PB Heat Peerless Combi 160 User Manual

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.

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.

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.

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.

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

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

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

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

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.

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.

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)

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

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

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

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.

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

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.

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

™

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.

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

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.

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

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.

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.

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

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

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

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

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.

+ 77 hidden pages

PB Heat Peerless Combi 160 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual