PB Heat Peerless Combi 160 User Manual

Download

Page 1

Boiler

Peerless

Gas

Installation, Operation & Maintenance Manual

Combi 160

™

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

WARNING!!!

This manual must be used by a qualified heating installer/service technician. Read all instructions, including this manual, before installing. Perform steps in the order given. Failure to comply could result in severe personal injury, death, or substantial property damage.

Save this manual for future reference.

As an ENERGY STAR®Partner, PB Heat, LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency.

Page 2

SAFETY INSTRUCTIONS

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

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

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier from

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

• If you cannot reach your gas supplier,

call the ﬁ re department.

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

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

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

- QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:

• Ne pas tenter d’allumer l’appareil.

• Ne touchez à aucun interrupteur, ne

pas vous servir des téléphones se trouvant dans le bâtiment

• Appelez immédiatement votre

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

• Si vous ne pouvez rejoindre le

fournisseur, appelez le service des incendies

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

Page 3

SAFETY INSTRUCTIONS

Page 4

SAFETY INSTRUCTIONS

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

 Liability

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

 Hazards and Your Safety - Hot Water Can Scald!

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

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

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

 Qualiﬁ ed Technicians:

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

 Installation and Alterations:

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

 For safety and environmental reasons, the packing

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

 In the event of a breakdown and/or malfunction

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

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

 Use the service switch to disconnect the boiler

from the electrical circuit before carrying out any

service or maintenance operations.

 Electrical

CAUTION: Label all wires prior to disconnection when

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

 ATTENTION: Au moment de l’entretien des

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

 Correct Use:

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

 Should overheating occur or the gas supply fail

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

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

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

ne peut être coupée, ne pas couper ni débranch

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

 Do not use this appliance if any part has been

under water. Immediately call a qualiﬁ ed service

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

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

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

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

 Do not obstruct the air intake or vent pipe

terminals. Failure to take proper precautions can

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

 Maintenance:

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

 Any optional extras or kit ﬁ tted subsequently

must be original Cosmogas parts.

Page 5

SAFETY INSTRUCTIONS

 Local approval: of the ﬂ ue system and the

condensate connection to the public sewer system may be required.

 Local approval: The local building regulations

stipulating the installation rules at the time of installation should be followed.

 Defects: If you ﬁ nd any defects you must inform the

owner of the system of the defect and associated hazard in writing.

 When servicing the boiler, to avoid severe burns,

allow the boiler to cool before performing maintenance.

 When calling or writing about the boiler- Please

have the boiler model and serial number from the boiler rating plate.

 Any claims for damage or shortage in shipment

must be ﬁ led immediately against the transportation company by the consignee.

 Factory warranty (shipped with unit) does

not apply to units improperly installed or improperly

operated.

Page 6

TABLE OF CONTENTS

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

TABLE OF CONTENTS ....................................................................................................................................................6

1 - INSTALLATION - CODE REQUIREMENTS .............................................................................................................. 10

1.1 - National installation legislation ...........................................................................................................................10

1.2 - Commonwealth of Massachusetts Installation Requirements ............................................................................10

2 - GENERAL INFORMATION ........................................................................................................................................ 12

2.1 - Key to symbols used ..........................................................................................................................................12

2.2 - Description of the Peerless

3 - MAIN COMPONENTS ............................................................................................................................................... 13

4 - FUNCTION OVERVIEW ............................................................................................................................................ 15

4.1 - Intended use and functions of the boiler ...........................................................................................................16

4.2 - Setting of the boiler ............................................................................................................................................16

4.3 - Efﬁ ciency up to 98% ...........................................................................................................................................17

4.4 - Characteristic curves of heating system’s residual head ...................................................................................18

4.5 - Characteristic curve of the domestic side ..........................................................................................................18

5 - INSTALLATION - Mounting & gas and water connections ................................................................................... 19

5.1 - Clearances for installation and servicing ............................................................................................................19

5.2 - Clearances from combustible material ...............................................................................................................19

5.3 - Choosing the installation location .......................................................................................................................20

5.4 - Mounting the boiler .............................................................................................................................................21

5.5 - Gas and water connections ................................................................................................................................21

5.6 - Condensate disposal ..........................................................................................................................................22

5.7 - Near boiler heating piping components ..............................................................................................................22

5.8 - Relief valve .........................................................................................................................................................23

5.9 - Supply and return piping ....................................................................................................................................23

5.9.1 - Converting a combi boiler into a heating only boiler .............................................................................24

5.10 - Low temperature heating systems ...................................................................................................................24

5.11 - Use of glycol and other chemicals ....................................................................................................................24

5.12 - Domestic hot and cold water ............................................................................................................................24

5.13 - Gas supply piping .............................................................................................................................................24

5.14 - Propane gas .....................................................................................................................................................25

5.15 - Operating at high altitudes ...............................................................................................................................25

5.16 - Convert the boiler from Natural Gas to Propane Gas or vice versa .................................................................26

5.17 - Suggested piping and wiring connections ........................................................................................................28

6 - INSTALLATION - Electrical connections ................................................................................................................29

6.1 - Electrical connections: overview ........................................................................................................................29

6.2 - Connecting the power supply cable ...................................................................................................................30

6.3 - Choosing the room thermostat ...........................................................................................................................30

6.4 - Thermostat wiring ...............................................................................................................................................30

6.5 - Installing the outdoor temperature sensor (optional) ..........................................................................................31

6.6 - Alarm output .......................................................................................................................................................31

7 - INSTALLATION - Indirect storage tank connections .............................................................................................32

7.1 - Connecting the boiler to an indirect storage tank ..............................................................................................32

7.2 - Indirect water heater priority selection ..............................................................................................................33

8 - INSTALLATION - Vent & combustion air ................................................................................................................ 34

8.1 - Removing of a boiler from a common venting system .......................................................................................34

8.2 - Venting systems .................................................................................................................................................35

8.3 - Design of the venting system .............................................................................................................................37

8.4 - Prevent Combustion air contamination ..............................................................................................................37

8.5 - Install Vent and Combustion air piping ...............................................................................................................37

Combi 160™: .........................................................................................................12

Page 7

TABLE OF CONTENTS

8.6 - Air inlet pipe materials ........................................................................................................................................39

8.6.1 - Sealing of Type “B” double-wall or galvanized air inlet pipe material ....................................................39

8.6.2 - Sealing of PVC, CPVC or ABS air inlet pipe .........................................................................................39

8.7 - PVC/CPVC vent piping materials .......................................................................................................................40

8.7.1 - Installing PVC/CPVC vent and air piping ..............................................................................................40

8.7.2 - PVC/CPVC air intake/vent connections ................................................................................................40

8.8 - Flue terminal location in compliance with CAN/CSA B149 ................................................................................42

8.9 - Single pipe vent (not sealed combustion) ..........................................................................................................43

8.9.1 - Combustion Air and Ventilation openings .............................................................................................43

8.9.2 - Determine location ................................................................................................................................44

8.10 - Sidewall termination - Two pipes ......................................................................................................................45

8.10.1 - Vent/air termination .............................................................................................................................45

8.10.2 - Determine location ..............................................................................................................................45

8.10.3 - Prepare wall penetrations ...................................................................................................................47

8.10.4 - Termination and ﬁ ttings .......................................................................................................................47

8.10.5 - Multiple vent/air terminations ..............................................................................................................47

8.11 - Sidewall termination - Concentric vent ............................................................................................................. 48

8.11.1 - Description and usage ........................................................................................................................48

8.11.2 - Sidewall termination installation .......................................................................................................... 48

8.11.3 - Multiventing sidewall terminations .......................................................................................................49

8.12 - Vertical termination - Two pipes ....................................................................................................................... 50

8.12.1 - Determine location ..............................................................................................................................50

8.12.2 - Prepare roof penetrations ...................................................................................................................50

8.12.3 - Termination and ﬁ ttings .......................................................................................................................50

8.12.4 - Multiple vent/air terminations ..............................................................................................................51

8.13 - Vertical termination - Concentric vent ..............................................................................................................52

8.13.1 - Description and usage ........................................................................................................................52

8.13.2 - Determine location ..............................................................................................................................52

8.13.3 - Vertical termination installation ...........................................................................................................52

8.13.4 - Multiventing vertical terminations ........................................................................................................53

8.13.5 - Alternate vertical concentric venting ...................................................................................................54

8.14 - Existing vent as a chase ..................................................................................................................................55

9 - INSTALLATION - Split venting system ...................................................................................................................56

9.1 - Split system (polypropylene) or AL29-4C (UL 1738/UL C 636) system .............................................................56

9.2 - Split system components ...................................................................................................................................58

9.3 - Split system components ...................................................................................................................................59

9.4 - Split system: installation examples ....................................................................................................................60

10 - INSTALLATION - Coaxial venting system ............................................................................................................61

10.1 - Coaxial system .................................................................................................................................................61

10.2 - Coaxial system components ............................................................................................................................62

10.3 - Coaxial system components ............................................................................................................................63

10.4 - Coaxial system: installation examples .............................................................................................................64

11 - OPERATING ............................................................................................................................................................65

11.1 - Operating ..........................................................................................................................................................65

11.1.1 - User instructions .................................................................................................................................65

11.1.2 - Filling the condensate trap .................................................................................................................. 65

11.1.3 - Filling the heating system ....................................................................................................................65

11.1.4 - Filling the domestic hot water heat exchanger ....................................................................................66

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

...................66

Page 8

TABLE OF CONTENTS

11.2 - General warnings concerning gas supply ........................................................................................................66

11.3 - Conﬁ rming the boiler’s gas type .......................................................................................................................66

11.4 - Gas type conversion .........................................................................................................................................66

11.5 - Start-up .............................................................................................................................................................66

11.6 - Ignition control testing ......................................................................................................................................67

11.7 - Gas supply pressure checking and adjustment ................................................................................................67

11.8 - Check the combustion air pressure ..................................................................................................................68

11.9 - Checking and adjusting CO2 levels .................................................................................................................69

11.10 - Adjusting the heating capacity ........................................................................................................................70

11.11 - Domestic hot water ﬂ ow rate adjustment ........................................................................................................70

11.12 - Cold start boiler ..............................................................................................................................................70

12 - USE ..........................................................................................................................................................................71

12.1 - Check heating system pressure .......................................................................................................................71

12.2 - Overview ..........................................................................................................................................................71

12.3 - Displays ............................................................................................................................................................71

12.4 - Start-up procedure ...........................................................................................................................................72

12.5 - Summer mode ..................................................................................................................................................72

12.6 - Winter mode .....................................................................................................................................................72

12.7 - Adjusting the domestic hot water temperature .................................................................................................73

12.8 - Heating system temperature adjustment .........................................................................................................73

12.9 - Heating system type selection .........................................................................................................................73

12.10 - Outdoor reset adjustment ...............................................................................................................................73

12.10.1 - Outdoor reset applications ................................................................................................................73

12.10.2 - Outdoor reset adjustment precautions ..............................................................................................74

12.10.3 - Outdoor reset: setting parameters ....................................................................................................74

12.10.4 - Outdoor reset: zone adjustments ......................................................................................................74

12.10.5 - Outdoor reset activation ....................................................................................................................74

12.10.6 - Outdoor reset with room compensation ............................................................................................74

12.11 - Boiler switch settings ......................................................................................................................................76

12.12 - Delays, alarms and protective actions ...........................................................................................................76

12.13 - Circulator pump and three way valve protection ............................................................................................76

12.14 - Freeze protection ...........................................................................................................................................76

12.15 - Display in energy saving mode .....................................................................................................................76

12.16 - “Users’ menu” .................................................................................................................................................77

12.17 - “Installer’s menu” ............................................................................................................................................78

12.18 - Diagnostics .....................................................................................................................................................80

12.18.1 - Diagnostics: “L” lock-outs ..................................................................................................................81

12.18.2 - Diagnostics: “E” blocking errors ........................................................................................................83

13 - MAINTENANCE .......................................................................................................................................................85

13.1 - General precaution ...........................................................................................................................................85

13.2 - Removing the casing ........................................................................................................................................86

13.3 - Cleaning the burner and primary heat exchanger, ﬂ ue gas side ...................................................................... 87

13.4 - Correct positioning of the ignition and ﬂ ame detection electrodes ..................................................................88

13.5 - Domestic hot water heat exchanger .................................................................................................................88

13.6 - Condensate trap cleaning ................................................................................................................................89

13.7 - Circulator pump motor replacement .................................................................................................................90

13.8 - Expansion tank pressure ..................................................................................................................................90

13.9 - 3-way valve removal ........................................................................................................................................91

13.10 - Draining the heating side of the boiler ............................................................................................................92

13.11 - Draining the domestic hot water side of the boiler .........................................................................................92

Page 9

TABLE OF CONTENTS

13.12 - Overrides ........................................................................................................................................................92

13.12.1 - Auto-purging ......................................................................................................................................92

13.12.2 - Fan ...................................................................................................................................................92

13.12.3 - Minimum and maximum output .........................................................................................................92

13.12.4 - Checking the ﬂ ame current ...............................................................................................................92

13.13 - Water and ﬂ ue temperature sensor ................................................................................................................93

13.14 - Outdoor temperature sensor (optional) ..........................................................................................................93

13.15 - Functional wiring diagram ..............................................................................................................................94

13.16 - Multiwire wiring diagram .................................................................................................................................96

14 - TECHNICAL DATA .................................................................................................................................................. 98

15 - SPARE PARTS ........................................................................................................................................................99

16 - READ OUT FLOW CHART ...................................................................................................................................102

Page 10

1 - INSTALLATION - CODE REQUIREMENTS

1.1 - National installation legislation

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

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

- Where required by the authority having jurisdiction, the installation must conform to the Standard for

Controls and Safety Devices for Automatically Fired Boilers, ANSI/ ASME CSD-1.

NOTICE!

This boiler meets the safety and other performance requirements as speciﬁ ed in ANSI Z21.13 standard

- Per DOE mandate, the operator control incorporates an automatic means (outdoor reset) of adjusting the boiler hot water temperature for hot water heating. The boiler must not operate without the automatic means enabled.

IMPORTANT!

In accordance with Section 325 (f)(3) of the energy policy and conservation Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external 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

multiple boiler system having a total input of 300,000 BTU/hr or greater.

 This boiler is equipped with a

tankless coil.

1.2- Commonwealth of Massachusetts Installation Requirements

In the Commonwealth of Massachusetts, the installation must be performed by a licensed plumber or gas ﬁ tter. WARNING!!!

WARNING!!! Improper

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

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

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasﬁ tter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the ﬂ oor level where the gas equipment is to be installed. In addition, the installing plumber or gasﬁ tter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equip-ment. It shall be the responsibility of the property owner to secure the services of qualiﬁ ed 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 ﬂ oor level.

b. In the event that the

requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty (30) days to comply with the above requirements; provided, however, that during said thirty (30) day period, a battery operated carbon monoxide detector with an alarm shall be installed.

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 certiﬁ ed.

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

BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS”.

4. 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.

Page 11

1 - INSTALLATION - CODE REQUIREMENTS

(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.

When the 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 the 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.

(e) A copy of all installation instructions for all Product Approved side wall horizontally vented gas fueled equipment, all venting instructions, all parts lists for venting instructions, and/ or all venting design instructions shall remain with the appliance or equipment at the completion of the installation.

(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 ﬂ ue gases, but identiﬁ es “special venting systems”, the following requirements shall be satisﬁ ed 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 systems” shall be Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

Page 12

2 - GENERAL INFORMATION

2.1 - Key to symbols used

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

CAUTION!!!

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

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

Operation symbol

Important indication symbol

2.2 - Description of the Peerless®

™

Combi 160

Combi version (space heating and instantaneous D.H.W. production).

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

Page 13

3 - MAIN COMPONENTS

1 - Automatic air vent 2 - Air intake and ﬂ ue gas discharge ﬁ tting (venting system) 3 - U7 ﬂ ue gas temp. sensor and ﬂ ue safety switch 4 - Expansion tank 5 - Inlet air plenum 6 - Air/gas mixer device 7 - U2 d.h.w. temp. sensor 8 - Heating pressure switch (low water cut-off) 9 - Heating supply connection 10 - DHW connection 11 - Gas inlet connection 12 - Cold water connection

Figure 1 - Main components

13 - Heating return connection 14 - Power Control Board 15 - Openterm interface board (optional) 16 - Connection board 17 - Primary heat exchanger 18 - Spark cable 19 - External jacket 20 - Combustion chamber door 21 - Instrument panel door

Page 14

3 - MAIN COMPONENTS

22 - Combustion analysis tap 23 - U1 supply temperature sensor 24 - Burner window 25 - Air/gas manifold 26 - U6 high temperature limit sensor 27 - Flue gas back ﬂ ow preventer 28 - Fan 29 - Gas valve 30 - Heating pressure gauge 31 - Display 32 - Domestic hot water temperature control 33 - Heating temperature control 34 - On/off power switch 35 - Three way valve 36 - U3 domestic cold water temp. sensor 37 - Cable clamp

Figure 1 - Main components

38 - ASME Safety relief valve 39 - U8 return temperature sensor 40 - By-pass pipe 41 - Condensation discharge pipe 42 - Secondary heat exchanger for domestic hot water production (For P/N see Section 15) 43 - Expansion tank connection pipe 44 - Circulator pump screw 45 - Circulator pump 46 - Condensation discharge trap 47 - Flame-proving electrode 48 - Burner 49 - Right ignition electrode 50 - Left ignition electrode 51 - Spark generator 52 - Flue pressure switch

Page 15

4 - FUNCTION OVERVIEW

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

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

Figure 2 - PC160™ Hydronic functional schematic

Page 16

4 - FUNCTION OVERVIEW

4.1 - Intended use and functions of the boiler

This gas-ﬁ red condensing boiler, is designed to be used for central heating and producing domestic hot water. The maximum output heat is always guaranteed for the production of domestic hot water since it is given priority over space heating demands. Follow the speciﬁ c procedure in section 12.7 for the adjustment of the domestic hot water temperature. Using a PC160™ boiler you can create a system for the production of instantaneous domestic hot water and a heating system with heating elements functioning at temperatures ranging between 68°F (20°C) and 189°F (87°C). The boiler can also function directly with a radiant ﬂ oor panel, see section

5.10. When connecting the boiler to the heating system the installer must consider the head loss of the heating system to verify that the boiler pump is adequate. Pump curve is shown in ﬁ gure 4. The same veriﬁ cation must be done for the domestic installation, see ﬁ gure 5.

The PC160 to an indirect storage tank for the production of domestic hot water, section 7.1.

The PC160 to a room thermostat, section 6.3 and

6.4. An outdoor air temperature sensor

can also be connected to the boiler for an outdoor reset supply temperature control for maximum fuel efﬁ ciency and comfort (see section 6.5). In this conﬁ guration the room thermostat will compensate by adjusting the room temperature. The room temperature compensation can be of an ON / OFF type or two-stage. For further information on the outdoor-air reset, refer to section 12.10.

™

can be connected

™

boiler can be connected

 The boiler must be connected to

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

 Before installation, thoroughly

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

 This boiler is designed for indoor

installation.

 Refer to ﬁ gure 6 for minimum

clearance distances for installation and future maintenance.

 Refer to section 5.2 for minimum

clearance distances from combustible material.

4.2 - Setting of the boiler

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

Page 17

4 - FUNCTION OVERVIEW

4.3 - Efﬁ ciency up to 98%

When the outdoor reset is activated (see section 12.10) and an outside sensor is connected, this boiler is designed to always work at the maximum efﬁ ciency. It will automatically change the supply temperature in relation with the outdoor temperature (Outdoor reset). The graph in ﬁ gure 3 shows an example on how it can work. This graph is an example where is represented an installation where the supply and return temperatures are 139°F and 115°F respectively , and the outside temperature is 23°F. The outdoor reset drives the boiler, to progressively reduce the supply temperature and thereby optimize the efﬁ ciency. It changes from 87% when outside is -10°F, to 94.8% when outside is 23°F and up to 98% when the outside temperature rises up to 67°F.

Figure 3 - Outdoor reset control to optimize the efﬁ ciency

Page 18

4 - FUNCTION OVERVIEW

Figure 4 - Available Head for heating circuit

4.4 - Characteristic curves of heating system’s residual head

The PC160™ boiler is ﬁ tted with a Grundfos circulator pump. The head available to supply ﬂ ow through the heating system at the boiler connections is shown in graph form in ﬁ gure 4.

4.5 - Characteristic curve of the

Figure 5 - Domestic Water Coil Head Loss

domestic side

The PC160™ boiler, offers resistance to the passage of domestic water (see graph ﬂ ow/pressure of ﬁ gure 5). The installer or the engineer must take account of this in order to ensure the correct domestic water ﬂ ow to the utilities.

Page 19

5 - INSTALLATION - Mounting & gas and water connections

5.1 - Clearances for installation and servicing

Figure 6 shows the clearances required for installation and servicing.

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

5.2 - Clearances from combustible material

This boiler may be installed directly onto a wall of combustible material with the following clearance: Ceiling: 2 inches (51 mm) Front: 2 inches (51 mm) Rear: 0 inches (0 mm) Sides: 2 inches (51 mm) Floor: 2 inches (51 mm)

Figure 6 - Recommended minimum clearance distances for proper installation and servicing

Concentric vent: 0 inches (0 mm) Split vent (ﬁ rst 12” from the boiler): 1 inch (25 mm) Split vent (after 12” from the boiler): 0 inches (0 mm)

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

Figure 7 - Dimensions for the PC160

™

Page 20

5 - INSTALLATION - Mounting & gas and water connections

5.3 - Choosing the installation location

WARNING!!! Do not store any ﬂ ammable materials or liquids in the immediate vicinity of the boiler. A ﬁ re or explosion can result, causing severe personal injury , death or substantial property damage.

WARNING!!! LIQUEFIED PETROLEUM (L.P.) PROP ANE GAS-FIRED BOILER LOCATION REQUIRES SPECIAL ATTENTION: 1994 UNIFORM MECHANICAL CODE section 304.6: “LGP Appliances. Liqueﬁ ed petroleum gas-burning appliances shall not be installed in a pit, basement or similar location where heavier than air gas might collect. Appliances so fueled shall not be installed in above-grade under-ﬂ oor space or basement unless such location is provided with an approved means for removal of unburned gas.” Failure to comply with this provision could result in severe personal injury or substantial property damage.

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

CAUTION!!! This boiler is not designed for direct outdoor installation. If installed outside of the structure that it supplies hot water too, it must be sheltered so it is protected from rain, wind, sun and frost. NEVER place this boiler in a location that would subject it to temperatures at or near freezing. Failure to properly locate this boiler can result in premature failure voiding the warranty .

When locating the boiler the following factors must be considered:

• the location of vent/air intake terminals;

• connection to the gas supply;

• connection to the water supply;

• connection to the heating system;

• connection to the domestic hot water system;

• connection to the electrical supply;

• disposal of the condensation produced by the boiler;

• connection to the room thermostat;

• piping of the safety relief valve discharge;

• possible connection of the outdoor temperature sensor;

• possible connection of an indirect storage tank, see

section 7.1.

Page 21

5 - INSTALLATION - Mounting & gas and water connections

5.4 - Mounting the boiler

Refer to ﬁ gure 8:

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

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

CAUTION!!! The wall bracket screws

must be screwed into the buildings framing or other material capable of supporting the weight of the boiler or the boiler and building may be damaged.

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

4. remove the cardboard template;

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

6. hang the boiler on the wall bracket, “A”, by hanging connections “B” and “C” on tabs “D”.

Figure 8 - Wall bracket installation

5.5 - Gas and water

connections

The boiler comes with the ﬁ ttings shown in ﬁ gure 9.

A = heating system supply (3/4”) B = domestic hot water supply (3/4”) C = Inlet gas connection (3/4”) D = domestic cold water (3/4”) E = heating system return (3/4”)

Figure 9 - Fittings supplied with the boiler

Page 22

5 - INSTALLATION - Mounting & gas and water connections

5.6 - Condensate disposal

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

This boiler produces water as a byproduct of combustion. The boiler is equipped with a condensate trap, ﬁ gure 1, item 46, for the evacuation of condensate and to prevent the leakage of combustion products. The condensate trap drains through pipe “C” shown in Figure 10. The condensation disposal system must:

be connected to the domestic

waste disposal system by means of an appropriate trap capable of preventing the pressurization of the condensate system and the return of sewer gases (see ﬁ gure 11);

comply with national and/or local

codes for condensate neutralizer between pipe “C” of ﬁ gure 10 and the waste disposal system;

be carried out with a pipe with

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

be installed in such a way so as to

avoid the freezing of the liquid;

never discharge into gutters or rain

collectors;

be properly pitched towards the

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

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

5.7 - Near boiler heating piping components

1. Boiler system piping: boiler system piping must be properly sized. Reducing the pipe size can restrict the ﬂ ow rate through the boiler, causing inadvertent high limit shutdowns and poor system performance.

2. Boiler system pump: Factory Installed. Circulators must be sized to meet the speciﬁ ed ﬂ ow requirements of 5 GPM.

3. Indirect water heater circulating pump: Field supplied. The pump must be sized to meet the speciﬁ ed minimum ﬂ ow requirements of 5 GPM. Consult the indirect water heater operating guide to determine the ﬂ ow characteristics of the selected product used.

4. Boiler isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in restricted ﬂ ow rate through the boiler.

5. Domestic indirect hot water isolation valves: Field supplied. Full port ball valves are required. Failure to use full port ball valves could result in a restricted ﬂ ow rate through the boiler.

6. Anti scald mixing valves: Field supplied. An anti scald mixing valve is recommended (see Figure

16). It is recommended also when an indirect water heater is present.

7. Unions: Field supplied. Recommended for unit serviceability.

8. Pressure relief valve: Factory supplied. The pressure relief valve is sized to ASME speciﬁ cations.

9. Indirect Water heaters: Field supplied. This boiler may be piped to an indirect water heater to heat domestic hot water with the space to heat transfer medium. There are two options when utilizing an indirect water heater.

a. The space heating piping will

branch off to ﬂ ow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.

b. The indirect water heater is

connected to the system supply piping. A pump controlled by the boilers control will regulate the ﬂ ow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the boiler’s control. The boiler is pre-conﬁ gured to control the operation of the DHW pump with Domestic Hot Water Prioritization programming.

CAUTION!- It is up to the installer to ensure the minimum system ﬂ ow is not less then 5 GPM at any time.

WARNING!!! The National Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform Plumbing Code limit the pressure of the heat transfer ﬂ uid to less then the minimum working pressure of the potable water system up to 30 psi maximum. Also, the heat transfer ﬂ uid must be water or other non-toxic ﬂ uid having a toxicity of Class 1, as listed in the Clinical T oxicology of Commercial Products, 5th Edition.

10. Filter: Field supplied. A Filter or

equivalent multipurpose strainer is recommended at the return pipe of the boiler to remove system particles from older hydronic systems and protect newer systems.

Page 23

5 - INSTALLATION - Mounting & gas and water connections

5.8 - Relief valve

Each boiler is equipped with a safety relief valve set at 30 psi (2 bar) which must be piped in accordance with the ANSI/ASME Boiler and Pressure Vessel Code, Section IV, to prevent scalding in the event of a discharge, see Figures 1, item “38” and ﬁ gure 10.

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

5.9 - Supply and return piping

CAUTION!!! All heating

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

CAUTION!!! This boiler

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

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

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

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

A = 3/4” pipe extension (not provided) B = Discharge device open to the atmosphere

(not provided)

C = Condensate discharge pipe

Figure 10 - Relief valve connection

CAUTION!!!

Minimum air gap of ½” between discharge pipe and drain. Failure to do this will damage the unit and void warranty .

Figure 11 - Condensate trap and drain

Page 24

5 - INSTALLATION - Mounting & gas and water connections

5.12 - Domestic hot

CAUTION!!! This boiler can supply heating water at a temperature up to 190°F (88°C). If the heating system is built with materials not able to resist to this temperature, you must to install a device that shut-off the boiler before the material’s limit temperature.

Figure 9 illustrates the position of

the supply and return pipes.

Install a metallic mesh ﬁ lter on the

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

Do not use the appliance for

adding any type of additive to the system.

5.9.1 - Converting a combi boiler into a heating only boiler

If you are in possession of a PC160™ boiler you can use it as a heating system only without using the domestic hot water circuit. To do so, simply plug the two ﬁ ttings, items “3” and “5” of ﬁ gure 7, and move switch No. 5 (see ﬁ gure 21) from OFF position to ON position. Now knob “32” of ﬁ gure 1 is disabled.

5.10 - Low temperature heating systems

CAUTION!!! When the boiler is installed in a low temperature system, the switch No. 6 in ﬁ gure 21 must be placed in the ON position to prevent the supply water temperature from exceeding 113°F (45°C) or damage to the low temperature system components could occur (see section 5.9).

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

CAUTION!!! To protect the ﬂ oor panel against over heating you must to install a safety device that shut-off the boiler before it reach the ﬂ oor panel’s limit temperature.

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

5.11 - Use of glycol and other chemicals

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

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

CAUTION!!! Any additives

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

and cold water

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

Figure 9 illustrates the positioning

of the domestic hot and cold water pipes.

For servicing purposes, install an

isolation valve upstream from the cold water inlet.

To correctly set the domestic water

ﬂ ow, install an adjustable ﬂ ow restrictor upstream the cold water inlet (see ﬁ gure 16 item “12”)

 The PC160

used as heating only boilers. No connection is needed to the domestic pipes “B” and “D” of ﬁ gure 9.

™

boiler can also be

5.13 - Gas supply piping

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

If the gas type and/or the supply

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

Page 25

5 - INSTALLATION - Mounting & gas and water connections

The boiler comes from the factory

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

Install a manual gas shutoff valve

and drip leg as shown in Figure 12.

Figure 12 - Gas supply piping

The gas supply piping to the boiler must be properly sized to guarantee that the gas supply meets the maximum requirements. If more than one appliance is supplied by the same gas supply pipe, the gas supply piping must be sized based on the maximum possible demand. Do not neglect the pressure drop due to pipe ﬁ ttings. Table 1 below, should be used in conjunction with Table 2 below, to ensure that the gas supply piping is sized properly. See section 14 for values of “maximum gas supply pressure” and “minimum gas supply pressure” and also section 11.7.

Before installation a thorough

internal cleaning of the gas supply line should be performed. Figure 9 shows the positioning of the gas connection on the heater.

The boiler and its gas connection

must be leak tested before placing the boiler in operation.

To avoid damaging the gas control,

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

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

The boiler and its individual shutoff

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

The boiler must be isolated from

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

Install 100% lockup gas pressure

regulator in supply line if inlet pressure can exceed 13”W.C. at any time. Adjust lockup regulator for 13”W.C. maximum.

Use pipe sealing compound

compatible with propane gas. Apply sparingly only to male threads of the pipe joints so that pipe dope does not block gas ﬂ ow.

5.14- Propane gas

WARNING!!! These boilers

are typically shipped ready to ﬁ re on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by following the instructions in Section 5.17. Failure to comply could result in severe personal injury , death, or substantial property damage.

Pipe sizing for propane gas

Contact gas supplier to size pipes, tanks and 100% lockup gas pressure regulator.

Propane supply pressure requirements:

1. Adjust propane supply regulator provided by the gas supplier for 13”W.C. maximum pressure.

2. Pressure required at gas valve inlet port: a. Maximum 13”W.C. with no ﬂ ow

(lockup) or with boiler on.

b. Minimum 3”W.C. with gas

ﬂ owing (verify at high ﬁ re).

WARNING!!! Ensure that the high pressure gas regulator is at least 6-10ft upstream of the appliance.

5.15 - Operating at high altitudes

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

Page 26

5 - INSTALLATION - Mounting & gas and water connections

5.16- Convert the boiler from Natural Gas to Propane Gas or vice versa

WARNING!!! The gas conversion shall be performed by a qualiﬁ ed service agency in accordance with this instructions and all applicable codes and requirements of the authority having jurisdiction. The information in these instructions must be followed to minimize the risk of ﬁ re or explosion or to prevent property damage, personal injury or death. The qualiﬁ ed service agency is responsible for the proper conversion of the boiler. The installation is not proper and complete until the operation of the converted appliance is checked as speciﬁ ed in this instructions.

WARNING!!! The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdition and in accordance with the requirements of the CAN-B149.1 and CAN1-B149.2 installation code.

Contents:

The conversion kit (supplied with the boiler) is composed of the following elements, which are necessary for the gas change:

- a label rating the new gas setting;

- an instruction sheet;

- an oriﬁ ce;

Installing:

in order to make the gas change please follow the instructions below:

1 - turn off power to the boiler; 2 - open the boiler’s casing (Follow

Section 14.2);

3 - open the instrument panel

(Follow Section 9.2);

4 - Move switch #7 (see Figure 9-2)

from OFF position to ON position; 5 - turn on power to the boiler; 6 - on the boiler’s display you’ll see

followed by a number;

7 - using the push buttons and

set the input to:

- 61 to convert the boiler from LP GAS to NATURAL GAS or

- 62 to convert the boiler from NATURAL GAS to LP GAS,

8 - push button to save the

new value;

9 - turn off power to the boiler;

10 - Move switch #7 (see Figure 9-2)

from ON position to OFF position;

11 - Replace the oriﬁ ce item “C” of

Figure 13 for the correct one for the type of gas used. Verify that the stamping on the oriﬁ ce matches the gas type (See Table

3). 11 - turn on power to the boiler; 12 - Turn completely counter

clockwise the screw E of Figure 13;

13 - Checking gas supply pressure

following Section 12.7. The Gas supply pressure must be between the maximum and minimum value as stated in Table 3.

14 - Verifying the CO2 rate and its

eventual adjustment following Section 12-9: The boiler during its normal operation, within a maximum altitude of 2000 ft, has a CO2 exhaust rate as shown in Table 3. If not within range of value shown, malfunctions will occur.

WARNING!!! The CO (carbon monoxide) level should not exceed values given in T able 3, when combustion is correct. Failure to comply with this requirement could result in severe personal injury , death or substantial property damage.

WARNING!!! All combustion measurements must be performed with calibrated equipment to ensure proper reading and accuracy . Failure to comply with this requirement could result in severe personal injury , death or substantial property damage.

TABLE 3 SETTINGS OF THE BOILER FOR NATURAL GAS AND LP GAS

313

CO2

content at

%%%%

CO2

content at

O2 content CO content at

Page 27

5 - INSTALLATION - Mounting & gas and water connections

WARNING!!! If the combustion levels are not within the range given in T able 3 for the ﬁ ring rate, shut the boiler down and contact your distributor or the boiler manufacturer (see reference in the last cover page). Failure to comply with this requirement could result in severe personal injury , death or substantial property damage.

15 - Attach to the front of the boiler the appropriate conversion label, found in the conversion kit (see Figure 14 or Figure 15), stating the new type of gas adjustment of the boiler.

a - Apply the label in Figure 15 if the

boiler has been converted to LP GAS;

b - Apply the label in Figure 14 if

the boiler has been converted to

NATURAL GAS.

Figure 13 - Gas valve

ATTENTION!!!

This heater has been converted for use with

NATURAL GAS

- Maximum inlet gas pressure: 13 In.W.C.

- Minimum inlet gas pressure: 3 In.W.C.

- Manifold pressure: (see rating plate)

- Input rating: (see rating plate) This water heater was converted on (day-month-year) ___________________to ___________________ gas

with kit nº by

_________________________________________

___________________________________

___________________________________________ (name and address of organization making this

conversion, who accepts the responsibility for the correctness of this conversion).

ATTENTION!!!

This heater has been converted for use with

LP GAS

- Maximum inlet gas pressure: 13 In.W.C.

- Minimum inlet gas pressure: 3 In.W.C.

- Manifold pressure: (see rating plate)

- Input rating: (see rating plate) This water heater was converted on (day-month-year) ___________________to ___________________ gas

with kit nº by

_________________________________________

___________________________________

___________________________________________ (name and address of organization making this

conversion, who accepts the responsibility for the correctness of this conversion).

Figure 14 - Label for Natural gas boiler

Figure 15 - Label for LP gas boiler

Page 28

5 - INSTALLATION - Mounting & gas and water connections

5.17 - Suggested piping and wiring connections

Figure 16 shows the suggested piping and wiring connection for the PC160™. All component listed below, except the ﬂ ue terminal must be ﬁ eld supplied.

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

Figure 16 - Typical piping and wiring connections

Page 29

6 - INSTALLATION - Electrical connections

6.1 - Electrical connections: overview

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

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

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

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

This is an essential safety requirement which must be checked.

Check that the electrical system is adequate

for the power consumption indicated on the rating plate.

Line voltage ﬁ eld wiring of any controls or

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

 A properly rated shut-off switch shall be

located at the boiler.

Ensure that the polarity between live and

neutral wires is maintained when connecting the boiler.

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

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

A = Junction box B = Plastic spring C = Opening direction D = Screws for junction box cover

E = Junction box cover F = Junction box cover opening direction G = Electrical supply cable H = Room thermostat cable (optional) L = Outside temperature sensor cable (optional) M = Storage tank temperature sensor

N = Remote command cable (optional)

Figure 17- Junction box

Page 30

6 - INSTALLATION - Electrical connections

Indirect water heater sensor (optional)

Outdoor sensor (optional)

Room thermostat

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

120Vac LINE (HOT) NEUTRAL GROUND

Figure 18 - Electrical connections

6.2 - Connecting the power supply cable

To connect the electrical power supply cable, follow the steps below while referring to ﬁ gures 17 and 18:  remove the boiler casing following

the instructions given in section

13.2;

 press the two plastic springs tabs

labeled “B” on the bottom side;

 open panel “A” in the “C” direction;  remove the three screws labeled

“D”;

 open door “E” in the “F” direction;  install the power supply wires, “G”

as shown;

 strip the power supply wires being

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

 connect the ground wire to the

ground terminal;

 connect the 120 volt hot wire to

terminal “L1”;

 connect the 120 volt neutral wire to

terminal “N”.

NOTICE! If the 120 volt power wires are inverted, the boiler will block, displaying error code E21.

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

6.3 - Choosing the room thermostat

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

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

- clean dry contact (not powered);

- electrical capacity of 24Vac, 1A.

External three way valve for indirect water heater (Optional)

6.4 - Thermostat wiring

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

Connect the room thermostat to the boiler by following the steps below:  remove the boiler casing according

to the instructions given in section

13.2 and open the junction box per section 6.2;

 use a two conductor cable with

a minimum cross section of # 18 AWG between the boiler and the room thermostat;

 route the cable through an empty

cable clamp in the junction box

 connect the cable leads to the “RT”

terminals as shown in ﬁ gures 17 and 18.

Page 31

6 - INSTALLATION - Electrical connections

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

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

6.5 - Installing the outdoor temperature sensor (optional)

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

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

13.2 and open the junction box per section 6.2;

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

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

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

3. connect the outdoor temperature sensor cable leads to terminals OS as shown in ﬁ gures 17 and 18;

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

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

1. press down the button for 12 seconds until the display starts

blinking and shows ;

2. then press and release the button several times until the

following parameter appears;

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

4. press the button repeatedly until exiting the menu; the display will no longer ﬂ ash.

6.6 - Alarm output

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

Figure 19 - Room thermostat location

Page 32

7 - INSTALLATION - Indirect storage tank connections

7.1 - Connecting the boiler to an indirect storage tank

This boiler, can be connected to an indirect storage tank as follows (the water and electrical connections must be made per ﬁ gure 20): To make the electrical connections, follow the steps below while refering also to ﬁ gure 20:

1. disconnect the boiler from the electrical supply;

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

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

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

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

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

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

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

9. use a # 18 AWG two wire cable to connect the indirect storage tank temperature

1 Outdoor temperature sensor (optional) 2 120Vac electrical supply 3 Heating system supply circuit 4 Room thermostat (ﬁ eld supplied) 5 Heating circuit drain valve (ﬁ eld supplied) 6 Boiler 7 8 Three way valve (ﬁ eld supplied) 9 Gas supply 10 Manual gas shutoff valve (ﬁ eld supplied) 11 12 - Expansion vessel (if the inside one is not sufﬁ cient) 13 Automatic ﬁ ll valve (ﬁ eld supplied ) 14 Cold water inlet connection 15 Indirect storage tank (ﬁ eld supplied) 16 Domestic hot water outlet 17 Domestic cold water inlet

Figure 20 - Indirect storage tank connections

sensor to terminals “TS”, item “M”, as per ﬁ gures 17 and 18;

10. insert the probe of the tank temperature sensor into the socket of the storage tank.

11. use a #18 AWG four wire cable to connect the three way valve to terminals “1”, “2”, “3” and Ground as per ﬁ gures 17 and 18, where:

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

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

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

Page 33

7 - INSTALLATION - Indirect storage tank connections

7.2 - Indirect water

heater priority selection

The boiler is factory set for DHW priority. This means that the boiler will stay in DHW mode until the capacity of the indirect water heater reaches temperature. In some cases this will result in house cooling because the central heating function was stopped by the DHW priority mode. Once the indirect water heater is satisﬁ ed the boiler will automatically return to central heating.

Priority selection is a functionality that toggles between CH and CHW when they are both active at the same time. The priority selection

is set with the dP (DHW priority) parameter in the “installer menu” (see section 12.17)

Each value set into the dP parameter will correspond to the minutes delay the boiler toggles between CH and DHW demand.

A = front cover of the electrical box B = plastic spring to open the electrical box C = Direction to open the electrical box

D = Switches for the functional setting of the boiler

Figure 21 - Control board and junction box board details

Page 34

8 - INSTALLATION - Vent & combustion air

8.1 - Removing of a boiler from a common venting system

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

When an existing boiler is removed from a common venting system, the common venting system is likely to be too large for proper venting of the appliances remaining connected to it. At the time of removal of an existing boiler, the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation, while the other appliances remaining connected to the common venting system are not in operation.

(a) Seal any unused openings in the

common venting system.

(b) Visually inspect the venting system

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

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

(d) Place in operation the appliance

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

(e) Test for spillage at the draft hood

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

(f) Alter it has been determined

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

(g) Any improper operation of the

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

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

(a) Sceller toutes les ouvertures non

utilisées du système d’évacuation.

(b) Inspecter de façon visuelle le

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

fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés du système d’évacuation sont installés et les autres espaces du bâtiment. Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinère et les ventilateurs des salles de bain. S’assurer que ces ventilateurs fonctionnent à la vitesse maximale. Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

(d) Mettre l’appareil inspecté en

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

(e) Faire fonctionner le brûleur

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

(f) Une fois qu’il a été déterminé,

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

(g) Tout mauvais fonctionnement

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

Page 35

8 - INSTALLATION - Vent & combustion air

8.2 - Venting systems

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

Horizontal vent runs must be

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

The vent system shall be installed

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

Horizontal vent systems shall

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

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

Due to the high efﬁ ciency of the

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

The minimum clearance

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

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

This Boiler requires a special vent system, designed for pressurized venting.

You must install air piping from outside to the boiler air intake. The resultant installation is Direct Vent (sealed combustion).

The boiler is to be used for either Direct Vent installation or for installation using room combustion air. When room air is considered see Section 8.6.

Vent and air must terminate near one another and may be vented vertically through the roof or out of a side wall, unless otherwise speciﬁ ed. Y ou may use any of the vent/air piping methods from Figure 22 thru Figure 27. Do not attempt to install boiler using any other means.

WARNING!!! DO NOT mix components from different systems. The vent system could fail, causing leakage into the living space. Use only approved materials listed on 8.1 and 8.2. Improper materials or mixing materials can result in excessive levels of carbon monoxide which can cause several personal injury or death!

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated. The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in Section 8.3.

Page 36

8 - INSTALLATION - Vent & combustion air

Figure 22 - Side wall two

pipes (Direct venting).

Figure 23 - Vertical two

pipes (Direct venting).

Figure 24 - Side wall air

intake, vertical vent (Direct venting).

Air

intake

Figure 25 - Vertical

concentric (Direct venting).

Figure 26 - Side wall

concentric (Direct venting).

Figure 27 - Side wall one

pipe venting, combustion air from room (Direct venting).

Page 37

8 - INSTALLATION - Vent & combustion air

8.3 - Design of the venting system

This boiler can be ﬁ tted with a very long venting system. However there is a relationship between the length of the venting system and the power input of the boiler. Figure 28 shows this relation which and installer must consider when in the designing stage of the venting.

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

The maximum length of the concentric system is 70 ft.

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

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

The minimum length of the venting system (two pipes or concentric) is 1 ft with one elbow.

8.4 Prevent Combustion air contamination

Install air inlet piping as described in Section 8. You must pipe combustion air to the boiler air intake. Do not terminate vent/air in locations that can allow contamination of combustion air.

WARNING!!! Contaminated combustion air will damage the boiler, resulting in possible severe personal injury , death or substantial property damage.

Ensure that that combustion air will not contain any of the following contaminants.

- Permanent wave solutions

- Chlorinated waxes/cleaners

- Chlorine based swimming pool

chemicals

- Calcium Chloride used for thawing

- Sodium Chloride used for water

softening

- Refrigerant leaks

- Paint or varnish removers

- Hydrochloric acid/muriatic acid

- Cements and glues

- Antistatic fabric softeners used in

clothes dryers.

- Chlorine-type bleaches, detergents

and cleaning solvents found in household laundry rooms

- Adhesives used to fasten building

products and other similar products.

Do not pipe combustion air near sources of products that may contaminate the air combustion, like:

- Dry cleaning/laundry areas and

establishments

- Swimming pools

- Metal fabrication Plants

- Beauty shops

- Refrigeration repair shops

- Photo processing plants

- Auto body shops

- Plastic manufacturing plants

- Furniture reﬁ nishing areas and establishments

- Remodeling areas

- Garages with workshops

8.5- Install Vent and

Combustion air piping

WARNING!!! This boiler must be vented and supplied with combustion and ventilation air as described in this section. Ensure the vent and combustion air supply comply with these instructions regarding vent system, air system and combustion air quality . Inspect ﬁ nished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all applicable codes. Failure to provide a properly installed vent and air system will cause severe personal injury or death.

WARNING!!! Using vent materials other than those listed in T able (4) and Table (5), failure to properly seal all seams and joints, mixing of venting materials a or failure to follow vent pipe and ﬁ ttings manufacturers instructions can result in personal injury , death or property damage.

WARNING!!! Never use cellular (foam) core pipe in vent pipe lines and ﬁ ttings. Failure to comply can result in personal injury , death or property damage.

Figure 28 - Relation between Power input and Vent system length

WARNING!!! Increasing or decreasing combustion air or vent piping is not authorized. Failure to comply can result in personal injury , death or property damage.

NOTICE Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for US installations or CSA B149.1 for Canadian installations.

For installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636.

Page 38

8 - INSTALLATION - Vent & combustion air

TABLE 4

Vent pipe materials and ﬁ ttings must comply with the following standards

Item Material

Vent pipe and

ﬁ ttings

Pipe cement/primer

Standard for

installation in USA

PVC Schedule 40, 80 ANSI/ASTM D1785

CPVC schedule 40/80 ANSI/ASTM F441

Polypropylene ULC-S636

Stainless steel AL29-4C UL1738

PVC ANSI/ASTM D2564

CPVC ANSI/ASTM F493

Standard for

installation in Canada

ULC-S636

WARNING!!! USE OF CELLULAR CORE PVC, CPVC AND RADEL FOR VENTING SYSTEM IS NOT ALLOWED.

TABLE 5 APPROVED VENT MANUFACTURERS AND ITEMS

Approved vent manufacturers and items

Item Materials Manufacturer/supplier Manufacturer/supplier part number Concentric roof or wall terminal PVC IPEX (System 636) 196006 Two pipes wall terminal PVC IPEX (System 636) 081219 or 196985 Single pipe wall terminal (90°elbow) PVC IPEX (System 636) 196025 Boiler adapter (80mm to 3” PVC) Polypropylene COSMOGAS 62617303 Bird Screen PVC IPEX (System 636) 196051

Two pipes roof terminal Polypropylene COSMOGAS 62617306 and 61302003 Two pipe wall terminal Polypropylene COSMOGAS 61302004 and 61302003 Single pipe roof terminal Polypropylene COSMOGAS 62617306 Single pipe wall terminal Polypropylene COSMOGAS 61302004 Two or single pipe boiler adapter (80mm to

80mm Polypropylene) Bird Screen Polypropylene COSMOGAS 61302003 Concentric boiler adapter Polypropylene COSMOGAS 62617224 Concentric roof terminal Polypropylene COSMOGAS 62617304 Concentric wall terminal Polypropylene COSMOGAS 62617232

Single pipe wall or roof terminal Polypropylene Centrotherm (Innoﬂ ue System) IESP0339 Two pipes wall or roof terminal Polypropylene Centrotherm (Innoﬂ ue System) ASEP0339 and ISEL0387UV Bird screen Polypropylene Centrotherm (Innoﬂ ue System) IASPP03

Single pipe wall or roof terminal Polypropylene Duravent ( PolyPro) 3PPS36B Two pipes wall or roof terminal Polypropylene Duravent ( PolyPro) 3PPS36B and 3PPS-E90B Bird Screen Polypropylene Duravent ( PolyPro) 3PPS-BG

Single pipe wall or roof terminal Stainless Steel Duravent (FasNSeal) FSVL3603 Two pipes wall or roof terminal Stainless Steel Duravent (FasNSeal) FSVL3603 and FSELB8803 Boiler adapter (80mm to 3” stainless steel) Stainless Steel Duravent (FasNSeal) FSA-80MM3 Bird Screen Stainless Steel Duravent (FasNSeal) FSBS3

Single pipe wall or roof terminal Stainless Steel Heat Fab ( SGV) SGV03L36 Two pipes wall or roof terminal Stainless Steel Heat Fab ( SGV) SGV03L36 and FSEL8803 Boiler adapter (80mm to 3” stainless Steel) Stainless Steel Heat Fab ( SGV) SGV03AD80 Bird screen Stainless Steel Heat Fab ( SGV) SGV03TM

Polypropylene COSMOGAS 62617286

Page 39

8 - INSTALLATION - Vent & combustion air

8.6 - Air inlet pipe materials

WARNING!!! The air inlet pipe(s) must be sealed. Improper sealed can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

Choose acceptable combustion air inlet pipe materials from the following list:

- PVC, CPVC or ABS Dryer Vent or Sealed Flexible Duct (not recommended for rooftop air inlet)

- Galvanized steel vent pipe with joints and seams sealed as speciﬁ ed in this section.

- Type “B” double-wall vent with joints and seams sealed as speciﬁ ed in this section.

- AL29-4C, stainless steel material to be sealed to speciﬁ cation of its manufacturer.

- Polypropylene material to be sealed to speciﬁ cation of its manufacturer.

NOTICE! PVC, CPVC, ABS Dryer Vent and stainless steel pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the air inlet pipe

WARNING!!! Using vent or air intake materials other than those speciﬁ ed, mixing the speciﬁ ed materials, failure to properly seal all seams and joints or failure to follow the manufacturer’s instructions can result in personal injury , death or property damage.

8.6.1 - Sealing of Type “B” double-wall or galvanized air inlet pipe material

Sealing of Type “B” double-wall or galvanized air inlet pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply System: a. Seal all joints and seams of the air

inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A-P or a high quality UL Listed silicone sealant.

b. Do not install seams of vent pipe on

the bottom of horizontal runs.

c. Secure all joints with a minimum

of three sheet metal screws or pop rivets. Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the pipe.

d. Ensure that the air inlet pipes are

properly supported.

WARNING!!! Failure to properly seal all joints and seams as required in the air inlet piping may result in

ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide

emissions causing severe personal injury or death.

8.6.2 - Sealing of PVC, CPVC or ABS air inlet pipe

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used. The PVC, CPVC, ABS Dryer Vent or Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or Flex Duct should use a screw type clamp to seal the pipe to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume. When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper volume.

WARNING!!! Failure to properly seal all joints and seams as required in the air inlet piping may result in

ﬂ ue gas recirculation, spillage of ﬂ ue products and carbon monoxide

emissions causing severe personal injury or death.

NOTICE The use of double-wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the incoming combustion air.

Page 40

8 - INSTALLATION - Vent & combustion air

8.7 - PVC/CPVC vent piping materials

WARNING!!! Use only the materials listed in T ables 4 and 5 for vent pipe, and ﬁ ttings. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury , death, or substantial property damage.

WARNING!!! This appliance requires a special venting system. The ﬁ eld provided vent ﬁ ttings must be connected to the boiler following Section 8.7.1. Use only the vent materials, primer, and cement speciﬁ ed in this manual to make the vent connections. Failure to follow this warning could result in ﬁ re, personal injury , or death.

WARNING!!! Do not insulate PVC/CPVC exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

WARNING!!! Improper installation of PVC or CPVC systems may result in injury or death.

NOTICE Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

NOTICE The installer must use a speciﬁ c vent starter adapter at the ﬂ ue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 5 for approved vent adapters.

For installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636 (see Table 4).

NOTICE All vent pipes must be glued, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).

NOTICE Installation of a PVC/CPVC vent system should adhere to the PVC/ CPVC vent manufacturer’s installation instructions supplied with the vent system.

NOTICE The installer must use a speciﬁ c vent starter adapter at the ﬂ ue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 5 for approved vent adapters.

8.7.1 - Installing PVC/ CPVC vent and air piping

NOTICE Use only cleaners, primers, and solvents that are approved for the materials which are joined together.

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in Section 8.3.

2. Cut pipe to the required lengths and deburr the inside and outside of the pipe ends.

3. Bevel outside of each pipe end to ensure even cement distribution when joining.

4. Clean all pipe ends and ﬁ ttings using a clean dry rag (Moisture will retard curing and dirt or grease will prevent adhesion).

5. Dry ﬁ t vent or air piping to ensure proper ﬁ t up before assembling any joint. The pipe should go a third to two-thirds into the ﬁ tting to ensure proper sealing after cement is applied.

6. Priming and Cementing: a. Handle ﬁ ttings and pipes

carefully to prevent contamination of surfaces.

b. Apply a liberal even coat of

primer to the ﬁ tting socket.

c. Apply a liberal even coat

of primer to the pipe end to approximately 1/2” beyond the socket depth.

d. Apply a second primer coat to

the ﬁ tting socket.

e. While primer is still wet, apply

an even coat of approved cement to the pipe equal to the depth of the ﬁ tting socket.

f. While primer is still wet, apply

an even coat of approved cement to the ﬁ tting socket.

g. Apply a second coat of cement

to the pipe.

h. While the cement is still wet,

insert the pipe into the ﬁ tting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufﬁ cient cement was not applied and joint could be defective.

i. Wipe excess cement from the

joint removing ring or beads as it will needlessly soften the pipe.

8.7.2 - PVC/CPVC air intake/vent connections

Combustion Air Intake connection (see Figure 29 Item “C”). This connection is used to

provide combustion air directly to the boiler from outdoors. Combustion air piping must be supported per guidelines listed in the National Mechanical Code, Section 305, Table

305.4 or as local codes dictate. To connect a PVC/CPVC pipe to the air intake connection proceed as follow while referring to Figure 29:

1. install boiler adapter “A” above boiler. Rotate boiler adapter “A” so as air intake and vent connections are in the desired left or right side. Check stamped arrow to understand which is the vent and air intake connection.

WARNING!!! Check stamped arrow on boiler adapter for the correct side of air intake. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

2. insert the clamp “D” into convertor

“A” in the “C” side.

3. insert the adapter “E” into

connection “C” of the convertor “A”;

Page 41

8 - INSTALLATION - Vent & combustion air

4. use the precedent clamp “D” to mechanically secure the adapter “E” to the adapter “A”. To do this tighten the half clamp on the adapter “A” and half clamp on the adapter “E”. Tight the clamps with a tork of 1.5 - 2 lbf ft (2-3 Nm).

5. insert the clamp “F” into convertor “E”.

6. insert the air inlet PVC/CPVC pipe, for 2” into the adapter “E”;

7. use the precedent clamp “F” to mechanically secure the pipe to the adapter “E”. To do this tighten the half clamp on the pipe and half clamp to the adapter “E”. Tight the clamps with a tork of 1.5 - 2 lbf ft (2-3 Nm).

Vent connection (see Figure 29 Item “B”).

This connection is used to provide a passageway for conveying combustion gas to the outside. Vent piping must be supported per the National Building Code, Section 305, Table 305.4 or as local codes dictate. To connect a PVC/CPVC pipe to the vent connection proceed as follow while referring to Figure 29:

WARNING!!! Check stamped arrow on boiler adapter for the correct side of vent. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

WARNING!!! Check stamped arrow on boiler adapter for the correct side of ﬂ ue exhaust and air intake. Failure to follow this warning could result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

2. Insert one side of clamp “D” onto the air intake of boiler adapter “A” (side C).

3. Insert adapter “E” into side “C” of boiler adapter “A”;

4. Use clamp “D” to mechanically secure adapter “E” to boiler adapter “A”. To do this, tighten one side of clamp “D” onto boiler adapter “A” and the other half of clamp “D” onto adapter “E”. Tight the clamps with a tork of 1.5 - 2 lbf ft (2-3 Nm).

5. Insert clamp “F” into adapter “E”.

6. Insert the PVC/CPVC pipe “G”, into adapter “E” for at least 2”;

7. Use clamp “F” to mechanically secure pipe “G” to adapter “E”. To do this, tighten one side of clamp “F” onto pipe “G” and the other side of clamp “F” to the adapter “E”. Tight the clamps with a tork of

1.5 - 2 lbf ft (2-3 Nm).

Figure 29 - PVC/CPVC Venting connection

Page 42

8 - INSTALLATION - Vent & combustion air

8.8 - Flue terminal

location in compliance with CAN/CSA B149

Vent Termination Minimum Clearances

A = 12” clearances above grade, veranda, porch, deck or balcony B = 12” clearances to window or door that may be opened D = 18” vertical clearance to ventilated sofﬁ t located above the terminal within a horizontal distance of 2 feet (0.6 m)

from the centre line of the terminal E = 18” clearance to unventilated sofﬁ t F = 9” clearance to outside corner G = 6” clearance to inside corner H = 4 ft (USA) not to be installed above a gas meter/regulator assembly within H horizontally from the centre line of

the regulator H = 3 ft (CANADA) not to be installed above a gas meter/regulator assembly within H horizontally from the centre line

of the regulator I = 3 ft (USA) clearance to service regulator vent outlet I = 6 ft (CANADA) clearance to service regulator vent outlet J = 9” (USA) clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other

appliance J = 12” (CANADA) clearance to non-mechanical air supply inlet to building or the combustion air inlet to any other

appliance K = 3 ft (USA) clearance to a mechanical air supply inlet K = 6 ft (CANADA) clearance to a mechanical air supply inlet L = 7 ft clearance above paved side-walk or a paved driveway located on public property (a vent shall not terminate

directly above a side-walk or paved driveway which is located between two single family dwellings and serves

both dwellings unless terminated 7ft above sidewalk) M = 18” clearance under veranda, porch, deck or balcony (only permitted if veranda, porch, deck or balcony is fully

open on a minimum of 2 sides beneath the ﬂ oor

Page 43

8 - INSTALLATION - Vent & combustion air

8.9 - Single pipe vent (not sealed combustion)

WARNING!!! When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

Commercial applications utilizing this boiler may be installed with a single pipe carrying the ﬂ ue products to the outside while using combustion air from the equipment room. In this case the following conditions and considerations must be followed.

WARNING!!! The equipment room MUST be provided with properly sized openings to assure adequate combustion air from outside. Failure to comply could result in severe personal injury , death, or substantial property damage.

• There will be a noticeable increase

in the noise level during normal operation from the inlet air opening.

• Vent system and terminations must

comply with the venting instructions set forth in sections 8.1, 8.2, 8.3,

8.4, 8.5, 8.6, 8.7, 8.8.

WARNING!!! Use only the materials, vent systems, and terminations listed in T ables 4 and 5. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury , death, or substantial property damage.

WARNING!!! Fire danger due to ﬂ ammable materials or liquids. Do not store ﬂ ammable materials and liquids in the immediate vicinity of the boiler.

WARNING!!! Boiler must be clear and free from combustible materials, gasoline and other ﬂ ammable vapors and liquids, and corrosive liquids and vapors. Never use chlorine and hydrocarbon containing chemicals (such as spray chemicals, solution and cleaning agents, paints, glues etc.) in the vicinity of the boiler. Do not store and use these chemicals in the boiler room. A void excessive dust formation and build-up.

WARNING!!! Where exhaust fans, clothes dryers, and kitchen ventilation systems interfere with the operation of appliances, makeup air shall be provided.

NOTICE Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For installation in Canada, vent pipe system must be certiﬁ ed to ULC-S636 (see Table 4).

NOTICE All vent pipes connections must be secured following manufacturer instruction, properly supported, and the exhaust must be pitched a minimum of a 1/4 inch per foot back to the boiler (to allow drainage of condensate).

8.9.1 - Combustion Air and Ventilation openings

WARNING!!! Make sure that combustion air and ventilation openings are sufﬁ ciently sized and no reduction or closure of openings takes place. Please note these restrictions and its dangers to the operator of the boiler and to the homeowner. Failure to comply could result in severe personal injury , death, or substantial property damage.

Outdoor combustion air shall be provided through opening(s) to the outdoors. The minimum dimension of air openings shall not be less than 3 in. (80 mm) diameter.

Two Permanent Openings Method.

Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within 12 in. (300 mm) of the bottom, of the room shall be provided. The openings shall communicate directly, or by ducts, with the outdoors or spaces that freely communicate with the outdoors, as follows:

1. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2 each 4000 Btu/ hr (550 mm2/kW) of total input rating of all appliances located in the room.

2. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2 each 2000 Btu/hr (1100 mm2/kW) of total input rating of all appliances located in the room.

One Permanent Opening Method.

One permanent opening, commencing within 12 in. (300 mm) of the top of the room, shall be provided. The appliances shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance. The opening shall directIy communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of 1 in2 each 3000 Btu/hr (700 mm2 / kW) of the total input rating of all appliances located in the room.

Page 44

8 - INSTALLATION - Vent & combustion air

8.9.2 - Determine location

Locate the vent termination using the following guidelines:

1. The total length of piping for vent must not exceed the limits given in the Section 8.3.

2. You must consider the surroundings when terminating the vent: a. Position the vent termination

where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The ﬂ ue products will form

a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause

freezing of condensate and water/ ice buildup where ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals.

e. Do not locate the terminations

where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

f. Do not terminate above any

door or window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

4. The vent piping must terminate in an elbow pointed outward as shown in Figure 46 or 49.

WARNING!!! Do not exceed the maximum lengths of the outside vent piping shown in Figures 46 or

49. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

5. Maintain clearances as shown in Figure 45 (get references to “Mechanical draft vent terminal” only). Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 4 feet below or horizontally from any door or window or any other gravity air inlet.

b. Do not terminate closer than

4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally. Item

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

6. Locate termination so it is not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

CAUTION!!! Increase the grade clearances of the snow line quote

Figure 30 - Vent position of a Direct vent boiler and of a Mechanical draft boiler (not sealed)

Page 45

8 - INSTALLATION - Vent & combustion air

8.10 - Sidewall termination - Two pipes

8.10.1 - Vent/air termination

WARNING!!! A gas vent extending through an exterior wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury , death, or substantial property damage.

WARNING!!! Do not connect any other appliance to the vent pipe or multiple boilers to a common vent pipe. Failure to comply could result in severe personal injury , death, or substantial property damage.

NOTICE Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

8.10.2 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the Section 8.3.

2. You must consider the surroundings when terminating the vent and air: a. Position the vent termination

where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The ﬂ ue products will form

a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause

freezing of condensate and water/ice buildup where ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals.

e. Do not locate the terminations

f. Do not terminate above any

door or window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

Page 46

8 - INSTALLATION - Vent & combustion air

Figure 31 - Two pipes sidewall termination of air and vent

3. The air piping must terminate in a down-turned elbow as shown in Figures 31 and 32. This arrangement avoids recirculation of ﬂ ue products into the combustion air stream.

4. The vent piping must terminate in an elbow pointed outward or away from the air inlet, as shown in Figures 31 and 32.

WARNING!!! Do not exceed the maximum lengths of the outside vent piping shown in Figures 31 and

32. Excessive length exposed to the outside could cause freezing of condensate in the vent pipe, resulting in potential boiler shutdown.

5. Maintain clearances as shown in

Figures 31 and 32. Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

• At least 3 feet above any forced air intake within 10 feet.

• No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet.

b. Air inlet must terminate at least

12 inches above grade or snow line; at least 12 inches below the vent termination;

c. Do not terminate closer than

6 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 6 feet horizontally.

6. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

Figure 32 - Two pipes sidewall termination of air and vent (if space permits)

Page 47

8 - INSTALLATION - Vent & combustion air

8.10.3 - Prepare wall penetrations

1. Air pipe penetration: a. Cut a hole for the air pipe. Size the air

pipe hole as close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For

either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter (4½ inch hole for 3 inch vent pipe)

b. Insert a galvanized metal thimble in the

vent pipe hole as shown in Figure 33.

3. Use a sidewall termination plate as a template for correct location of hole centers.

4. Follow all local codes for isolation of vent pipe when passing through ﬂ oors or walls.

Figure 33 - Two pipes sidewall termination assembly

5. Seal exterior openings thoroughly with exterior caulk.

8.10.4 - Termination and

ﬁ ttings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in Figures 31 and 32.

2. Maintain the required dimensions of the ﬁ nished termination piping as shown in Figures 31 and 32.

3. Do not extend exposed vent pipe outside of the building more than what is shown in Figures 31 and 32. Condensate could freeze and block vent pipe.

Figure 34 - Two pipes multiple boilers vent terminations

8.10.5 - Multiple vent/air

terminations

1. When terminating multiple boilers terminate each vent/air connection as shown in Figure 34.

WARNING!!! All vent pipes and air inlets must terminate at the same height to avoid possibility of severe personal injury , death, or substantial property damage.

2. Place wall penetrations to obtain minimum

clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in Figure 34 for U.S. installations. For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet is part of a direct vent

connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Page 48

8 - INSTALLATION - Vent & combustion air

8.11 - Sidewall termination – Concentric vent

8.11.1 - Description and usage

The termination kit must terminate outside the structure and must be installed as shown in Figure 35. The required concentric termination kit as well as combustion air and vent pipe materials are listed in Tables 4 and 5.

8.11.2 - Sidewall termination installation

1. Determine the best location for the

termination kit (see Figure 35).

2. The total length of piping for vent or air

must not exceed the limits given in Section

8.3.

3. You must consider the surroundings when

terminating the vent and air: a. Position the vent termination where

vapors will not damage nearby shrubs,

plants or air conditioning equipment or

be objectionable.

b. The ﬂ ue products will form a noticeable

plume as they condense in cold air.

Avoid areas where the plume could

obstruct window views.

c. Prevailing winds could cause freezing

of condensate and water/ice buildup

where ﬂ ue products impinge on building

surfaces or plants.

d. Avoid possibility of accidental contact of

ﬂ ue products with people or animals

e. Do not terminate above any door

or window. Condensate can freeze,

causing ice formations.

f. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

4. Cut one (1) hole 5 inch diameter into the

structure to install the termination kit.

5. Install the Concentric vent kit following the

concentric kit manufacturer’s instruction.

Figure 35- Concentric sidewall termination clearances

NOTICE Ensure termination location clearance dimensions are as shown in Figure

35.

Page 49

8 - INSTALLATION - Vent & combustion air

CAUTION!!! DO NOT use ﬁ eld-

supplied couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

6. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

8.11.3 - Multiventing sidewall terminations

When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 36. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gas.

Figure 36 - Concentric sidewall multiple boilers terminations

Page 50

8 - INSTALLATION - Vent & combustion air

8.12 - Vertical termination - Two pipes

WARNING!!! Follow instructions below when determining vent location to avoid possibility of severe personal injury , death or substantial property damage.

Installation must comply with local requirements and with the National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

8.12.1 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the Section 8.3.

2. The vent must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. The air piping must terminate in a down-turned 180° return pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of ﬂ ue products into the combustion air stream.

4. The vent piping must terminate at least 1 foot above the air intake. The air inlet pipe and vent pipe can be located in any desired position on the roof, but must always be no further than 2 feet apart and with the vent termination at least 1 foot above the air intake.

5. Locate terminations so they are not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

8.12.2 - Prepare roof penetrations

1. Air pipe penetration: cut a hole for the air pipe. Size the air pipe hole as close as desired to the air pipe outside diameter.

2. Vent pipe penetration: a. Cut a hole for the vent pipe.

For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter: 4 inch hole for 3 inch vent pipe

b. Insert a galvanized metal

thimble in the vent pipe hole.

3. Space the air and vent holes to provide the minimum spacing shown in Figure 37 and listed in section 10.13.1.

4. Follow all local codes for isolation of vent pipe when passing through ﬂ oors, ceilings, and roofs.

5. Provide ﬂ ashing and sealing boots sized for the vent pipe and air pipe.

8.12.3 - Termination and

ﬁ ttings

1. Prepare the vent termination and the air termination elbow (Figure

37) by inserting bird screens.

2. The air piping must terminate in a down-turned 180° return bend as shown in Figure 37. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe. This placement avoids recirculation of ﬂ ue products into the combustion air stream.

3. Maintain the required dimensions of the ﬁ nished termination piping as shown in Figure 37.

4. Do not extend exposed vent pipe outside of building more than shown in Figure 37. Condensate could freeze and block vent pipe.

Figure 37 - Two pipes vertical terminations of air and vent

Page 51

8 - INSTALLATION - Vent & combustion air

Air intake

snow line. Provide vent and air intake with bird screen.

Vent

Air intake

Vent

Figure 38 - Two pipes Multiple boilers vertical terminations

vertically from vent outlet to any air inlet

from edge of air intake pipe to adjacent vent pipe from another boiler

8.12.4 - Multiple vent/air

terminations

1. When terminating multiple boilers, terminate each vent/air connection as shown in Figures 38 and 39.

WARNING!!! Terminate all vent pipes at the same height and all air pipes at the same height to avoid possibility of severe personal injury , death, or substantial property damage.

2. Place roof penetrations to obtain

minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see Figure 38). For Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet is part of a direct vent

connection. It is not classiﬁ ed as a forced air intake with regard to spacing from adjacent boiler vents.

Vent

snow line. Provide vent and air intake with bird screen.

Air intake

Vent

Air intake

Figure 39 - Alternate vertical terminations with multiple boilers

vertically from vent outlet to any air inlet

Page 52

8 - INSTALLATION - Vent & combustion air

8.13 - Vertical termination – Concentric vent

8.13.1 - Description and usage

Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in Figure 40.

8.13.2 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in Section 8.3.

2. The concentric terminal must terminate at least 3 feet above the highest place in which the vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet.

3. Locate termination so it is not likely to be damaged by foreign objects, such as stones or balls, or subject to buildup of leaves or sediment.

8.13.3 - Vertical termination installation

1. Determine the best location for the termination kit (see Figure 40).

2. The total length of piping for vent or air must not exceed the limits given in Section 8.3.

3. You must consider the surroundings when terminating the vent and air: a. Position the vent termination

where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The ﬂ ue products will form

a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause

freezing of condensate and water/ice buildup where ﬂ ue products impinge on building surfaces or plants.

d. Avoid possibility of accidental

contact of ﬂ ue products with people or animals

e. Do not terminate above any

door or window. Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent

condensate damage to exterior ﬁ nishes.

4. Cut one (1) hole 6 inch diameter into the structure to install the termination kit.

5. Install the Concentric vent kit following the concentric kit manufacturer’s instruction.

NOTICE Ensure termination location clearance dimensions are as shown in Figure 40.

NOTICE Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or 18 inches in Canada) as shown in Figures 40.

CAUTION!!! DO NOT use ﬁ eld-

supplied couplings to extend pipes. Airﬂ ow restriction will occur and may cause intermittent operation.

6. Operate the appliance one (1) heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections.

Vent

Combustion

Air

Roof boot /

Combustion

Air

Vent

Combustion Air

Minimum clearance above highest anticipated snow level.

above roof.

Support

Figure 40 - Concentric vertical termination

Vent

Combustion air intake

Minimum clearance above snow

Page 53

8 - INSTALLATION - Vent & combustion air

8.13.4 - Multiventing

vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be individually vented (see Figure 41).

vent or breach vent this appliance to avoid possibility of severe personal injury , death, or substantial property damage.

When two or more direct vent appliances are vented near each other, two vent terminations may be installed as shown in Figure 41. It is important that vent terminations be made as shown to avoid recirculation of ﬂ ue gases.

WARNING!!! NEVER common

Figure 41 - Concentric multiple boilers vertical terminations

Page 54

8 - INSTALLATION - Vent & combustion air

8.13.5 - Alternate vertical concentric venting

This appliance may be installed with a concentric vent arrangement where the vent pipe is routed through an existing unused venting system; or by using the existing unused venting system as a chase for vent and combustion air routing.

Concentric Venting Arrangement

The venting is to be vertical through the roof. The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source. The minimum size of the existing vent system required to achieve enough annular space for combustion air is 7 inches. The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in Figures 42 and 43.

Figure 42 - Alternate concentric vertical venting (Example n°2)

Approved venting materials must be used as speciﬁ ed in Tables 4 and 5. Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code. The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from Section 8.3. If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance. See Section 8.4 for a list of corrosive contaminants and sources. Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in Figures 42 and 43.

Figure 43 - Alternate concentric vertical venting (Example n°1)

Page 55

8 - INSTALLATION - Vent & combustion air

8.14 - Existing vent

as a chase

Follow all existing termination and clearance requirements of section

8.12.

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from Section 8.3.

Use only approved venting materials listed in Tables 4 and 5.

Figure 44 - Alternate concentric vertical venting (Example n°3)

Page 56

9 - INSTALLATION - Split venting system

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

The boiler is not supplied with the ﬁ ttings needed for separate vent and combustion air systems. A special kit must be ordered to connect the boiler to separate vent and combustion air systems. Figure 45 shows ﬁ tting “A” that can freely turn 360 degrees for optimum installation versatility.

Pipes or elbows connected directly to the boiler, must be mechanically secure. Follow these instructions (make reference to ﬁ gure 46):

1. prepare the two collars “G” with springs

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

3. insert pipe “N” inside ﬁ tting “A”

4. tight the two collars “O” in a manner to

Figure 45 - Installation of Split ﬁ tting system

“E” and “F”;

mechanically secure pipe “N” to ﬁ tting “A”, DO NOT FORCE.

Horizontal vent sections must always

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

Figure 46 - Connecting the pipes to the ﬁ tting

Page 57

9 - INSTALLATION - Split venting system

Horizontal vent systems should be

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

WARNING!!! Carefully follow the installation steps below for the assembling the split pipe venting system (elbows and extensions), as illustrated in ﬁ gure 47. it is necessary to properly insert the male side onto the female side and mechanically secure them by using the proper clamps. Improper venting can result in excessive levels of carbon monoxide or a ﬁ re, which can result in severe personal injury or death!

Figure 47 - Connecting extensions and elbows

Mechanically secure each joint with

the supplied clamps as shown in ﬁ gure 47. Follow this procedure:

1. insert the Male side “B” into the

Female side “A”;

2. use clamp “C” to keep the two

pipes together;

3. use screws “E” to tighten the clamp

onto both pipes; DO NOT force.

CAUTION!!! If vent and

air intake terminals are located on the same wall or on the same roof,maintain the distances given in ﬁ gure 48, between the vent and air intake, or ﬂ ue gas recirculation may occur, causing improper boiler operation!

CAUTION!!! The air intake

terminal must be protected from wind by a 90° elbow, see ﬁ gure 48.

Figure 48 - Clearances of Split system

Page 58

9 - INSTALLATION - Split venting system

9.2 - Split system components

Some of the most commonly used components for installing the Split polypropylene vent and combustion air systems are listed below: 54301 - No. 1 - Split adaptor 80/80 PP 54344 - No. 2 - 3ft PP M/F extension 54387 - 60 ft PP ﬂ exible extension 54388 - Spacer for PP ﬂ exible extension 54345 - No. 3 - 90° PP M/F in line elbow 54346 - 45° PP M/F in line elbow 54347 - No. 4 - Secure clamp for PP

54352 - No. 5 - Split vertical terminal 54389 - No. 6 - Air intake grid 54417 - No. 7 - Flue exhaust grid

extensions

Figure 49 - Interaxes of Split system

54301

Note: the numbers after the codes correspond to the numbers in ﬁ gure 50

54389

54352

54387

54417

54344

54388

54345

54347 54346

Page 59

9 - INSTALLATION - Split venting system

9.3 - Split system

components

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

Terminal Type

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

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

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

Screen Termination 9392 FSBS3 2SVSTPF-3

Air Intake Tee SC03TAD3 n/a n/a

Heatfab Saf T Vent Part

Number

Pro Tech FasNSeal

Part Number

Z FLex

Part Number

Page 60

9 - INSTALLATION - Split venting system

9.4 - Split system: installation examples

Some installation examples can be seen in ﬁ gure 50:

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

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

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

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

Figure 50 - Installation examples of the Split system (see section 9.2 for the reference of the numbers)

Page 61

10 - INSTALLATION - Coaxial venting system

10.1 - Coaxial

system

The boiler is not supplied with the ﬁ tting needed for connecting a coaxial vent/combustion air system. A special kit must be ordered to connect the boiler with the Coaxial polypropylene vent. Figure 51 shows how to install the Coaxial ﬁ tting above the boiler:

WARNING!!! Carefully follow installation steps below, for the coaxial pipe assembly (elbows and extensions), as illustrated in ﬁ gure

52. it is necessary to properly

insert the internal and external pipe and mechanically secure

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

Figure 51 - Installation of the coaxial ﬁ tting

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

In particular:

1. slip-ﬁ t the extension “1” and “2”

2. drill a suitable hole “3” with a drill

3. insert a suitable stainless steel self

(see ﬁ gure 52) together; “4” (see ﬁ gure 52) in a position

where the two pipes “1” and “2” are overlapped;

tapping screw “5” and tight it with a screwdriver “6”

Figure 52 - Secure ﬁ xing extensions and elbows together

It is recommended that wall sleeve

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

Horizontal coaxial systems must

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

The Coaxial system should extend

out of the wall to the dimensions shown in ﬁ gure 54.

Page 62

10 - INSTALLATION - Coaxial venting system

10.2 - Coaxial system components

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

54303 - No. 1 - In line 90° PP coaxial M/F elbow

54303

54304 - No. 6 - In line 45° PP coaxial M/F elbow 54302 - No. 7 - 3ft (1m) PP coaxial extension 54348 - No. 3 - PP coaxial roof end piece 54342 - No. 5 - PP Coaxial wall end piece 54340 - No. 8 - PP straight coaxial adaptor

Note: the numbers after the codes correspond to the numbers in ﬁ gure 53.

54304

54340

54302

54348

54342

Page 63

10 - INSTALLATION - Coaxial venting system

10.3 - Coaxial system components

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

Terminal Type

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

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

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

Screen Termination 9392 FSBS3 2SVSTPF-3

Horizontal Termination Adapter SC03HT n/a n/a

Heatfab Saf T Vent

Part Number

Pro Tech FasNSeal

Part Number

Z FLex

Part Number

Page 64

10 - INSTALLATION - Coaxial venting system

10.4 - Coaxial

system: installation examples

When a coaxial vent and combustion air system is installed, ﬁ gure 53, whether vertical or horizontal, it must be sloped 1/4 in/ft, (21 mm/m) towards the boiler.

the distances given in ﬁ gure 54, between the vent terminal and the wall and also between the vent terminal and the ground level (snow line).

Maintain 3ft distance also between the vent terminals of two or multiple boilers (see ﬁ gure 54).

CAUTION!!! Maintain

Figure 53 - Installation examples for the coaxial pipe (see section 10.2 for

the reference of the numbers)

Figure 54 - Clearances for the coaxial vent terminals of two boilers, in a vertical wall or in a roof

Page 65

11 - OPERATING

11.1 - Operating

Before starting the boiler, the following must be done.

11.1.1 - User instructions

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

Make sure that the user keeps this

manual and all other documentation included with the boiler.

Make sure that the user

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

Make sure that the user is informed

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

Make sure that the user knows

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

11.1.2 - Filling the condensate trap

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

1. unscrew “E” screw (Figure 55);

2. remove ﬂ ange “D” and O-Rings “C” (Figure 55)

3. With a rubber tube and a funnel, slowly pour approximately 4 oz. (100 ml), of water into the “B” opening - DO NOT put water into the “A” opening (Figure 55);

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

55);

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

condensate trap.

11.1.3 - Filling the heating system

CAUTION!!! The heating

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

CAUTION!!! The addition

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

13.11 to prevent problems.

Figure 55 - Filling the condensate trap

To ﬁ ll the heating system, proceed as follows:

1. open the automatic air vent, shown as item “1” in ﬁ gure 1, two turns;

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

3. check that there is no water leaking from the ﬁ ttings. If there is the leaks must be eliminated;

4. close the ﬁ ll valve;

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

Figure 56 - A = Purge screw for the domestic hot water heat exchanger

Page 66

11 - OPERATING

11.1.4 - Filling the domestic hot water heat exchanger

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

1. connect a rubber tube to the pressure coupling “A” shown in ﬁ gure 56 and place the end in an empty bucket or sink;

2. loosen screw “A” as shown in ﬁ gure 56 until air can be heard escaping;

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

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

11.1.5 - Auto-purging the

heating system

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

11.2 - General

warnings concerning gas supply

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

That the boiler is supplied with the

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

That the gas supply pressure is

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

That the gas supply system is

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

That the vent and combustion

air terminals are free from any blockages.

That the condensate drain tube is

properly connected.

WARNING!!! If you smell gas:

 Do not try to light any appliance.  Do not touch any electrical

switch. Do not use any phone in your building.

 Immediately call your gas

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

 If you cannot reach your gas

supplier, call the ﬁ re depart-

ment. Failure to follow the above steps can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

11.3 - Conﬁ rming the boiler’s gas type

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

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

NATURAL GAS

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

LP Gas

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

11.4 - Gas type conversion

If the gas available at the installation site is not the type the boiler is conﬁ gured to use, the boiler must be converted. Special conversion kits are available for this purpose. The instruction inside the conversion kit must be followed.

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

11.5 - Start-up

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

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

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

4. Upon start-up, an is shown for 3 minutes while the boiler goes through its heating system purge cycle as described in section

11.1.5. To by-pass this stage, press the and keys together

until a blinking appears. Then press the button.

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

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

12.10.

7. If the pump indicator is illuminated, item “6” in ﬁ gure 64, but the pump is not running, item “45” in ﬁ gure 1, it may be stuck. If this is the case it can be released by removing screw “44” shown in ﬁ gure 1 and turning the screw underneath.

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

Page 67

11 - OPERATING

11.6 - Ignition control testing

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

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

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

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

4. wait a few minutes for the burner to light-up as indicated when light “3” shown in ﬁ gure 64 stays illuminated.

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

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

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

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

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

11.7 - Gas supply

pressure checking

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

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

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

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

;

9. press the key until the display shows . Now the

boiler will run for 10 minutes at maximum input;

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

After verifying the correct gas pressures disconnect the manometer, turn the screw in pressure connection “D” in ﬁ gure 57, clockwise until snug and check for any gas leaks.

C - Service pressure port

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

Figure 57 - Gas valve

and adjustment

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

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

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

3. turn the screw in pressure port “D” shown in ﬁ gure 57 three turns counterclockwise;

4. connect a manometer with graduations of at least 0.1 in.W.C. (0.25 mbar) to the inlet gas port “D” shown in ﬁ gure 57;

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

WARNING!!! Never use an open

ﬂ ame to check for gas leaks, a ﬁ re or an explosion could result

causing severe personal injury or death!

Page 68

11 - OPERATING

Figure 58 - Combustion air pressure probes

11.8 - Check the combustion air pressure

The boiler has a factory-set air/gas ratio. The pressure of the gas at the burner is indirectly controlled by the blower. The combustion air pressure must be checked as follows while refering to ﬁ gures 58 and 59:

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

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

3. open the boiler casing following section 13.2;

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

5. remove plug “B”;

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

7. insert tube “F”, from the negative side of the manometer, through the opening of plug “B”, and connect it to pressure probe “C” as shown in ﬁ gure 59;

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

9. the manometer connections must be made as shown in ﬁ gure 59, to get the correct pressure reading;

10. replace panel “H” of ﬁ gure 65 and latch it closed. If panel “H” is not properly in place the manometer reading will not be accurate;

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

Figure 59 - Checking the combustion air pressure

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

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

14. compare the pressure on the manometer with the table in section 14, “Combustion air pressure”.;

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

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

normal running mode;

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

Page 69

11 - OPERATING

11.9 - Checking and adjusting CO2 levels

Section 14 lists the correct CO2 ranges for a boiler running at normal operating conditions at an altitude below 3000 ft (1000m). CO2 values outside of the ranges given in section 14 may lead to malfunctioning of the boiler and cause it to prematurely fail. To check the CO2 value, carry out a combustion analysis as follows while referencing ﬁ gure 60:

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

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

3. press the for more than 10 seconds, the

display will show a blinking ;

4. press the key until the display shows if a call for

heat has been generated or until

is displayed if a domestic hot water demand has been generated. The boiler will now run for 10 minutes at low ﬁ re input.

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

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

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

To adjust the low ﬁ re CO2 proceed as follows:

1. use a screwdriver to remove the gas valve cap, item “F” in ﬁ gure 57;

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

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

4. replace the gas valve cap, item “F” in ﬁ gure 57;

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

and keys

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

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

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

To adjust the CO2 proceed as follows:

1. use a screwdriver to turn screw “E” shown in ﬁ gure 57;

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

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

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

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

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

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

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

Figure 60 - Combustion

analysis probes

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

Now check and, if necessary, adjust

high ﬁ re CO2:

6. press the display shows if a call for

heat has been generated or until

is displayed if a domestic hot water demand has been generated. The boiler will now run for 10 minutes at high ﬁ re input;

key until the

button.

Page 70

11 - OPERATING

11.10 - Adjusting the heating capacity

This boiler has been engineered with an “intelligent” micro-processor control that will adjust the heating output to match the system demand. To maximize the effectiveness of the

system, the parameters the “Installers menu”, in section 12.17, can be adjusted set the maximum heating output to the effective maximum load necessary for the

system. The parameter can be adjusted from 100 (factory set value),

to 1. The correspondence between value and heating output is given by table in ﬁ gure 61.

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

every value.

found in

11.11 - Domestic hot water ﬂ ow rate adjustment

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

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

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

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

4. set the mixing valve (item “10” of ﬁ gure 16 to its maximum values)

5. wait 5 minutes for the temperature to stabilize;

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

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

11.12 - Cold start boiler

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

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

*Factory set heat input. To adjust see section 11.10

Figure 61 - Correspondence table to set space heating input

Page 71

12 - USE

1 - Display of the parameters 2 - Display of the paramenters value. 3 - Light indicates the burner state: Light-on = Burner ON; Blinking = Burner OFF. 4 - Light indicating DHW service: Light-on = DHW service ON; Light-off = DHW service OFF. 5 - Light indicates the decimal. 6 - Light indicates CH service: Light-on = CH service in function; Light-off = CH service not function. 7 - Heating temperature control. 8 - Key for decreasing parameter values. 9 - Key for resetting shutdowns and for scrolling the list of parameters. 10 - Key for increasing parameter values. 11 - Domestic hot water temperature control. 12 - On/off power switch. 13 - Heating circuit pressure gauge.

Figure 62 - Instrument panel

12.1 - Check heating system pressure

If the pressure inside the heating circuit falls below 7psi (0,5 bar), the appliance switches off and the display “1” as per ﬁ gure 62, shows

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

1. open the ﬁ lling cock;

2. check the pressure on the pressure

gauge “13” of ﬁ gure 62, it must reach a pressure of 20 psi (1,5 bar)

and the indication must disappear;

3. close the ﬁ lling cock.

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

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

12.2 - Overview

The boiler is pre-set with standard parameters. However, it is possible to make a number of changes or consult the parameters by means of using the “Users’ Menu” (see section 12.16). During functioning display “1” of ﬁ gure “62” displays the status of the boiler and display “2” (see ﬁ gure 62) shows the value of the parameter. The various operating statuses are shown in section 12.18. Within the “Users’ Menu” (see section

12.16) it is possible to check the last lock-out or error which have occurred. In addition to the operating modes, the instrument panel provides important information on the current functioning of the boiler, via the

indicators “3”, “4”, “5” and “6” of ﬁ gure

62. In particular:

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

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

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

12.3 - Displays

During normal operations, the parameters’ display “1” and the values’ display “2” (see ﬁ gure 62) remain permanently on, if the ”Energy Saving” mode has not be activated (See section 12.15). The parameters which can be displayed are shown with their meaning in the table shown in section

12.18.

Page 72

12 - USE

12.4 - Start-up procedure

1. Open the manual shutoff gas valve;

2. switch on electric power to the boiler;

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

4. on initial start-up, the appliance carries out an auto-purging cycle lasting two minutes. This is

indicated by the appearance of on the display;

5. wait two minutes until the end of the auto-purging cycle;

6. turn knob “7” of ﬁ gure 62 until it reaches the heating temperature desired. Turn knob “11” of ﬁ gure 62 until it reaches the domestic water temperature desired.

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

01.

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

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

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

12.5 - Summer mode

To disable the heating functions for a prolonged period, leaving only the domestic hot water function, switch OFF the heating temperature, until the wording OFF appears, by turning knob “7” of ﬁ gure 62 to the minimum.

12.6 - Winter mode

In Winter mode, by means of the pump, the boiler sends the water to the system at the temperature set using knob “7” of ﬁ gure 62. When the temperature inside the boiler reaches the temperature set, the burner starts to modulate the ﬂ ame so as to reduce the output to a minimum. If the temperature rises further, the burner shuts down. Simultaneously, the pump which sends the water to the system is switched on and off by the room thermostat. This can be noted, because indicator “6” of ﬁ gure 62 switches on and off in correspondence with the on and off of the pump. At ﬁ rst the pump may make a noise. This is due to the presence of residual air in the hydraulic system which will soon disappear on its own. We recommend keeping the temperature set using knob “7” at the point shown by the symbols on the panel for a rational use of the boiler. If it is a particularly cold Winter and it is difﬁ cult to maintain the desired temperature, turn knob “7” to gradually higher values.

- if a domestic water request is

active;

- if a heating request is active;

- if there is no domestic water or

heating request active.

Page 73

12 - USE

12.7 - Adjusting the domestic hot water temperature

The domestic hot water temperature is adjusted by turning knob “11” shown in ﬁ gure 62. When the knob is turned, the display, item “1” in

ﬁ gure 62, shows a ﬂ ashing the temperature being selected. The range within which the domestic hot water can be set is 104°F (40°C) to 140°F (60°C) or from 104°F (40°C) to 158°F (70°C) when an indirect storage tank is used.

and

12.8 - Heating system temperature adjustment

The boiler provides hot water to the heating system at the temperature set by adjusting knob “7” as shown in ﬁ gure 62. The room thermostat turns the boiler’s circulator pump on in order to satisfy the heat demand of the rooms controlled by the thermostat. To maximize the boilers’ performance, temperature knob “7”, should be set at a value that is just sufﬁ cient to maintain the desired temperature of the rooms. As the weather gets colder, progressively increase the water temperature by adjusting knob “7”. When the weather gets milder turn the water temperature down. This extremely simple method is suitable for the following types of systems:

1. small systems with radiators where the thermostat is installed in a room whose temperature is characteristic of all the other rooms;

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

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

CAUTION!!! If the boiler is installed in a low temperature system follow the settings speciﬁ ed in section 5.10 or the heating system may be damaged.

12.9 - Heating system type selection

The boiler is factory set for wall stat control as per section 12.8. The heating system type can be changed by going to the “Installers’ Menu” in section 12.17 and changing

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

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

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

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

12.10 - Outdoor reset adjustment

While in the “Installers’ Menu”, set the

parameter to 01. In this mode the heating supply water temperature, calculated temperature in ﬁ gures 63 and 64, will be adjusted automatically based on the input from the outdoor temperature sensor. The relationship between the outdoor temperature and the supply water temperature, corresponds with the graphs shown in ﬁ gures 63 and 64. In order to change the relationship between the supply water temperature and the outdoor temperature, all the parameters listed in the sections below must be set.

12.10.1 - Outdoor reset applications

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

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

B - Iarge systems, with radiators,

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

C - small systems, with low tempera-

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

parameter in order to

compensate, see section 12.17.

D - Iarge systems with low

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

CAUTION! If the boiler is installed in a low temperature system, follow the settings speciﬁ ed in section 5.10 or the heating system may be damaged.

Page 74

12 - USE

12.10.2 - Outdoor reset adjustment precautions

When making adjustments to change the supply temperature, it is advisable to ﬁ rst set the suggested default values for the desired curves shown in ﬁ gures 63 and 64. If these default values do not produce a satisfactory result, then proceed to make the appropriate adjustments bearing in mind that: A - each parameter must be varied

gradually;

B - after each parameter change, wait

at least 24 hours in order to see the result;

C - the closer the adjustment curve

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

D - knob “7” in ﬁ gure 62 can be used

to make the small line shifts, “b”, shown in ﬁ gures 63 and 64. These shifts will change the supply water temperature up to 18 °F (10 °C).

12.10.3 - Outdoor reset: setting parameters

Refer to section 12.16 and set:

- = “The angle of the curve”, which can be adjusted between 0.1 and 5.0. Suggested starting values are: 0.6 for “low temperature” systems;

1.6 for “high temperature” systems;

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

- = “Maximum heating temperature”. This parameter is the limit of the supply heating temperature. Its range of adjustment is between 86 °F (30 °C) and 194 °F (90 °C). The suggested starting values are: 113 °F (45 °C) for “low temperature” systems; 176 °F (80 °C) for “high temperature” systems. Refer to section 12.11and set:

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

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

12.10.4 - Outdoor reset: zone adjustments

The default values previously suggested are for boilers using an outdoor temperature sensor installed in dwellings with average heat loss in areas where the outside temperature for the calculation of the heat requirement is 23 °F (-5°C). In the event that the climatic zone is different, adjust the gradient of the

curve, parameter calculated temperature of 176 °F (80 °C) for high temperature systems, see ﬁ gure 63. For “Low Temperature” systems adjust the gradient of the

curve, parameter a calculated temperature of 113 °F (45°C), see ﬁ gure 64.

, to obtain a

, to obtain

12.10.5 - Outdoor reset activation

Once selected, reset adjustment is completely automatic and will switch off at the end of the heating season and switch back on at the beginning of the heating season. When the

“Calculated temperature” is lower than the “Minimum heating temperature”,

parameter , the heating service switches off. When the “Calculated temperature” exceeds the “Minimum

heating temperature”, parameter , the heating service switches back on. If for some reason the heating service doesn’t match the load, use knob “7” in ﬁ gure 62, to raise or lower the calculated temperature and match the “Minimum heating temperature” on an advanced or delayed basis.

12.10.6 – Outdoor reset with room compensation

While in the “Installers’ Menu” set the

parameter to 02, see section

12.17. The system will function exactly as described in the previous “Outdoor reset adjustment” sections except that now the boiler pump will stay on permanently. The opening of the room thermostat contacts will translate into a parallel downward movement of the curve in ﬁ gure 63 or 64. The value by which the curve moves downwards can

be adjusted by the parameter present in the “Installers’ Menu”, see

section 12.17. The parameter can range from 1 °F (1 °C) to 36 °F, (20°C). The suggested values for this parameter are:

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

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

Values of this parameter that are too high may translate into room temperature instability. Values that are too low may make the action of the room thermostat ineffective. Climatic adjustment with room compensation can be used in all the systems described in section 12.10.1. The advantage being that the constant running of the pump will stabilize and standardize the room temperatures. This is especially true when some loops in the heating system have considerably greater volume than others.

Page 75

12 - USE

Calculated temperature (°F)

Calculated temperature (°C)

Calculated temperature (°F)

Calculated temperature (°C)

Outside temperature (°C)

Outside temperature (°F)

OA = Slope of the line Ob = Minimum heating temperature Oc = Maximum heating temperature br = “Fix point” of the angle fulcrum of the line b = parallel shift of the lin

e (adjusted by the heating knob, item “7” of ﬁ gure 62)

Outside temperature (°C)

Outside temperature (°F)

Figure 63 - Graphs of the outdoor reset adjustment for “high temperature” systems

Calculated temperature (°C)

Calculated temperature (°F)

OA = Slope of the line

Outside temperature (°C)

Outside temperature (°F)

Ob = Minimum heating temperature Oc = Maximum heating temperature

br = “Set point” of the angle fulcrum of the line b = parallel shift of the line (adjusted by the heating knob, item “7” of ﬁ gure 62)

Calculated temperature (°F)

Calculated temperature (°C)

Outside temperature (°C)

Outside temperature (°F)

Figure 64 - Graphs of the outdoor reset adjustment for “low temperature” systems

Page 76

12 - USE

12.11 - Boiler switch settings

The control board shown in ﬁ gure 1, item “14”, and ﬁ gure 21, contains a series of switches that allow the boiler to be conﬁ gured to match the application. The table below lists each switch and its corresponding funtions.

SWITCH Position Description

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

12.12 - Delays,

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

e - Time delay in restarting the burner:

alarms and protective actions

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

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

b - DHW delay: each time the

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

c - Protection against legionnaires

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

is displayed by .

d - DHW alarm: if the call for domestic

hot water lasts for longer than two hours, an 01 alarm is generated.

This function is only for boilers set up to provide instantaneous DHW.

12.13 - Circulator pump and three way valve protection

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

12.14 - Freeze protection

protection function to work, the boiler must remain connected to the electrical and gas supplies with knobs “7” and “11” in ﬁ gure 62, in the OFF position.

CAUTION!!! Improper

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

CAUTION!!! For the freeze

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

12.15 - Display in energy saving mode

If desired, the display, items “1” and “2” in ﬁ gure 62, can be switched permanently off, with the exception of when it displays errors or settings. To switch the display off, access the “Installers’ Menu”, in section 12.17

and set the parameter at a value other than zero. Keep in mind that each value will correspond to a delay in minutes until the display goes into Energy Saving mode.

Page 77

12 - USE

12.16 - “Users’ menu”

When entering the “Users’ menu”, the display, item “1” in ﬁ gure 62, will start blinking indicating that a change of mode has taken place. To access the “Users’ menu” (see also section 16 to better understand the several menus):

 press the button for 2

seconds until the display starts blinking;

 press and release the button

several times until the desired parameter is displayed;

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” of ﬁ gure 62

Adjustment of the curve angel as shown in ﬁ gures 63 and 64 when outdoor reset is active per section 12.9.

 use the or keys, to

change the value of the selected parameter.

 press to save the parameter

change before going to the next parameter.

When the last parameter has been reached and the button

pressed, the display will stop blinking indicating exit from the menu.

Setting range: 0,1 to 5,0

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

saved using the be lost.

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

button, will

Adjustment of the “Minimum heating temperature” as shown in ﬁ gures 63 and 64 when outdoor reset is active per section 12.9.

Adjustment of the “Maximum heating temperature” as shown in ﬁ gures 63 and 64 when outdoor reset is active per section 12.9.

Adjustment of the parallel shift of the curve as shown in ﬁ gures 63 and 64 when outdoor reset is active per section 12.9.

Display of the calculated heating temperature when outdoor reset is active per section 12.9, or display of the temperature set by knob “7” shown in ﬁ gure 62.

Display of the domestic hot water temperature when set by knob “11” shown in ﬁ gure 62.

Display of last error code registered, section

12.18.2

Setting range: see section 12.10.3

The adjustment is made by turning knob “7” shown in ﬁ gure 62. The selected curve can be shifted up or down by 18 °F (10 °C).

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

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

Error code display per section 12.18.2

Display of last lockout occurred, section 12.18.1

Fault code per section 12.18.1

Page 78

12 - USE

12.17 - “Installer’s menu”

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

The boiler’s micro-processor makes this menu of parameters available to the qualiﬁ ed technician for the analysis of the functioning and adjustment of the appliance to the system. When entering the “Installers’ Menu”, the display item “1” in ﬁ gure 62, will start to blink indicating that a change of mode has taken place. To access the “Installers’ Menu” just (see also section 16):

 press the button down for 12

seconds until the parameter is displayed;

 press and release the button

to scroll through the list of the parameters;

 once the parameter has been

displayed, it can be changed using the or keys;

 press and release the button

to conﬁ rm the amended data before moving to the next parameter.

When the last parameter has been reached and the button

pressed, the display will stop blinking indicating an exit from the menu.

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

saved using the button, will be lost.

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

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” OF Figure 62

Boiler and heating supply temperature, measured by U1 sensor

Domestic hot water temperature, measured by U2 sensor

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

Outdoor temperature, measured by U4 sensor

Ionization current value

High limit temperature, measured by U6 sensor

Flue gas temperature, measured by U7 sensor

Heating return temperature, measured by U8 sensor

Type of basic setting of control board

Status of room thermostat contact

Value in °F (cannot be changed)

Value in °F (cannot be changed) Value in °F (cannot be changed) (displayed only if outdoor reset is

active, as per section 12.9) Value from 0 to 99 (cannot be changed)

(30 corresponds to a current of 1uA) (99 corresponds to a current of 5.5 uA)

Value in °F (cannot be changed)

Value in °F (cannot be changed) Can be changed in accordance with the instructions indicated in the

gas conversion kit 00 = contact open (heating service off)

01 = contact closed (heating service on)

Measurement of fan speed rotation

BTU input for heating service

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

Adjustable according to the instructions of section 11.10

Continue

Page 79

12 - USE

Continued

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” OF Figure 62

Can be changed:

Heating service functioning mode

00 = thermostatic adjustment (see section 12.8); 01 = outdoor reset (see section 12.10); 02 = outdoor reset with room compensation (see section 12.10.6);

Reaction to external temperature

Angle fulcrum of climatic adjustment

Reduction of temperature generated by the opening of the room thermostat

Boiler knobs’ status

Display “1” and “2” as per ﬁ gure 62 energy saver

Parameter disabled for this kind of boiler

Domestic sensitivity setting

Minimum domestic setpoint during sleep mode

Proportional band of the heating PID modulation

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

Can be changed from 16°F (-9°C) to 149°F (65°C) (active only with outdoor reset). See section 12.10.3 for its adjustment.

Can be changed: from 1°F (1°C) to 36°F (20°C) (active only with outdoor reset featuring room compensation) See section 12.10.6 for its adjustment.

Can be changed: 01 = knobs presents; 00 = knobs absent.

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

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

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

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

Integral of the heating PID modulation

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

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

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

Page 80

12 - USE

12.18 Diagnostics

During the normal operation of the boiler, the display “1” and “2” of ﬁ gure 62, continually shows the operating status of the boiler as shown below (see also section 16):

PARAMETER DISPLAY (ITEM “1”, Figure 62)

PARAMETER REFERENCE DISPLAY READ OUT (ITEM “2”, Figure 62)

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

Anti-freeze function active

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

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

11.1.3. Domestic hot water service on

Heating service on

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

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

button. If

Boiler temperature (°F)

Boiler temperature (°F) 01 = Domestic hot water service active for more

than 120 minutes. Turn domestic hot water to OFF position to reinstate heating.

02 = Connection interrupted between boilers on a cascade boilers

No display Domestic hot water temperature (°F)

Heating temperature (°F)

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

Error code (see section 12.18.2 for decodiﬁ cation).

Auto-purging procedure that last 3 minutes in progress (see section 11.1.5).

Boiler in Anti-legionella functioning (see section 12.12)

Boiler temperature (°F)

Storage tank temperature (°F)

Page 81

12 - USE

12.18.1 - Diagnostics: “L” lock-outs

“L”

Code

L01

L02

L03 L04

L05 L06

Lock-out

description

No ﬂ ame detected after three ignition attempts.

Flame extinguishes three times.

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

Gas valve command relay Safety relay

Flue gas sensor over 230°F (110°C)

Checks to make

Check: a-correct gas supply pressure (see

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

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

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

end of the ignition attempt, check: that

the ionization current is set at a value

greater than 60 (follow procedure in

section 13.12.4)

Check: a-that the ionization current is set

at a value greater than 60 (follow

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

adversely affected by wind;

Check that the circulator pump is working

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

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

Solutions

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

the correct pressure;

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

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

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

system and eliminate any obstructions;

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

board must be replaced;

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

1.10 kohm, the gas valve must be replaced.

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

the the CO2 content is adjusted properly (see section

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

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

the the CO2 content is adjusted properly (see section

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

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

relocated.

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

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

replace the power control board. a-If the ﬂ ue gas sensor resistance does not correspond with the

correct values, replace it;

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

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

L07

L08 L09

L10 L12 L13 L14 L15 L16

L17

Electrical circuit of ﬂ ue gas sensor is interrupted

Spark generator relay RAM memory

E2prom memory damaged E2prom memory damaged

Program error Program error Program error Program error

The temperature difference between the U1 and U6 sensors is too great

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

graph in section 13.13;

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

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

Replace the power control board Replace the power control board

Replace the power control board Replace the power control board Replace the power control board Replace the power control board

a-If one or both sensors does not have the correct resistance

value, it must be replaced;

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

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

Page 82

12 - USE

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

“L”

Code

L18

L19

L20

L25

L32 L33

L45

L46

Lock-out description

Program error

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

Flame sensed before opening of the gas valve.

U1 or U6 sensor increase its temperature too fast

Program error Fan rotation error

Heating circuit ﬁ lling time longer than 10 minutes.

Filling of heating circuit repeated 16 times in 24 hours

Controls

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

low;

b - that the circulator pump is working

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

Check: a - that the heating pressure switch

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

b - check that there are no water leaks

in the heating system.

Solutions

Replace the power control board

Call technical service

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

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

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

Replace the power control board

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

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

replaced;

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

L47

Flue pressure switch open time longer than 60 minutes

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

discharge/air intake line

b - check the ﬂ ue pressure switch

setting point, setting is 4.5 in.W.C

c - check that the electrical resistance of

the ﬂ ue gas sensor corresponds with the graph in section 13.13;

d - check that the electrical connection

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

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

replaced;

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

replaced;

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

control board

Page 83

12 - USE

12.18.2 - Diagnostics: “E” blocking errors

“E”

Code

E01

E02

E04

E07

Blocking description

U1 boiler temperature sensor circuit interrupted.

U2 domestic hot water temperature sensor circuit interrupted.

U8 return temperature sensor circuit interrupted

U3 cold water temperature or storage tank sensor circuit interrupted

Checks to make

Check that the electrical resistance of the sensor corresponds with the graph in section 13.13; check that te electrical connection cables between the sensor and the power control board have continuity and carry current

Solutions

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

E08

E11

E12

E13

U6 boiler temperature sensor circuit interrupted.

U1boiler temperature sensor circuit shortcircuited.

U2 domestic hot water temperature sensor circuit short-circuited

Erroneous temperature reading.

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

Replace the power control board

Page 84

12 - USE

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

“E”

Code

E14

E15

E16 E17

E18

E19

Blocking description

U8 return temperature sensor short-circuited

U4 outside sensor shortcircuited

Erroneous temperature reading.

U3 cold water temperature or storage tank sensor circuit shorted

U6 boiler temperature sensor circuit shorted

E2prom memory damaged

Checks to make

Check that the electrical resistance of the sensor corresponds with the graph in section 13.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current Check that the electrical resistance of the sensor corresponds with the graph in section 13.14; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

Solutions

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

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

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

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

Replace the command and control board

E20 E21

E22

E23 E30 E31

E32 E33 E42

E50 E51

E52 E53

Flame presence with gas valve closed

Phase and neutral inverted

Electrical supply frequency other than 60Hz

Ground connection is absent

Erroneous temperature reading.

Program error Error in the boiler tY

parameter selection Reset button pressed too

often in a short period time Heating ﬂ ow switch

closed Heating ﬂ ow switch

is open

Invert phase and neutral

Check the electrical frequency of the system. Check if CS parameter is at 03 (see section 16)

Check if the boiler is properly grounded

Push ON switches 7 an set again the correct tY value (see section 16).

Check if heating pump is running. Check if ﬂ ow switch contact is stuck.

Check if heating pump is running. Check if ﬂ ow switch contact is broken.

Replace the gas valve

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

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

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

Replace the power control board

Replace the power control board If tY value is correct, change the power control board

The pump should not run and the contact should be open The contact must be open

The pump should run and the contact should be closed The contact must be closed

Page 85

13 - MAINTENANCE

13.1 - General

precaution

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

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

Service and maintenance schedules

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

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

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

Service Technician User maintenance

Annual Startup:

- Address reported problems

- Check all piping for leaks

- Verify ﬂ ue and air lines in good condition and sealed tight

- Check system water pressure/system piping/ expansion tank

- Check control settings

- Check ignition and ﬂ ame sense electrodes

- Check wiring and connections

- Perform Performance veriﬁ cation

- Flame Inspection

- Check ﬂ ame signal

- Clean the heat exchanger if ﬂ ue temperature is more than 72°F (40°C) above return water temperature.

- Clean condensate trap

- Check combustion air pressure

- Check relief valve

- Check for any air inside the domestic heat exchanger

- Check any domestic water softener for any needed maintenance (follow softener’s manufacturer instructions)

Daily:

- Check boiler area

- Check Pressure gauge

Monthly:

- Check vent piping

- Check air piping

- Check condensate drain system

Every six month:

- Check boiler piping (gas and water) for leaks

End of season months:

- Shut boiler down (unless boiler is used for domestic hot water)

Page 86

13 - MAINTENANCE

13.2 - Removing the casing

In order to remove the casing, follow the steps below while refering to ﬁ gure 65:

1. remove screws “A”;

2. raise latch “C”;

3. remove the front cover;

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

5. lower the electrical box;

6. lift latch “G”;

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

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

Figure 65 - Removing the casing

Page 87

13 - MAINTENANCE

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

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

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

2. unscrew nut “D” from the gas valve (taking care not to loose gasket “E” in ﬁ gure 68);

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

4. disconnect the wire from safety sensor “F” in ﬁ gure 66;

5. unscrew the four nuts “C” in ﬁ gure 66;

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

7. remove the entire fan - burner assembly, detail “A” in ﬁ gure 66;

8. use a cylindrical brush with plastic bristles to clean the inside of the combustion chamber, detail “H” in ﬁ gure 66;

9. use a vacuum cleaner to remove any unburned residue from the combustion chamber, detail “H” in ﬁ gure 66;

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

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

WARNING!!! while performing the next step, carefully wash only the inside of the combustion chamber “H” of ﬁ gure 66, and do not get water on the outside of the combustion chamber opening. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

11. using only water, wash the inside of the combustion chamber, detail “H” in ﬁ gure 66. The water, will drain into the condensate drain. Clean the condensate trap (see section 13.6) before reassembling components;

12. reassemble the components by proceeding in reverse order;

13. open the manual gas shutoff valve;

14. restore electrical power to the boiler;

15. check that there are no gas leaks.

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

Figure 66 - Remove the fan-burner assembly unit

Page 88

13 - MAINTENANCE

13.4 - Correct

positioning of the ignition and ﬂ ame detection electrodes

For the boiler to work properly the electrodes must be positioned as shown in ﬁ gure 67:

the distance between the ignition

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

the distance of the ignition

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

the distance of the ﬂ ame detection

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

A = Left ignition electrode B = Right ignition electrode

C = Flame detection electrode

Figure 67 - Positioning electrodes on burner (Use

an hand caliper to veriﬁ e the distances of the electrodes)

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

13.5 - Domestic

hot water heat exchanger

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

Page 89

13 - MAINTENANCE

13.6 - Condensate

trap cleaning

The condensate trap must be cleaned every year. Follow the steps below to properly clean the condensate trap and its associated components while refering to ﬁ gure 68:

1. run the fan as described in section

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

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

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

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

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

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

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

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

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

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

11. reﬁ ll the condensate trap per section 11.1.2.

Figure 68 - Removing the condensing trap

Page 90

13 - MAINTENANCE

Figure 69 - Replacing the pump motor

13.7 - Circulator

pump motor replacement

To replace the circulator pump follow the steps below while, refering to ﬁ gure 69:

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

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

3. remove screws “B”;

4. remove the circulator pump motor “A”;

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

6. disconnect the electrical wires from the circulator pump motor

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

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

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

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

13.8 - Expansion

tank pressure

To check the expansion tank pressure follow the steps below:

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

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

3. check the pressure of the expansion tank, item “4” of ﬁ gure 1 (The air inlet probe is on the top of the expansion tank). It must be 14 psi (1 bar). If the pressure is lower recharge the expansion tank while letting the water run out of the heating system drain valve.

Page 91

13 - MAINTENANCE

13.9 - 3-way valve

removal

The 3-way valve, details “M” and “Q” in ﬁ gures 70 and 71, directs hot water produced by the primary heat exchanger to the heating circuit or to the secondary heat exchanger for the production of D.H.W. To replace or clean it, follow the steps below while referring to ﬁ gures 70 and 71:

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

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

3. disconnect ﬁ ttings “A”;

4. remove screws “C”;

5. rotate “D” ﬂ ange in the sense of the black arrow (See particular ﬁ g. 1);

6. remove the bracket “E”;

5. remove ﬁ tting “F”;

6. remove ﬁ tting “L”;

7. remove ﬁ tting “M” and check its state.

8. remove spring “N”;

9. remove servomotor “O”;

10. remove the ﬁ tting “P”

11. remove the spring “Q” and check for any dirty.

Figure 70 - Supply ﬁ ttings removal (only for

160-C model)

Figure 71 - 3-way valve servomotor removal

Page 92

13 - MAINTENANCE

13.10 - Draining the heating side of the boiler

To drain the heating side of the boiler follow the steps below:

1. allow the water inside to cool by switching off the room thermostat and turning knob “7” in ﬁ gure 62 to minimum. Wait until the display, item “2” in ﬁ gure 62, shows a temperature less than 104°F (40°C);

2. turn off the boiler;

3. shut off electrical power to the boiler;

4. close the manual gas shutoff valve, ﬁ gure 16 item “3”;

5. close the boiler isolation valves in the heating system. If isolation valves haven’t been installed, the entire heating system will have to be drained.

6. close the heating system ﬁ ll valve;

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

8. connect a hose to the boiler drain valve and place the other end in a sink or some other suitable drain;

9. open the boiler drain valve and drain the boiler;

10. if boiler isolation valves have not been installed in the heating system open any bleed valves at the highest point of the system;

11. after draining out all the water, close the bleed valves and the boiler drain valve;

WARNING!!! Do not recover and/ or re-use water drained from the heating circuit for any purpose as it could be contaminated. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

13.11 - Draining the

domestic hot water side of the boiler

To drain the domestic hot water side of the boiler follow the steps below:

1. turn off the boiler;

2. close the valve in the water main supplying the DHW system;

3. open all the hot and cold faucets in the building;

4. if there isn’t a faucet or drain valve below the boiler level, disconnect DHW connections “10” and “12” in ﬁ gure 1.

13.12 – Overrides

To carry out speciﬁ c checks covered in the manual, it is possible to override the control logic of the boiler. See the next:

13.12.1 - Auto-purging

To reset the auto-purging procedure press the and keys

together for 10 seconds. When the blinking appears on the display,

press .

13.12.2 - Fan

To run just the fan at full speed press the and keys together

for 10 seconds, until the blinking

appears on the display. The fan will run at full speed for 10 minutes. To shut the fan off before the 10 minutes

is up press the key.

13.12.3 – Minimum and maximum output

The boiler can be run at its minimum or maximum output in both the heating and domestic hot water modes by following the steps below:

1. generate a demand for the mode to

be overridden:

- for heating turn up the room thermostat and turn knob “7” in ﬁ gure 62 to its maximum;

- for domestic hot water turn knob “11” in ﬁ gure 62 to its maximum and fully open a hot water faucet;

2. press the and keys together for more than 10 seconds,

until a blinking appears on the display;

3. press the key until the display shows:

- for minimum heating output;

- for maximum heating output adjusted by P parameter, see section 11.10;

- for maximum heating output;

- for minimum DHW output;

- for maximum DHW output;

4. press the key in order to restore the boiler to normal running conditions.

13.12.4 – Checking the

ﬂ ame current

While running at the minimum and maximum output described in section

13.12.3, the display will show the

letter of the mode checked. In the second part of the display the value of the ionization current will be shown. 30 corresponds to a current of 1 uA, 99 to a current of 5.5 uA. The ﬂ ame current must always be at the correspondent value as shown in section 14, header “ionisation current”. If the value is not within the above values, check: a - positioning of the ﬂ ame sensor

electrod as per section 13.4;

b - CO2 content as per section 11.9; c - combustion air pressure as per

section 11.8.

Page 93

13 - MAINTENANCE

13.13 - Water and

ﬂ ue temperature sensor

The boiler has a number of sensors that measure temperature. The electrical resistance between the sensor wires must correspond with the values shown in ﬁ gure 72.

The temperature sensors are: U1; U2, U3, U6, U7 and U8. The location of each sensor can be found in ﬁ gure 1 and sections 13.15 and 13.16.

Figure 72 - Water temperature sensor’s curve

13.14 - Outdoor

temperature sensor (optional)

An outdoor temperature sensor (U4) can be connected to the boiler (see section 6.5). The electrical resistance existing between the sensor wires must correspond with the values shown in ﬁ gure 73.

Figure 73- Outdoor temperature sensor’s curve

Page 94

13 - MAINTENANCE

13.15 - Functional wiring diagram

LEGEND: ALA - Alarm output

sensor

U3 TANK - Storage tank temperature sensor

(optional) U4 - Outside temperature sensor (optional) U6 - Heating Safety high limit temperature

sensor U7 - Flue gas temperature sensor U8 - Return temperature sensor PO1 - Heating pump PR - Heating pressure switch SDC - Electrical connection board RT1 - Room thermostat connection RT2 - Room thermostat connection on

remote control “CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Page 95

13 - MAINTENANCE

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

Page 96

13 - MAINTENANCE

13.16 - Multiwire wiring diagram

LEGEND: ALA - Alarm output

CM - Power control board CR - Remote command (optional) EA - Ignition electrode ER - Flame detection electrode EV3V - External three way valve (optional) F1 - Fuse 2Amps FPS - Flue pressure switch GS - Spark generator IG - Main electrical switch J1 - Six poles connector J2 - Four poles connector J3 - Twelve poles connector J4 - Four poles connector J5 - Sixteen poles connector J10 - Ten poles connector J18 - Height poles connector U1 - Supply temperature sensor U2 - Domestic hot water temperature sensor U3 - Domestic cold water temperature sensor U3 TANK - Storage tank temperature sensor (optional) U4 - Outside temperature sensor (optional) U6 - Heating Safety high limit temperature sensor U7 - Flue gases temperature sensor U8 - Return temperature sensor PO1 - Heating pump PR - Heating pressure switch SDC - Electrical connection board RT1 - Room thermostat connection RT2 - Room thermostat connection on remote control

“CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

Page 97

13 - MAINTENANCE

Page 98

14 - TECHNICAL DATA

MODEL PC-160-C

Country of destination USA and Canada Type of boiler Direct Vent boiler Category of discharge chimney IV CSA certiﬁ cate N° 2045300 (114696) Maximum Heat input Btu/hr 160,000 Minimum heat input Btu/hr 30,000 Annual Fuel Utilization Efﬁ ciency (AFUE) % 91.1 Maximum Heat output (160°F/140°F) Btu/hr 148,800 Steady State Efﬁ ciency at minimum heat input (122°F/86°F) % 97 Minimum heat output (122°F/86°F) Btu/hr 29,100 Gas ﬂ ow rate Natural gas cu. ft./hr 156 LP Gas gal/hr 1.75 Gas supply pressure Natural gas In.W.C. 7 LP Gas In.W.C. 11 Minimum gas supply pressure Natural gas In.W.C. 1.5 LP Gas In.W.C. 8 Maximum gas supply pressure Natural gas In.W.C. 11 LP Gas In.W.C. 13 Combustion air pressure with min. length Natural gas In.W.C. 2.5 to 3.1 LP Gas In.W.C. 2.1 to 2.7 Combustion air pressure with max. length Natural gas In.W.C. 2.1 to 2.7 LP Gas In.W.C. 1.8 to 2.4 Instantaneous d.h.w production (rise 75°F) gal/min 4.32 Maximum heating temperature °F 189 Minimum heating temperature °F 68 Maximum heating pressure PSI 30 Minimum heating pressure PSI 8 Maximum pressure of domestic hot water circuit PSI 150 Minimum pressure of domestic hot water circuit PSI 1 Capacity of expansion tank gal 2.64 Supply voltage 120Vac - 60Hz Absorbed electric power W 170 Flue gas pipes diameter (split) “ (mm) 3.15 (80) Max. length ﬂ ue gas pipes (split) ft 300 Flue gas pipes diameter (coaxial) “ (mm) 2.36/3.94 (60/100) Max. length ﬂ ue gas pipes (coaxial) ft 70 Equivalent length of one elbow ft 45° elbow = 3ft, 90° elbow = 5ft CO (Carbon monoxide) with natural gas ppm <150 CO (Carbon monoxide) with LP gas ppm <250 NOx (0% O2 with natural gas) ppm <30

CO2 (Carbon dioxide) for Natural gas at high ﬁ re % 8.6 to 9.2 CO2 (Carbon dioxide) for Natural gas at low ﬁ re % 8.2 to 8.6 CO2 (Carbon dioxide) for LP gas at high ﬁ re % 9.7 to 10.6 CO2 (Carbon dioxide) for LP gas at low ﬁ re % 9.2 to 9.8 Ionisation current for Natural gas at high ﬁ re 74 to 80 Ionisation current for Natural gas at low ﬁ re 81 to 87 Ionisation current for LP gas at high ﬁ re 71 to 77 Ionisation current for LP gas at low ﬁ re 83 to 89

Maximum ﬂ ue gas temperature °F 230 Flue gas ﬂ ow-mass lb/hr 160 Head pressure available for ﬂ ue vent/air intake line In.W.C. 3.6 Maximum condensation ﬂ ow rate gal/hr 1.32 Average acidity of condensation PH 4 Boiler weight lb 100

Page 99

15 - SPARE PARTS

Stock

Part No. Description

Code

1 60504206 CABLE UL IGNITOR CONN 90° L155 2 60802005 NUT ZINC COATED 6MA 3 60320001 SILICONE PIPE D 4 X 8 4 61405036 TEE FOR DRY WATER CONDENSATION 5 54311 60510022 SPARK GENERATOR NO CABLE UL 6 54328 62111016 SENSOR NTC 10 KOHM A KLIP DIAM.22 7 62622011 COPPER PIPE D22 M/F 3/4”G-1”G 8 60802018 3/4” RING NUT 9 60702030 O-RING NBR 2,62 X 20,63

10 62649004 PRIMARY HEAT EXCHANGER C.R.R ASME

11 60702047 GASKET EPDM X OSSIDO D84 H7 12 54329 62111017 SENSOR NTC 10 KOHM 1/8” 13 60803027 GASKET COPPER 1/8” SP.1,5 14 61405025 SILICONE TAP 15 60801116 SCREW 6 X 35 ZINC TC-CR 16 60803011 WASHER 6 X 18 X 1,5 PIA-ZIN-LAR UNI6593 17 60406074 BRACKET SIPHON L84 H130 P32 18 60702055 O-RING 134 EPDM 3,53 X 25,8 19 60801043 SCREW SELFTAPPING 3.9 X 9.5 CROSS HEAD

Stock

Code

20 62630136 SIPHON 21 60801100 SCREW SELFTAPPING 2.9 X 6.5 CROSS HEAD 22 60806020 SPRING 28,7 23 54331 62113041 PRESSURE SWITCH ON 4,5 INWC 24 60406092 BRACKET PRESSURE SWITCH 25 60322012 POLIETYLENE PIPE L=1000 26 60402037 SEALING CHAMBER DOOR 27 60701001 1”G GASKET 28 54344 62301031 PUMP GRUNDFOS UP 15/58U BRUTE USA 29 62622012 COPPER PIPE D22 RETURN SEALING CHAMBER 30 54327 62111015 SENSOR NTC 10K BAIO 31 XXX #N/D 32 60801132 SCREW 4,8 X 19 ZINC AF TC-CR UNI6954 33 61405164 PLUG FOR FLUE AIR FITTING 34 60702052 O-RING 2050 EPDM 1,78 X 12,42 35 61405160 DISCHARGE RACCORD PP 36 60702035 GASKET ROUND SPONGE D.3,5 MM IP44 S3 37 61206001 AUTOMATIC AIR VENT 38 60101119 3/8G MALE to 1/8NPT FEMALE BUSHING

Part No. Description

Page 100

15 - SPARE PARTS

Stock

Part No. Description

Code

39 60703033 GASKET EPDM D38 F20 SP6 40 60411085 45xx WALL MOUNTING BRACKET 41 60801097 SCREW SELFTAPPING 5 X 50 WOOD 42 54333 62201005 EXP TANK LT. 8 561 X 203 X 80 RETT. 43 60815012 GLASS WINDOW WITH GASKET 44 60701005 3/8” G GASKET 45 61102006 FAIRLEAD 6 POLES SILICONE 46 62625064 EXP TANK PIPE 47 61405219 PLASTIC CAP TPP 8.5 48 62110071 TANK SENSOR 49 62610067 EXTERNAL JACKET 500 X 840 X 245 50 61405167 DOOR SUPPORT 51 62610065 DOOR ABS 52 62630152 LP TO NATURAL CONVERSION KIT 53 62630167 NATURAL TO LP CONVERSION KIT 54 62630166 USER’S INSTRUCTIONS 55 PC8000 INSTALLER’S INSTRUCTIONS 56 54338 62629036 BURNER HEAD 57 61504029 EXTRUSION L.25MM 58 60909008 THERM. INSULATION VERMICULITE D117 F74 SP21,5 59 60703032 GASKET. SIL. D157 F145 H6,7 60 61404108 BASE MANIFOLD AIR ALUMINUM 61 60703030 GASKET SIL.MANIFOLD FAN D83 SP3,5 62 60801136 SCREW SELFTAPPING 4 X 12 TC S-TT UNI-8112 63 62651016 MANIFOLD AIR CUTTED 64 54321 61404114 MIXER AIR/GAS “COSMOMIX” 65 60702049 O-RING 3350 NBR 2,62 X 88,57 66 60702048 O-RING 3200 NBR 2,62 X 50,47

Stock

Part No. Description

Code

67 60408261 DIAPHRAGM COSMOMIX 9 HOLES D.10 68 60702056 O-RING 165 NBR 3,53 X 61,91 69 54322 61901029 FAN 45 KW USA 70 61405174 BACK FLUE-GASES PREVENTER 71 60702051 O-RING 3825 SIL 2,62 X 209,22 72 61404109 COVER MANIFOLD AIR ALUMINUM 73 60801080 SCREW SELFTAPPING 4 X 10 TC S-TT UNI-8112 74 60801111 SELFTAPPING BOLT 6.3 X 38 75 60701013 GASKET FRIZITE D15,5 F11,5 SP1,5 76 60815011 GLASS PIREX D15,5 SP3,3 77 60404253 FLANGE L21,2 H34 78 60801081 SCREW SELFTAPPING 4 X 8 TC S-TT NI-8112 79 54307 60505022 LEFT IGNITION ELECTRODE 80 54308 60505023 RIGHT IGNITION ELECTRODE 81 54309 60505024 DETECTION ELECTRODE 82 60801102 SCREW 5X12 EXAGONAL HEAD 83 60406069 SPRING MIXER 84 60702050 O-RING 3056 NBR (118) 2,62 X 13,95 85 62624125 GAS PIPE (SIT) USA 86 60701006 GASKET 3/4P 24 X 15 X 2 KLINSIL 87 60801014 SCREW 4X10 ZINC TC-CR 88 60101224 FLANGE GAS 32 X 32 3/4P 89 60702029 O-RING 130 2,62 X 22,22 90 54312 61201040 GAS VALVE SIGMA848 120V 91 60801021 BOLT 5X12 CROSS HEAD 92 62623249 PIPE D18 F/F 3/4P-3/4P SIT USA 93 62103009 CONTROL KNOB S3 94 60702041 O-RING NBR 1,6 X 11,1 95 61405203 FRONT INTERFACE 96 61405151 TREE POTMETER-KNOB 97 61405190 KEYS RUBBER 3 POSITIONS 98 54323 62102009 PRESSURE GAUGE DIAM.38 - 1/4” PSI

99 60506019 GAS VALVE SERVICE SWITCH 100 61405184 BASE ELECTRICAL BOX 101 61405186 FAIRLEAD SX 102 61405188 FAIRLEAD DX 103 54326 62110076 POWER CONTROL BOARD PHC 120V 104 60801138 SCREW 4 X 8 ZINC TC-CR DIN4042 105 54310 60507056 JUNCTION BOARD 45 106 54332 62118015 INTERFACE OPENTERM 107 61405185 COVER ELECTRICAL BOX 108 61103011 FAIRLEAD 7 EXIT 109 61405189 COVER JUNCTION BOX 110 62623246 PIPE SUPPLY SEALING CHAMBER

100