NTI TRX, TRX085, TRX150C, TRX120, TRX110C Maintenance Manual

Installation

Start-Up

Maintenance

Parts

Warranty

TRX

Residential Condensing Gas Boiler

Heat Exchanger Bears the ASME “H” Stamp

DANGER

THIS MANUAL MUST ONLY BE USED BY A QUALIFIED INSTALLER / SERVICE TECHNICIAN. READ ALL INSTRUCTIONS IN THIS MANUAL BEFORE INSTALLING. PERFORM STEPS IN THE GIVEN ORDER. FAILURE TO DO SO COULD RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

WARNING

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

NOTICE

The manufacturer reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

WARNING

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 vapors and liquids in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

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

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

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

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

Improper installation, adjustment, alteration, service, or maintenance can cause injury, property damage, or death. Refer to this manual. Installation and service must be performed by a qualified installer, service agency, or gas supplier.

SPECIAL ATTENTION BOXES

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

DANGER

DANGER indicates an imminently hazardous situation which, if not avoided, will result in serious personal injury or death.

WARNING

WARNING indicates a potentially hazardous situation which,

if not avoided, could result in personal injury or death.

CAUTION

CAUTION indicates a potentially hazardous situation which, if

not avoided, may result in moderate or minor personal injury.

CAUTION

CAUTION used without the safety alert symbol indicates a

potentially hazardous situation which, if not avoided, may result in property damage.

NOTICE

NOTICE is used to address practices not related to personal injury.

Foreword

This manual is intended to be used in conjunction with other literature provided with the boiler. This includes all related control information. It is important that this manual, all other documents included in this system, and additional publications including the National Fuel Gas

Code - ANSI Z223.1 in the United States and the Natural Gas and Propane Installation Code - B149.1 in Canada (latest versions), be reviewed in

their entirety before beginning any work.

Installation should be made in accordance with the regulations of the Authority Having Jurisdiction, local code authorities, and utility companies which pertain to this type of water heating equipment.

Authority Having Jurisdiction (AHJ) – The AHJ may be a federal, state, provincial, local government, or individual such as a ﬁre chief, ﬁre marshal, chief of a ﬁre prevention bureau, labor department or health department, building oﬃcial or electrical inspector, or others having statutory authority. In some circumstances, the property owner or his/her agent assumes the role, and at government installations, the commanding oﬃcer or departmental oﬃcial may be the AHJ.

NOTE: The manufacturer reserves the right to modify product technical speciﬁcations and components without prior notice.

For the Installer

This boiler must be installed by qualiﬁed and licensed personnel. The installer should be guided by the instructions furnished with the boiler, and by local codes and utility company requirements. In the absence of local codes, preference should be given to the National Fuel Gas

Code - ANSI Z223.1 in the United States and the Natural Gas and Propane Installation Code - B149.1 in Canada (latest versions).

Installations Must Comply With:

Local, state, provincial, and national codes, laws, regulations, and ordinances.

In the United States - The latest version of the National Fuel Gas Code, ANSI Z223.1, from American Gas Association Laboratories, 8501 East Pleasant Valley Road, Cleveland, OH 44131.

The latest version of the National Electrical Code, NFPA No. 70.

In Canada - The latest versions of the Natural Gas and Propane Installation Code, CSA B149.1, and the Canadian Electrical Code, C22.1, from CSA Group, 178 Rexdale Blvd, Toronto, Ontario, Canada M9W 1R3.

NOTE: The gas manifold and controls met safe lighting and other performance criteria when undergoing tests speciﬁed in ANSI Z21.13

- latest edition.

WARNING

NOTICE

The hydronic supply and return connections of these products are for installation in closed loop systems ONLY! Use of this

product in any manner other than described in this manual may result in premature product failure, substantial property damage, severe personal injury, or death. Damage or failure of this product (or the system in which it is installed) due to unauthorized use IS

NOT COVERED BY WARRANTY.

NOTICE

IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, NTI has provided this boiler with multiple features designed to save energy by reducing the boiler water temperature as heating load decreases. These features include:

• A modulating combustion system that adjusts ﬁring rate based on heat demand.

• Adjustment of boiler set point based on inferred heat load as determined by an outdoor sensor. The outdoor sensor is supplied with this boiler.

• This boiler does not include a standing pilot.

• This boiler is designed and shipped to assure the highest eﬃciency operation possible. Such high eﬃciency is achieved by limiting heating circuit water temperature to 140°F when there is no anticipated heat load, based upon the outdoor sensor and the Outdoor Reset Curve (sensor response curve) in the boiler software.

• This feature may be over-ridden as described below in speciﬁc installations:

• The boiler control is equipped with an outdoor sensor override for use with building management systems or in cascaded systems (for systems with total input of 300,000 BTU/hr or greater).

See statement below for an important notice on the use of the override.

ASME CSD-1, Section CW-400 requires the temperature controls of hot water heating boilers to

a) be accepted by a nationally recognized testing agency to conform to UL 353, b) shutoﬀ the fuel supply when the system water reaches a preset operating temperature, c) have a high temperature limit control that prevents the water temperature from exceeding the maximum allowable temperature by causing safety shutdown and lockout.

The temperature controls of this boiler have been accepted by a nationally recognized testing agency to conform to UL 353; they work to shutoﬀ the fuel supply when the system water temperature reaches the preset operating temperature; and they cause a safety shutdown and lockout, requiring a manual reset to start, when the water temperature reaches 212°F.

IMPORTANT In accordance with Section 325 (f) (3) of the Energy Policy and Conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:

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

• This boiler is not used for space heating.

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

Table of Contents

Part 1 - General Safety Information 6

A. Operation and Installation Warnings 6 B. Improper Combustion 7 C. Gas 7 D. When Servicing the Boiler 7 E. Boiler System 7 F. CH and DHW Loop Water Chemistry Requirements 8 G. Freeze Protection 8 H. Water Temperature Adjustment and Scalding 9 I. High Elevation Installations 9

Part 2 - Before You Start 10

A. What’s in the Box 10 B. Optional Equipment 12

Part 3 - Prepare the Boiler for Installation 13

A. Locating the Boiler 13 B. Leveling 14 C. Clearances for Service Access 14 D. Wall Mounting Considerations 14 E. Wall Mounting Instructions 15

1. Mounting to a Wood Studded Wall 15

2. Mounting to a Metal Frame 15

F. Residential Garage and Closet Installations 16 G. Exhaust Vent and Intake Pipe 16

1. Direct Vent of Exhaust and Intake 16

2. Power Venting, Indoor Combustion Air in Conﬁned or Unconﬁned Space 17

H. Carbon Monoxide Detectors 17 I. Prevent Combustion Air Contamination 17 J. Removing a Boiler from a Common Vent System 18 K. Technical Speciﬁcations 19

Part 4 - Water Piping 24

A. General Plumbing Information 24 B. Backﬂow Preventer 24 C. Expansion Tank 24 D. Piping the Boiler 24 E. Internal Circulation Pump 26 F. By-Pass Valve 26 G. CH and DHW Pressure Relief Valves 27 H. Air Elimination Device 28 I. Applications* 28 H. Floor Drying Function 35

Part 5 - Venting 36

A. General 36 B. Approved Materials for Exhaust Vent and Intake Pipe 37 C. Additional Requirements for Installation in Canada 37 D. Exhaust Vent and Intake Pipe Location 38 E. Exhaust Vent and Intake Pipe Sizing 39 F. Tightening Boiler Collar to Exhaust Vent and Intake Pipe 39 G. Exhaust Vent and Intake Pipe Installation 40 H. Applications 42

1. Direct Vent Installation of Exhaust and Intake 42

2. Venting Through an Existing System 48

3. Power Venting, Indoor Combustion Air in Conﬁned or Unconﬁned Space 49

Part 6 - Installing the Condensate Drain 50 Part 7 - Connecting Electrical Service 51

A. Wiring 51

1. Removing the Power Cord (To Hard Wire the Boiler) 52

2. Connecting Power (120V) for DHW and CH Circulators 53

3. Low Voltage Wiring Connections 53

4. Room Thermostat Wiring Connections 54

5. Outdoor Sensor Connections 54

6. Aquastat (Default) and Tank Sensor (Optional) Connections (Boiler Models) 54

B. Internal Wiring Details 55

Part 8 - Gas Connections 59

A. Gas Pipe Sizing Tables 59

1. Gas Pipe Sizing 59

2. Natural Gas Pipe Sizing 59

3. LP (Liquid Propane) Gas Pipe Sizing 59

B. Gas Connection Requirements 59 C. Additional Precaution for Excess Flow Valve (EFV) 60 D. Checking Gas Pressure at the Boiler for Proper Operation 60

Part 9 - Controls 61

A. Control and Display Overview 61 B. Ignition Procedure 62 C. Central Heating (CH) Temperature Adjustment 62 D. Domestic Hot Water (DHW) Temperature Adjustment 62 E. User Menu 63 F. INFO Menu 64 G. Date and Time 64 H. Automatic CH Temperature Control (AUTO) 65 I. Outdoor Heating Curve Slope 66 J. Outdoor Heating Curve Parallel Shift 66 K. Room temperature Day /Night (Only applicable when using NTI room sensor) 66 L. Time programs – heating schedule

(Only applicable when using NTI room sensor) 66

M. Automatic summer / winter changeover 67 N. Technical Menu

(Complete Programming & Troubleshooting Menus) 68

O. Boiler Control Menu Structure 69 P. Complete Menu Parameters 70

Part 10 - Start-Up Preparation 78

A. Check / Control Water Chemistry 78 B. Check for Gas Leaks 78 C. Freeze Protection (When Used) 78 D. System Water Fill, Purge, and Test 79 E. Purge Air from DHW System 79 F. Check Thermostat Circuit(s) 79 G. Condensate Removal 79

Part 11 - Start-Up 81

A. First Ignition 81 B. Combustion Checking Procedure 82 C. Checking Combustion Parameters 84 D. Converting the Appliance from Natural Gas to Propane Operation 84

Part 12 - Installation Checklist 85 Part 13 - Troubleshooting 87

A. Boiler Protection Devices 87

1. Blocking Error 87

2. Lockout Error 87

3. Malfunction Warning 87

B. Boiler Error Codes 88

Part 14 - Maintenance 92

A. Procedures 92 B. Maintenance That May be Performed by the User 92 C. Maintenance Only to be Performed by a Qualiﬁed Service Technician 93 D. Replacing Components 97 E. After Maintenance is Complete 100

Part 15 - Maintenance Report 100 Part 16 - Shutdown 102

A. Shutdown Procedure 102 B. Vacation Procedure 102 C. Failure to Operate 102 D. Important Notice 102

Part 17 - Replacement Parts 103

Maintenance Notes 114

Part 1 - General Safety Information

This boiler is approved for indoor installations only and is not intended for use as a pool heater. Clearance to combustible materials: 0” top, bottom, sides, and back. Boiler must have room for service: 18” front, 14” top, 12” bottom, 2” left and right sides and 0” back are minimum recommended service clearances. (A combustible door or removable panel is acceptable front clearance. A 3” minimum clearance must be provided from the boiler front cover to the removable panel or combustible door.) This boiler has been approved for closet installation and installation on combustible ﬂooring. Do not install directly on carpeting. Install the boiler in a location where relief valve discharge or a leak will not result in damage to the surrounding area. If such a location is not available install an auxiliary catch pan.

This appliance is rated Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting. Use only Category IV vent systems.

WARNING

This boiler must be installed by a qualied service technician.

Improper installation and/or operation can cause a potentially hazardous situation, which if not avoided will void the warranty and could result in serious injury or death.

The manufacturer cannot anticipate every circumstance that might involve a potential hazard. Each installation has its own specialized characteristics, requirements, and possible hazards. Therefore, all possible incidents are not included in these warnings. Proper and safe installation, operation, and service are the responsibility of

the qualied service technician.

Proper care of the boiler is the user’s responsibility. Ensure the user carefully reads and understands the User’s Information Manual before operating the boiler.

Installer - Read all instructions in this manual before installing. Perform steps in the given order.

User - This manual is for use only by a qualied service technician. Have this boiler serviced / inspected annually by a qualied service

technician.

FAILURE TO ADHERE TO THE GUIDELINES ON THIS PAGE CAN RESULT IN SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

NOTE: Obey all local codes. Obtain all applicable permits before

installing the boiler. NOTE: Install all system components and piping in such a manner

that does not reduce the performance of any re rated assembly.

A. Operation and Installation Warnings

To avoid serious injury or death, read, understand, and follow all of the precautions listed here.

DANGER

Vapors from ammable liquids will explode and cause a re,

resulting in personal injury or death. The boiler has a burner that can come on at any time and ignite vapors. DO NOT use or store

ammable liquids around the boiler.

Improper venting can cause a build-up of carbon monoxide. Breathing carbon monoxide can result in brain damage or death.

DO NOT operate the boiler unless it is properly vented to the outside and has an adequate fresh air supply for safe operation.

Inspect the exterior exhaust gas outlet port and fresh air inlet port

on a regular basis to ensure they are functioning properly.

A concentration of carbon monoxide as small as .04% (400 parts per million) in the air can be fatal. When making high re or low re adjustments, CO levels must be monitored using a calibrated combustion analyzer such that a CO level of no more than 150 ppm is exceeded at any time during operation.

Adjusting the “low re offset” or the “main ow restrictor” in small increments can result in a signicant increase in CO concentration.

To avoid serious injury or death, DO NOT make any adjustments to

the gas valve without monitoring the exhaust gases with a fully

functional and calibrated combustion analyzer.

Failure to follow these instructions will result in property damage, severe personal injury, or death.

Make sure the user knows the location of the gas shut-off valve and how to operate it. Immediately close the gas shut-off valve

if the appliance is subjected to re, overheating, ood, physical

damage, or any other damaging condition that might affect the

operation of the unit. Have the appliance checked by a qualied

service technician before resuming operation.

Do not power up the unit unless the gas and water supply valves

are fully opened. Make sure the fresh air intake port and exhaust

gas port are open and functional.

No one but a qualied service technician should attempt to install,

service, or repair this boiler. There are no serviceable parts which can be changed by the user / owner.

User / Owner: Contact the original qualied service technician if

the boiler needs repair / maintenance. If the original technician

is unavailable, ask your gas supplier for a list of qualied service

providers.

DO NOT store or place newspapers, laundry, or other combustible

items near the appliance or the exterior exhaust gas outlet and/or

fresh air inlet port.

The owner should inspect the system monthly for damage, water

stains, signs of rust, corrosion, and exhaust vent and air intake

blockage. If inspection of the unit shows signs of damage, the

boiler should be shut off until the problem is repaired by a qualied

technician.

After installation, all appliance safety devices should be tested.

The boiler is certied for indoor installations only. The boiler

consists of gas ignition system components which must be

protected from water (dripping, spraying, etc.) during operation and

service. Carefully consider installation location and the placement

of critical components (circulators, condensate neutralizers, etc.)

before installing the boiler.

DO NOT allow children to operate this boiler. DO NOT use this boiler

if it does not appear to be operating correctly. A qualied service

technician should service and inspect the boiler annually.

NOTE: If the boiler is exposed to re or water (or is any way damaged), do not operate. Immediately call a qualied service

technician. Failure to follow this information could result in property damage, severe personal injury, or death.

Part 1 - General Safety Information

WARNING

DO NOT USE THIS BOILER IF ANY PART HAS BEEN SUBMERGED IN WATER. Immediately call a qualied service

technician. The boiler MUST BE replaced if it has been submerged. Attempting to operate a boiler that has been submerged could create numerous harmful conditions, such as a potential gas

leakage causing a re and/or explosion, or the release of mold,

bacteria, or other harmful particulates into the air. Operating a previously submerged boiler could result in property damage, severe personal injury, or death.

NOTE: Boiler damage due to ood or submersion is considered an

Act of God, and IS NOT covered under product warranty.

WARNING

DO NOT alter or modify the appliance or appliance controls. Altering any NTI boiler with parts not manufactured by NTI WILL INSTANTLY VOID the boiler warranty and could result in property damage, personal injury, or death.

CAUTION

Due to the low water content of the boiler, improper sizing of the

boiler with regard to heating system load will result in excessive

cycling and accelerated component failure. DO NOT under or oversize the boiler to the system. Modular boiler installations greatly reduce the likelihood of boiler oversizing. NTI DOES NOT warrant failures caused by improperly sized boiler applications.

High heat sources (sources generating heat 100oF / 37oC or

greater, such as stove pipes, space heaters, etc.) may damage plastic components of the boiler as well as plastic vent pipe materials. Such damages ARE NOT covered by warranty. It is

recommended to keep a minimum clearance of 8” from high heat

sources. Observe heat source manufacturer instructions, as well as local, state, provincial, and national codes, laws, regulations and ordinances when installing this boiler and related components near high heat sources.

B. Improper Combustion

WARNING

Do not obstruct the ow of combustion and ventilating air.

Adequate air is necessary for safe operation. Failure to keep the

exhaust vent and combustion air intake clear of ice, snow, or other

debris could result in property damage, serious personal injury, or death.

C. Gas

Should overheating or gas supply fail to shut oﬀ, turn oﬀ the manual gas control valve to the boiler.

D. When Servicing the Boiler

WARNING

Be sure to disconnect electrical power before opening boiler cabinet or performing service. Label all wires while performing service to ensure proper re-wiring of the appliance. Wiring errors can cause improper or dangerous operation. Failure to do so could result in electrical shock, improper boiler or system operation, property damage, serious personal injury, or death.

• To avoid electric shock, disconnect electrical supply before performing maintenance.

• To avoid severe burns, allow boiler and associated equipment to cool before servicing.

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”. Substantial property damage, damage to boiler, and/or serious personal injury may result.

• Always verify proper operation after servicing the boiler.

NOTE: When inquiring about service or troubleshooting, reference the model and serial numbers from the boiler rating label.

Do not use this boiler for anything other than its intended purpose

(as described in this manual). Doing so could result in property

damage and WILL VOID product warranty.

NOTICE

This appliance is equipped with a three prong plug. It should only be plugged directly into a properly grounded three prong receptacle. DO NOT remove the ground plug from the plug.

This appliance provides an overheat shutdown limit. In the event the

appliance water temperature exceeds the setpoint of the control

limit, the cutoff will trip and the appliance will shut down. Certain local codes require additional temperature limits. In addition, certain types of systems may operate at temperatures below the minimum setpoint of the limit provided with the appliance. Contact the manufacturer for additional overheat controls.

E. Boiler System

• Thoroughly ﬂush the system (without the boiler connected) to remove sediment. The high-eﬃciency heat exchanger can be damaged by build-up or corrosion due to sediment. The manufacturer recommends a suction strainer in this type of system.

• Do not use petroleum-based cleaning or sealing compounds in boiler system. Gaskets and seals in the system may be damaged, possibly resulting in substantial property damage.

• Do not use “homemade cures” or “boiler patent medicines”. Substantial property damage, damage to boiler, and/or serious personal injury may result.

• Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen from make-up water can cause internal corrosion in system components. Leaks in the boiler or piping must be repaired at once.

NOTE: DO NOT add cold make up water to the system when the boiler is hot. Thermal shock can potentially cause cracks in the heat exchanger. Such damage IS NOT covered by warranty.

Part 1 - General Safety Information

F. CH and DHW Loop Water Chemistry Requirements

CAUTION

Chemical imbalance of the water supply may affect efciency and

cause severe damage to the boiler and associated equipment. Water quality must be professionally analyzed to determine whether it is necessary to treat the water. Various solutions are available to adjust water quality. Adverse water quality will affect the reliability of the system. In addition, operating temperatures above 135oF will accelerate the build-up of lime scale and possibly shorten boiler service life. Failure of a boiler due to lime scale build-up, low pH, or other chemical imbalance IS NOT covered by the warranty.

The water must be potable, free of corrosive chemicals, sand, dirt, and other contaminates. It is up to the installer to ensure the water does not contain corrosive chemicals or elements that can

damage the heat exchanger. Potable water is dened as drinkable

water supplied from utility or well water in compliance with EPA

secondary maximum contaminant levels (40 CFR Part 143.3). If

the water contains contaminants higher than outlined by the EPA, water treatment is recommended and additional, more frequent maintenance may be required. See Table 1. If you suspect that your water is contaminated in any way, discontinue use of the appliance and contact an authorized technician or licensed professional.

CH Loop Total Water Hardness Speciﬁcations

Contaminant Maximum Allowable Level

Total Hardness

DHW Loop Total Water Hardness Speciﬁcations

Contaminant Maximum Allowable Level

Total Hardness

(Below 140oF water temperature)

Total Hardness

(Above 140oF water temperature)

CH and DHW Loop Water Quality Speciﬁcations Contaminant Maximum Allowable Level

Aluminum 0.05 to 0.2 mg/l or PPM

Chloride 100 mg/l or PPM

Copper 1 mg/l or PPM

Iron 0.3 mg/l or PPM

Manganese 0.05 mg/l or PPM

pH 6.5 - 8.5

Sulfate 205 mg/l or PPM

Total Dissolved Solids (TDS) 500 mg/l or PPM

Zinc 5 mg/l or PPM

Dissolved Carbon Dioxide (CO2) 15 mg/l or PPM

Table 1 - Water Quality Speciﬁcations

G. Freeze Protection

120 mg/l

(7 grains/gallon)

200 mg/l

(12 grains/gallon)

120 mg/l

(7 grains/gallon)

WARNING

NEVER use any toxic chemical, including automotive, standard glycol antifreeze, or ethylene glycol made for hydronic (nonpotable) systems. These chemicals can attack gaskets and seals in water systems, are poisonous if consumed, and can cause personal injury or death.

NOTE: Loops Serving Indirect Water Heaters (IWHs)

Glycol used in IWH loops should be food grade propylene glycol, FDA rated as “generally recognized as safe” (GRAS). If using a glycol / potable water mix, the water chemistry must meet the requirements in this manual. The glycol content of the liquid must not exceed 50%, unless the manufacturer speciﬁes a diﬀerent ratio. Glycol should be checked periodically to prevent it from becoming acidic. Please refer to guidelines provided by the glycol manufacturer regarding glycol maintenance. NOTE: Glycol not recognized as GRAS may only be used in closed loop CH applications. NOTE: NTI DOES NOT WARRANT THE BOILER AGAINST FREEZE-RELATED DAMAGE. The boiler control is equipped with freeze protection that activates based on internal water temperature. See the following table for details on freeze protection operation.

NOTE: Freeze protection will not be active if the boiler loses power.

FREEZE PROTECTION OPERATION

STAGE 1

Condition

Events

Time

Condition

Events

The water temperature detected by probes NTC1 or NTC2 ranges between 39oF (4oC) and 46oF (8oC).

• The internal pump operates at high speed.

• The 3-Way Valve alternately switches positions - 1 minute on heating mode to 1 minute on DHW mode

• The display shows the icon.

Until the NTC1 and NTC2 temperature is greater than or

equal to 46°F (8°C)

If after 20 minutes the conditions described in Stage 1

are still present, the boiler proceeds to Stage 2.

STAGE 2

The water temperature detected by probes NTC1 or NTC2 is less than 39oF (4oC).

• The burner turns on at minimum power.

• The 3-Way Valve is positioned on DHW and switches every 30 seconds between CH and DHW.

• When the temperature is greater than or equal to 104oF (40oC) the burner will turn oﬀ. The boiler will maintain the temperature between 95oF (35oC) and 104oF (40oC) for 45 minutes.

• After 45 minutes there will be 2 minutes of post heating circulation.

• If the temperature falls below 46oF (8oC) within 150 minutes the burner will immediately power on again.

CAUTION

Consider piping and installation when determining boiler location. Damages resulting from incorrect installation or from use of products not approved by the manufacturer ARE NOT covered by warranty. Failure of the boiler due to freeze related damage IS NOT covered by product warranty.

• The display shows the icon.

Time

Table 2 - Freeze Protection Detail

Until the NTC1 temperature is greater than or equal to

104oF (40oC)

Part 1 - General Safety Information

CAUTION

On TRX085 / TRX120 Models ONLY If the boiler to be used only in Heating Mode (not connected to an indirect water heater), the electrical connection of the 3-way valve motor MUST BE DISCONNECTED while the boiler is operating in central heating mode. This will lock the valve motor in central heating mode and ensure freeze protection operates properly. Failure to disconnect the valve may disable boiler freeze protection and result in property damage.

H. Water Temperature Adjustment and Scalding

This boiler can deliver scalding water. Be careful whenever using hot water to avoid scalding injury. Certain appliances such as dishwashers and automatic clothes washers may require increased water temperatures. By setting the thermostat on this boiler to obtain the increased water temperature required by these appliances you may create the potential for scald injury.

To protect against injury, install a mixing valve in the water system. This valve will reduce point of use discharge temperatures by mixing cold and hot water in branch supply lines. Such valves are available from your local plumbing supplier.

Table 3 details the relationship of water temperature and time with regard to scald injury and may be used as a guide in determining the safest water temperature for your applications.

I. High Elevation Installations

WARNING

Natural gas at high elevation might contain less heating value than typical 1,000 BTU/cu ft and therefore can cause improper air / gas mix leading to improper combustion. For natural gas installations above 3,000 ft, call your gas provider to determine the heating value of the supplied natural gas.

Approximate Time / Temperature Relationships in Scalds

120oF More than 5 minutes

125oF 1 1/2 to 2 minutes

130oF About 30 seconds

135oF About 10 seconds

140oF Less than 5 seconds

145oF Less than 3 seconds

150oF About 1 1/2 seconds

155oF About 1 second

Table 3 - Time and Temperature Relationship in Scalds

Part 2 - Before You Start

NOTICE

UNCRATING THE BOILER - Any claims for damage or shortage

in shipment must be led immediately against the transportation

company by the consignee.

Remove the boiler from the packaging. Remove the accessory box from the boiler. Take care to place the boiler in a safe location prior to installation to prevent damage to the mechanical connections.

A. What’s in the Box

All models

14b

This appliance has been converted for use with Propane Gas, in accordance with the

instructions provided with the Natural to Propane Conversion Kit

by ______________________________________ , which accepts responsibility that

the conversion was performed properly.

THIS CONTROL WAS CONVERTED FOR USE WITH PROPANE GAS

Reference rating plate for Propane Input and Gas Pressure

14 15

TRX085

14a

Connectivity Quick Start Guide

TRX series

420060882600

14c

14f

14g

14d

Gas

14e

ACCESSORIES BOX

BOITE ACCESSOIRES

For Qualiﬁed Technician Installation Instructions

14h

Pour technicien qualiﬁé instructions d’installation

code

Read the code

Lire le code

TRX NATURAL TO PROPANE

CONVERSION INSTRUCTIONS

WARNING

This conversion kit shall be installed by a qualiﬁed service agency in accordance with the manufacturer’s instructions and all applicable codes and requirements of the authority having jurisdiction. If the information in these instructions is not followed exactly, a ﬁre, an explosion or production of carbon monoxide may result causing property damage, personal injury or loss of life. The qualiﬁed service agency is responsible for the proper installation of this kit. THE INSTALLATION IS NOT PROPER AND COMPLETE UNTIL THE OPERATION OF THE CONVERTED APPLIANCE IS CHECKED AS SPECIFIED IN THE MANUFACTURER’S INSTRUCTIONS SUPPLIED WITH THE KIT, WHICH NECESSITATES THE USE OF A CALIBRATED CO2/O2 AND CO COMBUSTION ANALYZER.

TRX110C

15c

Gas

User’s Information Manual

Installation

User Operating Instructions

Start-Up

Maintenance

NOTICE

Parts

The manufacturer reserves the right to make product changes or updates without notice and will not be held

Warranty

liable for typographical errors in literature.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

NOTE TO CONSUMER:

PLEASE KEEP ALL INSTRUCTIONS

FOR FUTURE REFERENCE.

For Qualiﬁed Technician Installation Instructions

15g

Residential Condensing Gas Boiler

Heat Exchanger Bears the ASME “H” Stamp

WARNING

IF THE INFORMATION IN THIS MANUAL IS NOT FOLLOWED EXACTLY, A FIRE OR EXPLOSION MAY RESULT, CAUSING PROPERTY DAMAGE, PERSONAL INJURY, OR LOSS OF LIFE. DO NOT STORE GASOLINE OR OTHER FLAMMABLE VAPORS AND LIQUIDS IN THE VICINITY OF THIS OR ANY OTHER BOILER.

• Do not try to light any boiler.

• Do not touch any electrical switch.

• Do not use any phone in your building.

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

• If you cannot reach your gas supplier, call the fire department. Installation and service must be provided by a qualified installer, service agency, or the gas supplier.

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, bir th defects, or other reproductive harm.

15d

ACCESSORIES BOX

BOITE ACCESSOIRES

TRX

Residential Condensing Gas Boiler

Heat Exchanger Bears the ASME “H” Stamp

WHAT TO DO IF YOU SMELL GAS

DANGER

WARNING

Improper installation, adjustment, alteration, service, or maintenance could void product warranty and cause property damage, severe personal injury, or death.

California Proposition 65 Warning: This product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

NOTICE

The manufacturer reserves the right to make product changes or updates without notice and will not be held liable for typographical errors in literature.

The surfaces of these products contacted by potable (consumable) water contain less than 0.25% lead by weight as required by the Safe Drinking Water Act, Section 1417.

15a

15e

For Qualiﬁed Technician Installation Instructions

Pour technicien qualiﬁé instructions d’installation

code

Read the code

Lire le code

0 250

TRX

psi

200

100 150

15b

15f

QSG

TEMPLATE

Components included with the boiler:

Nr. Quantity Description

ALL MODELS

1 1 Condensing Gas Boiler

2 1 Condensate Drain Pipe

3 1 Bracket

4 2 Assembly Screws (Fischer Type SX )

5 1+1 CH Pressure Relief Valve + Connection Tube

6 1 2” CPVC Pipe, 5.5” Long

7 1 Piping Bracket

8 1 Torx screw adapter

9 2 + 2 2” Vent Screen + 3” Vent Screen

10 1 Tridicator

1 Installation Manual (This Document)

1 User’s Information Manual

1 Connectivity Quick Start Guide

12 1 LP Gas Conversion Kit

13 1 Outdoor sensor Kit

14 1 Piping Adapter Kit - TRX085

14-a 2 Cap 1/2”

14-b 6 Gasket (2x1/2” + 2x3/4” + 1 x 1” + 1 gas ﬁber)

14-c 4 Clamp (2x3/4” + 2x1”)

14-d 1 Gas Adapter 3/4”

14-e 1 CH supply pipe 1”

14-f 1 CH return pipe 1”

14-g 1 Tank return pipe 3/4”

14-h 1 Accessory box components list

15 1 Piping Adapter Kit- TRX110C

15-a 6 Gasket (2x1/2” + 2x3/4” + 1 x 1” + 1 gas ﬁber)

15-b 4 Clamp (2x3/4” + 2x1”)

15-c 1 Gas Adapter 3/4”

15-d 1 CH supply pipe 1”

15-e 1 CH return pipe 1”

15-f 2 DHW outlet & inlet pipes 3/4”

15-g 1 Accessory box components list

16 1

16-a 7 Gasket (2x1/2” + 3x3/4” + 1 x 1” + 1 gas ﬁber)

16-b 4 Clamp (2x3/4” + 2x1”)

16-c 1 Gas Adapter 3/4”

16-d 1 CH supply pipe 1”

16-e 1 CH return pipe 1”

16-f 1 DHW outlet pipe (150C)/Tank return pipe (120) 3/4”

16-g 1 DHW inlet ﬂow restrictor (150C)1/2” x 3/4”

16-h 1 DHW inlet pipe 3/4”

16-i 2 Cap 1/2”

16-j 2 Accessory box components list

Table 4 - Included with the Boiler

1 LP Convertion Instructions

1 Warranty

1 Installation Quick Start Guide

1 Template

Piping Adapter Kit - TRX1120/ TRX150C

(see ﬁg. 1 part b - next page)

Figure 1 - Included with the Boiler - part a

TRX150C / TRX120

14a

16d

16b

16i

16f

16e

ACCESSORIES BOX

BOITE ACCESSOIRES

For Qualiﬁed Technician

16j

Installation Instructions

Pour technicien qualiﬁé instructions d’installation

code

Read the code

Lire le code

Figure 2 - Included with the Boiler - part b

psi

250

200

100 150

View from

the Front

Ø 1-1/8”

2-3/16” (55 mm)

6-3/8” (162 mm)

6-11/16” (169 mm)

16” (406 mm)

View from the Side

Figure 3 - Adapter Kit Dimensions and Speciﬁcations - Included with Adapter Kit

16c

16g

16h

Part 2 - Before You Start

How the Boiler Operates TRX condensing technology intelligently delivers hydronic heating

while maximizing eﬃciency. Outlined below are system features and operation:

Stainless Steel Heat Exchanger

The highly eﬃcient stainless steel heat exchanger is designed to extract all available heat from the supply line before it is exhausted.

Modulating Combustion System

The combustion system modulates the output of the burner during operation to match system demand and achieve the control set point while in operation. The set point can change by internal or external signals to enhance the overall performance of the system.

Control

The integrated control system monitors the system and regulates fan speed to control boiler output. This allows the boiler to deliver only the amount of heat energy required and nothing more. The control can be set to monitor outdoor temperature through an outdoor sensor to regulate boiler set point. The system can be further enhanced by installing an indirect water heater to provide domestic hot water. The control can regulate the output of multiple boilers through its cascade system function. The cascade system is capable of connecting up to eight boilers together in such a way that they function as one boiler system. This allows for greater turn down ratios and provides systematic control of the multiple boilers in an installation to minimize downtime and maximize eﬃciency. The cascade system works by establishing one boiler as the master and the other connected boilers as followers. The master boiler requires a sensor to provide feedback on set point temperature in order to adjust heating input from the connected boilers. Each cascaded boiler will have its own pump to provide maximum ﬂow and control heat exchanger ﬂow rate.

10" 1/16” (255 mm)

Ø 1-1/8” Ø 7/8” Ø 7/8”

Text Display and Operational Display Icons

The display allows the user to change system parameters and monitor system outputs.

Gas Valve

Senses suction from the blower, allowing gas to ﬂow only if powered and combustion air is ﬂowing.

Integrated Venturi

Controls air and gas ﬂow into the burner.

Burner

The high grade stainless steel burner uses premixed air and gas to provide a wide range of ﬁring rates.

Spark Ignition

The burner is ignited by applying high voltage through the system spark electrode. The spark from the electrode ignites mixed gas oﬀ of the burner.

Supply Water Temperature Sensor

This sensor monitors the boiler outlet water temperature (System Supply). The control adjusts boiler ﬁring rate so the supply temperature will match the boiler set point.

Return Water Temperature Sensor This sensor monitors boiler return water temperature (System Return). Flue Sensor

Monitors ﬂue temperature and adjusts ﬁring rate.

Temperature and Pressure Gauge

Allows the user to monitor system temperature and pressure.

Electrical ﬁeld connections with terminal strips

The electrical cover allows easy access to the clearly marked line voltage and low voltage terminal strips to facilitate wiring the boiler.

Part 2 - Before You Start

Condensate Collection System

This boiler is a high eﬃciency appliance and will produce condensate. The condensate collection system has a ﬂoat switch which monitors condensate level and prevents condensate from backing up into the combustion system. Inside the collection system is a built in trap which seals the combustion system from the connected drain. This condensate should be neutralized to avoid damage to the drainage system or piping.

Outdoor Sensor

Monitors outdoor temperature and adjusts unit set point to provide greater eﬃciency.

0-10 Volt Input / 4-20 mA Input (with Optional Connection Card)

Allows the installer to connect a BMS (Building Management System) to control the boiler.

Condensate Trap and Air Pressure Switch

The condensate trap and air pressure switch prevent condensate and heat exchanger exhaust from backing up into the boiler.

Pump Service Mode

Allows manual operation of pumps to commission system and check pump operation.

Internal By-Pass Valve

Protects the boiler from damage in low ﬂow conditions.

Internal ECM Pump

The internal ECM Pump uses less electricity than standard pumps, providing high performance operation.

B. Optional Equipment

Optional equipment available from NTI (and Part #):

• System Sensor (84010)

• 3” PVC Concentric Vent Kit (84634)

• 3” PVC Low Proﬁle Vent Kit (84357)

• 2” PVC Low Proﬁle Vent Kit (85062)

• Tank Sensor (84632)

NOTE: When using an optional system sensor, pipe insulation must be wrapped around it to improve temperature measurement accuracy and increase overall system eﬃciency.

Part 3 - Prepare the Boiler for Installation

CAUTION CAUTION

COLD WEATHER HANDLING - If the boiler has been stored in

a very cold location (BELOW 0oF) before installation, handle with

care until the components come to room temperature. Failure to do so could result in damage to the boiler.

Carefully consider installation when determining boiler location. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

A. Locating the Boiler

WARNING

This boiler is certied for indoor use only. DO NOT INSTALL

OUTDOORS. Outdoor installations ARE NOT covered by warranty. Failure to install the boiler indoors could result in property damage, severe personal injury, or death.

Incorrect ambient conditions can lead to damage to the heating system and put safe operation at risk. Ensure that the installation location adheres to the information included in this manual. Failure to do so could result in property damage, serious personal injury, or death. Failure of boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

This boiler must be installed upright in the vertical position as described in this manual. DO NOT attempt to install this boiler in any other orientation. Doing so will result in improper boiler operation and property damage, and could result in serious personal injury or death.

1. Installation Area (Mechanical Room) Operating Conditions

• Ensure ambient temperatures are higher than 32oF / 0oC and lower than 104oF / 40oC

• Prevent the air from becoming contaminated by the products, places, and conditions listed in this manual

• Avoid continuously high levels of humidity

• Never close existing ventilation openings

• Ensure a minimum 1” clearance around hot water and exhaust vent pipes

• NOTE: To prevent condensing in the fan, it is recommended to avoid prolonged exposure to temperatures below 45oF

The service life of the boiler’s exposed metallic surfaces, such

as the casing, as well as internal surfaces, such as the heat

exchanger, are directly inuenced by proximity to damp and salty

marine environments. In such areas higher concentration levels of chlorides from sea spray coupled with relative humidity can lead to degradation of boiler components. In these environments, boilers must not be installed using direct vent systems which draw outdoor air for combustion. Such boilers must be installed using room air for combustion. Indoor air will have a much lower relative humidity, and hence potential corrosion will be minimized.

Failure of the boiler or components due to incorrect operating conditions IS NOT covered by product warranty.

2. Check for nearby connections to:

• System water piping

• Venting connections

• Gas supply piping

• Electrical power

• Condensate drain

3. Check area around boiler. Remove any combustible materials, gasoline, and other ﬂammable liquids.

WARNING

Failure to keep the boiler area clear and free of combustible materials, liquids, and vapors can result in substantial property damage, severe personal injury, or death.

4. Gas control system components must be protected from dripping water during operation and service.

5. If the boiler is to replace an existing boiler, check for and correct any existing system problems, such as:

• System leaks

• Location that could cause the system and boiler to freeze and leak

• Incorrectly sized expansion tank

CAUTION

Always take future maintenance into consideration when locating the boiler. If the boiler is located in an installation location with limited clearances, it may be necessary to remove the boiler from the space to perform maintenance. Failure to consider maintenance when determining installation location could result in property damage.

WARNING

This boiler has a condensate disposal system that may freeze

if exposed to sustained temperatures below 32oF. Precautions

should be taken to protect the condensate trap and drain lines from sustained freezing conditions.

WARNING

Circulators suitable for DHW applications must be used.

Failure to take precautions could result in property damage, severe personal injury, or death.

6. Clean and ﬂush system when reinstalling a boiler.

WARNING

Do not introduce toxic chemicals, such as antifreeze or appliance

treatments, into any piping meant for potable water purposes.

Do not connect the appliance DHW connections to any heating systems or components that have been previously used for nonpotable applications.

Ensure that all piping and components connected to the appliance are suitable for potable water applications.

Failure to follow these instructions could result in serious personal injury or death.

Part 3 - Prepare the Boiler for Installation

Correct installation

Incorrect installation

NOTE: When installing in a zero clearance location, it may not be possible to read or view some product labeling. It is recommended to make note of the boiler model and serial number.

NOTE: A combustible door or removable panel is acceptable front clearance.

B. Leveling

NOTE: For closet installations, a combustible door or removable

panel is acceptable front clearance. A 3” minimum clearance must be provided from the appliance front cover to the removable panel or combustible door.

Minimum Clearances from Combustible Materials

• Hot water pipes - at least 1” from combustible materials

• Exhaust vent pipe - at least 1” from combustible materials

CAUTION

In order for the condensate to properly ow out of the collection

system, the area where you locate the boiler must be level. Failure to do so will result in improper appliance operation.

Figure 4 - Proper levelling

C. Clearances for Service Access

NOTE: If you do not provide the minimum clearances shown in Figure

5 and Table 5 it might not be possible to service the boiler without removing it from the space.

CAUTION

All boilers eventually leak. Locate the boiler where any leakage from the relief valve, related piping, tank, or connections will not result

in damage to surrounding areas or lower oors of the building. Any

boiler should be installed in such a manner that if it should leak

the resulting ow of water will not cause damage to the area in

which it is installed. If the boiler is installed in a location where a leak could cause damage, it is required to provide containment measures. Such measures include but are not limited to: a properly sized drain pan installed beneath the boiler and piped to an open

drain line, or installing the boiler on a concrete oor pitched to a free owing drain. Failure to provide containment measures is the

sole responsibility of the owner and/or installer. Leakage damages ARE NOT covered by warranty. In addition, water leak detection devices and automatic water shutoff valves are readily available at plumbing supply houses. IT IS HIGHLY RECOMMENDED BY THE MANUFACTURER TO INSTALL WATER LEAK DETECTION DEVICES AND AUTOMATIC SHUTOFF VALVES IN ANY BOILER INSTALLATION WHERE A LEAKAGE OF WATER COULD RESULT IN PROPERTY DAMAGES.

WARNING

The space must be provided with combustion / ventilation air openings correctly sized for all other appliances located in the same space as the boiler. The boiler cover must be securely fastened to prevent the boiler from drawing air from the boiler room. This is particularly important if the boiler is in a room with other appliances. Failure to comply with the above warnings could result in substantial property damage, severe personal injury, or death.

B B

Figure 5 - Minimum Clearances

Dimension Description Clearance

A Top 14” (355.6 mm)

B Right or Left Side 2” (50.8 mm)

C Front 18” (457.2 mm)

D Bottom 12” (304.8 mm)

Not Displayed Back 0” (0 mm)

Table 5 - Minimum Installation and Service Clearances

D. Wall Mounting Considerations

These boilers are wall mounted. Use only the wall mounting instructions included with this boiler. Ensure the wall that the boiler is intended to be mounted on is comprised of cement, brick, block, or wooden studs spaced 16” apart from center. Ensure the wall is capable of supporting at least 150 lbs (68 kgs). If ﬂooding is possible, elevate the boiler to prevent ﬂoodwater from reaching the boiler. Ensure the boiler is installed in a location that minimizes the risk of water damage due to leaking valves, pumps, unions, etc. The boiler may be installed on any suitable internal wall (suitable soundprooﬁng may be required when installing onto a stud partition wall).

WARNING

Ensure that the structure of the installation location is sufcient to

support the full installed weight of the boiler, including water content

of the heat exchanger and related piping and components. If the mounting location cannot support a minimum of 150 lbs. (68 kg), it

is recommended to locate the boiler in a mounting location that can support the minimum weight. Failure to ensure the structure of the installation location is structurally sound before installation of the boiler and properly mount the boiler can result in structural failure, substantial property damage, severe personal injury, or death.

WARNING

Do not mount the boiler to a hollow wall.

E. Wall Mounting Instructions

WARNING

This boiler is too heavy for one person to lift. It is highly recommended to install the boiler with two people. Use caution as to not drop the boiler, which could damage the boiler and cause property damage and/or severe personal injury. Verify that the boiler is properly and securely mounted before leaving unsupervised. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

1. Mounting to a concrete wall

Position the paper template on the concrete wall to locate the positions of the hanging bracket and piping bracket. Drill and plug the wall and secure the hanging bracket using the

screws provided (sher S 10x50). Ensure the hanging bracket is level. Secure the piping bracket on the concrete wall. Use suitable

hardware.

Part 3 - Prepare the Boiler for Installation

2. Mounting to a Wood Studded Wall

CAUTION

If the boiler is not installed upright, vertically plumb, and level,

improper and unsatisfactory operation may occur, causing excessive

condensation build-up, nuisance fault codes, and unnecessary maintenance.

To install the boiler on a standard wood studded wall with 16” centers, a plywood board is required. The minimum dimensions of the plywood board are: 24” wide x 48” high x 1/2” thick. Use at least fourteen (14) #12 x 3” (3/16” x 3”) round head tapping screws to secure the plywood board to the studded wall.

16 “

STUDSTUD

5-3/8”

(136,5 mm)

16”

(406,4 mm)

1-3/8”

2-5/8” 2-5/8”

1-1/8”

(34,2 mm)

(120 mm)

13”

(330 mm)

15-3/4”

(400 mm)

1/2”

(13,1 mm)

2-9/16”

(239,75 mm)

9-7/16”

(67 mm)(67 mm)

9/16”

3-7/16” 3-7/16”

Plywood board Dimensions: 24" wide x 48" high x 1/2" thick

(110 mm)

4-5/16”

(745 mm)

29-5/16”

43-5/8”

(1108,15 mm)

8-15/16”

(226,65 mm)

5-3/4”

(146,26 mm)

MOUNTING TO A WOOD STUDDED WALL To install the boiler on a standard wood studded wall a plywood board is required. The minimum dimensions of the plywood board are: 24" wide x 48" high x 1/2" thick. Use at least fourteen (14) #12 x 3" (3/16" x 3") round head tapping screws to secure the plywood board to the studded wall.

WALL MOUNTING INSTRUCTIONS After the plywood board has been installed to the studs, position the paper template on the plywood. Locate the positions of the hanging bracket and piping adapter bracket. Position the wall mounting and piping adapter brackets. Ensure the brackets are level. Then mark the bracket drilling holes. Mount the boiler bracket on the plywood board. Use the hardware delivered with the boiler (ﬁsher S 10x50) and washers for wood mounting. Mount the piping bracket on the plywood board. Use suitable hardware .

Position the paper template on the concrete wall to locate the positions of the hanging bracket and piping bracket. Drill and plug the wall and secure the hanging bracket using the screws provided (ﬁsher S 10x50). Ensure the hanging bracket is level. Secure the piping bracket on the concrete wall. Use suitable hardware.

WARNING

THE MANUFACTURER CANNOT ANTICIPATE ALL INSTALLATION CONDITIONS. THESE INSTRUCTIONS AND INCLUDED PARTS MAY NOT APPLY TO WALL-MOUNTING THE BOILER AT YOUR INSTALLATION LOCATION. THE BOILER MUST BE PROPERLY AND SECURELY MOUNTED BY A QUALIFIED INSTALLER ACCORDING TO INSTALLATION CONDITIONS, THE TECHNICAL SPECIFICATIONS OF THE APPLIANCE, AND TO MEET AHJ / BUILDING CODE REQUIREMENTS. ALL APPLICABLE PERMITS MUST BE OBTAINED BEFORE INSTALLING THE BOILER. FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH. ANY DAMAGES RESULTING FROM IMPROPER INSTALLATION ARE NOT COVERED BY PRODUCT WARRANTY.

2-9/16” (65 mm) (65 mm)

5-3/16”

(131,76 mm)

60 40

psi

250

200

100 150

3-7/16”

(87,2 mm) (87,2 mm)(87,6 mm) (87,6 mm)

4-3/4” 4-3/4”

(120 mm)

3-7/16”

Figure 6 - Mounting to a concrete wall

WARNING

This wall mounting system is not seismic rated and should not be applied as such. Failure to comply with the above and properly mount the boiler could result in substantial property damage, severe personal injury, or death.

Use extreme care not to drop the boiler or cause bodily injury while

lifting or mounting the boiler onto the wall mount bracket.

Failure to follow these instructions could result in property damage, severe personal injury, or death.

The manufacturer cannot anticipate all installation conditions. These instructions and included parts may not apply to wall-mounting the appliance at your installation location. The appliance must be

properly and securely mounted by a qualied installer according to installation conditions, the technical specications of the appliance,

and to meet AHJ / building code requirements. All applicable permits must be obtained before installing the appliance. Failure to follow these instructions could result in property damage, severe personal injury, or death. Any damages resulting from improper installation are not covered by product warranty.

Figure 7 - Mounting a playwood board

Part 3 - Prepare the Boiler for Installation

F. Residential Garage and Closet Installations

16 “

Plywood board Dimensions: 24" wide x 48" high x 1/2" thick

4-5/16”

29-5/16”

43-5/8”

(1108,15 mm)

8-15/16”

16 “

(110 mm)

(745 mm)

(226,65 mm)

(120 mm)

5-3/4”

(146,26 mm)

WARNING

2-9/16” (65 mm) (65 mm)

5-3/16”

(131,76 mm)

psi

250

200

100 150

3-7/16”

(87,2 mm) (87,2 mm)(87,6 mm) (87,6 mm)

16”

(406,4 mm)

4-3/4” 4-3/4”

13”

(330 mm)

15-3/4”

(400 mm)

(67 mm)(67 mm)

2-5/8” 2-5/8”

1-1/8”

9/16”

3-7/16”

(120 mm)

2-9/16”

3-7/16” 3-7/16”

STUDSTUD

5-3/8”

(136,5 mm)

1-3/8”

(34,2 mm)

Check with your local Authority Having Jurisdiction for requirements when installing boiler in a garage or closet. Please read the entire manual before attempting installation. Failure to properly take factors such as boiler venting, piping, condensate removal, and wiring into account before installation could result in wasted time, money, and possible property damage and personal injury.

Precautions

If the boiler is located in a residential garage, per ANSI Z223.1:

• Mount the bottom of the boiler a minimum of 18” above the ﬂoor of the garage to ensure the burner and ignition devices are well oﬀ the ﬂoor.

• Locate or protect the boiler so it cannot be damaged by a moving vehicle.

WARNING

1/2”

CAUTION

(13,1 mm)

(239,75 mm)

9-7/16”

16 “

The space must be provided with correctly sized combustion/ ventilation air openings for all other appliances located in the space with the boiler. For power venting installations using room air for combustion, refer to the boiler venting section, this manual, for

descriptions of conned and unconned spaces. Do not install the

boiler in an attic. Failure to comply with these warnings could result in substantial property damage, severe personal injury, or death.

G. Exhaust Vent and Intake Pipe

The boiler is rated ANSI Z21.13 Category IV (pressurized vent, likely to form condensate in the vent) and requires a special vent system designed for pressurized venting.

NOTE: The venting options described here (and further detailed in the Venting section, this manual) are the lone venting options approved for this boiler. Failure to vent the boiler in accordance with the provided venting instructions will void the warranty.

Figure 8 - Mounting the hanging bracket and piping bracket

After the plywood board has been installed to the studs, position the paper template on the plywood. Locate the positions of the hanging bracket and piping adapter bracket. Position the wall mounting and piping adapter brackets. Ensure the brackets are level. Then mark the bracket drilling holes. Mount the boiler bracket on the plywood board. Use the hardware delivered with the boiler (ﬁsher S 10x50) and washers for wood mounting. Mount the piping bracket on the plywood board. Use suitable hardware .

DANGER

Failure to vent the boiler properly will result in serious personal injury or death.

WARNING

Do not attempt to vent this boiler by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Vents must be properly supported. Boiler exhaust and intake

connections are not designed to carry heavy weight. Vent support

brackets must be within 1’ of the boiler and the balance at 4’

intervals. Boiler must be readily accessible for visual inspection for

rst 3’ from the boiler. Failure to properly support vents could result

in property damage, severe personal injury, or death.

The exhaust discharged by this boiler may be very hot. Avoid touching or other direct contact with the exhaust gases of the vent

termination assembly. Doing so could result in severe personal injury or death.

1. Direct Vent of Exhaust and Intake

If installing a direct vent option, combustion air must be drawn from the outdoors directly into the boiler intake and exhaust must terminate outdoors. There are three basic direct vent options detailed in this manual: 1. Side Wall Venting, 2. Roof Venting, and 3. Unbalanced

Venting. Be sure to locate the boiler such that the exhaust vent and intake piping can be routed through the building and properly terminated. Diﬀerent vent terminals can be used to simplify and eliminate multiple penetrations in the building structure (see Optional Equipment in Venting Section). The exhaust vent and intake piping lengths, routing, and termination methods must all comply with the methods and limits given in the Venting Section, this manual. When installing a combustion air intake from outdoors, care must be taken to utilize uncontaminated combustion air. To prevent

combustion air contamination, see Table 6.

2. Power Venting, Indoor Combustion Air in Conﬁned or Unconﬁned Space

This boiler requires fresh, uncontaminated air for safe operation and must be installed in a mechanical room where there is adequate combustion and ventilating air. NOTE: To prevent combustion air contamination, see Table 6. Combustion air from the indoor space can be used if the space has adequate area or when air is provided through a duct or louver to supply suﬃcient combustion air based on the boiler input. Never obstruct the supply of combustion air to the boiler. If the boiler is installed in areas where indoor air is contaminated (see Table 6) it is imperative that the boiler be installed as direct vent so that all combustion air is taken directly from the outdoors into the boiler intake connection. Unconﬁned space is space with volume greater than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuelburning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. See Venting Section for details. Conﬁned space is space with volume less than 50 cubic feet per 1,000 BTU/hr (4.8 cubic meters per kW) of the total input rating of all fuelburning appliances installed in that space. Rooms connected directly to this space through openings not furnished with doors are considered part of the space. When drawing combustion air from inside a conventionally constructed building to a conﬁned space, such space should be provided with two permanent openings: one located 6” (15 cm) below the space ceiling, the other 6” (15cm) above the space ﬂoor. Each opening should have a free area of one square inch per 1,000 BTU/hr (22cm2/kW) of the total input of all appliances in the space, but not less than 100 square inches (645cm2). If the conﬁned space is within a building of tight construction, air for combustion must be obtained from the outdoors as outlined in the Venting section of this manual.

CAUTION

When drawing combustion air from the outside into the mechanical room, care must be taken to provide adequate freeze protection.

WARNING

Failure to provide an adequate supply of fresh combustion air can

cause poisonous ue gases to enter the living space, resulting

in severe personal injury or death. To prevent combustion air

contamination, see Table 6.

H. Carbon Monoxide Detectors

In the Commonwealth of Massachusetts and As Required by State and Local Codes:

Installation of Carbon Monoxide Detectors: At the time of installation or replacement of the vented gas fueled appliance, the installing plumber or gas ﬁtter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂoor level where the gas appliance is installed, unless the appliance is located in a detached, uninhabitable structure separate from the dwelling, building, or structure used in whole or in part for residential purposes. In addition, the installing plumber or gas ﬁtter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is

Part 3 - Prepare the Boiler for Installation

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

a. In the event that the vented gas fueled appliance is installed in a crawl space or attic, the hard wired carbon monoxide detector with alarm and battery back-up shall be installed on the next adjacent ﬂoor level. b. In the event that these requirements cannot be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

WARNING

Do not attempt to vent this appliance by any means other than those described in this manual. Doing so will void the warranty and may result in severe personal injury or death.

Approved Carbon Monoxide Detectors: Each carbon monoxide detector as required in accordance with the above provisions shall comply with NFPA 70 and be ANSI/UL 2034 listed and IAS certiﬁed.

I. Prevent Combustion Air Contamination

Install intake air piping for the boiler as described in the Venting Section, this manual. Do not terminate exhaust in locations that can allow contamination of intake air.

WARNING

Ensure that the intake air will not contain any of the contaminants

in Table 6. Contaminated air will damage the boiler, resulting in

possible substantial property damage, severe personal injury, or

death. For example, do not pipe intake air near a swimming pool or

laundry facilities. These areas always contain contaminants.

Products to Avoid

Spray cans containing ﬂuorocarbons

Permanent wave solutions Swimming pools Chlorinated waxes / cleaners Metal fabrication plants Chlorine-based swimming pool

chemicals Calcium chloride used for

thawing Sodium chloride used for water sof-

tening Refrigerant leaks Auto body shops Paint or varnish removers Plastic manufacturing plants

Hydrochloric or Muriatic acid

Cements and glues New building construction Antistatic fabric softeners used in

clothes dryers Chlorine-type bleaches, laundry

detergents, and cleaning solvents Adhesives used to fasten building

products

Table 6 - Products and Areas Likely to Have Contaminants

NOTE: DAMAGE TO THE BOILER CAUSED BY EXPOSURE TO CORROSIVE VAPORS IS NOT COVERED BY WARRANTY. (Refer to

the limited warranty for complete terms and conditions.)

Areas Likely to H ave

Contaminants

Dry cleaning / laundry areas and establishments

Beauty shops

Refrigeration repair shops

Photo processing plants

Furniture reﬁnishing areas and establishments

Remodeling areas

Garages and workshops

Part 3 - Prepare the Boiler for Installation

Figure 9 - CO Warning Label

J. Removing a Boiler from a Common Vent System

DANGER

Do not install the boiler into a common vent with any other appliance.

This will cause ue gas spillage or appliance malfunction, resulting

in possible substantial property damage, severe personal injury, or death.

WARNING

Failure to follow all instructions can result in ue gas spillage and carbon monoxide emissions, causing severe personal injury or

death.

When removing an existing boiler, follow the steps below.

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

2. Visually inspect the venting system for proper size and horizontal pitch to determine if there is blockage, leakage, corrosion, or other deﬁciencies that could cause an unsafe condition.

3. If practical, close all building doors, windows, and doors between the space in which the boiler remains connected to the common venting system and other spaces in the building. Turn on clothes dryers and any appliances not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, at maximum speed. Do not operate a summer exhaust fan. Close all ﬁreplace dampers.

4. Place in operation the appliance being inspected. Follow the lighting instructions. Adjust the thermostat so the appliance will operate continuously.

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

6. After it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined, return doors, windows, exhaust fans, ﬁreplace dampers, and any other gas burning appliances to their previous condition of use.

7. Any improper operation of the common venting system should be corrected to conform to the National Fuel Gas Code, ANSI Z223.1. When resizing any portion of the common venting system, the system should approach the minimum size as determined using the appropriate tables in Appendix G of ANSI Z223.1.

K. Technical Speciﬁcations

Model TRX085 TRX120 TRX110C TRX150C

Type Boiler Combi

Installation Indoor, Wall Hung, Fully Condensing

Minimum / Maximum Input (Btu/Hr)

Hot Water Capacity

Minimum - Maximum Exhaust Vent Run

Minimum - Maximum Intake Air Pipe Run

Space Heating

Domestic Hot Water

DOE AFUE2 (%) 96 95 95.5 95

Heating Capacity

1, 2

(MBH) 79 111 98 111

35oF Rise N/A N/A 6.8 8.5

45oF Rise N/A N/A 5.3 6.6

77oF Rise N/A N/A 3.1 3.8

Flue System Category IV, Sealed Combustion Direct Vent, Power Vent

Part 3 - Prepare the Boiler for Installation

9,400 / 85,000 13,200 / 120,000 11,200 / 106,000 13,200 / 120,000

N/A N/A 11,200 / 114,000 13,200 / 150,000

2” (6 - 100 feet), 3” (6 - 150 feet)

2” (0 - 100 feet), 3” (0 - 150 feet)

Approved Exhaust Vent Materials

PVC, CPVC, PP, Stainless Steel

Shipping Weight (lbs) 78 84 83 84

Gas Supply

Pressure

NG 3.5” to 10.5” WC

LP 8” to 13” WC

Power Supply 120V, 60 Hz, less than 12A

General Operating Conditions

Ambient Temperature Range: 33 – 104oF (0.6 – 40oC)

Product Approvals and Requirements: ANSI Z21.13 / CSA 4.9

Ignition System Direct Electronic Spark Ignition / Flame Rectiﬁcation

Burner System Premixed Fuel Modulation / Stainless Steel Burner

Gas Valve System Air Ratio Valve

W 16” 3/64

Dimensions

(in Inches)

H 43” 5/8

D 15” 1/8

Approx. Full Boiler Weight (lbs) 88.2 88.6 91 92.8

Boiler Water Content (Gallons) 1.1 1.2 1.1 1.2

Boiler Setpoint Temperature Range 68 – 113oF Low Temperature / 95 - 179oF High Temperature

DHW Indirect Setpoint Temperature Range 104 – 149oF

DHW Setpoint Range (Combi Models) 97 – 140oF

Heat Exchanger MAWP 55

Water Pressure (PSI)

Pressure Relief Valve 30

DHW Max Pressure N/A N/A 125 125

Control Panel / Main Controller AristonThermo LCD Display / AristonThermo GALEVO2 Control

CH Supply / Return 1” Male Sweat with Adapter

Connection

Sizes

DHW Inlet / Outlet 3/4” Male Sweat with Adapter

Gas Inlet 3/4” Male NPT

Materials

Cabinet Painted Steel and Plastic

Heat Exchanger SA-312 Type 304L Stainless Steel Water Tube

Flame Rectiﬁer Probe, Temperature Limit Control (190oF), Water Pressure Switch (Min. 8 PSI), Freeze

Safety Devices

Protection, Blocked Condensate Pressure Switch, Condensate Trap, Flue Temperature High Limit Sensor (210oF), Blocked Vent Pressure Switch

Table 7 - Technical Speciﬁcations

NOTES:

Listed Input and Output Ratings are at minimum vent lengths at an altitude of 0 - 2000 ft. Numbers will be lower with longer venting and/or

altitudes greater than 2000 ft.

Ratings based on standard test procedures prescribed by the US Department of Energy.

The TRX requires a special venting system. Use only the vent materials and methods detailed in these installation instructions.

Part 3 - Prepare the Boiler for Installation

4-5/16”

(110 mm)

29-5/16”

(745 mm)

43-5/8”

(1108,15 mm)

(120 mm)

15-3/4”

(400 mm)

5-3/8”

(136,5 mm)

4-3/4”4-3/4”

(120 mm)

1-3/8”

(34,2 mm)

8-15/16”

(226,65 mm)

2-9/16”

(65mm) (67mm)

(67mm)

2-5/8”

2-9/16”2-5/8”

(65mm)

1/2”

13,1 mm

9-7/16”

(239,75 mm)

2-3/16”

3-7/16”

(87,2 mm)

(87,6 mm)

3-7/16”

(87,6 mm)

3-7/16”3-7/16”

(87,2 mm)

A B C D E

Figure 10 - Boiler Dimensions - NOTE: All Dimensions Are Approximate

15-5/16”

(390 mm)

(55,3mm)

5-7/8”

(150 mm)

Model TRX085 TRX120 Model TRX110C TRX150C

A - Central Heating Supply 1” A - Central Heating Supply 1”

B - Return from Indirect Water Heater 3/4” B - Domestic Hot Water Outlet 3/4”

C - Gas Inlet 3/4” C - Gas Inlet 3/4”

D - Domestic Hot Water Inlet Not Used D - Domestic Hot Water Inlet 3/4”

E - Central Heating Return 1” E - Central Heating Return 1”

F - Pressure Relief Valve F - Pressure Relief Valve

Table 8 - Boiler Adapter Dimensions

TRX085 - TRX120

Part 3 - Prepare the Boiler for Installation

3 4 5

19 18

1. Pressure relief valve

2. Air purge valve

3. Boiler outlet temperature sensor

4. Air pressure switch

5. Flue gas temperature sensor

6. Main heat exchanger

7. Flame detection electrode 8 Silencer

9. Junction box

11. Condensate trap

12. Gas valve

13. Control panel

14. CH circuit ﬁlter

Figure 11 - Boiler Component Locations and Descriptions

15. Circulation Pump with auto air vent

17. Water pressure switch

18. Modulating Fan

19. Boiler inlet temperature sensor

20. Frame

21. Ignition electrode

22. Spark generator

23. Combustion Analysis Test Point

24. Air intake connection

25. Exhaust vent connection

26. Diverter valve

Part 3 - Prepare the Boiler for Installation

TRX110C - TRX150C

3 4 5

1. Pressure relief valve

2. Air purge valve

3. Boiler outlet temperature sensor

4. Air pressure switch

5. Flue gas temperature sensor

6. Main heat exchanger

7. Flame detection electrode 8 Silencer

9. Junction box

10. DHW heat exchanger

11. Condensate trap

12. Gas valve

13. Control panel

14. CH circuit ﬁlter

15. Circulation Pump with auto air vent

16. DHW Flow switch

17. Water pressure switch

18. Modulating Fan

19. Boiler inlet temperature sensor

20. Frame

21. Ignition electrode

22. Spark generator

23. Combustion Analysis Test Point

24. Air intake connection

25. Exhaust vent connection

26. Diverter valve

Figure 12 - Combi Boiler Component Locations and Descriptions

Part 3 - Prepare the Boiler for Installation

B C D E

214

psi

°F

19 3

C E

19 3

psi

°F

TRX110C - TRX150C

TRX085 - TRX120

1. Pressure relief valve

2. Air purge valve

3. Boiler outlet temperature sensor

4. Air pressure switch

5. Flue gas temperature sensor

6. Main heat exchanger

7. Flame detection electrode 8 Silencer

9. Junction box

10. DHW heat exchanger

11. Condensate trap

12. Gas valve

13. Control panel

14. CH circuit ﬁlter

15. Circulation Pump with auto air vent

16. DHW Flow switch

17. Water pressure switch

18. Modulating Fan

19. Boiler inlet temperature sensor

20. Frame

21. Ignition electrode

22. Spark generator

23. Combustion Analysis Test Point

24. Air intake connection

25. Exhaust vent connection

26. Diverter valve

27. By-pass

28. Drain valve

29. Pressure gauge

Figure 13 - Water Circuit Diagrams

Part 4 - Water Piping

WARNING

Failure to follow the instructions in this section WILL VOID the warranty and may result in property damage, severe personal injury, or death.

The National Standard Plumbing Code, the National Plumbing Code

of Canada, and the Uniform Plumbing Code limit heat transfer uid

pressure to less than the minimum working pressure of the potable

water system up to 30 PSI maximum. In addition, the heat transfer uid must be water or another non-toxic uid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products,

5th Edition. Failure to follow this warning could result in property damage, severe personal injury, or death.

CAUTION

Do not apply a torch within 12” of the boiler. If sweat connections are used, sweat tubing to the adapter before tting adapter to the water

connections on the boiler. Damages due to improper installation practices ARE NOT covered by warranty.

Dielectric unions or galvanized steel ttings must not be used in a

system with this boiler. Doing so WILL VOID the warranty. Use only

copper, brass, or stainless steel ttings. Teon thread sealant must

be used on all connections.

Plumbing of this product should only be done by a qualiﬁed, licensed plumber in accordance with all local plumbing codes. The boiler may be connected to an indirect water heater to supply domestic hot water. NTI oﬀers indirect water heaters in a wide range of gallon sizes in either stainless steel or glass-lined construction.

A. General Plumbing Information

CAUTION

The building piping system must meet or exceed the the piping

requirements in this manual.

Use two wrenches when tightening water piping at boiler. Use one wrench to prevent the boiler return or supply line from turning. Failure to prevent piping connections from turning could cause damage to boiler components.

The boiler control module uses temperature sensors to provide both high limit protection and modulating temperature control. The control module may also provide low water protection by sensing

the water level in the heat exchanger. Some codes/jurisdictions may require additional external controls.

The water connections must be installed in accordance with all local and national plumbing codes, or any applicable standard with prevails.

• Pipe material must be suitable to meet local codes and industry

standards.

• The pipe must be cleaned and without blemish before any

connections are made.

• The size of the DHW pipes should be 3/4” diameter, and the CH

pipes should be 1” diameter.

• Isolation (shut-oﬀ valves) should be used on both the CH and DHW

loops to ease future servicing.

• All piping should be insulated.

It is recommended to install a sweat shut-oﬀ valve and a union in the return and supply piping to ease future servicing. If there is a backﬂow preventer or any type of a no return valve in the system, install an additional tee here suitable for an expansion tank. NOTE: The addition of a high temperature limiting device is important if the boiler is to be connected to a domestic hot water system.

B. Backﬂow Preventer

Use a backﬂow preventer speciﬁcally designed for hydronic boiler installations. This valve should be installed on the cold water ﬁll supply line per local codes.

C. Expansion Tank

Expansion Tank and Make-Up Water

1. Ensure that the expansion tank is designed and sized to correctly handle boiler and system water volume and temperature.

WARNING

Expansion tanks must be sized according to total system volume. This includes all length of pipe, all xtures, boilers, etc. Failure to properly size for system expansion could result in wasted time, money, possible

property damage, serious personal injury, or death.

CAUTION

Undersized expansion tanks cause system water to be lost from the

relief valve, causing make-up water to be added. Eventual boiler

failure can result due to excessive make-up water addition. SUCH FAILURE IS NOT COVERED BY WARRANTY.

DO NOT install automatic air vents on closed type expansion tank

systems. Air must remain in the system and return to the tank to provide an air cushion. An automatic air vent would cause air to leave

the system, resulting in improper operation of the expansion tank.

Model Heat Exchanger Volume (Gallons)

TRX085 1.1

TRX120 1.2

TRX110C 1.1

TRX150C 1.2

Table 9 - Heat Exchanger Water Volume (To Aid in Expansion Tank Sizing)

2. The expansion tank must be located as shown in Applications, this manual, or following recognized design methods. See expansion tank manufacturer’s instructions for details.

3. Connect the expansion tank to the air separator only if the air separator is on the suction side of the circulator. Always install the system ﬁll connection at the same point as the expansion tank connection to the system.

4. Most chilled water systems are piped using a closed type expansion tank.

DIAPHRAGM (OR BLADDER) EXPANSION TANK

Always install an automatic air vent on top of the air separator to remove residual air from the system.

D. Piping the Boiler

CAUTION

Boiler Models should not be operated as a direct potable hot water heater. Only Combi Models should be used to directly heat hot water.

Use at least the MINIMUM pipe size for all appliance loop piping.

This is to avoid the possibility of inadequate ow through the

appliance. Using less than the required minimum pipe size and piping could result in system problems, property damage, and premature appliance failure. Such problems ARE NOT covered by product warranty.

NOTE: Observe the minimum 1” clearance around all uninsulated hot water pipes when openings around pipes are not protected by noncombustible materials.

Part 4 - Water Piping

Connect the 3/4” DHW inlet and outlet pipes. A shut-oﬀ valve between the city water supply and DHW inlet is recommended for ease of service. NTI oﬀers threaded 3/4” DHW tankless isolation valves with a DHW pressure relief valve for ease of installation and future service. Connect the 1” CH return and supply pipes. Isolation valves are recommended for ease of service.

TRX085 or TRX120 only Heating

psi

250

50 200

100 150

TRX085 or TRX120 with Indirect Water Heater

TRX110C

I L

psi

50 200

100 150

250

I L

TRX150C

psi

50 200

100 150

250

TRX085 - TRX120

A. CH Supply 1” B. Return from Indirect Water Heater 3/4" C. Gas Inlet 3/4" D. Not Used E. CH Return 1” I. Drain Valve L. Condensate Discharge

I L

psi

50 200

250

100 150

I L

TRX110C - TRX150C

A. CH Supply 1” B. DHW Outlet 3/4" C. Gas Inlet 3/4" D. DHW Inlet 3/4" E. CH Return 1” I. Drain valve L. Condensate discharge

Figure 14 - Water / Gas Connections

Part 4 - Water Piping

By-Pass Valve

Location

By-pass valve location

E. Internal Circulation Pump

To calculate the size of the heating installation refer to the graph below.

Graph Representing the Available Circulation Pump Head

feet

0 1 2 3 4 5 6 7

gal/min

Table 10 - Internal Circulation Head Curve

F. By-Pass Valve

This boiler has a by-pass valve which requires no adjustment. The by-pass valve protects the heat exchanger from overheating by guaranteeing a minimum ﬂow rate of 2 gpm within the primary heat exchanger. This protects the primary heat exchanger from overheating when water circulation is insuﬃcient or heating system load is reduced (ex: due to the response of thermostatic valves or zone valves).

The by-pass valve is located:

- in the left hydraulic block for TRX085 and TRX120.

- in the right hydraulic block , behind the three-way valve, for

TRX110C

TRX085 - TRX120

and

TRX150C.

Figure 15 - Internal Circulation Pump NOTE: Ensure the Air Vent on the

Internal Circulation Pump Remains Open after Installation

TRX110C - TRX150C

Figure 16 - By-Pass Valve Location

Figure 17 - By-Pass Valve Assembly

Part 4 - Water Piping

G. CH and DHW Pressure Relief Valves

An external pressure relief valve must be installed on this appliance for the CH loop. When installing, observe the following guidelines.

This boiler has a high-temperature shut-oﬀ switch built in as a standard safety feature. Therefore, a “pressure only” relief valve is required.

DO NOT operate this appliance before the supplied pressure relief valve is installed with suﬃcient relieving capacity in accordance with the ASME rating plate on the appliance.

WARNING

The pressure relief valve must be installed with the provided adaptor pipe in the top of the boiler as detailed in Figure 19. No other valves should be placed between the pressure relief valve and the appliance. Failure to comply with these guidelines can result in substantial property damage, personal injury, or death.

CH Loop

This boiler is provided with a CH pressure relief valve that complies with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV (Heating Boilers). The included 30 psi CH Pressure Relief Valve must be installed at the top of the boiler, using the included pipe adapter and grommet, as illustrated below. DO NOT install a relief valve with a pressure rating in excess of 50 psi

- the maximum allowable operating pressure of the boiler. The relief

valve capacity must exceed the BTU/H input capaciy of the boiler. To install the pressure relief valve proceed as follows:

1. Remove the plastic cover on the top of the boiler.

2. Remove the nut on the ﬂow pipe.

4. Connect the pressure relief valve and gasket.

NOTE: To maintain an airtight seal, ensure the gasket boot is properly ﬁtted into the top of the boiler cabinet.

Figure 20 - Connect CH Pressure Relief Valve

DHW Loop (Combi Models)

The DHW piping must be provided with a DHW pressure relief valve that complies with local codes, but not less than valves certiﬁed as meeting the requirements of Relief Valves for Hot Water Supply Systems, ANSI Z21.22 / CSA4.4 by a nationally recognized lab that maintains periodic inspection of production listed equipment. A DHW pressure relief valve is not included with the boiler, and is to be ﬁeld supplied and installed in the DHW piping. DO NOT install a DHW relief valve with a pressure rating greater than 125 psi - the maximum allowable operating pressure of the boiler’s DHW circuit. After installing the relief valves and ﬁlling and pressurizing the system, test the operation of the valves by lifting the levers. Make sure the valves discharge freely. If a valve fails to operate correctly, replace it with a new relief valve. The relief valve capacity must exceed the BTU/H input capacity of the boiler.

Figure 18 - Remove the Caps

3. Insert the pipe and gasket.

Figure 19 - Insert the Pipe

Radiant heating

For appliances with underﬂoor heating, it is possible but not necessary to ﬁt a safety thermostat onto the radiant heating outlet.

If the thermostat cannot be installed, the radiant heating equipment must be protected by a thermostatic valve, or by a by-pass to prevent the ﬂoor from reaching too high a temperature.

Part 4 - Water Piping

WARNING

To avoid water damage or scalding due to relief valve operation:

• Discharge line must be connected to relief valve outlet and run to a safe place of disposal. Terminate the discharge line in a manner that will prevent possibility of severe burns or property damage should the relief valve discharge.

• Discharge line must be as short as possible and the same size as the valve discharge connection throughout its entire length.

• Discharge line must pitch downward from the valve and

terminate at least 6” above the oor drain, making discharge

clearly visible.

• The discharge line shall terminate plain, not threaded, with a material serviceable for temperatures of 375oF or greater.

• Do not pipe discharge to any location where freezing could occur.

• No valve may be installed between the relief valve and boiler or in the discharge line. Do not plug or place any obstruction in the discharge line.

• Test the operation of the relief valve after lling and pressurizing the system by lifting the lever. Make sure the valve discharges freely. If the valve fails to operate correctly, immediately replace with a new properly rated relief valve.

• Test relief valve at least once annually to ensure the waterway

is clear. If valve does not operate, turn the boiler “off” and call

a plumber immediately.

• Take care whenever operating relief valve to avoid scalding injury or property damage.

FAILURE TO COMPLY WITH THE ABOVE GUIDELINES COULD RESULT IN FAILURE OF RELIEF VALVE OPERATION, RESULTING IN POSSIBILITY OF SUBSTANTIAL PROPERTY DAMAGE, SEVERE PERSONAL INJURY, OR DEATH.

WARNING

Do not thread a cap or plug into the relief valve or relief valve line

under any circumstances! Explosion and property damage, serious

injury, or death may result.

RE-INSPECTION OF RELIEF VALVES: Relief valves should be inspected AT LEAST ONCE EVERY THREE YEARS, and replaced if necessary, by a licensed plumbing contractor or qualied service

technician to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occuring conditions may corrode the valve and its components over time, rendering the valve inoperative. Such conditions can only be detected if the valve and its components are physically removed and inspected. Do not attempt to conduct an inspection on your own. Contact your plumbing contractor for a re-inspection to assure continued safety.

FAILURE TO RE-INSPECT THE RELIEF VALVE AS DIRECTED COULD RESULT IN UNSAFE TEMPERATURE AND/OR PRESSURE BUILD-UP WHICH CAN RESULT IN PROPERTY DAMAGE, SERIOUS PERSONAL INJURY, OR DEATH.

H. Air Elimination Device

A micro bubble air elimination device must be installed in every boiler installation. Automatic air vents alone are not an acceptable substitute for a micro bubble air elimination device. Here are a few examples of acceptable devices.

• Spirovent

• TACO 4900 Series

• Caleﬃ Discal

I. Applications*

CAUTION

Mixing valves are required for the protection of low temperature loops.

Figure 21 - Piping Symbol Legend

Part 4 - Water Piping

Primary/Secondary Piping Shown

Cap this

ﬁtting

when not in

use

Figure 22 - TRX085 / TRX120 with Single Central Heating Circulator

NOTE: In piping applications utilizing a single zone, it is recommended

that the installer use ﬂow / check valves with weighted seats at or near the appliance to prevent gravity circulation.

NOTICE

Figure illustrates the basic plumbing requirements for a TRX085 / TRX120 boiler installation utilizing Primary/Secondary piping when the boiler circulator will not provide adequate ow for the system. Primary / Secondary is required to provide adequate ow for the

secondary circuits.

CAUTION

On TRX085 / TRX120 Models Only. If the boiler to be used only in Heating Mode (not connected to an indirect water heater), cap the fitting as indicated in the figure above and the electrical connection of the 3-way valve motor MUST BE DISCONNECTED while the boiler is operating in central heating mode. This will lock the valve motor in central heating mode and ensure freeze protection operates properly. Failure to disconnect the valve may disable boiler freeze protection and result in property damage.

WARNING

The piping will not support the weight of the circulators. Refer to the circulator manufacturer’s instructions to properly support the circulator. Failure to comply with these instructions could result in property damage, severe personal injury, or death.

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. All closely spaced tees shall be within 4 pipe diameters center to center spacing.

3. A minimum of 6 pipe diameters of straight pipe shall be installed upstream and downstream of all closely spaced tees.

4. The minimum pipe size of DHW piping should be ¾” diameter and CH piping should be 1” in diameter.

5. Circulators are shown with isolation ﬂanges. The alternative is standard ﬂanges with full port ball valves. Purge valves can be used with circulator ﬂanges as an alternative.

6. Piping shown is Primary/Secondary.

7. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

8. VERY IMPORTANT – Minimum ﬂow rates outlined in this manual (2 gpm) must be maintained through the heat exchanger to minimize short cycling.

9. In a valve-based system, each heating zone has a zone valve which opens when that zone calls for heat. Each zone thermostat is wired to its corresponding zone valve. Contacts in the zone valves provide a signal to the boiler to operate when there is a call for heat.

10. Unit is equipped with built-in primary pump. This pump is sized to ensure proper ﬂow rate through the boiler heat exchanger and related piping.

11. IWH Applications - a mixing valve is recommended if the DHW temperature is set above the factory setting of 119oF.

Part 4 - Water Piping

Cap this ﬁtting when not in use

Figure 23 - TRX085 / TRX120 without Central Heating Circulator

NOTE: In piping applications utilizing a single zone, it is recommended

that the installer use ﬂow / check valves with weighted seats at or near the appliance to prevent gravity circulation.

NOTICE

Figure illustrates the basic plumbing requirements for a TRX085 / TRX120 boiler installation without an external Central Heating circulator; the boiler’s internal circulator delivers ow to the heating system. Application is limited to zone valve (or non-circulator) distribution systems with small ow requirements (e.g. systems

requiring no more than 5 gpm at 9 ft. of head pressure)

WARNING

NOTES:

1. This drawing is meant to show system piping concept only. Installer is responsible for all equipment and detailing required by local codes.

2. The minimum pipe size of DHW piping should be ¾” diameter and CH piping should be 1” in diameter.

3. Circulators are shown with isolation ﬂanges. The alternative is standard ﬂanges with full port ball valves. Purge valves can be used with circulator ﬂanges as an alternative.

4. Install a minimum of 12 diameters of straight pipe upstream of all circulators.

5. VERY IMPORTANT – Minimum ﬂow rates outlined in this manual (2 gpm) must be maintained through the heat exchanger to minimize short cycling.

6. In a valve-based system, each heating zone has a zone valve which opens when that zone calls for heat. Each zone thermostat is wired to its corresponding zone valve. Contacts in the zone valves provide a signal to the boiler to operate when there is a call for heat.

7. Unit is equipped with built-in primary pump for the heating loop. This pump is sized to ensure proper ﬂow rate through the boiler heat exchanger and related piping.

8. IWH Applications - a mixing valve is recommended if the DHW temperature is set above the factory setting of 119oF.

9. In direct (not primary / secondary) piping applications, it is required to increase ﬁll pressure to 20 psi to ensure proper system operation.

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NTI TRX, TRX085, TRX150C, TRX120, TRX110C Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual