be above the height of the

laundry tub; must have a negative slope to properly drain)

o From combination water heater to condensate pump to laundry tub (for long distances between water

heater and laundry tub or when bottom of the water heater is installed below height of the laundry tub)

■ Failure to install the condensate discharge properly will affect the reliability of the water heater.

For all units installed with vertical exhaust, must have an additional approved condensate drain. Fittings must

be ULC S636 approved.

Failure to properly connect the condensate line will cause combustion gases to enter the room, possibly

causing serious injury to occupants or death.

Note: Check with your municipality, local codes, or local gas company to determine if disposal of combustion condensate is permitted. In the State of Massachusetts the condensate must be neutralized prior to entering a drain

■ Use only PVC, vinyl or CPVC pipe for the condensate drain line, metal pipe work is not suitable for condensate discharge system.

The condensate drain line should be a minimum of 1/2” diameter that connects to the 7/8” supplied hose and must be supported to prevent sagging. Manufacturer will supply a ¾” to ½” reducer for connection.

GENERAL INFORMATION

■ Keep the length of the condensate drain as short as possible. Long runs or applications where the nearest drain is above the water heater will require the use of a condensate pump. Size the pump to allow for a maximum condensate discharge of 2 gpm from the water heater. The end drain pipe must not be submerged in water or blocked in any way.

■ The condensate pump must be installed with an overflow safety switch that detects downstream clogs and shuts off the water heater before flooding occurs. See condensate pump manufacture for installation instructions.

■ Be sure to check that condensate is freely flowing from the drain piping after the system has been installed. Condensate will begin flowing out of the water heater within 15 minutes after operation has started.

■ Do not run condensate line outside and take measures to prevent the condensate drain lines from freezing (insulation, heat tape, electric heaters, etc.)

■ Be sure to clean the condensate trap at least once per year to prevent any problems, and after cleaning be sure to check for any leaks of condensed water or flue gas.

Space Heating

 Suitable for combination water (potable) heating and space heating and not suitable for space heating

applications only.

 Piping and components connected to the water heater for the space heating application shall be suitable for

use with potable water.

 Toxic chemicals used for water heater treatment shall not be introduced into the potable water.  A water heater which will be used to supply potable water shall not be connected to any heating system of

component(s) previously used with nonpotable water heating appliance.

 When the system requires water for the space heating at temperatures higher than required for other uses, a

means such as a mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential.

 The water heater can be used for potable hot water heating and combination space heating applications. Note: the following illustrations are conceptual designs only. There are many design variations of the equipment presented. Designers must add all necessary safety and auxiliary equipment to conform to Code requirement and proper design practice. For more details, contact the manufacturer or distributors of the products.

GENERAL INFORMATION

3.6 Schematic of Piping Installation

GENERAL INFORMATION

3.7 Gas Connection

3.7.1 Gas Piping Guidelines

Follow all local codes and/or the most recent edition of the National Fuel Gas Code (ANSI Z223.1/NFPA 54) in the

USA or the Natural Gas and Propane Installation Code in Canada (CAN/CSA B149.1).

3.7.2 Gas Supply Lines Pressures

The minimum and maximum inlet gas pressures are Natural Gas Min. 7.00”WC – Max. 14.00”WC.

Gas pressures over and above the specified range will result in adverse performance and dangerous operating

conditions; any damage resulting from extreme gas supply pressures will not be covered by the limited warranty.

Until pressure testing of the main gas supply line is completed, ensure the gas line to the FLOWMAX Combination

Water Heater is disconnected to avoid any damage to the water heater.

The appliance and its individual shut off valve must be disconnected from the gas supply piping system during any

pressure testing of that system at test pressures in excess of 0.5 psi (3.5 kPa)..

The appliance must be isolated from the gas supply piping system by closing its individual manual shut-off valve

during any pressure testing of the gas supply system at test pressures equal to or less that 0.5 psi (3.5 kPa).

The gas appliance and its gas connections must be leak tested before placing the appliance in operation. Leaks

can be found by using a gas leak detection device or by applying soapy water to all gas fittings. Should bubbles occur, tighten those connections and re-test.

Always purge the gas line for any debris before connecting to the water heater gas inlet.

Never use an open flame to test for gas leaks as property damage, personal injury or death could result.

The maximum inlet gas pressure must not exceed the valve specified by the manufacturer and that the minimum

valve listed as for the purposes of input adjustment.

The connection to the gas supply must be carried out by professionally qualified personnel in accordance with the

relevant standards.

■ Check the internal and external seals of the gas supply system.

■ A gas shut-off valve must be installed upstream of the appliance

■ Before starting up the water heater, make sure that the type of gas corresponds to that for which the appliance has

been set-up.

■ The gas supply pressure must be between the values reported on the rating plate.

■ Conversion of the appliance from natural gas to LPG or vice versa must be carried out by qualified personnel.

■ The power supply cable must be replaced by a qualified electrician. If the cable is damaged in any way, switch off

the appliance and have the cable replaced by a suitably qualified electrician.

When using an electrical appliance, a few fundamental rules must be observed:

• Do not touch the appliance with damp or wet parts of the body or when barefoot.

• Do not pull on the electric wires.

Do not allow the appliance to be used by children or anyone unfamiliar with its operation.

GENERAL INFORMATION

3.8 Electrical connections

3.8.1 General warnings

Follow the electrical code requirements of the local authority having jurisdiction. In the absence of such

requirements, follow the latest edition of the National Electrical Code (NFPA 70) in the U.S. or the latest edition of CGA C22.1 Canadian Electrical Code – Part 1 in Canada.

3.8.2 Electric Wiring: Ground and Surges

All units come with factory installed 3-pronged (grounded) plug end. The combination water heater can be

plugged into any standard electrical duplex outlet close to the unit as it requires only 4 Amps.

If the local jurisdiction requires the unit to be wired directly, remove and discard the factory installed plug. An

ON/OFF switch controlling the main power between the breaker and the FLOWMAX Water Heater should be provided to facilitate end-user maintenance and servicing. This should be done by a qualified electrician.

The combination water heater must be electrically grounded. Ensure the electrical receptacle, in which the water

heater will be plugged into, is properly grounded; if wiring directly, do not attach the ground wire to either the gas or the water piping as plastic pipe or dielectric unions may isolate the water heater electrically.

The use of a surge protector is recommended to protect from power surges.

Do not energize electric power to the unit until all plumbing and gas piping is complete and the combination water

heater has been filled with water.

The electrical supply required by the water heater is 120VAC at 60Hz with a maximum 4A rating with proper

grounding.

DO NOT connect 220-240VAC and any other voltage to this FLOWMAX Combination Water Heater. This will

damage the combination water heater and void the warranty.

Do not disconnect the power supply when the unit is in normal operation.

If there is a power failure in cold weather areas, the freeze prevention system in the water heater will not operate

and may result in freezing of the heat exchanger; in cold weather areas where power failures are common, you must completely drain the unit to prevent damage if the power will be off for any extended period of time.

Damage caused by freezing is not covered under warranty.

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

dangerous operation. Verify proper operation after servicing.

The connection to the main power supply must be carried out by professionally qualified electrical personnel,

registered in accordance with current legislation and local authorities.

Always check to make sure that the appliance has an efficient ground system. This requirement is only satisfied if

it has been properly connected to an efficient ground system installed in accordance with the requirements of current safety standards and carried out by professionally qualified personnel.

This basic safety measure must be checked, verified and carried out by professionally qualified personnel. Have the electrical system checked by a qualified electrician. The manufacturer will not be held liable for any damage or injury caused as a result of an inefficient or faulty ground system.

GENERAL INFORMATION

■ Ensure the domestic power supply is checked by a qualified electrician to ensure that it can support the maximum power absorption of the appliance, as indicated on the rating plate. In particular, make sure that the cable sizes are adequate for the power absorbed by the appliance;

■ The power supply cable must be replaced by a qualified electrician. If the cable is damaged in any way, switch off the appliance and have the cable replaced by a suitably qualified electrician;

When using an electrical appliance, a few fundamental rules must be observed:

• Do not touch the appliance with damp or wet parts of the body or when barefoot.

• Do not pull on the electric wires.

• Do not allow the appliance to be used by children or anyone unfamiliar with its operation;

If the unit fails to re-start after any fault, unplug the unit for 30 seconds, then re-plug in the unit and try to restart with the on/off

switch. If the unit fails to restart, call a qualified Technician for service.

GENERAL INFORMATION

3.8.3 Remote control connection

Electrical connections (Option)

Connect the power supply to the terminal board located onto the control panel as

follows:

switch off the power supply at the main switch;

remove the front case panel of the boiler.(see paragraph '6.3 Accessing the boiler');

Slacken the screws and remove plate A from the control panel (see fig. 1). With the plate removed, proceed with the following wires connection:

•

of the outdoor temperature sensor on contacts marked as Se·Se on the terminal board "B";

• remove jumper from Ta –Ta from the terminal board B and install the control field supplied control wire leading to a heating dry contact

When wires have been connected, place plate "A" back to position and then the front case panel.

In case of a simultaneously outdoor temperature sensor and remote control installation, the printed circuit board sends the outdoor temperature value to the remote control only, without using it for the modulation. The communication between the printed circuit board and the remote control happens separately from the boiler functioning mode selected and, once the connection has been established, the user interface on board is disabled

and displayed by the symbol

GENERAL INFORMATION

3.9 Venting

Improper venting of combination water heater can result in excessive levels of carbon monoxide, which can result in severe personal injury or death. This combination water heater must be vented in accordance with the “Venting of Equipment” section of the latest edition of the ANSI Z223.1 / NFPA 54 Natural Gas Code and/or the “Venting systems and air supply for appliances” section of the latest version of the CAN/CSA B149.1 Natural Gas and Propane Installation Code in Canada and in accordance with all applicable local building codes.

Venting Guidelines

• For best results, keep the vent system as short and straight as possible.

• Locate the combination water heater as close as possible to the vent termination.

• This combination water heater vent must not be common vented with any other gas appliance or vent stack.

Slope v

•

• V

• Vent and air intake pipe must be supported every 4 feet of horizontal run and every 5 feet of vertical run.

FLOWMAX and Direct Vent

ent upwards towards the vent terminal at a minimum rate of 1/8” per foot (1% slope).

ent termination must be a minimum of 12” above grade or expected snowfall.

• All FLOWMAX Combination Water Heaters are prepared at the factory to be direct vent (sealed combustion) units which draw all of their required combustible air directly from outside the building.

• All FLOWMAX Combination Water Heaters use 2” or 3” diameter exhaust and 2” or 3” diameter air intake pipe.

• The air intake vent materials can be made of ABS, CPVC, PVC materials and in accordance with all applicable

local building codes. .

Contaminated Make-Up Air Will Damage the Unit

• Recommend not to operate the combination water heater in an area that is or will be under construction or renovation.

• The FLOWMAX warranty will not cover damage and premature wear caused to the unit due to installation in a contaminated environment.

• All of the exhaust venting connections must be leak checked with a soap solution upon initial start up of the water heater. Any leaks must be repaired before continuing operation of the water heater.

• Warranty will not be available if the water heater is used for construction heat.

xhaust Vent Piping Materials

• Use only 2” or 3” solid PVC/CPVC schedule 40 PVC/CPVC or ULC S636 pipe and fittings

enting requirements in USA and Canada are different. Please consult with the most recent edition of the

• V National Fuel Gas Code (ANSI Z223.1 / NFPA 54) or CAN/CSA B-149.1 as well as local codes for applicable venting regulations and restrictions.

• For installation in Canada, field supplied plastic vent piping must comply with CAN/CSA B-149.1 (latest edition) and be certified to the standard for type BH Gas Venting Systems, ULC S636 components of this listed system shall not be interchanged with other vent systems or unlisted pipe/fittings. All plastic components and specified primers and glues of the certified vent system must be from a single manufacturer and not intermixed with other system manufacturer’s vent system parts. The supplied vent adaptors are certified as part of the combination water heater.

• For all units installed with vertical exhaust, must have an additional approved condensate drain installed on t

orizontal section of the exhaust vent. Fittings must be ULC S636 approved.

• PVC/CPVC pipe/fittings have been approved for use on this appliance with zero clearance to combustibles.

GENERAL INFORMATION

Model

Size

Max Equivalent

Vent Run

Type

Exhaust Vent

Intake Vent

FLOWMAX-90

2"/ 3" Diam

100 ft

Natural Gas or LP

Schedule 40 PVC/CPVC

PVC, CPVC or ABS

FLOWMAX-120

3” / 4"" Diam

100 ft

Natural Gas or LP

Schedule 40 PVC/CPVC

PVC, CPVC or ABS

FLOWMAX-170

3" Diam

100ft

Natural Gas or LP

Schedule 40 PVC/CPVC

PVC, CPVC or ABS

• This water requires a special venting system. Refer to the installation instructions for parts list and method of installation.

• Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel (polyphenylsulfone) in non-metallic venting systems is prohibitted. Covering non-metallic vent pipe and fittings with thermal insualtion is prohibitted.

ntake Vent Pipe Materials

PVC, CPVC or ULC S636 pipe and fittings and ABS pipe and fittings can be used for combustion air intake on FLOWMAX products.

• Transition cement must be used if ABS pipe is connected to the PVC appliance adaptors.

• All plastic components and specified primers and glues of the certified vent system must be from a single

manufacturer and not intermixed with other system manufacturers vent system parts.

• The vent for this appliance shall not terminate over public walkways, near soffit vents, crawl spaces or other areas where condensate or vapour could create a nuisance or hazard or cause property damage or wher c

ondensate vapour could cause damage or could be detrimental to the operation of regulators, relief valves of

other equipment.

llowable Vent Lengths

Length Vertical

and Horizontal per

quivalent Lengths

• Reduce the maximum vent length accordingly for each elbow used.

• Each 2”/3” 45⁰ elbow equates to 2.5 linear feet of vent pipe.

• Each 2”/3” 90⁰ short radius elbow equates to 7.5 linear feet of vent pipe.

• Each 2”/3” 90⁰ long radius elbow equates to 5 linear feet of vent pipe.

• The maximum length listed is for exhaust vent only. The intake length should be equal length.

• The total maximum equivalent vent pipe distance cannot exceed 100ft for horizontal and vertical venti

stance.

• The maximum lengths are not including elbows.

• Exceeding the maximum venting distances will cause the appliance to malfunction or cause an unsafe

inimum Vent Lengths

• 2" Diameter - 12" pipe (Iength) plus one elbow.

• 3" Diameter - 16" pipe (Iength) plus one elbow.

condition.

REGULATION INSTRUCTIONS

4. COMMISSIONING THE APPLIANCE

4.1 General warnings

The following operations must be carried out by professionally qualified personnel, registered in

accordance with current legislation.

The water heater leaves the factory pre-set and tested for burning either natural Gas or LPG.

Nevertheless, when starting the water heater for the first time, make sure that the information on the rating plate corresponds to the type of gas being supplied to the water heater.

Once the system has been filled and the necessary adjustments made, remember to tighten the screws of

the gas valve test point and make sure that there are no gas leaks from the test point and from any pipe fittings upstream of the gas valve.

■ Preliminary operations

Switching the water heater on for the first time means checking that the installation, regulation and operation of the appliance are correct:

• Check that the rating on the rating plate corresponds to that of the mains supply networks (gas, electricity, water));

• Check that the power supply voltage to the water heater complies with the rating plate (120 V – 60 Hz) and that the

live, neutral and ground wires are connected properly. Also make sure that the ground connection is sound;

• Check that the gas supply is correctly sized for the flow rate required by the water heater and that it is fitted with all the safety and control devices stipulated by current regulations;

• Check that the supply of combustion air and exhaust and condensate discharge systems are functioning correctly and in line with current law and national and local standards;

• Check for the presence of permanent aeration/ventilation openings as required by current law for the type of appliances installed;

• Check that the exhaust vent and its connections to the termination comply with the requirements of current law and national and local standards for the type of appliances installed;

• Check that the condensate drain system, including outside the water heater (exhaust system condensate collection devices), allows the condensate to flow freely to the drain.

• Check that there are no flammable materials or liquids in the immediate vicinity of the water heater;

• Flush out both primary and domestic hot water circuits (see 4.3 “Flushing the system”).

REGULATION INSTRUCTIONS

4.2 Filling the system

Check the properties of the water supply and install the

appropriate treatment devices if the mains water has a hardness rating more than 14.5 gpg (250 mg/L) i

prevent scaling and eventual damage to the D.H.W heat exchanger.

Use only clean tap water to fill the system.

A pre-filtering system can be installed on the incoming water

supply to help reduce impurities and limestone.

This water heater must have adequate water flowing through it

whenever the burner is on. Failure to do this will damage the unit and void the warranty.

Once the water pipes have been connected, close the gas feed valve and fill the system as follows:

n order to

• Check that the circulation pump runs freely;

• Check that the plug of the air vent valve has been slackened slightly

to allow air to escape from the system (fig.1);

• Open the main domestic water supply valve;

• Open the filling tap R (fig. 2);

• Unscrew the plug on the pump to remove any trapped air, check that

the pump is free then re-tighten it when water starts to flow out (fig.1);

• Before switching on the water heater, purge air completely from

the air vent valve positioned on the top of the condensing exchanger (fig. 3);

• Open the air vents on the radiators and monitor the air evacuation

process. When water starts to flow out of the radiators, close the air vents;

• Use the pressure gauge M (fig. 2), to check that the systems

pressure reaches the middle of the green area (equal to 1,2 bar, see fig. 4).

• On completion, make sure that the filling tap R is perfectly

closed.

REGULATION INSTRUCTIONS

Fig. 1

4.3 Flushing the system

Failure to flush and add inhibitor to the system will invalidate the appliance operation. All systems must be thoroughly drained and flushed out using additives – corrosion inhibitors and flushing agents/descalers. All flushing must be done for new and retrofit installs.

Warning: Failure to clean the system and add adequate inhibitor invalidates the warranty.

To flush out the primary side of this unit

a. Fill the water heater with clean water as per the filling instructions. b. Using a drain off cock on the lowest point of the system allow the water to drain from the system and water heater. c. In order to flush the system correctly, turn off all radiators or fan coils. Open the filling loop and drain cock

simultaneously and allow the water to flow through the water heater.

d. Open each individual radiator or fan coil, allowing water to flow through. Then turn that radiator or fan coil off

epeat for all radiators or fan coils on the system.

e. Turn off the filling loop and close the drain cock. Open all radiators or fan coils and open the filling to fill the

ystem.

f. Continue to fill the system until the pressure gauge reaches 14.5 psi (1 bar). g. Add an inhibitor to the system water to prevent limestone and magnetite deposits from forming and to protect t

ater heater from galvanic corrosion.

h. In areas where freezing might occur, an antifreeze (Gycol) may be added to the system water to protect the

system. Please adhere to the specifications given by the antifreeze manufacture. Do not use automotive silicate based antifreeze. Please observe that the antifreeze and water mixture does not exceed 40% of the antifreeze content. Do not use antifreeze other than that specifically made for hot water heating systems. Advise systems operator/ultimate owner that system is filled with antifreeze.

and

To flush out domestic hot water circuit

a. Open all hot water outlets. b. Turn on inlet group supply so water enters the water heater; leave to fill until water is released from the hot water

outlets. Turn off all hot water outlets.

c. Connect a hosepipe to the cylinder drain cock and open the drain cock. d. Allow water to flow through the water heater and out of the drain cock. e. Turn off water supply, disconnect the hosepipe, close the drain cock and refill the water heater. f.

4.4 Filling the condensate trap

he condensation trap must be pre-filled when starting the water heater for the first time in order to prevent flue gases

T from flowing back through the trap.

The filling operation is carried out as follows (see fig. 1):

• Remove plug T and fill the trap S three quarters

full with water;

• Replace plug T and connect the drainpipe P

into a condensate discharge trap conforming to current legislation;

ttention! It is recommended to clean the

condensate trap, after a few months of water heater operation, to remove deposits/residuals left after the first condensate passage within the water heater new components that may interfere with the correct operation of the trap itself.

REGULATION INSTRUCTIONS

Table n°1

Gas type

CO2 %

Natural Gas - G20

9.4

Liquid Propane Gas - G 31

10.96

Fig. 1

4.5 Starting up the water heater

Once the system has been filled, proceed as follows:

• Check that the exhaust vent is free of obstructions and correctly connected to the water heater;

• Switch on the power supply to the water heater;

• Open the gas isolation valve;

• Place switch 1 in the ON position (see 2.7

“Control Panel”), after a few seconds the circulating pump will start to run;

• Use button 6 to set the SUMMER, WINTER or SUMMER/WINTER function. The symbols

will light up (fixed light) to indicate that

the water heater is working;

• The automatic ignition system will then light the burner. This operation is repeated for times. It may however be necessary to repeat the operation in order to eliminate all the air from the pipes. To repeat the operation, wait approximately three minutes before reattempting to light the water heater. To reset the water heater Switch off switch 1 (see 2.

Control Panel”) and switch it back on again

“

and repeat the lighting procedure;

• With the water heater ignited, if the system still emits noises, the operations must be repeated until all the air has been removed;

• Check the pressure in the system. If t

essure has fallen, re-open the filling tap until

pr the code H2O disappears on the display and the pressure reaches the middle of the green area (1,2 bar). On completion, close the

filling tap.

• If the CO2 value does not correspond to the specified value, adjust screw V (see fig. 1) on the venture clockwise to reduce the CO2 value or anticlockwise to increase it

;

•

The combustion air and vent adapters with 1/2" test ports and plugs may be equipped in any orientation on units to allow easier access when preforming combustion analysis and other testing (Fig. 2).

REGULATION INSTRUCTIONS

PARAMETER

TYPE OF OPERATION

PARAMETER

VAL UE

FUNCTION

00 (do not use)

06 (do not use)

00 - 13 KW

06 - 100 KW

00 (do not use)

05 (do not use)

00 – Instantaneous w/ dual circuit Exchanger

05 - Only Heating Boiler

P02

Selects the type of gas supplied

00 - 01

02 (do not use)

00 - Natural Gas - 01 - LP Gas

02 - G25

P03

Sets the central heating temperature

00 - 01

Standard (30 - 80°C) - Reduced (25 - 45°C)

0 Seconds (Disabled)

400 Seconds

P05

Water hammer prevention function

00 - 01

Off - On

P06

DHW Priority Function

00 - 01

Off - On

P07

Central Heating Timer

00 - 90

Displayed in multiples of 5 seconds

(Default value 36 x 5 = 180”)

P08

Central heating Pump Overrun Timer

00 - 90

Displayed in multiples of 5 seconds

P09

DHW / Storage Cylinder Pump Overrun

Timer

00 - 90

Displayed in multiples of 5 seconds

(Default value 18 x 5 = 90”)

P10

Sets the Minimum Fan Speed

(displayed in Hertz)

66 Ng / 60 Lp

60 Ng / 60 Lp

Flowmax 90

Flowmax 170

P11

Sets the Maximum Fan Speed

(displayed in Hertz)

162 Ng / 149 Lp

155 Ng / 143 Lp

Flowmax 90

Flowmax 170

P12

Sets the Minimum Fan Speed

(displayed in Hertz)

66 Ng / 60 Lp

60 Ng / 60 Lp

Flowmax 90

Flowmax 170

P13

Sets the Maximum Fan Speed

(displayed in Hertz)

162 Ng / 149 Lp

155 Ng / 143 Lp

Flowmax 90

Flowmax 170

(displayed in Hertz)

90 Ng / 110 Lp

Flowmax 90

Flowmax 170

P15

Legionella prevention Function

(For storage boilers only)

00 - 01

Off - On

P16

Sets the climatic compensation curve

(w/outdoor temperature sensor only)

00 - 30

See the graph in the parameter setting explanation

P17

Sets the temperature measurement units

00 - 01

°C - °F

Disabled

Burner output control mode

P19

Central heating minimum set point

20 – 40

Displayed in °C

P20

Central heating maximum set point

40 – 88

Displayed in °C

P21

DHW maximum set point

45 – 75

Displayed in °C

P22

∆T set point T° flow / T° return

sensor connected only)

Disabled

P23

Modulating pump minimum speed

sensor connected only)

P24

Modulating pump maximum speed

sensor connected only)

70 – 100

Displayed in percentage

P25

∆T timing T° flow / T° return

sensor connected only)

20 – 100

Displayed in seconds

5. REGULATING THE APPLIANCE - NORDGAS

P00

P01

P04

Selects the model of boiler

Selects the type of boiler

Heating output rising time

(Domestic Mode)

01 (do not use)

03 (do not use)

04 05

01 02

(do not use)

01 02 03

55 Ng / 52 Lp

01 - 18 KW

02 – Flowmax 90

03 - 28 KW

04 – Flowmax 120 05 – Flowmax 170

01 - Instantaneous w/ secondary DHW Plate exchanger

02 - Storage Cylinder Boiler

03 - Boiler w comfort storage cylinder

04 - Instantaneous Comfort Mode w/ preheat function

50 Seconds (Default)

100 Seconds 200 Seconds

(Default value 36 x 5 = 180”)

Flowmax 120

P14

P18

(Domestic Mode)

(Central Heating Mode)

Sets the Ignition Sequence

Sets the 0-10v industrial bus piloting

(w/modulating pump and return temperature

164 Ng / 155 Lp

55 Ng / 52 Lp

164 Ng / 155 Lp

110 Ng / 130 Lp

10 - 40

50 – 70

Flowmax 120

Flow temperature Control mode

Displayed in °C

Displayed in percentage

NOTES:

P04

This parameter allows to modify the time the boiler takes (in heating mode) to reach the maximum power set.

P10, P11, & P12 P13

The maximum boiler power in heating mode, can be set according to the paragraph 5.5 "Heating output (Kw) - Fan frequency (Hz) diagram".

These parameters are automatically set according to the output value set in Parameter P00.

REGULATION INSTRUCTIONS

Accessing the parameters menu

To modify the preset values of the parameters reported in the previous table, open the parameter settings menu as follows:

1. Place mode selection button “ ” in OFF position,

visualized by

2. Keep pressed ' ' and ' ” buttons simultaneously and

wait for

3. Release buttons '

4. Use ' ' and “ ” buttons of heating temperature

setting

Adjust the value of the parameter using the procedure described in the following pages.

symbol and 'P00', to appear on the display.

to select the parameter to modify;

symbol;

‘ and ‘ ”:,

5.2 Setting the parameters

PARAMETER P00 – SELECTS THE MODEL OF BOILER

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

REGULATION INSTRUCTIONS

5. Use

value of the parameter: 00 = (do not use) 01 = (do not use) 02 = Flowmax 90 03 = (do not use)

04 = Flowmax 120 05 = Flowmax 170

06 = (do not use)

6. Press mode selection button parameter operative.

7. To exit from the parameters menu, press simultaneously buttons.

and buttons (D.H.W temperature setting) to modify the

to confirm and to render the new

and

PARAMETER P01 – SELECTS THE TYPE OF BOILER

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ steps 1-4).

5. Use value of the parameter: 00 = (do not use)

01 = Instantaneous w/ secondary DHW Plate exchanger 02 = storage cylinder boiler

03 = (do not use) 04 = Instantaneous Comfort Mode w/ preheat function 05= (do not use)

and buttons (D.H.W temperature setting) to modify the

6. Press mode selection button parameter operative.

7. To exit from the parameters menu, press simultaneously buttons.

to confirm and to render the new

and

PARAMETER P02 – SELECTS THE TYPE OF GAS SUPPLY

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ steps 1-4).

5. Use

value of the parameter: 00 = Natural Gas 01 = LPG

02 = G25 (do not use)

6. Press mode selection button to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

buttons.

and buttons (D.H.W temperature setting) to modify the

and

REGULATION INSTRUCTIONS

PARAMETER P03 – SETS THE CENTRAL HEATING TEMPERATURE

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -

steps 1-4).

5. Use value of the parameter:

00 = standard (30-80°C) 01 = reduced (25-45°C) for under-floor heating

6. Press mode selection button parameter operative.

7. To exit from the parameters menu, press simultaneously buttons.

and buttons (D.H.W temperature setting) to modify the

to confirm and to render the new

and

PARAMETER P04 – HEATING OUTPUT RISING TIME

This parameter is used to set the time the boiler takes to reach the maximum power set, during the starting up.

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use value of the parameter: 00 = 0 seconds (disabled) 01 = 50 seconds (default) 02 = 100 seconds 03 = 200 seconds 04 = 400 seconds

and buttons (D.H.W temperature setting) to modify the

6. Press mode selection button parameter operative.

7. To exit from the parameters menu, press simultaneously

buttons.

to confirm and to render the new

and

PARAMETER P05 – WATER HAMMER PREVENTION FUNCTION

Activating this function, the D.H.W contact is delayed for 2 seconds.

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -

steps 1-4)

5. Use and buttons (D.H.W temperature setting) to modify the value of the parameter:

00 = Off 01 = On

6. Press mode selection button parameter operative.

7. To exit from the parameters menu, press simultaneously buttons.

to confirm and to render the new

and

REGULATION INSTRUCTIONS

PARAMETER P06 – D.H.W PRIORITY FUNCTION

This parameter is used to maintain the diverter valve on D.H.W mode for a time equal to the post-circulation, keeping hot the secondary heat exchanger To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -steps 1-4)

5. Use value of the parameter:

00 = Off 01 = On

6. Press mode selection button operative.

7. To exit from the parameters menu, press simultaneously

and buttons (D.H.W temperature setting) to modify the

to confirm and to render the new parameter

and buttons.

PARAMETER P07 – CENTRAL HEATING TIMER

5. Use and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in multiples of 5 seconds min = 00 max = 90 For ex.: 90 = 90 x 5” = 450” (7,5 min) The default value is 36 = 180” = 3 min

6. Press mode selection button operative.

7. To exit from the parameters menu, press simultaneously

to confirm and to render the new parameter

and buttons.

PARAMETER P08 – CENTRAL HEATING PUMP OVERRUN TIMER

This parameter is used to set the pump functioning time, in heating mode, after switching off the main burner for the intervention of the room thermostat To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -steps 1-4)

5. Use and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in multiples of 5 seconds min = 00

max = 90 For ex.: 90 = 90 x 5” = 450” (7,5 min) The default value is 36 = 180” = 3 min

6. Press mode selection button operative.

7. To exit from the parameters menu, press simultaneously

to confirm and to render the new parameter

and buttons.

REGULATION INSTRUCTIONS

PARAMETER P09 – D.H.W/STORAGE CYLINDER PUMP OVERRUN TIMER

This parameter is used to set the pump functioning time, in D.H.W mode, after closing the water tap. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in multiples of 5 seconds): min = 00 max = 90 For ex.: 90 = 90 x 5” = 450” (7,5 min) The default value is 18 = 90” = 1.5 min

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and buttons. .

PARAMETER P10 – SETS THE MINIMUM FAN SPEED (DOMESTIC MODE)

This parameter is used to set the minimum fan speed, which corresponds to the minimum burner output. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Hertz):

66 Hz Ng / 60 Hz Lp – Flowmax 90 55 Hz Ng / 52 Hz Lp – Flowmax 120 60 Hz Ng / 60 Hz Lp – Flowmax 170 The default value is set according to the output value set in Parameter P00.

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P11 – SETS THE MAXIMUM FAN SPEED (DOMESTIC MODE)

This parameter is used to set the maximum fan speed, which corresponds to the maximum burner output. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Hertz):

162 Hz Ng / 149 Hz Lp – Flowmax 90 164 Hz Ng / 155 Hz Lp – Flowmax 120 155 Hz Ng / 143 Hz Lp – Flowmax 170 The default value is set according to the output value set in Parameter P00.

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

REGULATION INSTRUCTIONS

PARAMETER P12 – SETS THE MINIMUM FAN SPEED (CENTRAL HEATING)

This parameter is used to set the minimum fan speed in heating mode, which corresponds to the minimum burner output during a heating mode request. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Hertz):

66 Hz Ng / 60 Hz Lp – Flowmax 90 55 Hz Ng / 52 Hz Lp – Flowmax 120 60 Hz Ng / 60 Hz Lp – Flowmax 170 The default value is set according to the output value set in Parameter P00.

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P13 – SETS THE MAXIMUM FAN SPEED (CENTRAL HEATING)

This parameter is used to set the maximum fan speed in heating mode, which corresponds to the maximum burner output during a heating mode request [see paragraph 5.5 Heating output (kW) – Fan frequency (Hz) diagram]. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Hertz):

162 Hz Ng / 149 Hz Lp – Flowmax 90 164 Hz Ng / 155 Hz Lp – Flowmax 120 155 Hz Ng / 143 Hz Lp – Flowmax 170 The default value is set according to the output value set in Parameter P00

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P14 – SETS THE IGNITION SEQUENCE

This parameter is used to set the ignition sequence during the starting up of the boiler. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ –steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Hertz):

90 Hz Ng / 110 Hz Lp – Flowmax 90 110 Hz Ng / 130 Hz Lp – Flowmax 120 90 Hz Ng / 110 Hz Lp – Flowmax 170 The default value is set according to the output value set in Parameter P00.

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

REGULATION INSTRUCTIONS

PARAMETER P15 – LEGIONELLA PREVENTION FUNCTION

(For storage boilers only)

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter:

00 = Off 01 = On

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

PARAMETER P16 – SETS THE CLIMATIC COMPENSATION CURVE

(w/outdoor temperature sensor only installation) The installation of an outdoor temperature sensor (see paragraph 6.6 ‘Electrical connections’) allows to automatically modify the flow temperature in accordance

to the outdoor temperature. The factor governing the correction is the Kd thermoregulation value, indicating the flow temperature range selected (fig.1).

The maximum flow temperature Tm and the minimum outdoor temperature Te taking into consideration the house insulation degree determine the selection of the compensation curve.

The values of the flow temperature Tm, refer to standard 30-80 °C appliances or 25-45 °C for under-floor heating systems. The type of appliance can be set using parameter P03.

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4) and select

parameter P16.

5. Use

and buttons (D.H.W temperature setting) to modify the value of the parameter within the range of setting from 00 to 30. The value corresponds to the graph curves in figure n.1.

6. Press mode selection button

to confirm and to render the new parameter

operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

REGULATION INSTRUCTIONS

PARAMETER P17 – SETS THE TEMPERATURE MEASUREMENT UNIT

This parameter is used to set the temperature measurement unit displayed: Celsius ( ) or Fahrenheit ( ) degrees. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter:

00 = °C 01 = °F

6. Press mode selection button

to confirm and to render the new parameter

operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

PARAMETER P18 – SETS THE 0-10V INDUSTRIAL BUS PILOTING

This parameter is used to enable/disable the 0-10V industrial bus in order to set the

burner output and the flow temperature by outdoor bus. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the value

of the parameter

00 = Disabled 01 = Flow temperature control mode 02 = Burner output control mode

6. Press mode selection button

to confirm and to render the new parameter

operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

PARAMETER P19 – CENTRAL HEATING MINIMUM SET POINT

This parameter is used to set the central heating minimum user set point. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in Celsius degrees):

min = 20 °C max = 40 °C

6. Press mode selection button

to confirm and to render the new parameter

operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

REGULATION INSTRUCTIONS

PARAMETER P20 – CENTRAL HEATING MAXIMUM SET POINT

This parameter is used to set the central heating maximum user set point. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in Celsius degrees):

min = 40 °C max = 88 °C

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P21 – D.H.W. MAXIMUM SET POINT

This parameter is used to set the D.H.W maximum user set point. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in Celsius degrees):

min = 45 °C max = 75 °C

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P22 – ΔT SET POINT T° FLOW/ T° RETURN

(w/modulating pump and return temperature sensor connected only)

To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the value of the parameter within the prescribed limits (displayed in Celsius degrees):

Disable = 00 (must be set to 00) min = 10 °C max = 40 °C

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and buttons.

REGULATION INSTRUCTIONS

PARAMETER P23 – MODULATING PUMP MINIMUM SPEED

(w/modulating pump and return temperature sensor connected only)

This parameter is used to set the minimum modulating pump speed during a heating mode request. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in percentage);

min = 50 % max = 70 %

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P24 – MODULATING PUMP MAXIMUM SPEED

(w/modulating pump and return temperature sensor connected only)

This parameter is used to set the maximum modulating pump speed during a heating mode request. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ -steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in percentage);

min = 70 % max = 100 %

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

PARAMETER P25 – ΔT TIMING T° FLOW/ T° RETURN (w/modulating pump and return temperature sensor connected only)

This parameter is used to set the timing response of the modulating pump. To enter the parameters menu, follow the previously described procedure (see paragraph 5.2 ‘Accessing the parameters menu’ - steps 1-4).

5. Use

and buttons (D.H.W temperature setting) to modify the

value of the parameter within the prescribed limits (displayed in seconds);

min = 20 max = 100

6. Press mode selection button

to confirm and to render the new

parameter operative.

7. To exit from the parameters menu, press simultaneously

and

buttons.

REGULATION INSTRUCTIONS

Lower Wobbe Index (59°F; 14.5 psi)

Nominal supply gas pressure

mbar - “ wc

20 - 7

37 – 14

Consumption (59°F; 14.5 psi)

m3/h - ft3/h

2.65 - 93.58

1.01 - 35.67

Table no.1 - CO

2

Values

Natural Gas

9.4

Liquid Propane Gas

10.96

Table no.2 - Frequency

Natural Gas

162

Liquid Propane Gas

149

0 10 20 30 40 50 60 70 80

90 100 110 120 130 140 150 160 170

Frequenza Hz

Portata termica kW

Natural Gas

Liquid Propane

K w

5.3 Gas data

Gas type CO2 %

Gas type Minimum (Hz) Maximum (Hz)

Technical data tables

Heating Power (kW) – Fan frequency (Hz) diagram

e a t i n g

p o

e r

NATURAL GAS LIQUID PROPANE GAS

MJ/Nm3 45.67 70.69

INSTALLATION INSTRUCTIONS

6. MAINTENANCE (authorized personnel)

6.1 General Warnings

All maintenance operations must be carried out by professionally qualified personnel, authorized by

FLOWMAX.

The frequency of water heater maintenance is recommended to be carried out once a year.

In order to guarantee the long life of the appliance and in accordance with the current gas safety

regulations, only use original spare parts

Before carrying out any type of maintenance operation, disconnect the appliance from the electrical

supply and shut off the gas valve.

Warranty will not be offered if recommended maintenance is not followed.

6.2 Maintenance

Periodic examination of the entire venting system is recommended. Make sure all the venting

connections/joints are tight and in good condition where visible.

Clean the burner cylinder using a non-metal brush and without damaging the ceramic fibre.

Clean the heat exchanger using a recommended detergent from FLOWMAX Technologies for the stainless

steel. Do not wet the ceramic fibre coating.

Visually inspect the burner flame. The flame must burn with a clear blue, stable flame. If the burner flame

appearance is not satisfactory or debris is visible on the burners, remove and clean with a vacuum cleaner.

All electric motors are permanently lubricated and do not need oiling. Remove the combustion air blower

and clean wheel and housing with soft brush or vacuum.

Verify proper operation after any servicing.

Wipe the outside surface with a wet cloth; then dry the surface. Use a neutral detergent to clean any

stains.

Vent termination should be inspected for blockage during maintenance checks.

Check for blockage at the drain pipe and condensate trap.

Clean condensate trap and check for correct level of water.

Check for water leaks from the equipment and piping.

Warranty will not be offered if recommended maintenance is not followed.

INSTALLATION INSTRUCTIONS

6.3 Water heater inspection

In order to ensure that the water heater operates efficiently and safely, it is recommended that the appliance is inspected by a suitably competent technician at least once a year. The following operations should be carried out annually:

■ Check the condition of the gas seals and replace where necessary.

■ Check the condition of the water seals and replace where necessary.

■ Visually inspect the condition of the combustion chamber and flame.

■ Check that the combustion is correctly regulated and if necessary proceed in line with section “Commissioning the

water heater”.

■ Remove and clean any oxidation from the burner.

■ Check that the seal of the room-sealed chamber is undamaged and positioned correctly.

■ Check the primary heat exchanger and clean if necessary.

■ Check the maximum and minimum modulation pressures and the modulation itself.

■ Check the condition and operation of the ignition and gas safety systems. If necessary, remove and clean the

scaling from the ignition and flame detection electrodes, paying particular attention to replace them at the correct distance from the burner.

■ Check the heating safety systems: temperature limit safety thermostat, pressure limit safety device.

■ Check the pre-fill pressure of the expansion tank (see expansion tank rating plate).

■ For safety reasons, periodically check the integrity and operation of the exhaust system.

■ Check that the connection to the mains electricity supply complies with that reported in the water heater’s instruction

manual.

■ Check the electrical connections inside the control panel.

■ Check the D.H.W flow rate and temperature.

■ Check that the condensate drain system is working correctly, including any parts of the system outside the water

heater such as condensate collection devices along the length of the exhaust vent and/or any acid neutralising devices.

■ Check that the condensate flows freely and that there are no exhaust fumes present within the appliance.

Warranty will not be offered if recommended maintenance is not followed.

INSTALLATION INSTRUCTIONS

Fig. 1

Fig. 2

Fig. 3

Fig. 4 Fig. 5

Fig. 6

6.4 Accessing the water heater

All maintenance operations require one or more of the water heater casing panels to be removed.

The side panels can only be removed after the front panel has been removed.

Front panel:  Remove the fixing screws at the lower edge of the

front panel.

 Grasp the lower part of the panel and pull it

outwards (see fig. 1) and then up (see fig. 2).

Left and right side panel:  Remove the fixing screws at the front and lower

edge of the side panel to remove.

 Grasp the bottom of the panel, move it sideways

and then upwards to remove it.

To access the electrical connections of the control panel, proceed as follows:

• Remove the front panel (see fig. 1 and fig. 2).

• Grasp the left and right control panel support

brackets (see fig. 5) and pull them outwards, at the same time rotating the panel downwards.

• Unscrew the four fixing screws (see fig. 6) and remove the panel back piece.

6.5 Flushing out the primary side

• Fill the water heater as per the filling instructions.

• Using a drain off cock on the lowest point of the

system allow the water to drain from the system and water heater.

• In order to flush the system correctly turn off all

radiators open the filling loop and drain cock simultaneously and allow the water to flow through the water heater.

• Open each individual radiator, allowing water to

flow through then turn that radiator off and repeat for all radiators on the system.

• Turn off the filling loop and close the drain cock

open all radiators and open the filling to fill the system.

• Continue to fill the system until the pressure gauge

reaches 14.5 psi (1.0 bar).

INSTALLATION INSTRUCTIONS

Fig. 1

6.6 Draining the central heating system

If the need arises to drain the system, this can be done as follows:

• Switch the system to “WINTER” mode and ignite the

water heater.

• Switch off the power supply to the water heater.

• Wait for the water heater to cool down.

• Connect a hosepipe to the system drain point and locate

the other end of the hose in a suitable drainage system.

• Open the system drain valve (see fig. 1).

• Open the air vents on the radiators, starting with the

highest and moving down the system to the lowest.

• When the system has been drained, close the radiator

breather valves and the drain valve.

• If only the water heater needs to be drained, close

the flow/return isolating valves on the heating circuit and open the drain valve located at the bottom of the water heater on the pump manifold (see fig. 1);

Draining the domestic hot water system

■

If there is a danger of freezing, the domestic hot water system should be drained. This can be done as follows:

• Close the mains water supply valve.

• Open all the hot and cold water taps.

• On completion, close all the previously opened taps.

INSTALLATION INSTRUCTIONS

primary heat

flueconnecti stainless

steel pipe

ceramic fibre washer

Fig. 2

Fig.

premix burner burner

ionization

ignition

primary

Fig. 1

6.7 Maintenance operations

Before carrying out any cleaning or part replacement operations, ALWAYS turn off the ELECTRICITY,

WATER and GAS supplies to the water heater.

FLOWMAX will not be held responsible for damage to

any of the water heater’s components caused by noncompliance with this instruction.

For all maintenance operations requiring removal of the water heater casing, refer to the procedures described in paragraph 6.3 “Accessing the water heater”.

Cleaning the main exchanger module and combustion unit (see fig. 1)

• Disconnect the electrical connections of the electric fan.

• Disconnect the joint and remove the pipe linking the gas valve to

the injector unit (venturi).

• Disconnect the joint and remove the gas feed pipe from the gas

valve.

• Un-plug the ignition electrode and flame detection wires from the

ignition control unit.

• Unscrew the ring-nut at the bottom of the room-sealed chamber

and remove the gas valve.

• Unscrew the nuts securing the burner unit (consisting of a fan,

manifold and burner) to the primary heat exchanger.

• Remove the burner unit, paying particular attention not to

remove the ceramic fibre protection from the bottom of the heat exchanger.

• Check that the burner is not affected by deposits, scaling or

excessive oxidation. Check that all the holes in the burner are free;

• Clean the electrodes carefully without altering their positions with

respect to the burner;

• Clean the burner cylinder using a non-metal brush and without

damaging the ceramic fibre;

• Check the integrity of the washer on the cover of the burner;

• Clean the heat exchanger (see fig. 2) using a recommended

detergent available from FLOWMAX Technologies for stainless steel, distributing the product on the spirals of the exchanger using a brush. Do not wet the ceramic fibre coating. Wait a few minutes then remove the deposits using a non-metal brush. Then remove the residues under running water;

• Remove the pipe clip, remove the condensate drainpipe and

clean under running water.

• Unscrew the joint to the condensate trap, remove the trap and

wash under running water.

• With the cleaning completed, re-assemble the components

following the above procedure in reverse order.

• Finally, check the water heater to make sure that all gas and

exhaust joints are tight.

on chamber

INSTALLATION INSTRUCTIONS

7.5

0.5

3.5

ionization

ignition

Fig.

d.h.w heat exchanger

fixing screws

Fig. 1

Fig. 2

Cleaning the D.H.W heat exchanger

(see fig. 1)

• Close the shut-off valve and drain the domestic hot water circuit

and central heating circuit of the water heater;

• Use a 4 mm Allen key to unscrew the four screws securing the

heat exchanger to the multiplex unit;

• Remove the heat exchanger from the left side of the water heater,

note its orientation;

• De-scale the heat exchanger by chemically washing the plates

• Fit new rubber washer, inserting them in their housings on the

multiplex unit;

• Re-assemble the heat exchanger and components following the

above procedure in reverse order;

• Fill the system with water and check for any leaks from the joints.

Part replacement:

Ignition and/or flame detection electrodes

(see fig. 2)

• Un-Plug the electrode wires;

• Slacken the fixing screws;

• Remove the electrodes. When fitting the new ones, check that the

seals are not damaged. Replace if necessary;

• Reconnect the wires and re-assemble the components following

the above procedure in reverse order;

• Switch on the power supply and restart the appliance;

If the water heater does not restart, check the positions of the

electrodes (especially the ignition electrode). Make sure that original position and distances between the electrodes and the burner are respected to avoid a water heater malfunction).

POSITIONING THE IGNITION ELECTRODE AND THE IONISATION ELECTRODE

INSTALLATION INSTRUCTIONS

heating

safety gas valve

Fig. 2

Fig. 1

Safety thermostat (see fig. 1)

• Disconnect the connecting wire;

• Unscrew the fixing screws and remove the

thermostat;

• Replace the thermostat and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies and

restart the appliance.

Heating sensor (see fig. 1)

• Un-Plug the connecting wire;

• Replace the sensor and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies,

open the shut-off valves and fill the central heating circuit. Then restart the appliance, remembering to discharge any air that may be trapped in the system;

Gas valve (see fig. 2)

• Disconnect the joints and remove the gas pipe

connecting the gas valve to the venturi.

• Disconnect the gas feed pipe and valve ring-nut at

the bottom of the room-sealed chamber.

• Remove the flanged elbow coupling of the existing

valve and fit it to the new valve; also fit a new cork washer.

• Replace the gas valve and re-assemble the

components following the above procedure in reverse order.

• Replace all the gas seals.

• Fully tighten the gas connections.

• Switch on the electricity, water and gas supplies

and check for any gas leaks using a soapy solution or leak detector spray;

sensor

thermostat

INSTALLATION INSTRUCTIONS

fixing bracket

expansion tank

Fig. 2

Fig. 1

circulating

venturi

electric fan

Fig. 1

Electric fan (see fig. 1)

• Remove and dismantle the entire burner unit (see

“Cleaning the burner unit”).

• Use an 8 mm wrench to unscrew the four nuts

securing the electric fan to the gas manifold and then remove the electric fan, noting the positions of the washer and diaphragm.

• Remove the air intake duct, unscrew the two fixing

screws from the venturi and remove the electric fan, paying particular attention not to damage the cork gasket.

• Replace the electric fan and re-assemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies and

check the soundness of the joint by measuring the

levels;

Expansion tank (see fig. 2)

• Close the shut-off valves and drain the central

heating circuit of the water heater.

• Use a 19 mm wrench to unscrew the pipe coupling

to the tank.

• Unscrew the fixing screws and remove the upper

mounting bracket. Remove the expansion tank from the front of the water heater.

• Replace the expansion tank and re-assemble the

components following the above procedure in reverse order.

• Switch on the electricity, water and gas supplies

and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit;

Circulating pump (motor body) (see fig. 1)

• Close the shut-off valves and drain the central

heating circuit of the water heater;

• Use a 5 mm Allen key to unscrew the four screws

securing the motor body to the impeller body;

• Remove the motor body and check the condition of

the washer. If necessary, replace the washer;

• Replace the circulation pump and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies

and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the water heater.

pump

INSTALLATION INSTRUCTIONS

diverter valve body

diverter valve motor

Fig. 2

Fig. 3

Replacing the Diverter valve body (see fig. 2)

• Close the shut-off valves and drain the central heating

circuit of the water heater;

• Unscrew the fixing screws securing the transparent

cover of the diverter valve and remove the cover;

• Unscrew the four fixing screws and remove the diverter

valve body and washer;

• Replace the valve body and re-assemble the

components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies and fill

the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the water heater.

Replacing the motor

• Unscrew the fixing screws securing the transparent

cover of the diverter valve and remove the cover;

• Unscrew the two motor fixing screws and disconnect the wires;

• Replace the motor and re-assemble the components following the above procedure in reverse order;

3-way valve operation

Important: The working position of the 3-way valve is indicated by the color (Red or Blue) visible in the inside of the valve. (see Fig. 3).

• The RED color (with C-A) indicates the operation in the Heating mode.

• The BLUE color (with C-B) indicates the operation in Domestic Hot water mode.

INSTALLATION INSTRUCTIONS

Modulation circuit board

In order to access the computer control board, please proceed as follows:

DANGER

Remove the voltage from the unit.

• Grab the tabs at the sides of the control panel and slightly pry them apart from the control box (fig. 1) loosening them and turn the panel downwards;

• unscrew the four fixing screws and remove the modulation circuit board

• remove the crankcase pulling it upwards.

• Replace the circuit board and re-assemble the

components following the above procedure in reverse order;

• Add voltage to the unit,

(see fig. 1-2)

The pre-set parameters of the printed circuit board

correspond to an instantaneous type water heater fed by natural gas.

INSTALLATION INSTRUCTIONS

primary heat

flue connection stainless steel

ceramic fibre

Fig. 1

Primary heat exchanger (see fig. 1)

• Close the shut-off valves and drain the central heating circuit of the water heater;

• Switch off the power and gas supply to the water heater;

• Remove and dismantle the entire burner unit (see “Cleaning the condensation module and burner unit”);

• Remove the gas valve;

• Remove the spring and then the condensate

drainpipe;

• Remove the fixing springs and then the delivery and return pipes;

• Remove the support brackets and pull out the heat exchanger;

• Remove the regulation sensor from the old heat exchanger and refit it together with the two condensate drainpipes to the new one;

• Replace the heat exchanger and re-assemble the components following the above procedure in reverse order;

• Switch on the electricity, water and gas supplies and fill the system with water. Check for any leaks from the joints and bleed off any air from the circuit. Restart the water heater, making sure that there are no gas leaks;

exchanger

chamber

washer

pipe coil

6.8 Wiring Diagrams

SE:

MF:

TA:

VG:

VD:

INSTALLATION INSTRUCTIONS

: DETECTION ELECTRODE

A: START-UP ELECTRODE

: CIRCULATOR

GAS VALVE

RA:START-UP TRANSFORMER

F: FUMES THERMOFUSE 216°F (102°C) EV: ELECTRIC FAN

F MAX: THERMOFUSE 320°F (160°C)

S: SA FETY THERMOSTAT

ACQ:WATER PRESSURE SWITCH

MICRO-FLOW SWITCH

: HEATING PROBE

: DOMESTIC CIRCUIT PROBE

DIVERTER VALVE

P: PANEL TERMINAL

E XTERNAL PROBE

ENVIRONMENT THERMOSTAT AR: ORANGE

: LINE

NEUTRAL

E: BLACK

A: AIR PRESSURE SWITCH

GR. GREY

MA: BROWN

VE: GREEN

CE: BLUE

GI: YELLOW

BI: WHITE

INSTALLATION INSTRUCTIONS

Electrical connections (Option)

Connect the power supply to the terminal board located onto the control panel as follows:

a. switch off the power supply at the main switch. b. remove the front case panel of the water heater. c. slacken the screws and remove plate A (see fig.1). d. remove jumper Ta -Ta from the terminal board B; and install the control wires to a heating dry contact

disabled and displayed by the symbol

INSTALLATION INSTRUCTIONS

OUTDOOR SENSOR

DELIVERY TEMPERATURE CORRECTION AS A FUNCTION OF OUTSIDE

TEMPERATURE WITH RESPECT TO THE POSITION OF THE HEATING

TEMPERATURE CONTROL SET BY THE USER

TM-MAX/MIN = delivery temperature range selected

158

MIN

81 79

113 104

122

140 131

149

7577

73 7072 68 6164 63 59

MAX

104 176

167

Te = Outdoor temperature Tm = delivery temperature

10505452 4648

4143 39 3637 34 21273032 28 25 23 1619 18 14 12

Te (°F)

597

Fig. 1

Fig. 2

Regulating the Flow temperature in accordance with the outdoor temperature

The outdoor sensor has to be connected directly to circuit board SM20021. The sensor can thus be managed in one of two ways:

• In case of remote controller + outdoor temperature sensor installation, the climatic compensation curve is set by

the remote itself (see remote control installation and operating manual).

• In case of outdoor temperature sensor only installation, the climatic compensation curve is set using the central

heating control button. As the arrow up shown in figure 1 are displayed

The factors governing the correction are reported in figure 1.

The selection of the compensation curve is determined by the maximum delivery temperature Tm and the minimum outdoor temperature Te.

N.B. The y-axis values of the delivery temperature Tm refer to standard 167-86 °F appliances or 104-77 °F floor- mounted appliances. The type of appliance can be programmed using parameter 3 (see 5.1 “Parameter programming”).

button is (see fig. 2) is pressed, the numbers corresponding to the curve

INSTALLATION INSTRUCTIONS

SR:

RETURN PROBE

AREA VALVES LIMIT SWITCH

SRB

REMOTE LED FOR SIGNALLING STORAGE CYLIN. BLOCK

GR;

GREY

TAZ1

ENVIRONMENT THERMOSTAT AREA 1

AR:

ORANGE

TAZ2

ENVIRONMENT THERMOSTAT AREA 2

NE:

BLACK

VZ1

AREA 1 VALVE

BROWN

VZ2

AREA 2 VALVE

LIGHT BLUE

6.9 D.H.W. Sensor Connection

To wire the options below:

• (PM) MODULATING PUMP

• (TP) DOMESTIC HOT WATER PRE-HEATING DEACTIVATION TIMER

• (CT) TELEPHONE DIALER

• BUS 0-10V

• (SVZ) CONTROL BOARD FOR AREA VALVES CONNECTED TO A REMOTE CONTROL COD. 65- 00030

• (SB) DHW PROBE FOR REMOTE STORAGE CYLINDER - COD. 31368LA (MAX. LENGHT 8 m)use the

electronic board placed inside the control panel as follows:

DANGER Cut off the voltage from the main switch.

• remove the water heater's front casing (refer to chapter ACCESSING THE WATER HEATER).

• remove the crankcase of the control panel (see chapter ACCESSING THE ELECTRONIC BOARD).

• after removing the crankcase, connect the items below to the electronic board (see fig. 1):

After performing these operations, remount the crankcase and the front casing.

INSTALLATION INSTRUCTIONS

ERROR

PROBLEM

POSSIBLE CAUSE

REMEDY

RESET

dd. PRINTED CIRCUIT BOARD MALFUNCTION

dd. REPLACE PART

6.10 Troubleshooting

To display the last 5 errors, keep the

“ ”

INFO button pressed while in the off mode position for 5 seconds.

The errors will appear in chronological order (-1- = first fault… -5-= last fault).

Use the “

errors, press the “

” and “ ” of the heating temperature setting to scroll the list of saved errors. To reset the

” RESET button. Press the

“ ”

INFO button to exit the errors from the display

mode.

CODE

E01

E02

IONISATION PROBLEM

SAFETY THERMOSTAT TRIPPED 95°C AIR PRESSURE SWITCH TRIPPED

WITHOUT FLAME IGNITION

a. NO GAS

b. IGNITION ELECTRODE BROKEN OR EARTHED. c. GAS VALVE MALFUNCTION d. IGNITION SEQUENCE SET TOO LOW. e. GAS VALVE INLET PRESSURE TOO HIGH

(FOR LPG BOILERS ONLY).

WITH FLAME IGNITION

f. POWER SUPPLY LINE AND NEUTRAL CABLES

REVERSED. g. IONISATION ELECTRODE MALFUNCTION. h. IONISATION ELECTRODE CABLE DISCONNECTED.

I. THERMOSTAT MALFUNCTION OR OUT OF

CALIBRATION

j. THERMOSTAT CABLE DISCONNECTED

AIR PRESSURE SWITCH

k. SWITCH OUT OF ORDER l. INLET OR OUTLET FLUE GAS DUCTS OBTRUCTED j. SWITCH CABLE NOT STABLE

a. CHECK MAIN GAS SUPPLY. b. REPLACE PART.

c. REPLACE PART. d. SET THE IGNITION SEQUENCE. e. CHECK THE MAXIMUM

PRESSURE SETTING.

CONNECT THE BOILER

PROPERLY.

g. REPLACE PART. h. CONNECT THE IONISATION

ELECTRODE CABLE.

i. REPLACE PART j. CHECK WIRING

AIR PRESSURE SWITCH

k. REPLACE PART l. CHECK FLUE GAS DUCTS j. CHECK CABLE

GAS

Manual

Reset

Required

Manual Reset

Required

E03

E04

E05

E06

E15

E16

E18

E21

E22

102°C THERMO FUSE TRIPPED

NO WATER IN SYSTEM

HEATING SENSOR p. SENSOR MALFUCTION OR OUT OF CALIBRATION

DHW SENSOR

RETURN SENSOR

FAN

INADEQUATE CIRCULATION

GENERAL PCB MALFUCTION

PARAMETER PROGRAMMING REQUEST

k. THERMO FUSE OPEN l. THERMOFUSE CABLE DISCONNECTED

m. INSUFFICIENT WATER PRESSURE IN SYSTEM n. WATER PRESSURE SWITCH DISCONNECTED o. WATER PRESSURE SWITCH MALFUCTION

(RESISTANCE VALUE 10 kOhm’s AT 25°C)

q. SENSOR CABLE DISCONNECTED OR WET

r. SENSOR MALFUCTION OR OUT OF CALIBRATION

(RESISTANCE VALUE 10 kOhm’s AT 25°C)

s. SENSOR CABLE DISCONNECTED OR WET

t. SENSOR MALFUCTION OR OUT OF CALIBRATION

(RESISTANCE VALUE 10 kOhm’s AT 25°C)

u. SENSOR CABLE DISCONNECTED OR WET

v. BURNT FAN w. POWER SUPPLY CABLE MALFUNCTION

x. PRIMARY OR SECONDARY HEAT EXCHANGER

OBSTRUCTED.

y. PUMP MALFUNCTION OR IMPELLER DIRTY

z. MICROPROCESSOR MALFUNCTION W RONG

SIGNAL DETECTED

aa. LOSS OF MICROPROCESSOR MEMORY

k. REPLACE THERMOFUSE l. CHECK WIRING HARNESS

m. FILL THE SYSTEM n. CHECK WIRING HARNESS o. REPLACE PART

p. REPLACE PART q. CHECK POWER SUPPLY

CONNECTION

r. REPLACE PART s. CHECK POWER SUPPLY

CONNECTION

t. REPLACE PART u. CHECK POWER SUPPLY

CONNECTION

v. REPLACE PART w. REPLACE PART

x. CLEAN & OR REPLACE PART y. CLEAN & OR REPLACE PART

z. PCB AUTOMATICALLY RESETS

aa. REPROGRAM PARAMETERS

Manual Reset

Required

Automatic

Manual Reset

Required

E35

E40

FLAME DETECTION MALFUNCTION

ELECTRIC POWER SUPPLY

bb. IONISATION ELECTRODE MALFUNCTION cc. IONISATION ELECTRODE CABLE MALFUNCTION

ee. ELECTRIC POWER SUPPLY OUT OF OPERATING

RANGE

bb. REPLACE & OR CLEAN PART cc. REPLACE PART

ee. CHECK POWER SUPPLY.

ERROR DISAPPEARS WHEN PROPER POWER IS RESTORED

Manual Reset

Required

Automatic

INSTALLATION INSTRUCTIONS

6.11 Diagnostics

■ Error codes:

E01 Ionization Lock Out E02 Safety Thermostat Tripped / Air Pressure Switch Tripped E03 Flue Gas Thermostat Tripped E04 Low Water Condition E05 Heating Sensor Malfunction E06 D.H.W Sensor Malfunction E15 Return Sensor E16 Electric Fan Malfunction E18 Inadequate Circulation E21 General PCB Malfunction E22 Parameter Programming Request E35 Flame Detection Malfunction E40 Electric Power Supply

■ Function codes :

PARTS LIST

CODE

DESCRIPTION

20046LA

PLATE EXCHANGER 24 P.

20085LA

ISOTERMIQUE 4+1 COMBUSTION CHAMBER BACK PANEL

21042LA

PRIMARY EXCHANGER 4+1 PREMIX 0.70

25-00274

GRUNDFOS PUMP UPS 15-58 CACAO ETL MOLEX-PN98282128

25-00045

EXPANSION VESSEL 6 lt. – 1,58 gal

25-00274

SAFETY VALVE 3/4"M - 3/4"F 30 psi

27044LA

CONDENSATE TRAP

35031LA

IGNITION ELECTRODE

35032LA

IONISTATION ELECTRODE

36068LA

VENTURI MINIFOLD

36075LA

GAS VALVE UL/CSA

37033LA

FAN RG 128 / 1300 UL/CSA

59015LA

WATER PRESSURE SWITCH PC 5411 BRASS

59021LA

AIR PRESSURE SWITCH 3.28 UL/CSA

73507LA

D.H.W-HEATING 1/8" WHITE SENSOR S011001

73516LA

HTG CLIP SENSOR FOR PIPE 17/18 mm BLUE-T7335D1123B

73517LA

THERMO FUSE 102°C RED ISOTHERM. 1/4" 4X45

40-00147

NORDGAS PRINTED CIRCUIT BOARD

86006LA

SAFETY THERMOSTAT 95°C

25-00196

WATER PRESSURE GAUGE

40-00124

CARLIN IGNITION TRANSFORMER UL/CS ZAG 2XV

96018LA

NO-RETURN VALVE

96073LA

DIVERTER VALVE ACTUATOR UL/CSA

PARTS LIST

6.12 Parts List / Available from FLOWMAX

Main components

Multiplex FLOWMAX

CODE

DESCRIPTION

Qt.

20046LA

PLATE EXCHANGER 24 P.

25-00274

PUMP UPS 15-58 CACAO ETL MOLEX-PN98282128

26127LA

PUMP MANIFOLD – M.PLEX 2006

26134LA

D.H.W. OUTLET CONNECTION - INSTANTANEOUS M.PLEX 06

26283LA

D.COLD WATER/HTG FLOW CONNECTION W/N-R.V. M.PLEX

31428LA

FLOWSWITCH MICRO LEAD

33030LA

PUMP CONNECTION BODY SENSOR HOLDER – M.PLEX 2006

43001LA

WASHER D.23.5x17x2 3/4" -AFM34

43002LA

WASHER D.18.5x10.2x2 1/2" -AFM 34

43007LA

WASHER D.11.5x6x2 1/8" -AFM34

43135LA

DIVERTER VALVE FLANGE WASHER – M.PLEX NYLON 66

43139LA

PLATE EXCHANGER O-RING EPDM 70 SH PEROX BL.-M.PLEX

43145LA

DIVERTER VALVE O-RING M.PLEX

43150LA

OR MULTIPLEX EPDM ORM 14X30

43151LA

BY/PASS REGULATOR EPDM O-RING

43159LA

WASHER EPDM 80 SH M.PLEX 16x24x2,5 3/4"

43208LA

WASHER 23x30x3sp EPDM 80sh 1"

43248LA

O-RING 4081 EPDM Ø18,68X3,53 70SH

43276LA

O-RING 17,00x4 EPDM

54022LA

ZINC-PLATED STEEL FIXING CLIP MULTIPLEX

54023LA

BY PASS SPRING MULTIPLEX - STAINLESS STEEL

54032LA

FIXING CLIP - STAINLESS STEEL

56087LA

CL 2510 1/4"-1/2" CONNECTION

56091LA

NIPPLES 3/4"SAFETY VALVE CONN.

64066LA

FLOWSWITCH/PUMP CONNECTION CAP MULTIPLEX

64068LA

3-WAY VALVE BODY-CENTRAL SECTION M.PLEX

64075LA

BY PASS MULTIPLEX

64106LA

BY-PASS BUSH

64123LA

PUMP MANIFOLD CONNECTION BEND

64126LA

DIVERTER VALVE BODY BACK PC ZYTEL M.PLEX

64127LA

FLOWSWITCH GROUP - INSTANT. MOD .

73507LA

D.H.W.-HEATING 1/8" WHITE SENSOR

83546LP

PIPE D.8 BY-PASS

83965LP

PIPE D.8 N.RET.VALVE FLOW

25-00196

WATER PRESS.GAUGE

89134NA

SCREW 5x20 8.8 TCEI 5931-912

96018LA

NON-RETURN VALVE C014-1514214

96073LA

DIVERTER VALVE ACTUATOR

25-00247

SAFETY RELIEF VALVE 3/4"M-3/4"F 30 psi

PARTS LIST

Terms and Conditions of Sale

E-mail: info@flowmaxtechnologies.com

Warranty: Warranty period is twelve (12) months from date of purchase. Warranty includes parts and labour (check with

FLOWMAX Technologies Inc. for labour allowance rates). An extended twelve (12) month warranty is available, where applicable on parts; please consult FLOWMAX Technologies Inc. Cost of returning the goods to FLOWMAX Technologies Inc. is by others. All warranty parts are to be prepaid by the customer. No warranty will be in effect until the equipment is paid for in full. Warranty on all equipment sold to customer may be suspended, at FLOWMAX Technologies Inc.’s discretion, until the customer’s account is in good standing. Warranty covers defective components only. Normal wear and abuse is not covered. The customer’s account will be credited only after the defective part has been examined by FLOWMAX Technologies Inc. or the vendor and determined to be defective.

All Energy Star approved models have 5 year warranty on parts

FIRST YEAR

Limited Warranty for Condensing Water Heater (All Residential Water Heaters) (Includes Space Heating Domestic Water ‘Combo’ Heating Applications)

FLOWMAX warrants that its combo water heaters are free from defects in materials and workmanship for one (1) year from the date of installation. If any parts are found to be defective in manufacture, FLOWMAX will provide replacement of such defective parts.

SECOND THROUGH THE TENTH YEAR

Limited Warranty for Primary Heat Exchangers on all Energy Star approved models (Residential Water Heaters) (Space Heating Applications Only)

FLOWMAX warrants that the stainless steel tube (primary) heat exchanger of its residential condensing gas water heater is free from defects in material and workmanship from the date of installation for the second through the tenth year to the original purchaser only. If during such time period, any part of the stainless steel tube heat exchanger is found to be defective, FLOWMAX will provide replacement for the original heat exchanger.

SPECIAL FIVE YEAR WARRANTY

Limited Warranty for Flat Plate Heat Exchangers (Domestic Hot Water Heat Exchangers-Residential Use Only)

FLOWMAX warrants that the stainless steel, flat plate heat exchanger (used for the production of domestic hot water) is free from defects in material and workmanship for five (5) years from the date of installation. Any coagulation or blockage of the normal water flow through the heat exchanger, due to trapped sediment, heavy calcification, lime deposits minerals and or other waterborne build-up in the plate heat exchanger, or corrosion due to chemical antifreeze additive is not considered defects in workmanship and therefore any malfunction or damage to other parts or components resulting from these build-ups in the plate heat exchanger is not covered under the terms of this warranty.

Limitations on Liability This Warranty Does Not Cover

1. Installations by other than licensed plumber, gas installer or heating contractor.

2. Installations of equipment for other purposes than those intended by the instructions supplied with this equipment.

3. Installations of equipment for purposes other than residential space heating and domestic hot water production.

4. Any product which is improperly installed or moved from its original place of installation.

5. Any product which has been repaired or replaced with other than FLOWMAX factory parts.

6. Any product modified in any way, misused or damaged or which has been used contrary to warrantor’s written instructions.

7. Introduction of liquids other than potable water or potable water/glycol mixtures into this product.

8. Any damage to the product caused by failure to maintain the unit properly, improper voltage, improper gas pressure, improper water pressure, flood, freezing, electrical surges, fire, lightning, or Acts of God.

9. Nicks, scratches or discoloration of decorative finishes.

10. Installation, plumbing, gas piping and wiring not integral to the product.

11. Any FLOWMAX product installed in an improper environment (e.g. Corrosive, dusty, and or chemically contaminated).

12. Condensate damage due to improperly installed or lack of a condensate trap (drain).

13. Damages due to accidents, abuse, misuse, improper installations, misapplication or incorrect sizing and lack of regular recommended maintenance.

14. The water heater is installed outdoors.

15. Failures resulting in the FLOWMAX unit not being properly maintained as per the recommended maintenance.

16. Failures not reported to FLOWMAX Technologies Inc. within the time period specified above.

17. Products damaged in shipment or storage or otherwise without fault of FLOWMAX Technologies Inc.

18. The water heater has not been installed in accordance with all applicable local plumbing and/or building code and/or regulations or in their absence with the latest edition of the natural gas and propane installation code and/or the National Electrical Code or Canadian Electrical code.

19. This warranty does not cover any expenses related to the removal or re-installation process. The homeowner will be responsible for the cost of removing and re-installing the alleged defective part or its replacement and all labor and material connected therewith, and transportation to and from FLOWMAX.

Terms and Conditions of Sale

E-mail: info@flowmaxtechnologies.com

Owner’s Responsibilities

20. The warranty cannot be considered as a guarantee of workmanship of an installer connected with the installation of the condensing water heater or as imposing a liability of any nature for unsatisfactory performance as a result of faulty workmanship in the installation, which liability is expressly disclaimed.

Exclusion of Incidental and Consequential Damages/ Disclaimers

FLOWMAX will not pay in contract or in tort, consequential or incidental damages under this warranty, both of which are specifically excluded. This means we shall not be responsible for any loss, expense or damage caused by any defect in the water heater, other than the water heater itself. The maximum liability of FLOWMAX in connection with this limited warranty shall not in any case exceed price of the part claimed to be defective, or price of the water heater if the entire water heater is claimed to be defective. “Incidental” damages include expenses of inspection, obtaining substitute goods, transportation, etc. “Consequential” damages include injury to persons or property inconvenience or other consequential damage resulting from a breach of warranty.

This Warranty is issued to the original purchaser only. This product must be used and cared for in accordance with the instruction manual. You are responsible for required periodic maintenance or service. See your instruction manual for details. You must be able to verify the installation date of the product against which you make and warranty claim. The original bill of sale, installer’s invoice or other similar document is required to verify warranty. If you cannot show evidence of the actual date of installation, warranty coverage will be considered to start on the date the product is shipped from our distributor. The attached Warranty Registration Form must be filled out completely and returned to FLOWMAX. Failure to do so will prevent or delay our being able to contact you (or the person residing at this address) in case of a recall or important product safety alert. Your warranty information will be held strictly confidential.

Warranty Registration Form

E-mail: info@flowmaxtechnologies.com Website

www@flowmaxtechnologies.com

PLEASE COMPLETE THE FOLLOWING INFORMATION AND RETURN WITHIN 30 DAYS OF

COMMISSIONING THE APPLIANCE (HOT WATER HEATER)

Please Print Clearly

Sold To:

Homeowners Name:

Address: Unit #:

City: Province: Postal Code:

Phone No. Fax:

Email Address:

Item Purchased:

Unit Model: Serial No.

Date of Purchase: Date of Startup:

Purchased From:

Installing Contractors Name: Address:

City:

Province: Postal Code: Phone No.

Fax:

Email Address:

Signature: Date:

To ensure your warranty protection, please complete and return this form to

FLOWMAX Technologies Inc.

Attention: Product Registration

Warranty Registration Form

E-mail: info@flowmaxtechnologies.com Website

www@flowmaxtechnologies.com

Please complete the following information and return it with the part request

Date:

Contractor / Distributor / Rental Provider Name:

Address: Unit #

City: Prov. Postal Code:

Phone # Other #

Email:

Homeowner Name:

Address: Unit #

City: Prov. Postal Code:

Phone # Other #

Email:

Model Number: Serial number:

Date installed: Date Failed: Date Serviced:

Failed Part Number: Replacement Part Number:

Failed Part Description:

Reason for Failure:

is not acceptable and will be considered incomplete.

Incomplete warranty forms will not be accepted or considered.

Only a detailed explanation will be considered for warranty.

All parts returned must be accompanied with a completed warranty tag.

“FAILED, NOT WORKING, DEFECTIVE” etc.,

Warranty Registration Form

E-mail: info@flowmaxtechnologies.com Website

www@flowmaxtechnologies.com

FLOWMAX 90 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Instruction Manual

for model

WARNING

Installation, operating, commissioning and maintenance instructions.

2.3 Internal parts of the water heater 12

2.4 Water circuit 13

2.5 Circulation pump head/flow graph 14

3.3 Installing the water heater 20

3.4 Water connections 21

3.5 Domestic Hot Water Circuit/Hard Water Warning/ Condensate Drain 22

3.6 Schematic of Piping Installation 24

3.7 Gas connection 26

LEGEND

LEGEND

MAIN NEWS

INFO Menu display

Fig. 1

Fig. 2

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Fig. 1

Use only clean tap water to fill the system.

Once the water pipes have been connected, close the gas feed valve and fill the system as follows:

Table n°1

Gas type

CO2 %

Fig. 1

Table no.1 - CO 2 Values

Table no.2 - Frequency

Gas type CO2 %

Gas type Minimum (Hz) Maximum (Hz)

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Fig. 2

Fig. 3

Fig. 6

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Fig. 2

For all maintenance operations requiring removal of the water heater casing, refer to the procedures described in paragraph 6.3 “Accessing the water heater”.

Cleaning the main exchanger module and combustion unit (see fig. 1)

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Fig. 2

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Fig. 2

6.10 Troubleshooting

■ Error codes:

■ Function codes :

CODE

DESCRIPTION

PRIMARY EXCHANGER 4+1 PREMIX 0.70

Table no.1 - CO

2

Values