NTI VM110, VM110P Installation And Operation Instructions Manual

Download

Page 1

Vmax Boiler

Model Number: VM110, VM110P Version Date: 2015-02-09

INSTALLATION AND OPERATION INSTRUCTIONS FOR Vmax BOILER

TABLE OF CONTENTS

HAZARD SYMBOLS AND DEFINITIONS

Danger Sign: Indicates a hazardous situation which, if not avoided, will result in serious injury or death.

Warning Sign: Indicates a hazardous situation which, if not avoided, could result in serious injury or death.

Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury.

Caution Sign without Safety Alert Symbol: Indicates a hazardous situation which, if not avoided, could result in property damage.

Notice Sign: Indicates a hazardous situation which, if not avoided, could result in property damage.

This Boiler must be installed by a licensed and trained Heating Technician or the Warranty is Void. Failure to properly install this

unit may result in property damage, serious injury to occupants, or possibly death.

NEW PRODUCT

Fire-tube Boiler

w/ Built-in Pump

NTI # 85171

Page 2

Warnings │ Vmax I&O Manual

Read Before Proceeding

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

A) This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

B) BEFORE OPERATING smell all around the boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any boiler.

• Do not touch any electric 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.

C) Use only your hand to turn the gas “shutoff” valve. Never use tools. If the handle will not turn by hand,

do not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D) Do not use this boiler if any part has been under water. Immediately call a qualified service technician

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

OPERATING INSTRUCTIONS_

1. STOP! Read the safety information above very carefully.

2. Set the thermostat to lowest setting. Turn off all electric power to the boiler.

3. This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

4. Turn the manual gas valve to the OFF position. Remove front access panel.

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

STOP! Follow “B” in the safety information above. If you do not smell gas, go to the next step.

6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas.

7. Replace the front access panel.

8. Set thermostat to highest setting. Turn on all electric power to the boiler.

9. Ignition sequence is automatic. Combustion will occur after a brief fan purge.

10. If ignition does not occur, follow the instructions “To Turn Off Gas To Boiler” and call your service

technician or gas supplier.

TO TURN OFF GAS TO THE BOILER_

1. STOP! Read the safety information above very carefully.

2. Turn off all electric power to the boiler.

3. Turn the manual gas valve to the OFF position.

Crystalline Silica - Certain components confined in the combustion chamber may

contain this potential carcinogen. Improper installation, adjustment, alteration, service or maintenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to Section 15.0 for information on handling instructions and recommended personal protective equipment. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

Void Warranty - This Boiler must have water flowing through it whenever the burner is

on or it will damage the unit and void the warranty. Failure to follow these instructions may result in serious injury or death.

Page 3

Vmax I&O Manual │Introduction

Energy Saving Feature - This boiler is equipped with a feature that saves energy by

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

 An external energy management system is installed that reduces the boiler water temperature as the heating

load decreases.

 This boiler is not used for any space heating.  This boiler is part of a modular or multiple boiler system having a total input of 300,000 BTU/hr. or greater.  This boiler is equipped with a tankless coil.

1.0 INTRODUCTION General Installation Requirements

The installation of your NTI Vmax gas boiler must conform to the requirements of this manual, your local authority, and the National Fuel Gas Code ANSI Z223.1 and or CAN/CGA B149 Installation Codes. Where

required by the Authority, the installation must conform to the standard for “Controls and Safety Devices for

Automatically Fired Boilers ANSI/ASME CSD-1.” This document pertains to the correct installation and operation of NTI Vmax boiler models VM110 and

VM110P (Vmax Plus). The instructions detailed in this document supersede any and all previous instructions provided by NTI, written or otherwise. Each unit is provided with the following:

1. Installation and Operating Instructions,

2. Vmax Users’ Manual, and

3. Natural Gas to LP Conversion Kit* * The conversion kit is required to convert the boiler so it will safely operate with Propane Gas.

Read and understand this entire document prior to proceeding with the installation of the Vmax boiler. Failure to follow the instructions outlined in this document will result in property damage, serious injury or death.

User Responsibilities

This boiler must be installed and serviced by a qualified installer or service technician. This boiler must be serviced and inspected annually when operating in normal residential applications. Demanding applications or extreme conditions (i.e. when operating with LP-Propane) may require more frequent service and inspection. As the User/Owner of this equipment, you are responsible for ensuring the maintenance is performed at the required intervals (see Section 16.0 – Annual Maintenance and Inspection).

Failure to have the boiler properly serviced and inspected on a regular basis by a qualified service technician may result in property damage, serious injury or death.

Failure to keep the Vent and Combustion Air Intake clear of ice, snow, and other debris may result in property damage, serious injury, or death.

Installer Responsibilities

As the installing technician it is your responsibility to ensure the installation is performed in accordance with this instruction manual as well as any applicable local or National installation codes. It is also your responsibility to inform the User/Owner of their obligation with respect to the above description under “User Responsibilities.” Failure to follow this warning could result in fire, serious injury, or death.

Page 4

Introduction │ Vmax I&O Manual

ATTENTION: LIQUEFIED PETROLEUM (LP) PROPANE for applicable conversion kit and LP orifice number.

Failure to use the appropriate Natural to LP Conversion Kit and Orifice when operating the Vmax boiler with Propane will result in extremely dangerous burner operation leading to property damage, serious injury or death. Refer to section titled

ATTENTION: LIQUEFIED PETROLEUM (LP) PROPANE

The Vmax boiler is factory set to operate with Natural Gas. BEFORE OPERATING WITH PROPANE, the specified LP Conversion Kit and Orifice must be installed to convert the boiler so it will operate safely with LP Propane. The correct kit and LP orifice is listed below (Each kit comes with conversion instructions).

Liquefied Petroleum (LP) propane gas is heavier than air; therefore, it is imperative that your Vmax boiler is not installed in a pit or similar location that will permit heavier than air gas to collect. Local Codes may require boilers fueled with LP gas be provided with an approved means of removing unburned gases from the room. Check your local codes for this requirement.

Natural to LP Propane Conversion Kit_

Conversion Kit P/N LP Orifice Size Orifice P/N

84867-4 5.05 mm 84795

Exhaust Vent / Air-Inlet Piping

The Vmax VM110 and VM110P are certified as a “Category IV” boiler, and require a “Special Venting System” designed for pressurized venting. The exhaust gases must be

piped directly to the outdoors using the vent materials and rules outlined in these instructions. Failure to follow these instructions will result in serious injury or death.

Page 5

IN THE STATE OF MASSACHUSETTS ONLY

(a) For all horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or

in part for residential purposes, including those owned and operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied:

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

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

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

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

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

installation, the owner shall have a period of 30 days to comply with the above requirements; provided, however, that during said 30 day period a battery operated carbon monoxide detector with an alarm shall be installed.

2. APPROVED CARBON MONOXIDE DETECTORS Each carbon monoxide detector as required in accordance

with the above provisions shall comply with NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

3. SIGNAGE A metal or plastic identification plate shall be permanently mounted to the exterior of the building

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

4. INSPECTION The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall

not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

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

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be Vented” in the most current

edition of NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate

from the dwelling, building or structure used in whole or in part for residential purposes.

manufacturer of Product Approved side wall horizontally vented gas equipment provides a venting system design or venting system components with the equipment, the instructions provided by the manufacturer for installation of the equipment and the venting system shall include:

1. Detailed instructions for installation of the venting system design or the venting system components; and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED:

When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems,” the following requirements shall be satisfied by the manufacturer:

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

installation instructions; and

2. The “special venting system” shall be Product Approved by the Board, and the instructions for that system shall

include a parts list and detailed installation instructions.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment,

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

Vmax I&O Manual │Introduction

Page 6

Specifications │ Vmax I&O Manual

DESCRIPTION

VM110

VM110P

CSA Input Modulation

[MBH]

17 - 110

DOE Heating Capacity

1,2

[MBH]

101

Net I=B=R Rating

1,2

[MBH]

DOE AFUE2 [%]

Boiler Water Connections – NPT [in.]

1” (Male)

¾” (Male)

Domestic Hot Water Connections – NPT

[in.]

¾” (Male)

Gas Connection - NPT, in.

½” (Male)

Vent/Air-inlet Pipe Diameter [in.] 3

2 or 3

Dimensions H x W x D [in.]

35-1/8 x 18-3/4 x 14-1/8

38-3/8 x 28-1/4 x 17-3/4

Approx. Boiler Weight with Water [lbs.]

132

275

Approx. Boiler Water Content [Gallons]

3.2

Approx. Domestic Hot Water Content

[Gallons]

Electrical Rating

120V/1Ph/60Hz/less than 12A

Notes:

Listed Input and Output ratings are at minimum vent lengths using 3” venting, at an altitude of 0-2000 ft. Numbers will be lower with longer venting and/or altitudes greater than 2000 ft. When operating with Natural Gas using 2” venting at the minimum vent length, the Input ratings are reduced to 15 MBH at minimum and 102 MBH at maximum.

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

Vmax boilers require a special venting system, use only vent materials and methods detailed in these instructions.

Elevations

2001 ft [610 m]

3000 ft [914 m]

4000 ft [1219 m]

4500 ft [1372 m]

5000 ft [1524 m]

In Canada 1

de-rate by 10%

de-rate % may vary

In USA 2

de-rate by 12%

de-rate by 16%

de-rate by 18%

de-rate by 20%

Notes:

Canada: Altitudes between 2000-4500 ft [610-1372 m], de-rate by 10%. Consult local authorities for de-rating for

altitudes above 4500ft [1372 m].

USA: De-rate capacity by 4% for every 1000 ft [305 m], if altitude is above 2000 ft [610 m].

2.0 SPECIFICATIONS

Table 2-1 Vmax Specifications

Wall mounting of unit requires two people to lift the boiler into place. Failure to follow these instructions may result in property damage or personal injury.

High Altitude Operation

The Vmax is designed to operate at its maximum listed capacity in installations located at 0-2000 ft above Sea Level. Since the density of air decreases as elevation increases, maximum specified capacity should be de-rated for elevations above 2000 ft [610 m] in accordance with Table 2-2.

Table 2-2 De-rate % for High Altitudes

Combustion – At elevations above 2000 feet, the combustion of the boiler must be checked with a calibrated combustion analyzer to ensure safe and reliable operation. It is

the Installers responsibility to check the combustion and to adjust the combustion in accordance with

Section 9.0. Failure to follow these instructions may result in property damage, serious injury, or death.

Page 7

Clearances

Dimensions - inches

Front

Top

Sides

Back

Bottom

Flue Pipe

Minimum

24 1

12 4 0

Recommended

12 0 24

Notes:

6 in. if surface is removable allowing a minimum of 24 in. clearance (i.e. closet installation). See Ventilation Air Opening dimensions in Figure 3-1.

Vmax I&O Manual │Boiler Location

3.0 BOILER LOCATION

In all cases, the Vmax VM110 & VM110P must be installed indoors in a dry location where the ambient temperature must be maintained above freezing and below 100F [38C]. All boiler components must be protected from dripping, spraying water, or rain during operation and servicing. Consider the proximity of system piping, gas and electrical supply, condensate disposal drain, and proximity to vent termination when determining the best boiler location.

Boiler Area Ventilation Air Openings

If boiler area clearances are less than the recommended clearances specified in Table 3-1, the boiler area must be ventilated (Exception: if the boiler area/room has a volume of 150 ft3 or greater, ventilation of the boiler room is not required). Each ventilation air opening must meet the minimum requirements of 1 in2 per 1000 Btu/hr., but not less than 100 in2. The lower ventilation opening must be located within 6 in. of the floor while the upper opening must be located 6 in. from the top of the space.

US/Canada, PVC vent pipe and fittings shall not be used within the closet or alcove; only approved CPVC, Polypropylene or Stainless Steel vent pipe and fittings can be used. See Table 4-4 for a list of approved materials. Under all circumstances, the minimum clearances listed in Table 3-1 must be provided.

Closet Installations

For closet installations it is necessary to provide two ventilation air openings as shown in Figure 3-1, each providing a minimum area equal to 1 in2 per 1000 Btu/hr., but not less than 100 in2 and within 6 in. of the top and bottom of the closet door. See Table 3-1 for minimum clearances.

Alcove Installations

Alcove installations have the same minimum clearances as closet installations, except the front must be completely open to the room at a distance no greater than 18 in. [457 mm] from the front of the boiler and the room is at least three (3) times the size of the alcove. Provided these conditions are met, the boiler requires no extra ventilation air openings to the space. See Table 3-1 for minimum clearances.

Residential Garage Installations

When installed in a residential garage, mount the boiler a minimum of 18 in. [457 mm] above the floor. Locate or protect the boiler so it cannot be damaged by a moving vehicle. Check with your local authorities for other possible regulations pertaining to the installation of a boiler in a garage.

Wall Mounting Installations

The Vmax VM110 & VM110P are provided with integrated wall mounting brackets. Refer to Figure 3-2 for instructions and illustrations on wall mounting.

Table 3-1 Minimum Clearances for Installation and Service

Water or flood damaged components must be replaced immediately with new factoryapproved components as failure to do so may result in fire, serious injury, or death.

If the "Boiler Area" does not meet the recommended clearances listed in Table 3-1, and if the boiler area has a volume less than 150 ft3, it is considered a Closet or Alcove. In

Closet/Alcove installations in US and Canada require approved CPVC, Polypropylene or Stainless Steel vent and air-inlet pipe and fittings (see Table 4-4); PVC is not permitted.

Failure to follow these instructions may result in damage or serious injury.

Page 8

Figure 3-1 Closet Installation, Minimum Clearances

Ventilation Air Openings are not required if the boiler area meets the Recommended Clearances listed in Table 3-1.

Top ventilation opening Max. 6” below ceiling / top

Ventilation air opening 1in2 per 1000 Btu/hr,

Removable surface / closet door

Ventilation air opening 1in2 per 1000 Btu/hr, min. 100in

Bottom ventilation opening Max. 6” above floor / bottom

Top = 12”

Bottom = 16”

Min. 1” clearance

for hot water and

vent pipes

Front = 6”

(if removable)

Boiler Location │ Vmax I&O Manual

Page 9

Figure 3-2 Wall Mounting Instructions

 Leave the Top Wall-mount Bracket (A) intact

and remove the Bottom Wall-mount Bracket (B) that is attached to the bottom-back of the

boiler.

 Secure Bottom Bracket (B), removed from the

bottom back of the boiler in Step 1, to a solid wall using field supplied lag screws (anchors when mounting to a concrete wall) that are adequate to support the weight of the appliance when filled with water (refer to Table 2-1 Specifications). Ensure the bracket is level and flush to the wall. Mounting holes to be on the bottom with flange pointed upward and angled away from the wall.

 Mount the boiler to the wall by aligning the

two wall mount brackets, Top Bracket (A) with the Bottom bracket (B). Slide the top bracket fastened to the boiler down over the wall-mounted bracket until it hooks.

 Once the boiler is resting securely on the wall,

attach the L-shaped Brackets (C) to the underside of the appliance using the mounting hardware supplied in the boiler kit box – adjust to plumb the boiler. Anchor the L-shaped Brackets (C) to the wall as shown using field supplied hardware.

Failure to follow instructions may result in fire, serious injury, or death.

This unit requires two people to lift it or damage and injury may result.



Bottom Bracket (B)

Wall

Boiler



Ensure Bracket (A) fully inserts into Bracket (B)

(B)

(A)



L-shaped Brackets

boiler kit box

Top Bracket (A)



Bottom

Bracket (B)

Vmax I&O Manual │Boiler Location

Page 10

Products to Avoid

Contaminated Sources to Avoid

Antistatic fabric softeners, bleaches, detergents, cleaners

Laundry facilities

Perchloroethylene (PCE), hydrocarbon based cleaners

Dry cleaning facilities

Chemical fertilizer, herbicides/pesticides, dust, methane gas

Farms or areas with livestock and manure

Paint or varnish removers, cements or glues, sawdust

Wood working or furniture refinishing shops

Water chlorination chemicals (chloride, fluoride)

Swimming pools, hot tubs

Solvents, cutting oils, fiberglass, cleaning solvents

Auto body or metal working shops

Refrigerant charge with CFC or HCFC

Refrigerant repair shops

Permanent wave solutions

Beauty shops

Fixer, hydrochloric acid (muriatic acid), bromide, iodine

Photo labs, chemical / plastics processing plants

Cement powder, crack fill dust, cellulose, fiber based insulation

Concrete plant or construction site

General Venting │ Vmax I&O Manual

4.0 GENERAL VENTING

The Vmax VM110 & VM110P are certified as a “Category IV” boiler requiring a “Special Venting System” designed for pressurized venting. The Exhaust Vent must be piped to the outdoors, using the vent materials and rules outlined in this section. Under no conditions may this unit vent gases into a masonry chimney, unless it is vacant, and utilizes the approved venting material and rules described in this section.

Direct Vent Installation (Best Practice)

When installed as a Direct Vent boiler the combustion air-inlet must also be piped directly to the outdoors using the methods described in this section and in accordance with the National Fuel Gas Code, ANSI Z223.1 (U.S.) or CSA B149.1 (Canada) and local requirements.

Installation Using Indoor Combustion Air

When the installation uses Indoor Combustion Air (i.e. piping is not directly connecting the appliance air-inlet fitting to the outdoors), provisions for combustion and ventilation air, in accordance with section “Air for Combustion and Ventilation,” of the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (U.S.), or Clause 8.2, 8.3 or 8.4 of Natural Gas and Propane Installation Code, CAN/CSA B149.1 (Canada), or applicable provisions of the local building codes, must be adhered to.

Combustion Air-inlet Contamination

Be careful not to locate the air-inlet termination in an area where contaminants can be drawn in and used for combustion. Combustion air containing dust, debris or air-borne contaminants will drastically increase the required maintenance and may cause a corrosive reaction in the Heat Exchanger which could result in premature failure, fire, serious injury, or death. See Table 4-1 for a list of areas to avoid when terminating air-inlet piping:

Table 4-1 Corrosive Products and Contaminant Sources

Vent and Air-inlet are to be piped separately. The Vmax VM110 & VM110P cannot share a common vent or air-inlet with multiple boilers. Failure to comply will result in serious injury or death.

The boiler shall be located so as not to interfere with proper circulation of combustion, ventilation, and dilution air.

Make up air requirements for the operation of exhaust fans, kitchen ventilation systems, clothes dryers, and fireplaces shall be considered in determining the adequacy of a space to provide combustion air requirements. Failure to ensure adequate make up air to all appliances may result in personal injury or death.

Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other boiler. Failure to follow instructions may result in serious injury or death.

It is BEST PRACTICE to pipe the combustion air-inlet directly to the outdoors (Direct Vent installation) to avoid contamination often contained in indoor air.

Page 11

Vmax I&O Manual │General Venting

Flammable Solvents and Plastic Piping

Due to the extremely flammable characteristics of most glues, cements, solvents and primers used in the process of joining plastic vent and air-inlet pipe, explosive solvent vapors must be evacuated from the vent and air-inlet prior to start-up. Avoid using excess cement or primer that may lead to pooling inside the pipe assembly. Freshly assembled piping assembly should be allowed to cure for a minimum of 8 hours before applying power to the gas fired boiler. Refer to Mandatory Pre-commissioning Procedure for Plastic Venting in this section.

Flammable Cements and Primers – It is the installers’ responsibility to familiarize themselves with the hazards associated with explosive solvents and to take all precautions

to reduce these risks. Failure to follow these instructions can cause explosions, property damage, injury or death.

Mandatory Pre-commissioning Procedure for Plastic Venting (PVC or CPVC)

Do not apply power to the boiler prior to Step 4 in the Mandatory Pre-commissioning Procedure for Plastic Venting.

1) Working with the power turned off to the boiler, completely install the vent and air intake system, securely

cementing joints together. If possible, allow primers/cements to cure for 8 hours before firing the burner. If curing time is less than 8 hours, proceed with Steps 2 through 6.

2) Maintain the boiler gas supply shut-off valve in the off position.

3) Remove the cable from the Spark Ignition Electrode and Ignition Controller.

Spark Ignition Circuit - Maintain a safe distance (2 in. minimum) from the spark ignition circuit to avoid injury from electrical shock.

4) Turn power on to the boiler and apply a heat demand.

5) Allow for 5 complete trials for ignition, consisting of pre and post purge of the combustion blower, until an

ignition lockout occurs. Repeat the process one more time (i.e. 10 complete ignition sequences in total).

6) Turn power off and reconnect the cable to the Spark Ignition Transformer.

Near Boiler Vent/Air-inlet Piping

The Vmax employs universal Exhaust-vent and Air-inlet appliance adapters that accept 3 in. PVC/CPVC, Polypropylene (PP) or FasNSeal Stainless Steel (SS) piping, without the need for additional adapters. The universal adapters incorporate three seals, one for 3 in. PVC/CPVC pipe (3.5 in. OD), one for 3 in. PP pipe (3.15 in. OD) and one for 3 in. FasNSeal SS pipe (3 in. OD). See Figure 4-2(a) for gasket identification and pipe insertion depth based on pipe material used. Prior to inserting the piping into the universal adapter, ensure it is properly bevel (approximately 1/8 in.) to avoid damaging or dislodging the sealing gasket during installation; see Figure 4-2(b).

Gasket Seating - Improper seating can cause leakage and eventual failure of the sealing gasket. Ensure the vent pipe is properly beveled, prior to installation, and that the pipe is fully inserted into universal applicance adapter. Failure to follow these instructions may result in serious injury or death.

PVC/CPVC Piping – Ensure the upper gasket of the universal appliance adapter is in place and properly

positioned prior to installation. Ensure the venting system does not apply a load or strain on the boiler flue outlet adapter; recommend using two elbows to create a “swing joint” to reduce potential strain on vent piping and cemented joints. When exhaust venting with PVC, use the supplied 5” long CPVC Transition Pipe provided with the boiler; insert the CPVC pipe into the exhaust adapter and cement the other end to the PVC exhaust venting using a field supplied PVC or CPVC coupling. See Figures 4-3(a) and 4-3(b).

PVC Exhaust Venting – DO NOT insert PVC pipe directly into the appliance exhaust adapter, as it can deform from the clamping force of the gear clamp. Failure to follow these instructions may result in gasket failure and/or the dislodging of the exhaust pipe from the appliance adapter, resulting in property damage, serious injury or death.

PP Piping – Ensure the middle gasket of the universal appliance adapter is in place and properly positioned

prior to installation. Ensure the venting system does not apply a load or strain on the boiler flue outlet adapter; recommend using an elbow with an offset to reduce potential strain on vent piping and cemented joints. See Figure 4-3(c).

Page 12

Figure 4-2 (a) Universial Exhaust-vent & Air-inlet Appliance Adapter

Gasket Identification and Pipe Insertion Depth

Figure 4-2 (b) Universial Exhaust-vent & Air-inlet Appliance Adapter

Proper Exhaust Vent Connection

Lower Gasket – 3” OD Seal

use with Stainless Steel

Middle Gasket – 3.14” OD Seal

use with Polypropylene

Upper Gasket – 3.5” OD Seal

use with CPVC (PVC for Air-inlet)

2.36” (CPVC/PVC)

3.46” (PP)

4.17” (SS)

CPVC/PP/SS Exhaust Pipe With 1/8” bevel to prevent damage to gasket. When venting

with PVC, use 5” long CPVC

Transition Pipe (factory supplied)

Exhaust-Vent

Air-Inlet

Tighten Gear Clamp after

fulling inserting piping

General Venting │ Vmax I&O Manual

Stainless Steel Piping – The Vmax universal appliance adapter is designed to connect directly to DuraVent –

FasNSeal AL29-4C Stainless Steel Special Gas Vent. Ensure the lower gasket of the universal appliance adapter is in place and properly positioned prior to installation. Ensure the venting system does not apply a

load or strain on the boiler flue outlet adapter; recommend using two elbows to create a “swing joint” to

reduce potential strain on vent piping and cemented joints. See Figure 4-3(d).

Exhaust venting must be supported to reduce strain on piping joints. Failure to follow these instructions may result in result in damage, serious injury or death.

In Canada, the first 3 ft (915 mm) of vent piping must be readily accessible for inspection.

Page 13

Figure 4-3(a) VM110 & VM110P

Figure 4-3(b) VM110 & VM110P

Near Boiler Venting (PVC)

Near Boiler Venting (CPVC)

Figure 4-3(c) VM110 & VM110P

Figure 4-3(d) VM110 & VM110P

Near Boiler Venting (PPs)

Near Boiler Venting (SS)

PP Elbow w. offset angle to account for slope

PP Exhaust Vent

Flue Outlet Adapter

(factory supplied)

Air-inlet Adapter

(factory supplied)

PP Air-inlet Pipe*

Swing Joint to attain

slope in horizontal runs

SS Exhaust Vent

Flue Outlet Adapter

(factory supplied)

Air-inlet Adapter

(factory supplied)

SS Air-inlet Pipe

Air Inlet Pipe*

Swing Joint to attain

slope in horizontal runs

CPVC Exhaust Vent

Air Inlet Adapter

(factory supplied)

Flue Outlet Adapter (factory supplied)

Swing Joint

to attain slope in horizontal runs

CPVC Transition Pipe **minimum 5” long (factory supplied)

Flue Outlet Adapter (factory supplied)

**CPVC Transition Pipe

is mandatory when

venting with PVC

PVC Coupling

Air Inlet Adapter

(factory supplied)

PVC Air Inlet Pipe*

PVC Exhaust Vent

Vmax I&O Manual │General Venting



Air-inlet - check with applicable local codes for acceptable pipe material.

Page 14

Items 1

Materials

2, 3

Venting System Standards

All Vent and Air-Inlet materials installed on gas fired appliances in CAN/US must meet the Standards listed in this Table. Failure to comply could result in fire, serious injury or death.

United States

Canada 4

Vent Piping

and Fittings

PVC - DWV

ANSI/ASTM D2265

All venting material in

Canada must be

ULC S636 approved.

See Note 4 below for

appropriate temperature

applications.

PVC Schedule 40

ANSI/ASTM D1785

CPVC Schedule 40

ANSI/ASTM F441

Stainless Steel (SS)

UL-1738

Polypropylene (PP)

Pipe Cement PVC

ANSI/ASTM D2564

CPVC

ANSI/ASTM F493

Primers

PVC / CPVC

ANSI/ASTM F656

Notes:

Refer to Table 4-5 for Allowable Vent and Air-inlet Pipe Sizes and Lengths.

PVC venting (exhaust and air-inlet) is not permitted within the Closet/alcove of a Closet/alcove installation.

The Air-inlet does not require high temperature pipe material. Check applicable local codes for acceptable materials.

ULC S636 PVC is approved for flue gas temperatures up to 149oF (65oC) and must only be used for low temperature applications. High temperature applications requiring boiler supply water temperatures greater than 140oF (60oC) must use ULC S636 CPVC, PP or SS.

Pipe Size

Length (ft) 2

Number of Elbows (90’s or 45’s) and Equivalent Feet

1 2 3 4 5 6 7 8 9

2” 1 100 3

3”

150

145

140

135

130

125

120

115

110

105

Note:

See WARNING below.

Minimum length of each the exhaust vent and combustion air-inlet piping is 5 feet equivalent.

When using 2 in., the combustion air-inlet piping must not exceed the length of the exhaust vent piping by more than 25 equivalent feet.

General Venting │ Vmax I&O Manual

Vent/Air-inlet Pipe Material

Table 4-2 Approved Vent and Air-Inlet Pipe Material

The use of cellular core PVC (ASTM F891), cellular core CPVC, or Radel® (polyphenolsulfone) in the exhaust venting system is prohibited. Failure to follow these instructions may result in property damage, personal injury or death.

Covering non-metallic vent pipe and fittings with thermal insulation is prohibited. Failure to follow these instructions may result in property damage, personal injury or death.

Vent/Air-inlet Pipe Length Determination Use Table 4-3 to determine the maximum pipe length that can be used. The table calculates 90º elbows, and 45º

elbows at 5 equivalent feet each. Example: When using 3 in. pipe, the Vmax can be installed with 150 equivalent feet of air-inlet piping and 150

equivalent feet of exhaust-vent piping. See Table 4-3 for more details.

Table 4-3 Allowable Vent and Air-inlet Pipe Size and Lengths

PVC Exhaust Venting – When using 2 inch PVC venting, the first seven (7) equivalent feet of exhaust venting must be approved 2 inch CPVC or 3 inch PVC; see exceptions in Table 4-2.

Page 15

Description

Vent

Size

Supplier P/N

Figure

Vent Material

Compatibility

Vent Option

Roof

Wall

IPEX Low Profile (Montage affleurant)

2”

196984

4-4(b), 4-6(c)

PVC/CPVC





3”

196985 (NTI P/N 84357)

IPEX Concentric (Mur / toit)

5,6,7

2”

196005

4-4(c), 4-5(c),

4-6(b), 4-7(b)



3”

196116 (NTI P/N 82666)

197009

DuraVent - PolyPro Concentric (mur)

2”

2PPS-HK

4-4(c), 4-6(d)

PVC/CPVC/PP





3”

3PPS-HK

DuraVent - PolyPro Concentric (toit)

2”

2PPS-VK

4-5(c), 4-7(c)





3”

3PPS-VK

Centrotherm – InnoFlue

(Flush Mount)

2”

ISLPT0202

4-4(b), 4-6(c)





3”

ISLPT0303

Centrotherm – InnoFlue Concentric (Wall)

2”

ICWS2413 & ICTC0224

4-4(c), 4-6(d)





3”

ICWS3513 & ICTC0335

ICWT352 & ICTC0335

Centrotherm – InnoFlue Concentric (Roof)

2”

ICRT2439 & ICTC0224

4-5(c), 4-7(c)





3”

ICRT3539 & ICTC0335

Notes:

Instructions included with termination kits contain detailed assembly and installation instructions.

All factory termination kits are ULC S636 approved.

Clearance requirements in this manual supersede those of the instructions included with the vent terminal.

Piping MUST be secured to the vent terminal during installation.

IPEX Concentric Terminal MUST be cemented together and to the vent pipes during installation.

Vent Screens provided with boiler may be used with the IPEX Concentric Vent Kits; otherwise use IPEX vent screens

(2 in. vent screen P/N 196050; 3 in. vent screen P/N 196051 – each sold separately).

IPEX Low Profile and Concentric kits (excluding P/N 197009) are constructed out of ULC S636 approved PVC; check

with your local authority for the acceptance of PVC as a venting material prior to use.

Centrotherm Concentric termination kits must use the applicable “Twin pipe to concentric adapter,” part number

ICTC0224 or ICTC0335.

Vmax I&O Manual │General Venting

Termination Options – Direct Vent Installation

The venting system of the VM110 and VM110P may be terminated using field supplied piping to construct a “Two-Pipe” termination, see Figures 4-4(a), 4-5(a), 4-5(d), 4-6(a), 4-7(a) and 4-7(d); alternatively the venting may be terminated using a factory kit selected from Table 4-4.

Optional Termination Kits – Direct Vent Installation Kits certified with the Vmax VM110 & VM110P are listed in Table 4-4 and available from IPEX, DuraVent,

Centrotherm and/or NTI. For more information on System 636 Vent Kits or wholesaler locations contact IPEX directly USA: 1-800-463-9572 or www.IPEXamerica.com │ CAN: 1-866-473-9462 or www.ipexinc.com. For more information on PolyPro Vent Kits or wholesaler locations contact DuraVent directly 1-800-835-4429 or

www.duravent.com. For more information on InnoFlue Vent Kits or wholesaler locations contact Centrotherm

directly at 1-877-434-3432 or www.centrotherm.us.com.

Table 4-4 Optional Vent Termination Kits

Venting Options - Due to potential moisture loading (build-up) along the exterior wall,

sidewall venting may not be the preferred venting option (see Figures 4-5 and 4-7).

The vent for this appliance shall not terminate over public walkways; or near soffit vents or crawl space vents or other area where condensate of vapor could create a nuisance or hazard or cause property damage; or where condensate or vapor could cause damage or could be detrimental to the operation of regulators, relief valves, or other equipment.

Page 16

Figure 4-4(a)

Figure 4-4(b)

Two-pipe Termination (Sidewall)

Low Profile Termination (Sidewall)

Figure 4-4(c) Concentric Termination (Sidewall)

Exhaust must terminate a minimum of 18” above Air-inlet termination; see Figure 4-6(a) for more details.

Exhaust

Inlet

3” IPEX Low Profile Termination

illustrated; see Figure 4-6(c) for more details.

Exhaust

Inlet

3” DuraVent Concentric

Termination illustrated, see Figure 4-6(d) for more details.

Exhaust

Inlet

3” IPEX Concentric Termination

illustrated, see Figure 4-6(b) for more details.

Exhaust

Inlet

General Venting │ Vmax I&O Manual

Page 17

Figure 4-5(a)

Figure 4-5(b)

Two-pipe Termination (Roof)

Two-pipe Termination (Roof-exhaust / Sidewall-inlet)

Figure 4-5(c)

Concentric Termination (Roof)

3” DuraVent Concentric

Termination illustrated, see Figure 4-7(c) for more details.

Exhaust

Inlet

Exhaust

Inlet

Exhaust must terminate a minimum of 18” above the Airinlet termination; see Figure 47(a) for more details.

3” IPEX Concentric termination

illustrated, see Figure 4-7(b) for more details.

Exhaust

Inlet

Exhaust

Inlet

Exhaust must terminate a

minimum of 12” above snow

level; see Figure 4-7(d) for more details.

Vmax I&O Manual │General Venting

Page 18

Sidewall Termination Details – Direct Vent Installation

Figure 4-6(a)

Figure 4-6(b)

Two-Pipe Termination (Sidewall)

IPEX Concentric Termination (Sidewall)

Refer to documentation included with termination kit for complete installation instructions.

Figure 4-6(c)

Figure 4-6(d)

Low Profile Termination (Sidewall)

PolyPro / InnoFlue Termination (Sidewall)

Refer to documentation included with termination kit for complete installation instructions.

Min. 12”

above grade or snow level

Exhaust

Air-inlet

Exhaust

Air-inlet around

perimeter

Min. 12”

above grade or snow level

Exhaust center

Air-inlet bottom

Exhaust

Air-inlet

Gas Vent Directly Below

Keep Free of Obstructions

Refer to documentation included with termination kit for complete installation instructions.

Exhaust

Air-inlet

Min. 12”

above grade or snow level

Vertical

Min. 18”

Horizontal 4-12” or greater than 36”

Exhaust

Air-inlet

Vent Screen

Vent pipe piece to retain vent screen

Gas Vent Directly Below

Keep Free of Obstructions

Exhaust

Air-inlet

Min. 12”

above grade or snow level

Air-inlet around perimeter (1-2” from wall)

Exhaust through center

Vent Screen

Vent pipe piece to retain vent screen

General Venting │ Vmax I&O Manual

Page 19

Vmax I&O Manual │General Venting

Roof Termination Details – Direct Vent Installation

Figure 4-7(a)

Figure 4-7(b)

Two-Pipe Termination (Roof)

IPEX Concentric Termination (Roof)

Figure 4-7(c)

Figure 4-7(d)

PolyPro / InnoFlue Termination (Roof)

Exhaust only Termination (Roof)

Min. 12”

above grade or snow level

Vent Screen

Vent pipe piece to retain vent screen

Exhaust

Air-inlet

Vertical

Min. 18”

Horizontal

4-12” or greater

than 36”

Flashing

Min. 12”

above grade or snow level

Vent Screen

Vent pipe piece to retain vent screen

Exhaust center

Air-inlet around

perimeter

Flashing

Refer to documentation included with termination kit for complete installation instructions.

Min. 12”

above grade

or snow level

Flashing

Exhaust

Air-inlet

Figure illustrates two options for exhaust termination only; neither vent pipe illustrated is for combustion air-inlet.

Min. 12”

above grade or snow level

Flashing

Vent pipe piece to retain vent screen

Vent Screen

Exhaust Option 1

Exhaust Option 2



Page 20

General Venting │ Vmax I&O Manual

Venting Rules and Guidelines

1. Prevailing Winds: Ensure the vent is located where it will not be exposed to normal prevailing winds.

2. Combustion Air-inlet Contamination: Air for combustion must be drawn from an area free of dust and

contaminants. Combustion air containing chemicals such as chloride, fluoride, bromine or iodine or dust and debris will cause corrosion damage of the heat exchanger voiding your NTI warranty. Refer to Table 4-1 for a list of corrosive products and contaminants sources to avoid.

3. Vertical Separation: The exhaust must be a minimum of 18 in. above the air inlet, and the air inlet must

always be a minimum of 12 in. plus snow allowance above any surface that will support snow. (Two feet plus snow allowance is highly recommended). Consult your weather office for the maximum typical snowfall for your region. Example: New Brunswick Canada - typical maximum snowfall is 19 in., thus the inlet must be (12”+19”) = 31 in. above grade and exhaust must be (31”+18”) = 49” above grade.

4. Horizontal Separation: The horizontal distance between the inlet and exhaust must be a minimum of 4”

[102 mm] center to center.

5. Wall Flashing: Under normal operating conditions this boiler will produce a plume of white gases, and

should be taken into consideration when selecting an adequate location. A 36 in. diameter stainless, plastic, or vinyl shield can be used to flash the exterior of the residence.

6. Flue Gas Hazard: Position the vent termination where vapors cannot make accidental contact with people

and pets or damage nearby shrubs and plants.

7. Elbow Extensions: Elbows on outside of wall must be no more than ½ in. away from the wall.

8. Vent Sloping: All indoor exhaust piping must be on a slope back to the boiler a minimum of ¼ in. per

linear foot of vent. For applications where excessive condensation is possible ½ in. per linear foot is recommended.

9. Vent Supports: Where required Vent and Air-inlet piping shall be secured to the wall for more rigidity. All

interior vent pipe shall be supported a minimum of every 36 in..

10. Roof Exhaust: In all roof applications the discharge must point away from the pitch of the roof.

11. Roof Flashing: Install adequate flashing where the pipe enters the roof, to prevent water leakage.

12. Rain Cap: Install and seal a rain cap over existing chimney openings, in vacant chimney applications.

13. Venting Below Grade: For installations that exit the wall below grade refer to Figure 4-8.

14. Vent Screens: Install factory supplied vent screens on the outside of the last elbow for both the inlet and

exhaust vent terminal elbows. Install the screen into the female opening of the elbow, and then cut a small piece of pipe to sandwich the screen into the elbow. NOTE: ensure the small piece of pipe cut, does not extend past the end of the elbow. Two screens are provided in the package. See Figures 4-6 and 4-7.

15. Condensate Hazard: Do not locate vent over public walkways, driveways or parking lots. Condensate

could drip and freeze resulting in a slip hazard or damage to vehicles and machinery.

16. Warning Plate: For Sidewall Venting, install the warning plate “Gas Vent Directly Below”, directly above

(within 4 ft. vertically) the location of the air-inlet pipe, so it is visible from at least 8 ft away. See Figure 4-

17. Wall Thickness: Direct vent terminations are designed to work with any standard wall thickness.

Installation guidelines for min/max wall thickness are as follows: Min. = 1 in., Max. = 60 in..

18. Venting Options: Due to potential moisture loading (build-up) along the exterior wall, sidewall venting

may not be the preferred venting option. Refer to Figures 4-5 and 4-7 for roof top venting options.

Page 21

Figure 4-8 Venting Below Grade

For installations that exit the wall below grade:

1. Excavate site to a point below where the pipes

are to exit as shown.

2. Ensure the wall is fully sealed where the pipes

penetrate.

3. The Vent/Air-inlet piping MUST be secured to

the side of the building above grade, as shown, to provide rigidity.

4. Optional mounting bracket P/N. 82075 for

securing the exhaust pipes (only applicable for 3 in. PVC/CPVC venting).

5. Ensure that the Vent/Air-inlet clearances are

maintained, see Section 5.0 for details.

Figure 4-9 Outdoor Venting

Vent piping outside the building is permitted under the following conditions:

1. The maximum length outside the building is 20 ft.

Note that outdoor length must be included in the overall vent length calculation.

2. All normal termination clearances are maintained.

3. The pipe is supported every 24 in..

4. The exhaust and inlet are sloped back to the boiler

½ in. elevation for every linear foot.

Figure 4-10 Existing Chimney Chase Way

It is permissible to use an existing chimney as a chase way to run the Vent/Air-inlet piping as long as:

1. The chimney is not being used by any other

boiler.

2. Flue gases do not enter the vacant chimney.

3. Only Vmax certified venting materials are used,

see Table 4-2.

4. Vent lengths are within the maximums specified.

5. The top of the chimney is capped and the

Vent/Air-inlet pipes are flashed to prevent leakage into the vacant chimney.

Exhaust

Air-inlet

Wall Brackets

Supports every 24 in. [610 mm]

12 in. [305 mm] plus snow

allowance above grade

Air-Inlet

Maximum of 20 ft. [6.1 m] is permitted for piping outside a building.

Exhaust Vent

Gas Vent Directly Below

Keep Free of Obstructions

Air-Inlet

Existing Chimney (used as a chase way)

Chimney Cap

Exhaust Vent

Exhaust Vent Min. 18 in. above airinlet

Air-Inlet Min. 12 in. above roof and snow level

Vmax I&O Manual │General Venting

Page 22

Clearances to Air-Inlet Termination

Canada 1

USA 2

Min. Distance

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

Above roof line - Concentric Vent

6, 11, 13

24 in.

610 mm

24 in.

610 mm

To exhaust vent from any other boiler

36 in.

915 mm

12 in.

305 mm

Clearances to Exhaust Vent Termination

Min. Distance

Above grade/roofline and snow level 8

12 in.

305 mm

12 in.

305 mm

Minimum vertical separation above air inlet 9

18 in.

457 mm

18 in.

457 mm

Minimum horizontal separation from air inlet 3

4 in.

102 mm

4 in.

102 mm

Window or door that may be opened, or other building opening

36 in.

915 mm

12 in.

305 mm

To combustion air inlet of any other appliance

36 in.

915 mm

12 in.

305 mm

Non-mechanical air supply inlet to building

36 in.

915 mm

12 in.

305 mm

Mechanical air supply inlet to building 4

6 ft.

1.83 m

3 ft.

915 mm

Soffit, overhang, eave or parapet

24 in.

610 mm

24 in.

610 mm

Soffit vent or vent opening in an overhang, eave or parapet

6 ft.

1.83 m

6 ft.

1.83 m

Outside corner 10

- - -

Inside corner of an L-shaped structure (including walls and fences)

36 in.

915 mm

36 in.

915 mm

Service regulator / vent outlet

36 in.

915 mm

36 in.

915 mm

Each side of center line above or below meter / regulator assembly 5

36 in.

915 mm

36 in.

915 mm

Above a paved sidewalk, driveway, or parking lot on public property if adjacent 12

7 ft.

2.13 m

7 ft.

2.13 m

Above a public walkway

X X X

Above a sidewalk or paved driveway that is located between two single family dwellings and services both dwellings

X X X

Under a concrete veranda, porch, deck, or balcony 7

24 in.

610 mm

24 in.

610 mm

Above, under or near exterior stairs

X X X

Into a canopy or carport

X X X

Notes:

1 - Canadian installations must comply with the current CSA B149.1 Natural Gas and Propane Installation Code and local

building codes. 2 - US installations must comply with current ANSI Z223.1/ NFPA 54 National Fuel Gas Code and local building codes. 3 - Horizontal separation center-to-center (c.c.) 4”-12” (102-305 mm).

4 - For US installations, an exhaust vent must be 3 ft above a mechanical air supply inlet if within 10 ft. [3 m] horizontally. 5 - Horizontal clearance must be observed up to a height of 15 ft. [4.6 m] above/below the meter, regulator, or relief devices. 6 - Concentric Vent must protrude from the roof precisely 24” [610 mm] measuring from the terminal end-cap vanes. 7 - Permitted if veranda, porch, deck, or balcony is made of concrete and a minimum of two sides are fully open beneath. 8 - 24” is the recommended snow level allowance above grade/roofline or any surface that will support snow, debris, or ice

(i.e. for roof venting clearances - roofline and snow level). If living in a snowfall region, consult your local weather office for the maximum typical snowfall for your area.

9 - Note that the vent must maintain a minimum vertical distance above the air-inlet. Example: Vent height = 18” (457

mm) above air inlet + 12” (305 mm) for air inlet above grade/roof line and snow level = 30” (762 mm) above grade and

snow level. 10 - Clearances to an outside corner to be in accordance with local installation codes. 11 - In Canada, concentric vent materials are subject to approval by local inspectors. See Termination Kits in Section 4.0.

12 - Above public walkways, driveways or parking lots if adjacent to it and condensate cannot drip, freeze, or create a hazard. 13 - Contact the manufacturer for special exemptions relating to multiple boiler installations using concentric vents.

Termination Clearances │ Vmax I&O Manual

5.0 VENT/AIR-INLET TERMINATION CLEARANCES

instructions detailed in this section are a combination of Vmax specific and National Gas Code restrictions. Compliance alone does not insure a satisfactory installation as good common sense must also be applied. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Table 5-1 Termination Clearances Quick Reference Table (See Figures 5-1 and 5-2)

The quick reference table below is to be read in conjunction with the numbered notes as indicated, Figures 5-1 and 5-2, and the Venting Rules and Guidelines in Section 4.0. The

Page 23

G – Letter represents a specific Termination Position. Refer to Table 5-1 for corresponding termination clearances.

Concentric Vent Termination

Two-Pipe Termination

Clearance “Q” Adjacent to Public Walkway or Driveway Minimum 7ft. [2.13 m]

Clearances “F” and “G” Canada – Minimum 3 ft. [915 mm] The US – Minimum 1 ft. [305 mm]

Vmax I&O Manual │Termination Clearances

Figure 5-1 Termination Clearance Quick Reference Diagram (See Table 5-1)

Illustrations of Termination Clearances

Figure 5-2 Sidewall Termination (See Table 5-1)

Page 24

Termination Clearances │ Vmax I&O Manual

Removing an Existing Boiler from Common Venting System

Upon removal of an existing boiler, the following steps shall be followed for each boiler remaining in the common venting system; prior to commencing this procedure, shutdown all boilers remaining in the common venting system.

Steps to Removing an Existing Boiler:

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

2. Visually inspect the venting system for proper size and horizontal pitch. Verify that there is no blockage,

restriction, leakage, corrosion or other deficiencies which could cause an unsafe condition.

3. Insofar as is practical, close fireplace dampers, all building doors and windows and all doors between the

space in which the boilers remaining connected to the common venting system are located and other spaces of the building. Turn on clothes dryers and any boiler not connected to the common venting system. Turn on any exhaust fans, such as range hoods and bathroom exhausts, so they will operate at maximum speed. Do not operate a summer exhaust fan.

4. Place in operation the boiler being inspected. Follow the applicable lighting instructions. Adjust thermostat

so boiler 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, cigar or pipe.

6. After it has been determined that each boiler remaining connected to the common venting system properly

vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gas burning boiler to their previous condition of use.

7. Any improper operation of the common venting system should be corrected so the installation conforms to

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

Extra precaution must be taken to adequately support the weight of the Vent/Air-inlet piping in applications using roof-top terminations. Failure to follow these instructions may result in venting or boiler component failure resulting in flue gas spillage leading to property damage, serious injury or death.

Under no circumstances may an existing chimney or chase-way be used to vent or provide combustion intake air to a Vmax VM110 or VM110P. Failure to follow these instructions will result in fire, property damage, serious injury or death.

Do not install the Vmax VM110 or VM110P into a common venting system with any other boiler. Failure to comply with this warning will cause flue gas spillage and leech carbon monoxide emissions into the surrounding air resulting in serious injury or death.

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the remaining boilers connected to it. Instructions have been provided on how to remove the existing boiler and how to resize the remaining venting system. Failure to follow these instructions may result in property damage, serious injury or death.

Page 25

Vmax I&O Manual │Condensate Drain

6.0 CONDENSATE DRAIN

The Vmax boiler produces liquid condensate in the heat exchanger and venting system as a product of combustion. Steps must be taken to ensure condensate does not collect in the venting system; therefore, all exhaust piping must slope back to the boiler a minimum ¼ in. per linear foot of vent. Condensate must be drained from the unit into a household drain.

Check with your municipality, or local gas company to determine if the disposal of combustion condensate is permitted in your area (e.g. in the State of Massachusetts the

The following are important notes that must be taken into consideration when constructing the condensate drain system (see Condensate Trap Installation Instructions for further details):

 DO NOT install condensate lines outside. A frozen or blocked drain will cause the condensate to back-up

and leak. This may result in damage to boiler components resulting in a no heat condition; property damage may also occur.

 NEVER use copper, steel, or galvanized piping in the construction of the condensate system (condensate is

very corrosive and will corrode most metals).

 When a condensate pump is used or required, select a pump that is designed for residential furnaces.

Condensate Trap Installation Instructions (see Figure 6-1)

(Note: the Condensate Trap is factory supplied with the boiler and must be field installed)

1. Inspect Condensate Trap Assembly – Inspect the Condensate Trap to ensure all parts were shipped with

the assembly (see Figure 6-1). The Condensate Trap must be periodically disassembled and cleaned as part of a regular maintenance plan.

2. Attach to Boiler Condensate Drain – Insert the inlet fitting of the Condensate Trap into the boiler

condensate drain; secure with the factory supplied gear clamp (see Figure 6-1). Pull down on the Condensate Trap and ensure that it remains securely fastened.

3. Outlet to Drain – Direct condensate from the outlet of the Condensate Trap to a household drain,

condensate pump or neutralizer (check with your local authority regarding the disposal of condensate). If necessary connect suitable ¾” tubing to the bottom of the Condensate Trap and route it to drain, being careful NOT to route it higher than the Condensate Trap outlet (see Figure 6-1).

condensate must be neutralized prior to entering a drain).

All tubing, drains and surfaces that come in contact with condensate draining from the boiler, must be constructed out of corrosion resistant material; copper, steel and galvanized are not acceptable materials for draining condensate. Failure to abide by this caution will result in property damage.

The Condensate Trap must be periodically disassembled and cleaned as part of a regular maintenance plan. Failure to clean the trap regularly can cause condensate drain blockage leading to boiler malfunction, property damage and even personal injury.

Carefully follow the above instructions and the accompanying figure – check to ensure the condensate trap is secure to the bottom of the boiler and that no strain is placed on it. Failure to install the condensate trap properly will result in flue gas spillage and leeching of carbon monoxide emissions into the surroundings resulting in serious injury or death.

Page 26

Figure 6-1 Condensate Drain Piping

Inspect Condensate

Trap assembly

Attach to Boiler Condensate Drain

Condensate Trap

(factory supplied)

 Outlet to Drain

Gear Clamp

(factory supplied)

Boiler Condensate Drain

Direct condensate to a vented drain, ensure no strain is

applied to the Condensate Trap and Boiler Condensate

Drain. If necessary, add a piece of ¾” tubing to the

bottom of the Condensate Trap as illustrated.

Tighten gear clamps and pull down on Condensate Trap to test secureness

Condensate Drain│ Vmax I&O Manual

Page 27

Kit Number

LP Orifice Size

Orifice Part Number

84867-4

5.05 mm

84795

Vmax I&O Manual │Lighting the Boiler

7.0 INSTALLING GAS PIPING

Natural to LP Conversion Kit (see Table 7-1) must be installed prior to installing the gas piping to the boiler. Failure to properly convert the unit to operate with Propane may result in property damage, serious injury or death.

Codes as they may require boilers fueled with LP gas to be provided with an approved means of removing unburned gases from the room. Failure to follow these instructions may result in serious injury or death.

Table 7-1 Natural to LP Propane Conversion Kit

Installation

Refer to the current National Fuel Gas Code ANSI Z223.1/NFPA 54 or CAN/CGA B149.1 installation codes, and local codes for gas piping requirements and sizing. Pipe size running to the unit depends on:

 Length of pipe.  Number of fittings.  Type of gas.  Maximum input requirement of all gas boilers in the residence.

Ensure that:

 The gas line connection to the boiler does not apply any weight to the gas valve. NTI recommends using

approved flexible gas piping (if acceptable by local codes) to connect the boiler to the gas supply (see Figure 7-1 for details).

 You plan the installation so the piping does not interfere with the vent pipe, or the removal of the valve,

burner, and serviceable components.

 The Boiler is installed such that the gas ignition system components are protected from water (dripping,

spraying, rain etc.) during installation and servicing.

 The gas piping is large enough for all the gas appliances in the home. No appreciable drop in line pressure

should occur when any unit (or combination of units) lights or runs. Use common gas-line sizing practices.

 Always use a pipe-threading compound that is resistant to Propane (LP) gas solvent action. Apply sparingly

to all male threads, starting at two threads from the end. Over doping or applying dope to the female end, can result in a blocked gas line.

 DO NOT TIGHTEN FITTINGS WITHOUT SUPPORTING THE INTERNAL GAS LINE CONNECTION

WITHIN THE BOILER as damage to the boiler’s internal gas carrying components could occur.

 Install a manual “Equipment Shut-Off Valve” as shown in Figure 7-1. Valve must be listed by a nationally

recognized testing laboratory.

 The gas line piping can safely be removed from the boiler for servicing, by strategically placing the gas line

shutoff and union; see example in Figure 7-1.

 All gas piping, including gas components in the boiler, are checked for leaks using a “Bubble Test”, prior to

operating the boiler.

The Vmax VM110 & VM110P are factory equipped to operate with Natural Gas, the installation of a conversion kit is required prior to operating with Propane Gas. The

Liquefied Petroleum (LP) propane gas is heavier than air. Do not install the boiler in a pit or similar location that will permit heavier than air gas to collect. Check with Local

Strain on the gas valve and fittings may result in vibration, premature component failure and leakage and may result in a fire, explosion, property damage, serious injury or death.

Do not use an open flame to test for gas leaks. Failure to follow these instructions may result in fire, property damage, serious injury or death.

When performing a pressure test on the gas line piping, be sure the boiler is disconnected or isolated if the test pressure is expected to exceed 1/2 PSI (14 in. w.c.), as damage to the gas valve could occur resulting in fire, property damage, serious injury or death.

Page 28

Figure 7-1 Gas Line Connection (Typical)

Test all gas piping, internal and external to the boiler, for leaks. Failure to follow these instructions may result in fire, property damage, serious injury or death.

Manual Gas Shutoff Valve

Should overheating occur or the gas supply fails to shutoff, close the Manual Gas Shutoff Valve to the boiler.

Flexible Gas Line Piping

Recommended to eliminate strain on the boiler gas components (only use if acceptable by local codes).

Rigid Gas Line Piping

Use only rigid gas line piping within the boiler cabinet. Rigid piping must protrude beyond the outside of the cabinet wall.

Drip Leg

Lighting the Boiler│ Vmax I&O Manual

Page 29

Vmax I&O Manual │Lighting the Boiler

8.0 LIGHTING THE BOILER

Before Start-up refer to Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosions, injury or death.

Prior to turning the gas supply on and lighting the boiler, ensure all aspects of the

installation are complete and in conformance with the instructions provided in this manual, including the Vent/Air-inlet, Condensate Drain, and System Water Piping. Failure to precisely follow these instructions will cause a fire or explosion resulting in property damage, serious injury or death.

A) This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

B) BEFORE OPERATING smell all around the boiler area for gas. Be sure to smell next to the floor because some gas is heavier than air and will settle on the floor. WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any boiler.

• Do not touch any electric 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.

C) Use only your hand to turn the gas “shutoff” valve. Never use tools. If the handle will not turn by hand, do

not try to repair it, call a qualified service technician. Force or attempted repair may result in a fire or explosion.

D) Do not use this boiler if any part has been under water. Immediately call a qualified service technician to inspect the boiler and to replace any part of the control system and any gas control which has been under water.

1. STOP! Read the safety information above very carefully.

2. Set the thermostat to lowest setting. Turn off all electric power to the boiler.

3. This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the

burner. Do not try to light the burner by hand.

4. Turn the manual gas valve to the OFF position. Remove front access panel.

5. Wait five (5) minutes to clear out any gas. Then smell for gas, including near the floor. If you smell gas,

STOP! Follow “B” in the safety information above. If you do not smell gas, go to the next step.

6. Turn the manual gas valve ON. Wait an additional five (5) minutes smelling for gas.

7. Replace the front access panel.

8. Set thermostat to highest setting. Turn on all electric power to the boiler.

9. Ignition sequence is automatic. Combustion will occur after a brief fan purge.

10. If ignition does not occur, follow the instructions “To Turn Off Gas To Boiler” and call your service

technician or gas supplier.

1. STOP! Read the safety information above very carefully.

2. Turn off all electric power to the boiler

3. Turn the manual gas valve to the OFF position

Do not store or use gasoline or other flammable vapors & liquids in the vicinity of this or any other boiler. Failure to follow instructions could result in explosion causing property damage, serious injury or death.

If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death.

Should overheating occur or the gas supply fails to shutoff, close the Manual Gas Shutoff Valve to the boiler. Failure to follow instructions could result in explosion causing property damage, serious injury or death.

FOR YOUR SAFETY, READ BEFORE OPERATING_

OPERATING INSTRUCTIONS_

TO TURN OFF GAS TO THE BOILER_

Page 30

Lighting the Boiler│ Vmax I&O Manual

 Ensure the boiler is wired in accordance with this manual.  Ensure the gas shutoff valve is turned on, and that the gas system has been fully tested for leaks.  Ensure the system is completely filled with water, and that ALL the air is purged out.  Ensure the Vent and Air-inlet piping is completely installed in accordance with this manual.

Initial Start-Up

Each time the power is turned on to the boiler, the control will go through a “de-air” sequence designed to purge air from the boiler. The de-air sequence takes 14 minutes to execute, during which time the circulators will be operating in a cyclical manner and the burner will not attempt to function. Once the de-air sequence has been executed at least once, subsequent de-air sequences can be bypassed by holding the “OK” button until “de-Air” is no longer displayed on the screen; see Section 17.0 for more details.

1. Turn on power to the Vmax VM110 or VM110P and turn-up the Thermostat(s). The boiler should run

through a purge, and combustion should occur. (The control system has a built-in ignition retry, allowing the system to try at least five times, before locking-out.)

2. With the unit operating at full capacity, verify that the gas line pressure is 4-10.5 inches w.c. for Natural gas,

and 9-13 inches w.c. for Propane (see Section 9.0 for details).

3. Using an appropriate Oxygen (O2) or Carbon Dioxide (CO2) analyzer, take a sample of the flue gas. The

sample must fall within the acceptable ranges for CO2 (see Section 9.0 for details).

4. Perform at least three ignitions in succession to ensure proper operation.

5. After the three successive ignitions, unplug the flame sensor and allow the unit to cycle again. The flame

safety system will allow the unit to go through 5 ignition cycles before going to “Loc 1”. Once you have confirmed this behavior, reinstall the wire on the flame sensor, press the reset button and reconfirm proper ignition.

located in the burner plate); this device is used for spark ignition and produces 20,000 Volts potential which would result in an EXTREME ELECTRICAL SHOCK possibly causing serious injury or death.

burner is rough or erratic. Failure to follow these instructions may result in serious injury or death.

Re-lighting Unit

1. Stop and read these instructions very carefully.

2. Set the thermostat to the lowest setting, and then turn off all power to the boiler.

3. This boiler does not have a pilot. It is equipped with an ignition device that automatically lights the burner.

Do not try to light the burner by hand.

4. Turn the gas shutoff valve to the off position, and then remove the front cover.

5. Wait five (5) minutes to clear out any gas. Then check for gas, including near the floor. If you smell gas

“Stop” and follow “B” above (see FOR YOUR SAFETY, READ BEFORE OPERATING). If you do not detect any gas proceed to the next step.

6. Turn the gas shutoff valve to the on position, wait an addition five (5) minutes and check for gas.

7. Replace the front cover.

8. Set the thermostat to the highest setting, and then turn on all power to the boiler.

9. Ignition sequence is automatic, combustion will occur after a brief fan purge. Ignition will retry 3 times.

10. If ignition does not occur, “Turn off the gas and electricity to the boiler” and contact a qualified service

technician, or gas supplier.

The initial lighting of the boiler must be performed by a licensed Gas Technician. Failure to follow instructions may result in property damage, serious injury or death.

Allow primers/cements to cure for 8 hours prior to Start-up. If curing time is less than 8 hours, first perform Steps 2 through 6 of Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosion, serious injury or death.

The flame probe is located in the burner plate; it has a single white/semi-transparent wire connected to it. DO NOT remove the orange spark cable from the ignition electrode (also

If the unit fails to light consistently and smoothly, contact NTI for technical assistance at 1-800-688-2575. Never allow the boiler to operate if the ignition or operation of the

Page 31

Vmax I&O Manual │Lighting the Boiler

Turning Off the Boiler

1. Set the thermostat to the lowest setting, and then turn off all power to the boiler.

2. Turn the gas shutoff valve to the off position.

Page 32

Gas

Line Pressure (inches wc)

CO2 (%)*

CO (ppm)

Max.*

Nominal/Desired

Min.

Max.

Min.

Max.

Natural

7 4 10.5

9.0

9.8

175

Propane

11 8 13

10.0

10.8

175

Gas

Appliance Number

Min. Modulation Rate (RPM)

Max. Modulation Rate (RPM)

NG 8 1320

6960

1320

6960

Gas Valve and Burner Set-up │ Vmax I&O Manual

9.0 GAS VALVE AND BURNER SET-UP

Set-up of the Vmax VM110 & VM110P gas valve must be performed by a licensed Gas Technician. Failure to perform the set-up correctly may result in incorrect operation,

Gas Line Pressure

The boiler gas valve is equipped with a line pressure test port; see Figure 9-1. Use the following procedure to measure the gas line pressure to the boiler to ensure if falls within the range given in Table 9-1:

1. Turn the supply of gas to the boiler off.

2. Open the bleed screw of the line pressure test port approximately 1-1/2 turns. This port is directly connected

to the gas line feeding the boiler. See Figure 9-1.

3. Force ¼ in. ID tubing over the housing of the line pressure test port; install the other end of the tubing to an

appropriate line pressure test gauge or manometer. Ensure both ends of the tubing make a tight connection.

4. Open the supply of gas to the boiler and check for gas leaks.

5. Observe the line pressure under static conditions and compare it to Table 9-1. The pressure will be greatest

under static conditions.

6. With all other gas appliances in the application running, operate the burner to the maximum firing rate (see

Table 9-2) and compare the observed line pressure with Table 9-1. The pressure will be lowest during the maximum flow of gas.

7. Adjust the gas line pressure to ensure the parameters in Table 9-1 are attained under all conditions (see

NOTICE below). If possible adjust the line pressure to the "Nominal/Desired" value listed in Table 9-1, while the unit is operating at the maximum modulation rate, see Table 9-2.

8. Continue observing the gas line pressure until the completion of the combustion analyses, in case

adjustments need to be made.

9. Complete pressure testing, and then return the bleed screw of the Line Pressure Test Port to the closed

position.

gas valve influence or be used to adjust the gas line pressure.

Table 9-1 Line Pressure and Combustion Parameters

component failure, property damage, serious injury or death.

The line pressure is a function of the gas supply and is affected solely by field provided parameters such as line size and regulator settings. Under no circumstances can the boiler

Failure to close the bleed screw of the Line Pressure Test Port will cause a severe leakage of gas, resulting in a fire or explosion causing property damage, serious injury or death.

*Note: Observe the combustion products with the burner operating at the maximum modulation rate, CO2 and CO values will be lower at minimum modulation rate.

Table 9-2 Minimum and Maximum Modulation Rates

Carbon Monoxide - Never leave the unit operating while producing Carbon Monoxide

(CO) concentrations in excess of 175ppm. Failure to follow this warning may result in serious injury or death.

Manifold Pressure - DO NOT adjust or measure the Manifold Pressure of the boiler. Correct manifold pressure is factory set. Field adjustment could result in improper burner operation resulting in fire, explosion, property damage or death.

Page 33

Throttle/Input Adjustment Screw

Increase gas Turn Counter Clockwise

Decrease gas Turn Clockwise

Vmax I&O Manual │Gas Valve and Burner Set-up

Adjustments to the Throttle/Input Screw may only be made by a qualified gas technician,

while using a calibrated combustion analyzer capable of measuring CO2 and CO. Adjustments may only be performed if the gas line pressure is maintained above minimum levels throughout the duration of the test, see Table 9-1. Failure to follow these instructions may result in serious injury or death.

Adjustment

Throttle / Input Screw Adjustments - The boiler is equipped with a Throttle/Input Adjustment Screw, located

on the Gas Valve. It is used to adjust the flow of gas leaving the gas valve entering the Venturi and then the combustion air stream. Turn the Throttle screw in (clockwise) to reduce the flow of gas, make combustion leaner, and reduce the concentration of CO2 in the flue gases. Turn the Throttle screw out (counterclockwise) to increase the CO2 level and flow of gas in the combustion air stream. Typical adjustment required is 0-1/2 full turns in or out from the factory setting. See Figure 9-1 for Throttle screw location and Table 9-1 for appropriate CO2 levels.

Combustion Calibration - To calibrate burner operation, perform the following procedure using a calibrated

combustion analyzer capable of measuring CO2 and CO from Natural and Propane Gas burning boilers:

1. Operate the unit at the maximum modulation rate, see Table 9-2.

2. Ensure the gas line pressure is maintained within tolerance, see Table 9-1.

3. While at the maximum modulation rate, measure the CO2 and CO; adjust as necessary, using the Throttle

Screw, to be within the limits listed in Table 9-1.

4. Operate the unit at the minimum modulation rate (see Table 9-2). Ensure the combustion remains smooth

and CO2 and CO values are lower than the values obtained during maximum modulation (Table 9-1). If not, do not adjust further, contact NTI for assistance.

Flue Gas Analysis and Adjustment

Each Vmax VM110 & VM110P are factory set to operate with Natural Gas, for boilers field converted to operate with Propane Gas, a flue gas analysis and adjustment is mandatory. See Table 7-1 and Propane conversion instructions.

consumption, reduced component life, heat exchanger combustion deposits, and general unsafe operation. Failure to follow these instructions may result in serious injury or death.

Analysis – Perform flue gas analysis, and adjust throttle/input screw as required until CO2 and CO levels are

within acceptable limits.

Failure to perform the flue gas analysis and adjustment detailed in this section may result

in erratic and unreliable burner operation, leading to reduced efficiency, increased fuel

Page 34

Figure 9-1 Gas Valve and Venturi Assembly

DO NOT Adjust

Gas Valve

Manifold Pressure Test Port

Throttle / Input Adjustment Screw

Line Pressure Test Port

Venturi

Gas Valve and Burner Set-up │ Vmax I&O Manual

Page 35

Vmax I&O Manual │Field Wiring

Table 10-1 Boiler System Cleansers and Corrosion Inhibitors

Application

Fernox Product

NTI Part #

Description

Boiler Water Treatment

F1 Protector

83448

Corrosion inhibitor.

Cleanser for new and old systems

F3 Cleaner

83449

Removes flux, grease and carbon residue.

Cleanser for Retrofits

DS-40 System Cleaner

83450

Removes heavy limescale and sludge deposits.

 PH – between 6.6 and 8.5.

 Iron – less than 0.5mg/l.

 Chloride – less than 125mg/l.

 Copper – less than 0.1mg/l.

 Conductivity – less than 400µS/cm (at 25ºC); [TDS < 200ppm or Total Hardness < 11.6grains/USgal.]

10.0 BOILER AND HEATING SYSTEM PIPING

The fire tube design of the Vmax VM110 & VM110P heat exchanger results in minimal head loss, however it must be considered when sizing system piping and circulators. Furthermore, the low mass of the Vmax heat exchanger requires a minimum flow rate anytime the burner is operating. To maintain the efficient and reliable operation of the heat exchanger, and to avoid heat exchanger failure, it is critical to ensure the rules and guidelines in this section are followed.

Failure to follow the instructions provided in this section will void the NTI warranty and

may result in property damage, fire, serious injury or death.

Boiler System Preparation

Prior to connecting plumbing to the boiler, flush the entire system to ensure it is free of sediment, flux, solder, scale, debris or other impurities that may be harmful to the system and boiler. During the assembly of the heating system, it is important to keep the inside of the piping free of any debris including construction and copper dust, sand and dirt.

For retrofits, all system piping, including radiators, must be cleansed of build-up including sludge and scale. All systems, old and new, must be cleansed to remove flux, grease and carbon residue; NTI recommends cleaning the boiler system with “Fernox F3 Cleaner.” For retrofit applications with heavy limescale and sludge deposits, a heavier duty cleaner may be required; NTI recommends the use of “Fernox DS-40 System Cleaner.” For information on performing the cleaning, follow the instructions included with the applicable Fernox Cleaner. See Table 10-1 for a list of recommended boiler system cleaning and treatment products.

Failure to rid the heating system of the contaminants listed above will void your NTI

warranty and may result in premature heat exchanger failure and property damage.

Boiler Water

Pressure - Vmax boilers are intended solely for use in pressurized closed-loop heating systems operating with a

minimum pressure of 12 PSI at the boiler outlet. To obtain the minimum system design pressure, follow the piping diagrams illustrated in this section.

Oxygen Elimination - This boiler may only be installed in a pressurized closed-loop heating system, free of air

and other impurities. To avoid the presence of oxygen, ensure all of the air is removed from the system during commissioning via strategically placed, adequately sized air-removal devices; located throughout the heating system. See figures in this section detailing the location of the primary air-removal device required for the boiler. Immediately repair any leaks in the system plumbing to avoid the addition of make-up water; make-up water provides a source of oxygen and minerals that may lead to heat exchanger failure. Failure to follow these instructions will result in poor performance, unnecessary wear of system components and premature failure.

The Vmax VM110 & VM110P are not approved for operation in an “open system,” thus

it cannot be used for direct potable water heating or process heating of any kind. Water Chemistry – The installer of the Vmax boiler must consider the condition of the water in the heating

system. Ensure the condition of the boiler water falls within the following parameters:

Page 36

Figure 10-1 Installation of Optional LWCO

Low Water Cutoff Location

(when required by local authorities)

Install the LWCO in a suitable tee (reference

installation instructions provided with the LWCO) as illustrated. DO NOT install

isolation valves between the boiler and the LWCO. The LWCO switch must be wired to break the boiler limit circuit or line power to the boiler (see Section 12.0 – Field Wiring).

NTI offers the following LWCO kits:

 VM110 LWCO Kit – P/N TBD  VM110P LWCO Kit – P/N TBD

When the installation is complete, TEST THE LWCO to ensure the burner shuts

down when the water level drops.

Auto Air Vent – keep open to avoid false trips of the LWCO

Field Wiring │ Vmax I&O Manual

Treatment - Boiler water that falls outside of the conditions listed above must be treated with a corrosion

inhibitor. For information on performing the treatment, follow the instructions included with the corrosion inhibitor. See Table 10-1 for a list of recommended boiler system cleaners and corrosion inhibitors.

Anti-freeze - For systems requiring freeze protection, use only inhibited propylene glycol, specially formulated

for hydronic heating systems; use of other types of antifreeze may be harmful to the system and will void the warranty. Note: the use of glycol may reduce the usable output capacity of the boiler, thus requiring the unit to be “down-fired” by limiting the maximum operating capacity and/or the maximum water temperature. NTI recommends against exceeding 35% concentration of glycol.

Near Boiler Plumbing (Central Heating)

Pressure Relief Valve - A Pressure Relief Valve is factory supplied with each unit. Vmax VM110 and VM110P

boilers have a maximum allowable operating pressure of 30 PSI. The pressure relief valve must be installed in the vertical position, as illustrated in Figures 10-1, 10-2(a), 10-2(b) and 10-3(a), with the drain pipe outlet exiting the side of the pressure relief valve horizontally. Pipe the outlet of the relief valve towards the floor, away from where it could be harmful.

Pressure Gauge – Vmax VM110 and VM110P units come with a factory supplied 60 PSI Pressure Gauge. The

pressure gauge must be installed at the boiler outlet prior to any circulators. See Figures 10-2(c) and 10-3(b).

Low Water Cutoff (LWCO) – Vmax boilers are provided with a factory installed Water Pressure Sensor. The

sensor provides a reading of the boiler inlet water pressure on the display; in the event the pressure drops below 7 PSI, the control will go to a blocking error “FILL”, inhibiting burner operation. Where required by the Authority having jurisdiction, an external LWCO may have to be installed; see Figure 10-1.

To maintain protection, the level of corrosion inhibitor must be monitored periodically

for the correct concentration.

DO NOT use inhibited glycol with non-compatible boiler inhibitors. Non-compatible

inhibitors may counteract each other rendering them ineffective.

If installed in the incorrect orientation (horizontally with drain pipe out the bottom) the relief valve may not function properly resulting in property damage or personal injury.

Ensure the discharge of the pressure relief is piped to a location where the steam or water

will not cause property damage or serious injury.

Page 37

Figure 10-2(a) VM110 Top – Option A

Figure 10-2(b) VM110 Top – Option B

Figure 10-2(c) VM110 Bottom

Central Heat Outlet

Inlet from Indirect Water Heater

(and location for boiler drain)

Condensate Drain

60 PSI Pressure Gauge

(factory supplied)

Tee Fitting - Typical

(field supplied)

Central Heat Inlet

1x3/4” Brass Bushing

(factory supplied)

30 PSI Relief Valve

(factory supplied)

Auto Air Vent

(factory supplied)

3/4” Brass Street Elbow

(factory supplied)

1x1/2x1” Brass Tee

(factory supplied)

1” Nipple

(field supplied)

30 PSI Relief Valve

(factory supplied)

Auto Air Vent

(factory supplied)

1x1/2x1” Brass Tee

(factory supplied)

1x1x3/4” Brass Tee

(field supplied)

Outlet to Indirect Water Heater

Vmax I&O Manual │Field Wiring

Near Boiler Piping (Central Heating – CH)

Page 38

Figure 10-3(a) VM110P (Plus) Top

Figure 10-3(b) VM110P (Plus) Bottom

DHW Out

60 PSI Pressure Gauge

(factory supplied)

Condensate Drain

Boiler Outlet

Primary Loop (factory supplied)

DHW Recirc.

Central Heat Inlet

Central Heat Outlet

DHW In

Gaskets

(factory supplied)

Boiler Inlet

150 PSI T&P Relief Valve

(factory supplied)

Auto Air Vent

(factory supplied)

3/4x1/2x3/4” Brass Tee

(factory supplied)

3/4” Brass Street Elbow

(factory supplied)

30 PSI Relief Valve

(factory supplied)

Field Wiring │ Vmax I&O Manual

Page 39

Model

Temp.

Rise (ºF)

Boiler Flow

Rate (GPM)

Boiler Head

Loss (ft)

Minimum

Pipe Size

Minimum Primary Loop Pump Size

B&G

Grundfos

Taco

Armstrong

VM110

3.9

1”

NRF-22

UPS15-58 (3)

0010

Astro 230 (3)

25 8 3.4

1”

NRF-22

UPS15-58 (2)

007

Astro 230 (2)

35 6 2.7

1”

NRF-22

UPS15-58 (2)

005

Astro 230 (2)

Notes:

Pump sizing accounts for the head loss associated with the boiler, a Trin & Stor S40 Indirect Water Heater and up to 30

equivalent feet of the specified minimum pipe diameter.

Only the pump responsible for generating flow through the Indirect Water Heater connected to a VM110, needs to be

sized to ensure adequate flow rate through the boiler.

Vmax I&O Manual │Field Wiring

Boiler System Plumbing

Vmax boilers use a low mass heat exchanger that requires a minimum of 3.5 GPM of forced water circulation any time the burner is operating. To ensure the minimum flow rate is attained, carefully following the plumbing instructions in this section.

Circulating Pumps (VM110) – VM110 models incorporate a Central Heat Pump and “Primary Loop” with

“Closely Spaced Tees”; therefore, only the DHW Pump ( Indirect Fired Water Heater Pump) needs to be

sized to ensure adequate water flow through the boiler. See Table 10-2 and Figure 10-4 for assistance in sizing the DHW Pump for Vmax model VM110.

Circulating Pumps (VM110P) – Vmax Plus models incorporate a Boiler Pump, Diverter Valve and “Primary

Loop” with “Closely Spaced Tees” (Note: the Primary Loop is field installed below the boiler – see Figure 10-

3(b)). Sizing circulators to ensure minimum flow through the VM110P boiler is NOT necessary.

Circulating Pump Outputs – Vmax boilers are equipped with three 120VAC pump outputs:

1. DHW PUMP - operates during a Domestic Hot Water demand (DHW). The DHW PUMP output is not

used on VM110P (Plus) models.

2. CH PUMP - operates during a Central Heat demand (CH). The VM110 internal pump is factory wired to

the CH PUMP output.

3. BOILER PUMP - operates during any demand. The VM110P (Plus) internal pump is factory wired to the

BOILER PUMP output. NOTICE: the BOILER PUMP output is only used to operate boiler pump of a

Ensure circulating pumps are oriented as per the manufacturers’ instructions. Wiring of these circulators will depend on the system configuration selected; see Figures 10-5 through 10-9. For further wiring details see Section 12.0.

and may also cause overheating and premature failure which will void the warranty. Failure to follow instructions may result in fire, property damage, serious injury or death.

Table 10-2 VM110 DHW Circulator and Pipe Size Requirements

VM110 that is part of a cascade system, see Figure 13-1.

Failure to ensure the minimum water flow rate through the boiler when the burner is

operating will result in “short-cycling”, reduced performance and operating efficiency,

Page 40

Figure 10-4 VM110 Head Loss Curve (Only Applicable for DHW Demands)

2 4 6 8 10 12

Flow Rate (US gpm)

Head Loss (ft)

Field Wiring │ Vmax I&O Manual

Air Removal – The boiler and system plumbing layout must be configured to promote the removal of air from

the water. Air vents and bleeders must be strategically placed throughout the system to aid in purging the air from the system during commissioning of the boiler. The system must also employ the use of a strategically located air removal device, such as an air-scoop or micro-bubbler, designed to remove the air from the water as it flows through the system.

Follow the installation instructions included with the air removal device when placing it

in the system; air removal devices generally work better when placed higher in the

system. Always locate air removal devices in areas of the system that have a guaranteed

Expansion Tank – The expansion tank must be sized in accordance with the water volume of the system as well

as the firing rate of the appliance. It is important to locate the expansion tank, and make-up water fill, on the inlet side of any circulator in the system, as doing so will guarantee the lowest pressure in the system will be at least equal to the tank and make-up water pressure. See examples in Figures 10-5 through 10-9.

Indirect Fired Water Heater (IWH) – If installing an IWH with a VM110, there are various installation

options to be considered, consult Figures 10-2 and 10-5 through 10-7 for specific examples. The Vmax VM110P (Plus) incorporates an IWH, one cannot be installed external to the unit.

isolation valves, drain and purge valves, etc. It is the responsibility of the installing contractor and system designer to determine which system best meets the need of the installation and to consider all aspects of a proper

system design. Contractor modifications to these instructions may be required, based upon existing piping and system design; consult NTI for required assistance (1-800-688-2575).

positive pressure, e.g., in close proximity to the water fill and expansion tank.

Vmax VM110 & VM110P boilers are equipped with an automatic air vent to aid in

purging of air from the boiler during the initial fill. This air vent is not intended to be the

primary air removal device in the system.

Ensure the expansion tank cannot become isolated from the boiler anytime the system is

operating. The installation of flow checks, motorized valves or other shutoff devices

(other than for the purpose of servicing) are not permitted between the outlet of the boiler

and the expansion tank; see Figures 10-5 through 10-9. Failure to follow these

instructions may result in discharge of the Pressure Relief Valve resulting in property

damage or personal injury.

Figures 10-5 through 10-9 illustrate typical piping systems. These piping schematics do

not illustrate all of the required concepts and components required to have a proper

installation. Concepts not shown include: prevention of thermal-siphoning (heat traps),

Page 41

Figure 10-5 VM110 Plumbing Schematic – Single CH Pump

w/ Indirect Fired Water Heater (Option A)

Figure illustrates the basic

plumbing requirements for a VM110 boiler installation with a single Central Heating circulator, and an Indirect Fired Water Heater installed using Option A. Refer to Figures 10-2(a) and 10-2(c) for boiler fitting identification.

Vmax I&O Manual │Field Wiring

Page 42

Figure 10-6 VM110 Plumbing Schematic – Single CH Pump

w/ Indirect Fired Water Heater (Option B)

Figure illustrates the basic

plumbing requirements for a VM110 boiler installation with a single Central Heating circulator, and an Indirect Fired Water Heater installed using Option B. Refer to Figures 10-2(b) and 10-2(c) for boiler fitting identification.

Field Wiring │ Vmax I&O Manual

Page 43

Figure 10-7 VM110 Plumbing Schematic – Multiple CH Pumps

w/ Indirect Fired Water Heater

Figure illustrates the basic

plumbing requirements for a VM110 boiler installation with multiple Central Heating circulators, and an Indirect Fired Water Heater. Refer to Figures 10-2(b) and 10-2(c) for boiler fitting identification.

Vmax I&O Manual │Field Wiring

Page 44

Figure 10-8 VM110P (Plus) Plumbing Schematic – Single CH Pump

Figure illustrates the basic

plumbing requirements for a VM110P boiler installation with a single Central Heating circulator. Refer to Figures 10-3(a) and 103(b) for boiler fitting identification.

Field Wiring │ Vmax I&O Manual

Page 45

Figure 10-9 VM110P (Plus) Plumbing Schematic – Multiple CH Pumps

Figure illustrates the basic

plumbing requirements for a VM110P boiler installation with multiple Central Heating circulators. Refer to Figures 10-3(a) and 103(b) for boiler fitting identification.

Vmax I&O Manual │Field Wiring

Page 46

Figure 11-1 Near Boiler DHW Piping (VM110P)

DHW Outlet (Hot)

Cold Water Supply

DHW to Fixtures

Tempering Valve

(Check local codes)

Recirculation Optional

(cap if not in use)

Isolation Valve

Drain Valve

DHW Inlet (Cold)

Condensate Drain

(install factory supplied trap)

Field Wiring │ Vmax I&O Manual

11.0 DOMESTIC HOT WATER (DHW) PIPING DHW Description of Operation

The VM110P (Vmax Plus) incorporates a Stainless Steel 16 gallon DHW storage tank with an internal Stainless Steel heat exchanger coil (i.e. an Indirect Fired Hot Water Heater). This allows the Vmax Plus to heat DHW without the need for a separate water heater. A temperature sensor continuously monitors the temperature of the potable water in the tank, thereby ensuring that a constant supply of hot water is available. The tank temperature can be adjusted via Installer Menu setting 2-07 (“DHW Setpoint”). Set “DHW Setpoint” to the desired hot water temperature; to avoid the risk of scalding a Thermostatic Mixing Valve must be installed, see Figure 11-1.

VM110P DHW Plumbing & Set-up

DHW Connections – The VM110P has three potable water connections, Inlet/Drain, Outlet and Recirculation;

see Figure 11-1. If a recirculation line is not being used, be sure to cap the Recirculaiton connection on the bottom of the Vmax Plus.

Throttling Valve – Use one of the isolation valves, installed hot water line, as a throttle valve to regulate the

maximum hot water flow rate. The VM110P has a limited firing rate (110 MBH); therefore excessive flow rates will quickly deplete the hot water stored in the tank – recommend not to exceed 4 GPM.

Drain and Isolation Valves – Install drain and isolation valves on the cold water inlet and hot water outlet lines,

as shown in Figure 11-1, to allow for servicing of the storage tank and other potable water components. It may be necessary to flush or clean the inside of the storage tank.

Page 47

Vmax I&O Manual │Field Wiring

Safe Temperatures for Potable Water Two factors used to determine safe hot water temperatures are Legionella and scalding. Potable water needs to be stored at temperatures hot enough to limit the growth of Legionella, yet be cool enough to prevent scalding. Since both hazards present a potential risk to the user, they must be monitored and controlled. Table 1-4 indicates how water temperature affects Legionella bacteria and contributes to scald injury. Use of a thermostatic mixing valve in the indirect water heater plumbing system can help protect against both of these hazards. By storing potable water at higher temperatures, bacteria growth is controlled, while still providing high temperature water for dishwasher applications and low temperature water for bathing. Before proceeding, read the following carefully and take all necessary precautions to avoid potential illness and/or injury that can result from Legionella or scalding hazards.

Legionella Hazard - This bacteria is naturally occurring in surface water and ponds. It

can also be found in man-made water systems around the world such as water storage tanks, water distribution systems, fountains, hot tubs, humidification systems, refrigeration systems and grocery produce misters. Health authorities agree that Legionella bacteria most often enter the lungs due to aspiration when contaminated water spray is breathed in as opposed to ingesting drinking water contaminated with the bacteria. Typical illnesses attributed to Legionella include flue like symptoms (Pontiac Fever) and a potentially fatal type of pneumonia (Legionnaires’ disease). Failure to follow instructions may result in illness or death.

Contributing Factors to Legionella - Experts acknowledge that Legionella is an identified risk in most water

systems. Although eradicating Legionella is improbable, precautions can be taken to control and monitor conditions that promote bacteria growth. According to the World Health Organization (WHO); American Society of Heating, Refrigeration, and Air-conditioning Engineers (ASHRAE); Canada Safety Council (CSC); and Centers for Disease Control (CDC), contributing factors to the growth of Legionella in potable water systems include:

 Minerals and nutrients present in the source water and systems materials  Stagnation or low flow characteristic of dead ends in distribution piping systems and storage tanks  Scale, corrosion, and bio film  Tepid water in cold water lines  Water storage temperatures optimal for bacteria growth  Chlorine concentration



Scald Hazard - Hotter water increases the risk of scald injury. There is a hot water scald

potential if the storage tank thermostat is set too high. Before changing the temperature setting on the tank thermostat, refer to the thermostat manufacturers recommended settings. Failure to follow these instructions may result in serious injury or death.

A scald injury can occur when hot steam or liquid makes contact with one or more layers

of skin. Scald severity (degree of burn) is directly impacted by exposure time and

temperature. Refer to Table 1-4. The following basic precautions are common sense:

 Young children and elderly adults burn more quickly and should use cooler water.  Never leave a child alone while drawing water in a bathtub.  Test the water temperature before bathing or showering.  Turn cold water on first and then add hot water until the temperature is comfortable.

Thermostatic Mixing Valve - When the system requires water at temperatures higher

than required for other uses, such as high temperature applications typically greater than 46oC (115oF), a means such as a thermostatic mixing valve shall be installed to temper the water for those uses in order to reduce scald hazard potential. Anit-scald devices such as a thermostatic mixing valve allows potable water to be stored at a higher temperature to limit bacteria growth, and allows water at the tap to be delivered at a lower temperature to prevent scalds. Failure to follow these instructions may result in serious injury or death.

Page 48

Water Temperature 1

Legionella Bacteria 1

Water Temperature

2,5

158-176oF

70-80oC

Disinfection range

158oF

70oC

1 second - 2nd or 3rd degree burn

140-149oF

60-65oC

Bacteria die within minutes

140oF

60oC

5 seconds - 2nd or 3rd degree burn

122-131oF

50-55oC

Bacteria die within hours

131oF

55oC

5 seconds - 1st degree burn

68-113oF

20-45oC

Bacteria thrive and multiply

122oF

50oC

1 minute - 1st degree burn

below 68oF

below 20oC

Bacteria is dormant

111oF

44oC

5 hours - 1st degree burn

3,4

Notes:

Published by Chartered Institute of Plumbing and Heating Engineering, Databyte series, "Safe Hot Water Temperatures."

The elderly and small children are susceptible to bad burns at shorter exposure times than listed in this table.

A thermostatic mixing valve should be installed on DHW storage tanks when outlet temperatures exceed 115oF [46oC].

Typical water temperature for bathing or showering range between 98-113oF [37-45oC].

Temperature-Time-Burn Chart published by John Hopkins University, excluding notes.

Field Wiring │ Vmax I&O Manual

Legislation and Guidelines - At the time this document was written, standards and

guidelines regulating the prevention of Legionella in the United States and Canada were mostly voluntary. The American Society of Heating, Refrigerating and Air-Conditioning Engineers, Inc. (ASHRAE) is currently in the process of converting its guideline entitled "Minimizing the Risk of Legionellosis Associated with Building Water Systems" (ASHRAE Guideline 12-2000) into an official standard. Consult with your local authorities as to recommended guidelines for controlling Legionella in potable water systems.

Storing water at temperatures >140°F may not be permitted in some States, so check with

the authorities having jurisdictions. In Canada, recent changes to the National Plumbing Code requires that domestic hot water be stored at or above 61oC (140oF) and then mixed down to safe temperatures at the tank outlet using a “Thermostatic Mixing Valve”; see Figure 11-1.

General Guidelines - In the absence of a National standard or local code, the following are general guidelines

for “good practice” on maintaining, monitoring and operating your potable water system:

 Store domestic hot water at temperatures > 61oC (140oF).  Store and distribute cold water at temperatures below 20oC (68oF).  System supply for uses other than high temperature applications typically greater than 46oC (115oF)

shall be equipped with a thermostatic mixing valve on the hot water outlet to reduce potential scald hazards.

 Clean aerators and nozzles on water fixtures on a regular basis to reduce scale build-up.  Clean storage tanks and remove sediment. Flush storage tanks and piping systems regularly for 10-30

minutes at high water temperatures (depending on guidelines used) to rid the system of sediment and scale that develops, typically in the bottom of storage tanks where water temperature is coolest; and piping runs where water can stagnate.

 Abandoned water lines should be capped off at the distribution main, not at the most convenient place.  Avoid dead-ends in piping system. If unavoidable, provide a drainage port in these areas at the lowest

point to flush out stagnant water regularly.

 Insulate Domestic Hot Water piping and recirculation lines to R-2.6.  Insulate the last 5 ft of the cold water line entering the tank to R-2.6.  Keep pipe runs as short as possible to avoid unnecessary heat loss.  Recommend annual water testing of water in your tank and piping system(s) to monitor water

conditions.

 Keep a maintenance record of when your indirect water heater and storage tank were cleaned, piping

Table 11-1 How Water Temperature relates to Legionella and Scald Hazard

systems flushed and who did the service work.

Page 49

Figure 12-1 Wiring Terminal Access

Field Wiring Terminals

Control Panel Cover

Wire Protection - When passing any

wiring through the cabinet of the boiler, the installer must use wire grommets suitable for securing the wiring and preventing chafing. Failure to follow instructions may result in component failure, serious injury or death.

Vmax I&O Manual │Field Wiring

12.0 FIELD WIRING

All wiring must be in accordance with the Canadian Electrical code, CSA C22.2 and any applicable local codes. Ensure that the wiring complies with this manual. The boiler must be electrically grounded in accordance with the National Electrical Code ANSI/NFPA 70, local codes, and/or the Canadian Electrical Code CSA C22.1.

wiring connections are being made. Failure to follow these instructions may result in component failure, serious injury or death.

Wiring Connections

Electrical rating for the Vmax is 120V / 1 Phase / 60 Hz / 12A. All line voltage wiring connections to the Vmax are made at the junction box on the control panel located at the bottom of the boiler cabinet. The connections are accessed by removing the front door of the boiler, followed by the removal of the control panel cover; see Figure 12-1. Field wiring enters the cabinet through holes located on the bottom (underside) of the boiler cabinet; use suitable strain-relief grommets to protect the wires. Field wiring connections are to be installed in accordance with instructions provided in Figure 12-2 and Table 12-1.

Fuse (120VAC) - The Vmax VM110 & VM110P are equipped with a 3.15 Amp fuse located at “F1” on the

boiler controller at the top left; the fuse protects all 120VAC circuits within the boiler, as well as any circulators connected to it. A spare fuse is located directly below the operating fuse in an open holder; see Figure 18-1.

Avoid Shocks - To Avoid Electrical Shock, turn off electrical power to the boiler prior to

opening any electrical box within the unit. Ensure the power remains off while any

Field Wiring - Wire grommets must be used to secure wiring and prevent chafing when

passing wiring through the cabinet wall. Failure to follow instructions may damage unit.

Power Supply - The Vmax VM110 & VM110P are designed to be powered using a

single phase 120VAC power supply that is fused (or protected via a circuit breaker) to

allow a maximum of 15 Amps. Failure to follow instructions may result in component

failure, serious injury or death.

Page 50

Connection

Location

Description

ARGUS LINK –

Argus Link Communication – used to cascade up to 16 boilers, also for connection to USB interface for PC-connection and BMS Modbus/Expansion Interface Module.

ARGUS LINK +

SENSOR

COMMON

Sensor Common – Common port for field inputs SYSTEM, OUTDOOR and DHW.

SYSTEM

System Temperature Sensor (Optional) – Wire to terminals 3 and 4 of the main boiler in a cascade. Sensor would be installed on the system supply pipe feeding the Central Heating system to allow accurate control of system temperature. Sensor is available from NTI, P/N: 84010.

OUTDOOR

Outdoor Temperature Sensor – A wall mountable OD Sensor is included with

each boiler; connect to terminals 3 and 5. In a cascade, the OD Sensor only needs to be connected to the main boiler. The use of the OD Sensor is required to allow the boiler control to automatically infer the heat load of a central heating system.

DHW

Tank Thermostat / Sensor – Connect the contacts of a DHW Tank Thermostat, or leads of an approved DHW Tank Sensor (NTI P/N: 84632), to terminals 3 and 6. When using a Thermostat, set DHW mode = 2 (menu setting 2-08). When using a Sensor, set DHW mode = 1. A Tank Sensor is factory wired to terminals 3 and 6 on Vmax Plus models (VM110P). See Section 17.0 for more details.

THERMOSTAT

24VAC Room Thermostat Input – Connect central heat demand switch (room thermostats or zone control end switch), or “nighttime setback” / “time of day” switch to terminals 7 and 8. Switch must be an isolated end switch.

EXT. LIM

120VAC Safety Limit Circuit (Factory jumpered) – wire the output contacts of any optional external limit device (i.e. LWCO) in series with terminals 9 and 10. Note: if using an external limit device, the factory jumper must be removed.

DHW PUMP

120VAC output to the DHW circulator; powered during a demand for DHW. Total load of DHW PUMP and BOILER PUMP must not exceed 2.6Amps. Not applicable for VM110P model.

CH PUMP

120VAC output to the Central Heating circulator; powered during a demand for Central Heat. Total load of CH PUMP and BOILER PUMP must not exceed

2.6Amps. Note: the VM110 internal pump is wired to this output.

BOILER PUMP

120VAC output to the main boiler circulator; powered during all demands. Total load of BOILER PUMP and CH PUMP (or DHW PUMP) must not exceed 2.6Amps. Not applicable for VM110P models – internal pump is factory wired to this output.

L2 NEUTRAL

Location for connecting neutral of the power supply and all circulators.

L1 120VAC

Location for connecting line voltage of the power supply. Note; most installation codes require the installation of a service switch to break line voltage to the appliance.

Ground

Green Wire

Location for connecting earth ground and for grounding all circulators.

Field Wiring │ Vmax I&O Manual

Labeling - Label all wires prior to disconnecting them when servicing controls. Wiring

errors can cause improper and dangerous operation. Failure to follow instructions may

result in property damage or personal injury.

Continuity - Before connecting the line voltage wiring, perform a continuity check

between all wires and ground to make sure that there are no electrical leaks that could blow a fuse or damage electrical components. Also check the polarity of the line and neutral wires. Line must measure 120VAC to ground; neutral must measure zero. Failure to follow instructions may damage the unit.

Max Load – The total load rating of circulators powered by outputs BOILER PUMP and

CH PUMP, or BOILER PUMP and DHW PUMP cannot exceed 2.6 Amps.

Page 51

Vmax I&O Manual │Field Wiring

Figure 12-2 Field Wiring

Page 52

Cascade Instructions │ Vmax I&O Manual

13.0 CASCADE INSTRUCTIONS

The Vmax controller has the internal capacity to cascade (lead-lag / stage) up to 16 VM110 boilers, without the use of an external controller. Use the instructions detailed in this section to set-up and install the cascade system.

Vmax Plus (VM110P) – NTI recommends against cascading multiple Vmax Plus boilers

together.

Figure 13-1 VM110 Cascade Plumbing Schematic

Communication Wiring – for each boiler in the cascade, wire in parallel electrical connections Argus Link (-)

and Argus Link (+), terminals 1 and 2 (see Figure 12-2).

Establish Managing Boiler – choose one boiler to be the Managing Boiler, this boiler will receive all control

wiring and will be used for setting control parameters (see steps below). All non-Managing Boilers must have the “S4” switch (located on the top right side of the control) switched OFF. *

*Note: the “S4” switch is factory set to ON. The switch is in the off position when it is closest to the “S4”

marking. The “S4” switch must remain in the ON position on the Managing Boiler.

Plumbing – install the boilers in parallel in a primary/secondary plumbing configuration as illustrated in Figure

13-1.

Page 53

Vmax I&O Manual │Cascade Instructions

System Sensor – install a system sensor (NTI P/N: 84010) on the outlet (supply) pipe feeding the heating system,

see Figure 13-1. ire the system sensor to terminals 3 and 4 of the Managing Boiler (left boiler in illustration).

IMPORTANT: the use of the system sensor is mandatory for proper operation of the boiler cascade system.

Outdoor Sensor – when using an outdoor sensor it must be connected to terminals 3 and 5 of the Managing

boiler (left boiler in illustration); outdoor sensors connected to non-Managing boilers will be ignored.

Boiler Pump – each boiler in the cascade must have its own circulator (see Figure 13-1) which is operated by

each respective boiler, via the BOILER PUMP output (terminal 13). The VM110 internal circulator, which is factory wired to the CH PUMP output, must be rewired to the BOILER PUMP output for the boiler to operate properly as part of a cascade.

CH Pump – the Managing Boiler can control the Central Heating Pump via its CH PUMP output (terminal 12).

IMPORTANT: due to the limited switching capacity of the CH PUMP output, it may be necessary to use an

isolation relay to activate the CH Pump, see Table 12-1.

DHW Pump – the Managing Boiler can control the DHW Pump via its DHW PUMP output (terminal 11).

IMPORTANT: due to the limited switching capacity of the DHW PUMP output, it may be necessary to use

an isolation relay to activate the DHW Pump, see Table 12-1.

Central Heat Demand Switch (Room Thermostat) – connect to terminals 7 and 8 (T, T) of the Managing

Boiler. Switch must be an isolated end switch (dry contact). Central Heat settings are programed from the Managing Boiler only, i.e. Installer menu settings 2-01, 2-02, 2-03, 2-04, 2-05 and 2-06.

Tank Thermostat / Sensor – connect to terminals 3 and 6 of the Managing Boiler. DHW settings are programed

from the Managing Boiler only, i.e. Installer menu settings 2-07, 2-08 and 2-09. Set DHW Mode (Installer menu setting 2-08) according to device used; Thermostat = 2, Sensor = 1.

Boiler Address – assign a unique boiler address for each boiler in the cascade via Installer menu setting 2-20.

Managing boiler must be set = 1; other boilers must be set from 2 to 16.

Rotation Interval – establishes the time, in days, between advancements of the staging sequence of boilers in the

cascade; set via Installer menu setting 2-22 of the Managing Boiler.

Emergency Setpoint – establishes an emergency (back-up) boiler operating setpoint in the event communication

is lost between boilers, or if the system sensor is not connected. Set via Installer menu setting 2-21 of each boiler in the cascade.

Page 54

Figure 14-1 Vmax Connection Diagram

Wiring Schematics │ Vmax I&O Manual

14.0 WIRING SCHEMATICS

Page 55

Figure 14-2 Vmax Ladder-Logic Diagram

Vmax I&O Manual │Wiring Schematics

Page 56

Wiring Schematics │ Vmax I&O Manual

15.0 INSTALLATION CHECKLIST Installation

 1. If operating on Propane Gas, convert boiler using appropriate conversion orifice. See Table 7-1.  2. Locate the boiler in accordance with Section 3.0 of this manual.  3. Install the Vent/Air-inlet piping in accordance with Sections 4.0 and 5.0 of this manual. Ensure all

joints are secured and cemented properly. Both the Vent and Air-inlet pipes must terminate outdoors. Perform the Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0.

 4. Connect the condensate trap and drain in accordance with Section 6.0 of this manual.  5. Connect the gas supply in accordance with Section 7.0 of this manual.  6. Install the plumbing in accordance with this manual. Flush/cleanse the internals of the heating system.

Treat system water with Fernox F1 Protector when needed.

 7. Connect field wiring in accordance with Section 12.0 of this manual.  8. Advise home/building owner of their responsibilities with respect to maintaining the boiler.

The building owner is responsible for keeping the Vent/Air-inlet termination free of snow, ice, or other potential blockages and for scheduling boiler routine maintenance as

described in the next section. Failure to properly maintain the boiler may result in serious injury or death.

Start-up

Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosion, serious injury or death.

 1. Turn gas shut-off valve to the ON position.  2. Turn Power on to the boiler.  3. Set Controller to the desired settings.  4. Turn thermostat up, Ignition will occur.

Operational Checklist

 1. System is free of gas leaks.  2. System is free of water leaks.  3. Water pressure is maintained above 15 PSI.  4. All air is purged from the heating system piping.  5. Ensure proper water flow rate; unit must not kettle, bang, hiss or flash the water to steam.  6. Ensure gas line pressure is in accordance with Section 9.0.  7. System is free of combustion leaks.  8. Unit must operate smoothly.  9. Ensure the flue gas combustion readings are within the tolerances listed in Table 9-1.  10. Each ignition must be smooth.  11. Verify that all condensate lines are clean and drain freely.

Before Leaving

 1. Remove line pressure gauge from gas valve, tighten bleed screw, test screw for leaks. See Section 9.0.  2. Install plug into the flue gas test port and test for leaks, see Section 9.0.  3. Allow the boiler to complete at least one heating cycle, or to operate for at least 15 minutes.  4. Always verify proper operation after servicing.

Instructions to Installing Contractor

 1. Ensure that the customer receives the Warranty Documentation included with the installation manual.  2. Leave the manual with the customer so they know when to call for annual maintenance and inspection.

Allow primers/cements to cure for 8 hours prior to Start-up. If curing time is less than 8 hours, first perform Steps 2 through 6 of Mandatory Pre-commissioning Procedure for

This boiler must have water flowing through it whenever the burner is firing. Failure to comply may damage the unit, void the warranty, and cause serious injury or death.

Allowing the boiler to operate with a dirty combustion chamber will adversely affect its operation and void the warranty. Failure to clean the heat exchanger on a frequency that matches the need of the application may result in fire, property damage, or death.

Page 57

Annual Maintenance and Inspection │ Vmax I&O Manual

16.0 ANNUAL MAINTENANCE AND INSPECTION

This unit must be inspected at the beginning of every heating season by a Qualified Technician.

Annual Inspection Checklist

 1. Lighting is smooth and consistent, and the combustion fan is noise & vibration free.  2. The condensate drain freely flows, and is cleaned of sediment.  3. Relief Valve and air vents are not weeping.  4. Low water cut off is tested (if applicable)  5. Examine all venting for evidence of leaks. Ensure vent screens are cleaned and clear of debris.  6. Check the burner plate for signs of leaking.  7. The combustion chamber must be inspected and if necessary cleaned.  8. Keep boiler area clear/free from combustible materials, gasoline, and other flammable vapors and liquids.  9. Ensure there is nothing obstructing the flow of combustion and ventilation air.  10. Listen for water flow noises indicating a drop in boiler water flow rate.

Important - The hydronic system may need to be flushed to eliminate hard water scale (Use Fernox DS-40 Descaler, NTI PN: 83450).

 11. Verify proper operation after servicing.

Combustion Chamber Cleaning Procedure

NTI recommends having the combustion chamber cleaned after the first year of operation, with subsequent cleanings scheduled based on the condition of the combustion chamber at the time of the first cleaning. Units operating with LP Gas or in an industrial environment may require more frequent cleanings.

chamber. Take all necessary precautions and use recommended personal protective equipment as required.

Cleaning Checklist

 1. Remove the demand for heat, allow the post-purge cycle to finish, turn gas and power supply off.  2. Working inside the cabinet, swing the control panel out of the way, disconnect the cabling to the

combustion blower, gas valve, spark igniter and flame sensor, then remove the air-inlet and gas supply piping.

 3. Once the combustion chamber has cooled, remove the four (4) nuts securing the burner assembly to the

heat exchanger, then remove the assembly (burner door, blower and gas valve) – be careful not to damage the insulation disc located behind the burner door. Replace insulation if it is damaged.

 4. Inspect the condition of the insulation at the back of the chamber; cover it to protect it from becoming wet

during the cleaning process. If the insulation is damaged, remove it and install new insulation once the heat exchanger cleaning is complete.

 5. Use a vacuum with a high efficiency filter to remove any loose debris or dust.  6. Remove the condensate trap from the bottom of the boiler and place a drain under the boiler condensate

drain.

 7. Wet the inside of the combustion chamber with warm water (do not use any chemicals). Use a garden hose

with a trigger nozzle to direct pressurized water between the heat exchanger tubes; the water will exit via the condensate drain on the bottom. Continue process until the gaps between the tubes are clear and the water runs clean. Use dry rags or plastic to protect electrical components from being damaged by dripping or spraying water.

 8. Disassemble the condensate trap and thoroughly clean it; then reassemble and securely connect it to the

boiler condensate drain, see Section 6.0.

 9. Reassemble the boiler in the reverse order of disassembly.  10. Perform the Start-up and Operational Checklist detailed in the previous section.

Wiring Labels - Label all wires prior to disconnection when servicing controls. Wiring

errors can cause improper and dangerous operation.

Cleansers and Potable Water - Boiler system cleansers and corrosion inhibitors must not

be used to flush contaminants from water heaters or potable water systems.

Crystalline Silica - Read carefully the warnings and handling instructions pertaining to

Refractory Ceramic Fibers before commencing any service work in the combustion

Replace any gaskets or insulation discs that show any signs of damage and do not re-use. Failure to follow these instructions may result in fire, property damage or death.

Page 58

Reduce the Risk of Exposure

Precautions and Recommended Personal Protective Equipment

Avoid contact with skin and eyes

 Wear long-sleeved clothing, gloves, and safety goggles or glasses.

Avoid breathing in silica dust

 Wear a respirator with an N95-rated filter efficiency or better. 1  Use water to reduce airborne dust levels when cleaning the combustion chamber.  Do not dry sweep silica dust. Pre-wet or use a vacuum with a high efficiency filter.

Avoid transferring contamination

 When installing or removing RFCs, place the material in a sealable plastic bag.  Remove contaminated clothing after use. Store in sealable container until cleaned.  Wash contaminated clothing separately from other laundry.

First Aid Measures

If irritation persists after implementing first aid measures consult a physician.

 Skin - Wash with soap and water.  Eyes - Do not rub eyes; flush with water immediately.  Inhalation – Breathe in fresh air; drink water, sneeze or cough to clear irritated

passage ways.

Notes:

Respirator recommendations based on CCOHS and OSHA requirements at the time this document was written. Consult

your local regulatory authority regarding current requirements for respirators, personal protective equipment, handling, and disposal of RCFs.

For more information on Refractory Ceramic Fibers, the risks, recommended handling procedures and acceptable disposal practices contact the organization(s) listed below:

Canada (CCOHS): Telephone directory listing under Government Blue Pages Canada—Health and Safety—Canadian Centre for Occupational Health and Safety; or website http://www.ccohs.ca.

United States (OSHA): Telephone directory listing under United States Government—Department of Labor—Occupational Safety and Health Administration; or website http://www.osha.gov.

Vmax I&O Manual Annual Maintenance and Inspection

Refractory Ceramic Fibers (RFC)

chamber. The insulating material on the inside of the burner plate contains Refractory Ceramic Fibers and should not be handled without personal protective equipment.

(cristobalite), a respirable silica dust. Repeated airborne exposure to crystalline silica dust may result in chronic lung infections, acute respiratory illness, or death. Crystalline silica is listed as a (potential) occupational carcinogen by the following regulatory organizations: International Agency for Research on Cancer (IARC), Canadian Centre for Occupational Health and Safety (CCOHS), Occupational Safety and Health Administration (OSHA), and National Institute for Occupational Safety and Health (NIOSH). Failure to comply with handling instructions in Table 16-1 may result in serious injury or death.

maintenance can cause property damage, serious injury (exposure to hazardous materials) or death. Refer to Table 16-1 for handling instruction and recommended personal protective equipment. Installation and service must be performed by a qualified installer, service agency or the gas supplier (who must read and follow the supplied instructions before installing, servicing, or removing this boiler. This boiler contains materials that have been identified as carcinogenic, or possibly carcinogenic, to humans).

Table 16-1 Handling Instructions for Refractory Ceramic Fibers (RCF)

Personal Protective Equipment Recommended - Read the following warnings and

handling instructions carefully before commencing any service work in the combustion

Potential Carcinogen - Use of Refractory Ceramic Fibers in high temperature applications (above 1000oC) can result in the formation of Crystalline Silica

Crystalline Silica - Certain components confined in the combustion chamber may contain this potential carcinogen. Improper installation, adjustment, alteration, service or

Page 59

Figure 17-1 de-Air Sequence

dAir – indicates the

boiler is performing

the de-Air sequence.

Temperature unit

Boiler outlet temperature

Ok button – press and

hold to skip the de-Air

sequence.

Vmax I&O Manual │Display Menu Guide

17.0 DISPLAY MENU GUIDE Initial Power-up

Immediately following power-up of the boiler, the display reads, “conn”, indicating it is connecting to the controller; this is followed by a momentary reading of the display software version, e.g. init d349. After which the controller performs a de-air sequence that is designed to purge air from the boiler water. The de-air sequence cycles the circulators off and on, for a period of 14 minutes, in an attempt to free air pockets that may exists in the heat exchanger and boiler piping.

The de-air sequence is initiated following each power-up of the boiler; if air has already been adequately purged from the system the de-air sequence can be stopped by holding the OK button until “dAir” is no longer displayed on the screen, see Figure 17-1.

The de-air sequence is designed to remove air from the system; failure to adequately remove air from the system can damage the heat exchanger and void the warranty, and may lead to property damage and personal injury.

Main Screen

Following power-up of the boiler (after the de-air sequence), or after 60 seconds of inactivity (no buttons pressed), the boiler defaults to the Main Screen, see Figure 17-2. Under normal operating conditions the Main Screen displays the boiler outlet temperature and water pressure, as well as an indication of the current heat demand (CH or DHW), burner status and outdoor reset function. See Figure 17-2 for more details.

User Menu access – from the Main Screen, access to the User Menu is accomplished simply by pressing the UP

or DOWN button on the console; see User Menu section below for more details.

Installer Menu access – from the Main Screen or User Menu, access to the Installer Menu is accomplished by

pressing and holding the MENU and OK buttons simultaneously; see Installer Menu section below for more details.

Return to Main Screen – from the User Menu, return to the Main Screen by pressing the OK button. From the

Installer Menu, return to the Main Screen by pressing and holding the RESET button.

Page 60

Figure 17-2 Control Console – Main Screen

Figure 17-3 User Menu Navigation

Item ID # - 14

parameters can be

viewed from the User

Menu (1-01 to 1-14),

see Table 17-1 for

description of each

Units (if applicable)

Value of displayed parameter

Down button – press

to scroll down through the menu parameters

Up button – press to scroll up through the menu parameters

Ok button – press to

return to Main Screen

Water pressure

Water pressure units

Radiator – flashes

during CH demands

Faucet – flashes

during DHW demands

Menu button

Reset button – press

and hold to clear

lockouts or exit Installer

Power button

Temperature units

Boiler outlet temperature

OD reset indicator –

illuminates when OD sensor is enabled

Down button

No flame – displayed

during lockout or error

Flame – displayed when flame is on

Wrench – displayed

when installer settings

are accessed

Ok button – select to exit User Menu

Up button

Display Menu Guide │ Vmax I&O Manual

User Menu

The User Menu allows for easy viewing of the current boiler operating conditions, including pump status, sensor inputs, common set points, and boiler target temperature. Access the User Menu from the Main Screen by pressing the UP or DOWN button on the display console. Exit the User Menu by pressing the OK button.

The User Menu only permits the user to view boiler information; editing of settings must be done from the Installer Menu. Access the Installer Menu by pressing and holding the MENU and OK buttons simultaneously; see Installer Menu section for more details.

Page 61

Menu Item

Description

1-01

Current target temperature – displays the current target temperature of the boiler outlet sensor for the active demand (DHW or Central Heating). For central heating with outdoor reset, the calculated central heating target temperature will be displayed. NOTICE: model VM110P models will display “---” during DHW demands.

1-02

CH setpoint (at OD = 0⁰F) – displays the maximum central heat setpoint, set via Installer Menu setting 2-

01. Setting establishes the boiler operating temperature during central heat demands when the outdoor temperature is 0⁰F or less.

1-03

DHW temperature – displays the temperature reading from; (i) Tank Sensor (NTI P/N: 84632) located in an external indirect water heater or (ii) Tank Sensor (NTI P/N: 85139) located inside the VM110P boiler. When no sensor is used, “OPEn” indicates an open circuit, and “CLOS” indicates a closed circuit – i.e. contact closure from an indirect thermostat. See Table 18-1, Thermistor Resistence vs. Temperature.

1-04

DHW setpoint – displays the DHW setpoint, set via Installer Menu setting 2-07.

1-05

DHW flow rate (gpm) – Not Applicable for Vmax boilers

1-06

Fan speed actual (rpm) – displays speed at which the combustion blower is operating.

1-07

Flame signal (µA) – displays the flame strength signal sensed from the ionization electrode, NTI P/N: 84740; minimum signal to sustain normal burner operation is 3µA. Burner operation is completely prohibited when the signal drops below 1.5µA.

1-08

Outdoor sensor temperature – displays reading from outdoor temperature sensor, NTI P/N: 83604. NOTICE: when sensor is open (not connected) display indicates -40⁰F/C or “OPEn”; when sensor is

shorted display indicates 176⁰F/80⁰C or “OPEn”. See Table 18-1, Thermistor Resistence vs. Temperature.

1-09

Return sensor temperature – displays reading from boiler inlet temperature sensor, NTI P/N: 84745.

1-10

Flue sensor temperature – displays reading from boiler flue temperature sensor, NTI P/N: 83608. Burner operation is inhibited when the flue temperature reading is in excess of 225⁰F. NOTICE: an open circuit is displayed as 50⁰F/10⁰C and a blocking error “Err 78” occurs; a short circuit is displayed as 278⁰F/137⁰C and a blocking error “Err 86” occurs. See Table 18-1, Thermistor Resistence vs. Temperature.

1-11

Boiler pump – indicates the status (On/Off) of the Boiler Pump output. Note: the Boiler Pump output is on during all demands.

1-12

Central heat pump – indicates the status (On/Off) of the CH Pump output. Note: the CH Pump output is on during central heat demands; the CH Pump will turn off during priority DHW demands.

1-13

DHW pump – indicates the status (On/Off) of the DHW Pump output. Note: the DHW Pump output is on during priority DHW demands.

1-14

System sensor temperature – for use only in cascade systems, displays reading from a system temperature sensor, NTI P/N: 84010. When used, the system sensor is only wired to the managing boiler, i.e. boiler with S4 switch set to on, and boiler address (Installer Menu setting 2-20) set to 1. NOTICE: an open circuit is displayed as “OPEn”; a short circuit is displayed as “CLOS”. See Table 18-1, Thermistor Resistence vs. Temperature.

Notes:

Enter User Menu by pressing the UP or DOWN button; to scroll through menu options, continue pressing the UP or

DOWN button.

Exit User Menu by pressing the OK button.

User Menu is for viewing only; to adjust settings refer to the Installer Menu.

Vmax I&O Manual │Display Menu Guide

Table 17-1 User Menu

Page 62

Figure 17-4 Installer Menu Navigation

Setting

Description

Factory

Setting

2-01

CH setpoint (at OD = 0⁰F) – establishes the boiler operating temperature during central heat demands when the outdoor temperature is 0⁰F or less. Set to the maximum desired boiler temperature for the application, e.g. 100-120⁰F for infloor; 140-160⁰F for cast-iron; 160-190⁰F for baseboard. Range = 80 to 190⁰F

140⁰F

2-02

CH setpoint differential – establishes how much the boiler outlet temperature must exceed the CH setpoint before the burner is turned off. Also establishes how much the boiler outlet temperature must drop below the CH setpoint before the burner is turned on. Range = 3 to 36⁰F

9⁰F

Item ID # - 35

parameters can be

viewed and/or adjusted

from the Installer Menu

(2-01 to 2-35), see

Table 17-2 for

description of each.

Units (if applicable)

Value of displayed parameter

Down button – press

to scroll down through the menu parameters, or to decrease selected setting.

UP button – press to scroll up through the menu parameters, or to increase selected setting.

Installer Menu

Access – press and

hold MENU and OK

buttons to enter

Installer Menu.

OK button – press to select parameter for adjustment. Press again to save new setting.

Installer Menu Exit –

press and hold the

RESET button to exit

the Installer Menu.

Display Menu Guide │ Vmax I&O Manual

Installer Menu

The Installer Menu allows access to all settings for adjustment, as well as viewing of statistical data for troubleshooting. Access the Installer Menu from any screen by pressing the MENU and OK buttons simultaneously until “2-01” is displayed on the top left of the screen. Exit the Installer Menu by pressing and holding the RESET button.

control settings may negatively affect the operation of the boiler and/or the heating system; resulting in property damage, serious injury or even death.

Adjusting settings – once the Installer Menu is accessed; adjust settings using the following procedure:

1. Use the UP or DOWN button to scroll through the menu until the desired setting number is displayed in the

top-left of the screen (i.e. 2-01).

2. Press the OK button to access the setting; at this time the setting will flash (Note: if the value does not flash

after pressing the OK button, then the parameter is not adjustable – refer to Table 17-2).

3. With the value flashing, use the UP or DOWN button to increase or decrease the setting. Once the desired

value is displayed, press the OK button to enter/save the new value. At this point the value will stop flashing.

4. Repeat for the next setting. Once complete, return to the Main Screen by holding the RESET button.

Installer Menu settings shall only to be adjusted by a qualified installer or service technician that understands the repercussions of incorrect control settings. Improper

Table 17-2 Installer Menu

Page 63

Setting

Description

Factory

Setting

2-03

CH mode – determines the operational mode for central heating:

 0 – no outdoor sensor is needed; central heat demand is generated by a thermostat call to

boiler terminals 7 and 8. Boiler operates to setting 2-01; there is no outdoor reset.

 1 – outdoor sensor is needed; central heat demand is generated by a thermostat call to boiler

terminals 7 and 8. Boiler operates in-between settings 2-01 and 2-05 depending on OD temp.

 2 – outdoor sensor is needed; central heat demand is generated when the OD temp is below

the Warm weather shutdown setting (2-04). Boiler operates in-between settings 2-01 and 205 depending on OD temp. An optional “nighttime setback” or “time of day” switch can be

applied to terminals 7 and 8; contact closure initiates “Night Setback Mode”, where the boiler

target temperature is reduced by the Night Setback Temperature setting (2-33).

 3 – no outdoor sensor is needed; central heat demand is always present, boiler operates to

setting 2-01.

 4 – setpoint from external analog input (0-10VDC); 2 volts for minimum CH setpoint, 10

volts for maximum CH setpoint. Use of an addition interface board through Argus Link is required.

 5 – modulation from external analog input (0-10VDC); 2 volts for minimum modulation, 10

volts for maximum modulation. Use of an addition interface board through Argus Link is required.

2-04

Warm weather shutdown – inhibits central heat operation when the outdoor temperature reading goes above this setting. Range = 35 to 100⁰F

100⁰F

2-05

CH setpoint (at OD = 70⁰F) – establishes the boiler operating temperature during central heat demands when the outdoor temperature is 70⁰F or greater. Set to the minimum desired boiler temperature for the application, e.g. 70-90⁰F for infloor; 100-120⁰F for cast-iron; 110-140⁰F for baseboard. Range = 60 to 140⁰F

95⁰F

2-06

Temperature boost – determines the increase in boiler target temperature for every 15 minutes of continuous central heat demand. Only applicable when an outdoor sensor is used (i.e. CH modes 1 &

2). Target temperature will not exceed CH setpoint setting 2-01. Range = 0 to 36⁰F

0⁰F

2-07

DHW setpoint – establishes: a) tank temperature setting for DHW mode 1 [e.g. 130-140⁰F], when using a tank sensor, or b) boiler outlet setpoint for DHW mode 2 [e.g. 170-190⁰F]. Note: the Vmax Plus (VM110P) must have DHW mode = 1, i.e. Tank sensor. Range = 104-190⁰F

136⁰F

2-08

DHW mode – determines the operational mode for DHW; for VM110 model choose between options 0, 1 and 2; for VM110P model choose between options 0 and 1:

 0 – off; boiler will not attempt to heat DHW in any way.  1 – control anticipates a reading from a Tank Sensor wired to terminals 3 and 6; tank

temperature is controlled by the boiler via setting 2-07 (mandatory for VM110P model).

 2 – control anticipates an open/closed input from a tank thermostat wired to boiler terminals 3

and 6. Setting 2-07 determines boiler outlet temperature during DHW demands. (Default setting for VM110 – not applicable for VM110P models)

 3, 4 & 5 – settings are not applicable for Vmax boilers.

1 or 2

2-09

DHW priority timer – a timer that accumulates during a simultaneous DHW and CH demand. Each

time the timer exceeds the “DHW priority timer” setting, the priority switches from one demand to the

other (i.e. DHW to CH). Note: DHW is assigned priority first. Range = 1-240 minutes

60 min

2-10

Preheat mode – Not Applicable for Vmax boilers

OFF

2-11

Appliance selection (type) – indicates what boiler model the controller is configured to operate with:

 8 = Vmax VM110

 9 = Vmax Plus VM110P

(See Section 17.0 for instruction on changing the appliance selection (type)).

8 or 9

2-12

Minimum firing rate – allows the installer to increase the minimum modulation/firing rate of the boiler; this may be necessary for troubleshooting. Range = 20-44%

20%

2-13

Maximum firing rate CH – allows the installer to decrease the maximum modulation/firing rate of the boiler when operating on a central heat demand; this may be necessary for troubleshooting or derating the boiler for operation with glycol. Range = 60-100%

100%

Vmax I&O Manual │Display Menu Guide

Page 64

Setting

Description

Factory

Setting

2-14

Maximum firing rate DHW – allows the installer to decrease the maximum modulation/firing rate of the boiler when operating on a domestic hot water demand; this may be necessary for troubleshooting or de-rating the boiler for operation with glycol. Range = 60-100%

100%

2-15

Firing rate test – allows the installer to force maximum or minimum modulation rates for the purpose of troubleshooting and burner setup (i.e. combustion analysis):

 0 = Automatic; burner modulation is controlled by the controller.  1 = Minimum; burner operates at the minimum modulation rate.  2 = Ignition; burner operates at the ignition/light-off modulation rate.  3 = Maximum; burner operates at the maximum modulation rate.

Note: control will end test (return setting to 0) if the boiler outlet temperature exceeds 176⁰F. Return setting to 0 when testing is complete.

2-16

Service reminder status – a service reminder, indicated by “Att 7” on the screen, occurs every 365 days. The service reminder is reset by adjusting 2-16 to “OFF”.

OFF

2-17

Boiler pump postpurge – length of time the Boiler Pump output remains powered once all demands end. Range = 10-90seconds

30 sec

2-18

CH pump postpurge – length of time the CH Pump output remains powered at the end of a central heat demand. Range = 0-90seconds

30 sec

2-19

DHW pump postpurge – length of time the DHW Pump output remains powered at the end of a DHW demand. Range = 0-255seconds

10 sec

2-20

Cascade boiler address – assign a unique boiler address for each boiler in a cascade; managing boiler address must be set to 1. Managing boiler must have S4 switch set to ON; all others must be set to OFF. Central heat and DHW demands and setpoints are received and set at the managing boiler only. A boiler that is not part of a cascade must have the boiler address set to 0. Range = 0-16

2-21

Emergency setpoint – used only for a cascade system, assigns a permanent boiler operating temperature that is used if communication between boilers is lost, or if the system temperature sensor becomes disconnected. Must be set on each boiler in the cascade. Range = 104-190⁰F

113⁰F

2-22

Rotation interval – establishes the time between the rotation of start and stop sequences of boilers in a cascade. Range = 0-30days (0=disable)

5 days

2-23

DHW boiler address – Not Applicable for Vmax boilers.

2-24

System pump postpurge – Not Applicable for Vmax boilers.

2-25

Flame failures – accumulation of the number of flame outages that occurred during run.

2-26

Ignition attempts success – accumulation of the number of successful ignitions.

2-27

Ignition attempts failed – accumulation of the number of failed ignition attempts.

2-28

Run time CH – accumulation of the number of hours that the burner has been firing for the purpose of central heating.

2-29

Run time DHW – accumulation of the number of hours that the burner has been firing for the purpose of DHW.

2-30

Post purge time – length of time the combustion blower operates at the end of a burner sequence. Recommend increasing post purge time for installations with long exhaust venting. Range = 5-60seconds

60 sec

2-31

Units selection – allows the installer to select US or metric units. Range = ⁰F or ⁰C

⁰F

2-32

External Ignition – determines the power source for the igniter spark. Parameter must be set to On.

2-33

Night Setback Temperature – applicable only when CH mode is set to 2 (menu setting 2-03), determines the reduction in boiler target temperature during “Night Setback Mode”, i.e. when

terminals 7 and 8 receive a demand (contact closure) from a “nighttime setback” or “time of day”

switch. Range = 0-54⁰F

15⁰F

2-34

Lockout History – displays the last 16 lockouts (Loc) and the time interval between each. The most recent lockout is displayed first; see description below.

2-35

Blocking Error History – displays the last 16 blocking errors (Err) and the time interval between each. The most recent error is displayed first; see description below.

Display Menu Guide │ Vmax I&O Manual

Page 65

Figure 17-5(a) Lockout and Error History Navigation

Figure 17-5(b) Lockout and Error History Navigation (Submenu)

Lockout / Error –

indicates the applicable

error code, e.g. Loc 1.

UP button – press to view the preceding lockout or error.

Time (in min.) since the preceding lockout or error. If followed by “d”, the number is an indication of how many days (e.g. 21 days).

2-34 (Loc History)

2-35 (Err History)

Time (in min.) since the

most recent lockout or error occurred. If

followed by “d”, the

number is an indication of how many days (e.g. 7 days).

OK button – press to view the most recent Lockout or Error.

Vmax I&O Manual │Display Menu Guide

Lockout & Error History

The Vmax controller stores in its memory the 16 most recent Lockouts (Loc) and Blocking Errors (Err); these errors can be accessed from the Installer Menu via settings 2-34 (Lockout History) and 2-35 (Blocking Error History). The History submenus indicate which Lockout or Error occurred, and the time interval between each occurrence. Navigate the Lockout and Error History submenus as follows:

1. Navigate to Installer Menu setting 2-34 (Lockout History) or 2-35 (Blocking Error History). From this

screen the display indicates how long ago the most recent error occurred; see Figure 17-5(a).

2. Press the “OK” button to display the most recent error, and the time between it and the preceding error;

see Figure 17-5(b).

3. Press the UP button to display the next most recent error, and time between it and the preceding error; see

Figure 17-5(b). When you have reached the end of the recorded errors, the display will indicate “End 0.” To exit the History submenu, press the “OK” button; see Figure 17-5(c).

Page 66

Figure 17-5(c) Lockout and Error History Navigation (End)

Figure 17-6 Lockout Navigation

End – indicates that you have reached the end of

the recorded lockout or

error messages.

OK button – press to exit the 2-34 or 2-35 History submenu.

Loc – indicates the

boiler is in lockout.

Lockout code - see Table 17-3 for description

Clear Lockout –

press and hold the

RESET button to clear

the lockout.

Installer Menu –

press and hold MENU

and OK buttons to

view settings.

User Menu – press the UP or Down button to view boiler parameters.

Display Menu Guide │ Vmax I&O Manual

Lockouts

A lockout is indicated when “Loc” is displayed at the top-left of the screen; the specific lockout code/number is displayed in large text to the right, see Figure 17-6. Some lockouts (e.g. Loc 1 and 2) are considered “hard lockouts,” meaning the lockout cannot be cleared by cycling the power supply off and on; the lockout can only be cleared by pressing and holding the RESET button on the display console. While the boiler is in lockout, the User and Installer Menus are still accessible as before, and may be accessed to identify boiler sensor readings and settings.

Blocking Errors

A blocking error is indicated when “Err” is displayed at the top-left of the screen; the specific error code/number is displayed in large text to the right, see Figure 17-7. Blocking errors are only displayed while a problem exists; during which time the burner is not permitted to operate. To clear a blocking error the problem must be corrected, i.e. the blocking error will not be cleared by cycling the power off and on, or by pressing the RESET button. While the blocking error is display, the User and Installer Menus are still accessible as before, and may be accessed to identify boiler sensor readings and settings.

Page 67

Figure 17-7 Blocking Error Navigation

Figure 17-8 Fill – Low Water Pressure

Code

Description

Loc 1

Ignition Error – five unsuccessful ignition attempts in a row; perform the following checks:

1. Check venting for blockages.

2. Check condensate trap from proper draining.

3. Static gas pressure – if insufficient check gas supply-lines and regulator.

4. Gas pressure during ignition – if the static gas pressure is sufficient, check pressure during ignition

sequence, i.e. when gas valve opens.

a. If pressure drops below minimum (4” for NG / 8” for LP), check gas supply-line and regulator. b. If pressure does not move, verify 120VDC at valve during ignition; if no power, check wiring

– replace control; if power is present – replace gas valve.

c. If pressure drops slightly – proceed to next step

5. Unit ignites but immediately goes out – check flame sensor (clean or replace) and flame sensor

cable, clean combustion chamber, replace control. If a combustion analyzer is available, adjust throttle screw out 1 turn – check/adjust combustion once unit is operational.

6. Unit fails to ignite – check spark electrode and cable (replace). Verify the spark electrode is arcing.

WARNING!! – maintain clearance from ignition components while the power is on to avoid risk of severe electrical shock.

7. Unit ignites and runs – check combustion at maximum and minimum modulation rates.

Err – indicates the

boiler has a blocking

error.

Error code - see Table 17-3 for description.

User Menu – press the UP or Down button to view boiler parameters.

Installer Menu – press

and hold MENU and

OK buttons to view

settings.

Water Pressure

FILL – indicates the

water pressure is too low.

Vmax I&O Manual │Display Menu Guide

Fill – Low Water Pressure

The Vmax boiler is equipped with a water pressure sensor located in the return piping inside the boiler cabinet, see Figure 19-1(e), item 24 for sensor location; the reading from the sensor is displayed on the Main Screen, see Figure 17-2. If the control senses a pressure below 7 PSI, burner operation is inhibited and “FILL” is displayed on the screen, see Figure 17-8. As long as the water pressure is above 3 PSI the circulators will be permitted to operate; otherwise they are only operated 5 seconds every minute.

Table 17-3 Lockout and Error Code Descriptions

Page 68

Code

Description

Loc 2 - 4

Gas Valve Circuit Fault (Safety) – control has sensed a fault in the gas valve electrical circuit, check for a loose connection in the gas valve wiring harness. Also see “Loc 5”.

Loc 5

Limit Circuit Open (Safety) – control has sensed a fault in the safety limit circuit; check the following:

1. External Limit (Purple wire) – if an external limit device (i.e. LWCO) is connected to the purple

wire at the field wiring terminal, check to ensure it has not tripped, and that it is wired correctly.

2. Internal Limit (Heat Exchanger Thermal Fuse) – the heat exchanger is equipped with a normally

closed thermal fuse; the fuse opens when the heat exchanger gets too hot. If the fuse is open, contact NTI [see Figure 19-1(a), item 48].

Loc 6 & 7

Power Supply Electrical Interference – check for poor line, neutral and ground connections in the wiring leading to the boiler. Check the internal ground connections within the boiler. Eliminate sources of electrical noise, i.e. welders, large pump inverters, etc. If power is being supplied by a generator, install an appropriately sized UPS (Uninterruptible Power Supply).

Loc 8-9

Controller Malfunction – contact NTI, check field wiring, replace controller.

Loc 10

Supply Sensor Fault – controller has sensed an invalid reading at the Supply/Outlet sensor; check cable, then replace sensor [see Figure 19-1(a), item 15].

Loc 11

Uncorrected Blocking Error – a blocking error (Err) has lasted for 20 consecutive hours.

Loc 12

Incorrect Fan Speed – measured fan speed is not reaching target fan speed within 60 seconds. Check wiring to fan, replace fan.

Loc 13-24

Controller Malfunction – contact NTI, check field wiring, replace controller.

Loc 25

Excessive Supply Temperature Reading – controller has sensed an excessive temperature reading at the Supply/Outlet sensor; verify proper water circulation, check supply sensor cable, then replace sensor [see Figure 19-1(a), item 15].

Loc 26

Flue Sensor Fault – controller has sensed an invalid reading at the Flue sensor; check cable, then replace sensor [see Figure 19-1(a), item 20].

Loc 27

Flame present 10 seconds after closing gas valve – verify flame is going out immediately following the end of a burner demand; check flame sensor (replace); check condensate drain for blockages; increase post purge setting (Installer Menu setting 2-30).

Loc 28

Flame present before ignition – check flame sensor (replace); check condensate drain for blockages; increase post purge setting (Installer Menu setting 2-30).

Loc 29-30

Controller Malfunction – contact NTI, check field wiring, replace controller.

Loc 31

Flame lost three times during one demand – see Loc 1.

Loc 32 up

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 45-51

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 52

Incorrect Field Wiring – check electrical connections to field terminal strip; ensure the Thermostat is connected to terminals 7 and 8.

Err 53

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 54

Flame detected out of sequence – check/replace flame sensor; check flame sensor wiring; check condensate drain for blockages; replace controller.

Err 55-57

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 58-59

Water Pressure Error – increase system water pressure to a minimum of 12 PSI. If water pressure reading at the external pressure gauge exceeds 15 PSI, inspect water pressure sensor and cable; if water pressure sensor is dirty, gently clean with a calcium/rust remover. If necessary, replace water pressure sensor [see Figure 19-1(a), item 24].

Err 60

Flue Sensor Error – flue temperature reading exceeds 220⁰F or the sensor is shorted, check flue sensor connection and wiring. Temporarily disconnect the electrical connector from the flue sensor, if problem goes away, replace flue sensor [see Figure 19-1(a), item 20]; if problem persists, replace the controller [see Figure 19-1(d), item 61].

Err 61

Return Sensor Error – inlet temperature exceeded 203⁰F; error clears when inlet temperature drops below 190⁰F: (1) ensure there is water flow through the boiler, (2) check for correct return sensor reading (menu reading 1-09), (3) check wiring to return sensor; replace sensor [see Figure 19-1(a), item 24].

Err 62-63

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 64

Faulty Grounding – check appliance grounding to breaker panel, check internal ground connections.

Display Menu Guide │ Vmax I&O Manual

Page 69

Code

Description

Err 65

Incorrect Polarity – controller has sensed reversed polarity of the 120VAC power supply; check field wiring to L2 NEUTRAL (terminals 14 &15) and L1 120VAC (terminal 16). There should be 120VAC potential between L1 120VAC and ground, and 0VAC potential between L2 NEUTRAL and ground.

Err 66

Incorrect Frequency – the controller accepts a line voltage frequency of 60Hz ± 2%; if outside this range the controller may be damaged or function incorrectly. If using a generator as a power source, install a UPS (uninterruptible power supply) between the generator and boiler.

Err 67

Faulty Earth Ground – check grounding of boiler and power supply; replace controller.

Err 68-71

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 72

Supply Sensor Open – check wiring to supply sensor; replace sensor [see Figure 19-1(a), item 15].

Err 73

Supply Sensor Fault – check wiring to supply sensor; replace sensor [see Figure 19-1(a), item 15].

Err 74-77

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 78

Flue Sensor Open – check wiring to flue sensor; replace sensor [see Figure 19-1(a), item 20].

Err 79

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 80

Supply Sensor Shorted – check wiring to supply sensor; replace sensor [see Figure 19-1(a), item 15].

Err 81

Supply Sensor Shorted – check wiring to supply sensor; replace sensor [see Figure 19-1(a), item 15].

Err 82-85

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 86

Flue Sensor Shorted – see Err 60.

Err 87

Reset Button Error – controller has sensed that the “Reset” button (see Figure 17.2) is stuck, inspect

button, try pressing and releasing it to “unstick” it, if necessary remove plastic overlay from display. Turn

power off and on, if problem persists, replace display.

Err 88-92

Controller Malfunction – contact NTI, check field wiring, replace controller.

Err 93

Appliance Type – the appliance type stored in the display does not match the appliance type stored in the

controller. Set the appropriate appliance type using the procedure described under “Controller Replacement

Instructions”; see page 73.

Err 94 & up

Controller Malfunction – contact NTI, check field wiring, replace controller.

Att 2

Outdoor Sensor Shorted – controller has sensed a short circuit at the Outdoor sensor; check wiring to terminals 3 and 5 and outdoor sensor.

Att 3

DHW Sensor Open – controller has sensed an open circuit at the DHW tank sensor; check wiring to terminals 3 and 6 and tank sensor. If no tank sensor is being used, set DHW Mode (setting 2-08) to the appropriate setting; see Table 17-2.

Att 4

DHW Sensor Shorted – controller has sensed a short circuit at the DHW tank sensor; check wiring to terminals 3 and 6 and tank sensor. If no tank sensor is being used, set DHW Mode (setting 2-08) to the appropriate setting; see Table 17-2.

Att 6

Warm Weather Shutdown (WWSD) Active – when the outdoor temperature (menu reading 1-08) exceeds the WWSD setting (menu setting 2-04), “Att 6” is displayed during central heat demands, and the boiler only responds to DHW demands. To avoid this error, increase menu setting 2-04. If the indicated temperature reading does not match the actual outdoor temperature, inspect the outdoor sensor wiring. If wiring is fine, disconnect the outdoor sensor, menu reading 1-08 should indicate “OPEn,” if not, replace the controller, if “OPEn” is indicated replace the outdoor sensor.

Att 7

Service Reminder – occurs every 365 days; service the boiler and clear the warning by adjusting menu setting 2-16 to “OFF”.

FILL

Low Water Pressure – increase system water pressure to a minimum of 12 PSI. If water pressure reading at the external pressure gauge exceeds 15 PSI, inspect water pressure sensor and cable; if water pressure sensor is dirty, gently clean with a calcium/rust remover. If necessary, replace water pressure sensor [see Figure 19-1(a), item 24].

Notes:

While displaying a lockout or blocking error, the User and Installer Menus can be accessed to view the status of boiler

sensors and settings.

Blocking errors (Err) and some lockouts (Loc) will not clear until the fault is correct.

Some lockouts (Loc) can only be cleared by holding the RESET button on the display console.

Vmax I&O Manual │Display Menu Guide

Page 70

Model

Appliance Number

VM110

VM110P

Figure 17-9 Appliance Selection

Step 1a – turn power off

Step 2a – set

Appliance Type per Table 17-4.

tYPE – indicates that the

Appliance Type setting is

ready to be adjusted.

Step 1b – while holding the UP and DOWN buttons, turn the power on; continue to hold until tYPE is displayed.

Step 2b – once correct

Appliance Type setting is

displayed, press OK to

enter the value.

Display Menu Guide │ Vmax I&O Manual

Controller Replacement Instructions

This section provides important information necessary to successfully replace the boiler controller, NTI P/N 84712, in the event the original controller fails. The replacement controller must be field configured to operate on the Vmax boiler model it is being installed on. This is achieved by adjusting the controller’s Appliance Type setting.

Appliance Type – the Appliance Type setting is retained in the boiler controller; the setting determines certain

operating characteristics specific to a particular boiler model, such as combustion blower RPM (i.e. firing rate); see Table 17-4 for a list of Appliance Types and corresponding boiler models.

Table 17-4 Appliance Type Setting by Boiler Model

Replacement Procedure – the replacement controller is factory set with an Appliance Type setting of zero (0);

upon replacement of the control the display will prompt you to set the appliance type, i.e. “tYPE 0” will

automatically be displayed on the screen (see Notice below). Adjust to the applicable Appliance Type setting (see Table 17-4) using the UP & DOWN buttons; press the OK button to enter the value. Check the appliance setting via Installer Menu setting 2-11; make sure it matches the correct boiler model as per Table 17-4. Set the remainder of the control settings as desired. Verify proper boiler operation for DHW and Central Heat demands.

Appliance Selection Method – to change the Appliance Type setting, perform the following steps:

1. Turn the power off; while holding the UP and DOWN buttons, turn the power on using power switch on

the display console; see Figure 17-9. Continue holding the UP and DOWN buttons until “tYPE 0” is displayed on the screen, then release the UP and DOWN buttons.

2. Increase the setting by press the UP button. When the correct setting is displayed, see Table 17-4; press the

OK button to enter the value.

3. Wait for a minimum of 1 minute, then cycle the power off and on.

4. Check the appliance setting via Installer Menu setting 2-11; make sure it matches the correct boiler model

as per Table 17-4. Set the remainder of the control settings as desired. Verify proper boiler operation on Domestic Hot Water and Central Heat demands.

If “tYPE 0” does not automatically display upon replacing the controller, the Appliance Type setting must be adjusted using the “Appliance Selection Method” detailed below.

Page 71

Vmax I&O Manual │Troubleshooting

18.0 TROUBLESHOOTING

Servicing the Boiler

 Disconnect or shutoff all energy sources to the boiler: 120VAC power, water and gas.  Identify and mark wires before disconnecting or removing them.  Never bypass electrical fuses or limit devices except temporarily for testing.  Use proper personal protective equipment (PPE) i.e. eye protection, safety footwear.

These procedures should only be performed by qualified service personnel, when abnormal operation of the boiler is suspected. The boiler incorporates a sophisticated microprocessor based control which normally responds appropriately to varying conditions. If the boiler operation appears to be incorrect, or it is not responding at all to a demand for heat, the following is suggested to determine and correct the problem.

Diagnosing an Inoperative Boiler

1) Blank Display – perform the following steps:

 Ensure the boiler service switch located on the front of the boiler is in the ON (1) position.  Ensure the main service switch (if applicable) is in the ON position.  Ensure the circuit breaker in the electrical panel supplying power to the boiler in on.  Measure across boiler terminals 16 and 15 (L1 120VAC and L2 NEUTRAL) for 120VAC, see Figure 12-2.

If 120VAC is present, check fuse located on the boiler controller, see Figure 18-1. If 120VAC is not present, check wiring between the boiler and electrical panel for poor connections.

 Check the electrical connection to the display – connector is located behind display.

2) Display Normal but no heat to radiators – perform the following steps:

 Ensure there is a heat call from the thermostat (radiator symbol on the display will flash during a thermostat

demand). If uncertain about thermostat operation, place a jumper between the boiler’s Thermostat terminals. If the radiator symbol does not display, check outdoor sensor reading (User Menu reading 1-08), and compare to the warm weather shutdown setting (Installer Menu setting 2-04); central heat call will not activate if the outdoor temperature is above the warm weather shutdown setting.

 If the radiator symbol is flashing, but the boiler is not firing, compare the boiler outlet temperature

(temperature displayed on the main screen) with the Current target temp (User Menu reading 1-01). Boiler will not fire until the outlet temperature drops below the Current target temp by the CH setpoint differential (Installer Menu setting 2-02 – default setting = 9ºF).

o Ensure the central heating pump(s) is running – if not ensure it is wired to pump output CH PUMP or

BOILER PUMP.

o If Current target temp is insufficient, increase CH setpoints (Installer Menu settings 2-01 and 2-05).

 If the radiator symbol is on but not flashing, and the faucet symbol is flashing, then the boiler is actively

servicing a DHW demand; at which time no hot water will go to the radiators. If condition continues, consider increasing the DHW setpoint (Installer Menu setting 2-07), or decreasing the DHW priority time (Installer Menu setting 2-09).

3) Display Normal but no DHW – perform the following steps:

 VM110 and Indirect Tank with Tank Sensor, or VM110P:

o Verify DHW Mode is set to 1 (Installer Menu setting 2-08). o Verify there is a Tank sensor wired to COMMON and DHW (boiler terminals 3 and 6), see Figure 12-2.

Tank sensor temperature, DHW temp, is viewed from User Menu reading 1-03.

o Compare DHW setpoint (User Menu reading 1-04) with the DHW temp (User Menu reading 1-03).

DHW Tank demand is generated when the DHW temp drops 4ºF below the DHW setpoint; after which burner demand starts when the boiler outlet temperature (displayed on Main Screen) drops below the

Observe the following precautions when servicing the boiler. Failure to comply with these may result in fire, property damage, serious injury or death.

Before undertaking any troubleshooting procedures it is highly recommended to have available a digital multimeter (s) capable of measuring AC and DC volts, Amperes, Resistance (Ohms) and Continuity.

Page 72

Troubleshooting │ Vmax I&O Manual

Current target temp (User Menu reading 1-01) by 10ºF. Current target temp for a DHW Tank demand is equal to DHW setpoint + 50ºF; if necessary increase DHW setpoint (Installer Menu setting 2-07) – 130 to 140ºF recommended.

o If the radiator symbol is flashing on the display, the DHW priority time may have expired. Cycle power

and consider increasing the DHW priority time (Installer Menu setting 2-09) and/or DHW setpoint (Installer Menu setting 2-07).

o If the faucet symbol is flashing on the display, verify the DHW circulator is operating – DHW circulator

should be wired to DHW PUMP and L2 NEUTRAL (boiler terminals 11 and 14/15); see Figure 12-2.

o Verify plumbing is in accordance with instructions in Section 10.0.

 Indirect Tank with Tank Thermostat (Not Applicable for VM110P):

o Verify DHW Mode is set to 2 (Installer Menu setting 2-08). o Verify there is a Tank thermostat wired to COMMON and DHW (boiler terminals 3 and 6), see Figure

12-2.

o Verify there is a demand from the thermostat; when the demand is on, DHW temp (User Menu reading

1-03) will indicate “CLOS”; when demand is off, DHW temp will indicate “OPEn”. If uncertain about thermostat operation, place a jumper between terminals 3 and 6; the faucet symbol will flash on display when there is a DHW demand.

o Compare DHW setpoint (User Menu reading 1-04) with the boiler outlet temperature (displayed on

Main Screen); burner demand starts with the boiler outlet temperature drops below the DHW setpoint by 10ºF. If necessary increase DHW setpoint (Installer Menu setting 2-07) – 160 to 190ºF recommended.

o If the radiator symbol is flashing on the display, the DHW priority time may have expired. Cycle power

and consider increasing the DHW priority time (Installer Menu setting 2-09) and/or DHW setpoint (Installer Menu setting 2-07).

o If the faucet symbol is flashing on the display, verify the DHW circulator is operating – DHW circulator

should be wired to DHW PUMP and L2 NEUTRAL (boiler terminals 11 and 14/15); see Figure 12-2.

4) Display Normal but DHW is not hot enough – perform the following steps:

o Verify plumbing is in accordance with Section 10.0.

 Increase DHW setpoint (Installer menu setting 2-07):

o Indirect Tank with Tank Sensor (DHW Mode = 1) – recommended setting = 130 to 140ºF. o Indirect Tank with Tank Thermostat (DHW Mode = 2) – recommended setting = 160 to190ºF.

 Vmax VM110P – DHW flow rate is too great; NTI does not recommend exceeding 4 GPM. If necessary,

restrict overall DHW flow rate.

 Indirect Tank – verify plumbing is in accordance with Section 10.0.

5) Display indicates an error (Err), lockout (Loc) or warning (Att); reference Table 17-3 in Section 17.0.

Page 73

Figure 18-1 Vmax Fuse Location (Display Assembly Removed for Illustration Purposes)

Table 18-1 Thermistor Resistance vs. Temperature

Temp °F (°C)

Resistance Ohms (Ω)

Temp °F (°C)

Resistance Ohms (Ω)

-22 (-30)

176,133

122 (50)

3,603

-4 (-20)

96,761

131 (55)

2,986

14 (-10)

55,218

140 (60)

2,488

32 (0)

32,650

149 (65)

2,083

41 (5)

25,390

158 (70)

1,752

50 (10)

19,900

167 (75)

1,481

59 (15)

15,710

176 (80)

1,258

68 (20)

12,490

185 (85)

1,072

77 (25)

10,000

194 (90)

918

86 (30)

8,057

203 (95)

789

95 (35)

6,531

212 (100)

680

104 (40)

5,327

230 (110)

506

113 (45)

4,369 - -

* Not applicable for Return Sensor, P/N 84745

Operating Fuse, LFT

3.15A – “Slow-blow”

Spare Fuse

Boiler Controller

Vmax I&O Manual │Troubleshooting

Only replace Vmax VM110 & VM110P controller fuse with identical part (LFT 3.15A, 250V “slow-blow”). Failure to follow this warning may result in component failure or property damage.

Page 74

Figure 19-1(a) VM110P Heat Exchanger, Water Piping & Sensors

118

115

Parts List │ Vmax I&O Manual

19.0 PARTS LIST

For a list of parts that corresponds to the item numbers in the callouts, refer to Table 19-1. Note that some item numbers may appear more than once in the parts list depending on which model number is being referenced.

Building Owners - Replacement parts are available from your stocking wholesaler. Contact your local Installer

or Wholesaler for assistance with parts.

Wholesalers - Contact NY Thermal Inc. directly when ordering replacement parts, 1-506-657-6000. Installers - Contact NY Thermal Inc. directly if technical assistance required, 1-800-688-2575.

Page 75

Figure 19-1(b) VM110 Heat Exchanger, Water Piping & Sensors

Figure 19-1(c) Vmax Gas Train

79 9 14

Vmax I&O Manual │ Parts List

Page 76

Figure 19-1(d) Vmax Cabinet & Controls (VM110P illustrated)

107

Parts List │ Vmax I&O Manual

Page 77

Figure 19-1(e) Vmax Installation Kit Box

Item

Part #

Model

Description

84541

VM110, VM110P

Premix Burner

84542

VM110, VM110P

Premix Burner Gasket

84441

VM110, VM110P

Blower Gasket

85206

VM110, VM110P

Blower/Venturi Assembly

84795

VM110, VM110P

LP Orifice, 5.05

84713

VM110, VM110P

Gas Valve

83870

VM110, VM110P

Ignition Electrode, Dual (c/w gasket)

85108

VM110, VM110P

Gas Valve Adapter ½” NPT (c/w screws & O-ring)

84419

VM110, VM110P

Outlet Sensor (Dual)

84733

VM110P

O-ring, 2.76 x 17.72mm

84463

VM110, VM110P

Pipe Coupling, groove joint, 1”

85096

VM110P

Supply Pipe, VM110P

85118

VM110

Supply Pipe, VM110

84474

VM110, VM110P

Auto Air Vent, ½” NPT

83608

VM110, VM110P

Flue Sensor, Dual

85095

VM110P

Return Pipe, VM110P

85117

VM110

Return Pipe, VM110

85122

VM110P

Indirect Fired Water Heater (60L)

84423

VM110, VM110P

Receptacle, 120VAC

84745

VM110, VM110P

Inlet/Pressure Sensor

84546

VM110, VM110P

Sight Glass Assembly

84453

VM110, VM110P

Heat Exchanger ASME

85208

VM110, VM110P

Flue Sensor Grommet

84915

VM110P

Diverter Valve Stepper Motor

Each Vmax comes with an LP (Propane) Conversion Kit, containing the required LP orifice, decal and converions instructions.

113

112

Natural Gas to LP Conversion Kit

119

109

111

Common

(VM110 & VM110P)

VM110

VM110P

115

114

116

110

108

Vmax I&O Manual │ Parts List

Table 19-1 Parts List: Vmax Series

Page 78

Item

Part #

Model

Description

85119

VM110, VM110P

Condensate Trap

84479

VM110, VM110P

Elbow, Brass, Street 90, ¾”

84545

VM110, VM110P

Burner Plate Gasket

84544

VM110, VM110P

Burner Plate Ceramic Disc

84543

VM110, VM110P

Burner Plate

84214

VM110, VM110P

Grommet, Diapharam, ½”

82762

VM110, VM110P

Flame Sensor

84755

VM110, VM110P

MJ Coupling, 1-1/2” x 1-1/4”

82615

VM110, VM110P

Round Mesh Vent Screen, 2”

85152

VM110, VM110P

Air Inlet Assembly Vmax

85132

VM110, VM110P

Flue Outlet Adapter PP 3”

85133

VM110, VM110P

Air Inlet Adapter PP 3”

TBD

VM110P

Wall Mounting Bracket Top, VM110P

TBD

VM110

Wall Mounting Bracket Top, VM110

84917

VM110P

Circulator Cartridge, VM110P, UPS15-78

85114

VM110

Circulator, VM110, UPS15-58RU

85163

VM110, VM110P

Blocked Condensate Drain / Blocked Vent Switch

TBD

VM110, VM110P

Bottom Wall Mounting Bracket Set

84732

VM110P

Retaining Clip, 18mm, VM110P

84764-1

VM110, VM110P

Display Assembly, 210LB

85100

VM110P

Heat Exchanger Inlet Connector, VM110P

84476

VM110, VM110P

Terminal, Barrier Double Row, 8 Position

TBD

VM110P

Control Panel Support, VM110P

TBD

VM110

Control Panel Support, VM110

83707

VM110, VM110P

Ignition Coil 4180002F

83724

VM110, VM110P

Spark Igniter Cable 12”

84803

VM110, VM110P

Pressure Sensor Retaining Clip

85097

VM110P

Outlet Pipe, VM110P, 25mm

85120

VM110, VM110P

Plug, 1/8” BSP

84712

VM110, VM110P

Controller, 210MN

TBD

VM110, VM110P

Control Panel Cover

TBD

VM110, VM110P

Control Panel

85167

VM110

Circulator Inlet/Outlet Gasket, VM110

85113

VM110

Circulator Check Valve, VM110

84918

VM110, VM110P

Fuse, LFT 3.15, 250V

82869

VM110

Bushing, Brass, 1 x ¾” NPT, VM110

TBD

VM110, VM110P

Control Panel Sheet Metal

81027-1

VM110, VM110P

Outdoor Sensor

TBD

VM110P

Front Cover, VM110P

TBD

VM110

Front Cover, VM110

TBD

VM110P

Right Side, VM110P

TBD

VM110

Right Side, VM110

TBD

VM110P

Left Side, VM110P

TBD

VM110

Left Side, VM110

TBD

VM110P

Top Panel Access Cover, VM110P

TBD

VM110P

Top, VM110P

TBD

VM110

Top, VM110

84569

VM110, VM110P

Bottom Heat Exchanger Support

84568

VM110, VM110P

Top Heat Exchanger Support

84919

VM110, VM110P

Gas Valve to Venturi Gasket

Parts List │ Vmax I&O Manual

Page 79

Item

Part #

Model

Description

TBD

VM110P

Back, VM110P

TBD

VM110

Back / Bottom, VM110

85116

VM110P

Tee, Brass, ¾ x ½ x ¾”, VM110P

84466

VM110

Tee, Brass, 1 x ½ x 1”, VM110

TBD

VM110P

Bottom, VM110P

83135

VM110, VM110P

Hose Clamp, 9/16 to 1-1/16”

85131

VM110, VM110P

Flue Outlet Pipe, 80mm PP

TBD

VM110, VM110P

Spark Generator Support Bracket

TBD

VM110P

Tank Hold-out Bracket, VM110P

85139

VM110P

Tank Sensor, VM110P

84749

VM110P

O-Ring, Inlet/Outlet, 4 x 17 mm, VM110P

84921

VM110P

Retaining Clips, Inlet/Outlet, VM110P

84095

VM110, VM110P

Plug, 7/8” Black Dome

84923

VM110P

CH Fittings, IWC, ¾” NPT, VM110P

107

84422

VM110, VM110P

Rocker Power Switch, On/Off

108

83911

VM110, VM110P

CPVC Pipe 3”, System 636, 5” Long

109

13701

VM110, VM110P

Pressure Relief Valve, ASME, ¾” NPT, 30 PSI (Boiler)

110

84859

VM110, VM110P

Pressure Gauge, Back Mount, 60 PSI

111

82616

VM110, VM110P

Round Mesh Vent Screen, 3”

112

84925

VM110, VM110P

Natural Gas to LP Conversion Instructions

113

84867

VM110, VM110P

LP Conversion Decal

114

84156

VM110P

Temp. & Pressure Relief Valve, 150 PSI, ¾”, 100XL-8, VM110P

115

82368

VM110P

Compression Gasket, Rubber, VM110P

116

85110

VM110P

Low Loss Header Pipe, VM110P

118

85111

VM110P

IWC – Integrated Water Control, Vmax Plus, VM110P

119

84867-4

VM110, VM110P

NG to LP Conversion Kit

Vmax I&O Manual │ Parts List

Page 80

NY Thermal Inc. 30 Stonegate Drive, Saint John, NB E2H 0A4 Canada

Technical Assistance: 1-800-688-2575

Website: www.nythermal.com

Fax: 1-506-432-1135

NTI VM110, VM110P Installation And Operation Instructions Manual

Specifications and Main Features

Frequently Asked Questions

User Manual