Boiler
Peerless
®
Gas
Installation,
Operation &
Maintenance
Manual
Combi 160
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.
2
SAFETY INSTRUCTIONS
3
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!
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.
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
Maintenance:
at least once a year the user must call in a licensed
authorized technician for routine maintenance.
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!
Any optional extras or kit fi tted subsequently
must be original Cosmogas parts.
4
TABLE OF CONTENTS
SAFETY INSTRUCTIONS .....................................................................................................................................................................2
TABLE OF CONTENTS .........................................................................................................................................................................5
1 - INSTALLATION - CODE REQUIREMENTS .....................................................................................................................................7
1.1 - National installation legislation .................................................................................................................................................7
2 - GENERAL INFORMATION ...............................................................................................................................................................8
2.1 - Key to symbols used ................................................................................................................................................................8
2.2 - Description of the Peerless Combi 160: ..................................................................................................................................8
3 - MAIN COMPONENTS ......................................................................................................................................................................9
4 - FUNCTION OVERVIEW .................................................................................................................................................................11
4.1 - Intended use and functions of the boiler ................................................................................................................................12
4.2 - Setting of the boiler .................................................................................................................................................................12
4.3 - Effi ciency up to 98% ...............................................................................................................................................................13
4.4 - Characteristic curves of heating system’s residual head ........................................................................................................14
4.5 - Characteristic curve of the domestic side ...............................................................................................................................14
5 - INSTALLATION - Mounting & gas and water connections ........................................................................................................ 15
5.1 - Clearances for installation and servicing ................................................................................................................................15
5.2 - Clearances from combustible material ...................................................................................................................................15
5.3 - Choosing the installation location ...........................................................................................................................................15
5.4 - Mounting the boiler .................................................................................................................................................................16
5.5 - Gas and water connections ....................................................................................................................................................16
5.6 - Condensate disposal ..............................................................................................................................................................17
5.7 - Relief valve .............................................................................................................................................................................17
5.8 - Supply and return piping .........................................................................................................................................................18
5.8.1 - Converting a combi boiler into a heating only boiler.................................................................................................18
5.9 - Low temperature heating systems ..........................................................................................................................................18
5.10 - Use of glycol and other chemicals ........................................................................................................................................18
5.11 - Domestic hot and cold water.................................................................................................................................................18
5.12 - Gas supply piping .................................................................................................................................................................19
5.13 - Operating at high altitudes ....................................................................................................................................................19
5.14 - Suggested piping and wiring connections ............................................................................................................................ 20
6 - INSTALLATION - Electrical connections .....................................................................................................................................21
6.1 - Electrical connections: overview .............................................................................................................................................21
6.2 - Connecting the power supply cable ........................................................................................................................................22
6.3 - Choosing the room thermostat ...............................................................................................................................................22
6.4 - Thermostat wiring ...................................................................................................................................................................22
6.5 - Installing the outdoor temperature sensor (optional) ..............................................................................................................23
6.6 - Alarm output ...........................................................................................................................................................................23
7 - INSTALLATION - Indirect storage tank connections .................................................................................................................. 24
7.1 - Connecting the boiler to an indirect storage tank .................................................................................................................. 24
8 - INSTALLATION - Vent & combustion air .....................................................................................................................................26
8.1 - Removing of a boiler from a common venting system ............................................................................................................26
8.2 - Venting systems .....................................................................................................................................................................27
8.3 - Design of the venting system .................................................................................................................................................27
8.4 - Flue terminal location in compliance with CAN/CSA B149 .....................................................................................................28
9 - INSTALLATION - Split venting system ........................................................................................................................................ 29
9.1 - Split system (polypropylene) or AL29-4C (UL 1738/UL C 636) system ..................................................................................29
9.2 - Split system components ........................................................................................................................................................31
9.3 - Split system components ........................................................................................................................................................32
9.4 - Split system: installation examples .........................................................................................................................................33
10 - INSTALLATION - Coaxial venting system ....................................................................................
10.1 - Coaxial system ..................................................................................................................................................................... 34
10.2 - Coaxial system components .................................................................................................................................................35
10.3 - Coaxial system components .................................................................................................................................................36
10.4 - Coaxial system: installation examples .................................................................................................................................37
11 - OPERATING .................................................................................................................................................................................38
11.1 - Operating ..............................................................................................................................................................................38
11.1.1 - User instructions .....................................................................................................................................................38
11.1.2 - Filling the condensate trap .....................................................................................................................................38
11.1.3 - Filling the heating system .......................................................................................................................................38
11.1.4 - Filling the domestic hot water heat exchanger ....................................................................................................... 39
11.1.5 – Auto-purging the heating system ...........................................................................................................................39
11.2 - General warnings concerning gas supply .............................................................................................................................39
.............................................34
5
TABLE OF CONTENTS
11.3 - Confi rming the boiler’s gas type ...........................................................................................................................................39
11.4 - Gas type conversion .............................................................................................................................................................39
11.5 - Start-up .................................................................................................................................................................................39
11.6 - Ignition control testing ...........................................................................................................................................................40
11.7 - Gas supply pressure checking and adjustment ....................................................................................................................40
11.8 - Check the combustion air pressure .....................................................................................................................................41
11.9 - Checking and adjusting CO2 levels ......................................................................................................................................42
11.10 - Adjusting the heating capacity ............................................................................................................................................43
11.11 - Domestic hot water fl ow rate adjustment ............................................................................................................................ 43
11.12 - Cold start boiler ................................................................................................................................................................... 43
12 - USE ...............................................................................................................................................................................................44
12.1 - Check heating system pressure ...........................................................................................................................................44
12.2 - Overview ...............................................................................................................................................................................44
12.3 - Displays ................................................................................................................................................................................44
12.4 - Start-up procedure ................................................................................................................................................................45
12.5 - Summer mode ......................................................................................................................................................................45
12.6 - Winter mode ......................................................................................................................................................................... 45
12.7 - Adjusting the domestic hot water temperature .................................................................................................................... 46
12.8 - Heating system temperature adjustment ..............................................................................................................................46
12.9 - Heating system type selection ..............................................................................................................................................46
12.10 - Outdoor reset adjustment ...................................................................................................................................................46
12.10.1 - Outdoor reset applications ...................................................................................................................................46
12.10.2 - Outdoor reset adjustment precautions .................................................................................................................47
12.10.3 - Outdoor reset: setting parameters........................................................................................................................47
12.10.4 - Outdoor reset: zone adjustments .........................................................................................................................47
12.10.5 - Outdoor reset activation .......................................................................................................................................47
12.10.6 – Outdoor reset with room compensation...............................................................................................................47
12.11 - Boiler switch settings ..........................................................................................................................................................49
12.12 - Delays, alarms and protective actions ................................................................................................................................49
12.13 - Circulator pump and three way valve protection ................................................................................................................49
12.14 - Freeze protection ................................................................................................................................................................49
12.15 - Display in energy saving mode ..........................................................................................................................................49
12.16 - “Users’ menu” .....................................................................................................................................................................50
12.17 - “Installer’s menu” ................................................................................................................................................................51
12.18 - Diagnostics .........................................................................................................................................................................53
12.18.1 - Diagnostics: “L” lock-outs .....................................................................................................................................54
12.18.2 - Diagnostics: “E” blocking errors ...........................................................................................................................56
13 - MAINTENANCE ............................................................................................................................................................................ 58
13.1 - General precaution ...............................................................................................................................................................58
13.2 - Removing the casing .............................................................................................................................................................58
13.3 - Cleaning the burner and primary heat exchanger, fl ue gas side .........................................................................................59
13.4 - Correct positioning of the ignition and fl ame detection electrodes ......................................................................................60
13.5 - Domestic hot water heat exchanger .....................................................................................................................................60
13.6 - Condensate trap cleaning .....................................................................................................................................................61
13.7 - Circulator pump motor replacement .....................................................................................................................................62
13.8 - Expansion tank pressure ......................................................................................................................................................62
13.9 - 3-way valve removal ....................................................................................................
13.10 - Draining the heating side of the boiler ................................................................................................................................64
13.11 - Draining the domestic hot water side of the boiler ..............................................................................................................64
13.12 – Overrides ...........................................................................................................................................................................64
13.12.1 - Auto-purging ......................................................................................................................................................... 64
13.12.2 - Fan ......................................................................................................................................................................64
13.12.3 – Minimum and maximum output ...........................................................................................................................64
13.12.4 – Checking the fl ame current.................................................................................................................................. 64
13.13 - Water and fl ue temperature sensor ....................................................................................................................................65
13.14 - Outdoor temperature sensor (optional) ..............................................................................................................................65
13.15 - Functional wiring diagram ...................................................................................................................................................66
13.16 - Multiwire wiring diagram .....................................................................................................................................................68
14 - TECHNICAL DATA .......................................................................................................................................................................70
15 - SPARE PARTS .............................................................................................................................................................................71
16 - READ OUT FLOW CHART ..........................................................................................................................................................74
.........................................................63
6
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
7
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)
8
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
9
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 gases 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
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
10
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
11
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
5.9.
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 can be connected to
an indirect storage tank for the
production of domestic hot water,
section 7.1.
The PC160 boiler can be connected
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.
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.
12
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
13
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.
14
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
5.3 - Choosing the
installation location
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.
Figure 7 - Dimensions for the PC160
15
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
16
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 - 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!
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
Figure 11 - Condensate trap and drain
17
5 - INSTALLATION - Mounting & gas and water connections
5.8 - 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.
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.
5.8.1 - 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 18) from OFF
position to ON position. Now knob
“32” of fi gure 1 is disabled.
5.9 - Low
temperature
heating systems
CAUTION!!! When the boiler
is installed in a low temperature
system, the switch No. 6 in fi gure
18 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 5.8).
With switch No. 6 in fi gure 18, 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
18
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.
5.10 - 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.
5.11 - Domestic hot
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 13 item “12”)
The PC160 boiler can also be
used as heating only boilers.
No connection is needed to the
domestic pipes “B” and “D” of
fi gure 9.
5 - INSTALLATION - Mounting & gas and water connections
5.12 - 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.
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.
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).
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.
5.13 - 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.
19
5 - INSTALLATION - Mounting & gas and water connections
5.14 - Suggested
piping and wiring
connections
Figure 13 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 13 - Typical piping and wiring connections
20
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 14 - Junction box
21
6 - INSTALLATION - Electrical connections
Indirect water heater sensor (optional)
Outdoor sensor (optional)
Room thermostat
120Vac Line central heating
Neutral
120Vac Line domestic hot water
120Vac LINE (HOT)
NEUTRAL
GROUND
Figure 15 - 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 14 and 15:
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 16).
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 14
and 15.
22
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 14 and 15;
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 16 - Room thermostat location
23
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 17): To make the electrical connections,
follow the steps below while refering also to
fi gure 17:
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 18;
4. open the front half of the electrical box in
the “C” direction as shown in fi gure 18;
5. move switch #1, item “D” in fi gure 18, 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 18, 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 17 - Indirect storage tank connections
sensor to terminals “TS”, item “M”, as per
fi gures 14 and 15;
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 14 and 15,
where:
“1” = 120Vac Line for domestic side
”2” = Neutral
“3” = 120Vac Line for heating 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.
24
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