Slant/Fin VSL-160C User Manual Part C

13 - USE

13.10.6 – Outdoor reset with room compensation

While in the “Installers’ Menu” (section

13.17) set the parameter to 02. The system will function exactly as described in the previous “Outdoor reset adjustment” sections except that now the boiler pump will stay on permanently . The opening of the room thermostat contacts will translate into a parallel downward movement of the curve in Figures 13-2 and 13-3. The value by which the curve moves downwards can be adjusted by the

parameter present in the

“Installers’ Menu”, see section 13.17. The parameter can range

from 1 °F (1 °C) to 36 °F, (20°C). The suggested values for this parameter are:

- 18 °F (10°C) for high temperature radiator systems;

- 6 °F (3°C) for low temperature radiant panel systems

Calculated temperature (°F)

Outside temperature (°F)

Figure 13-2 - Graph of the outdoor reset adjustment

(inﬂ uence of parameters “br”, “OA”, “Ob” and “Oc”)

Calculated temperature (°F)

Outside temperature (°F)

Figure 13-3 - Graphs of the outdoor reset adjustment

(inﬂ uence of parameter “b”)

V alues of this parameter that are too high may translate into room temperature instability . Values that are too low may make the action of the room thermostat ineffective.

Climatic adjustment with room compensation can be used in all the systems described in Section 13.10.1. The advantage being that the constant running of the pump will stabilize and standardize the room temperatures. This is especially true when some loops in the heating system have considerably greater volume than others.

OA = Slope of the line Ob = Minimum heating

temperature

Oc = Maximum heating

temperature

br = “Fix point” of the angle

fulcrum of the line

b = parallel shift of the line

(adjusted by the heating knob, item “7” of ﬁ gure 13-1)

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13 - USE

13.11 - Boiler switch settings

The control board shown in Figure 3-1, item “14”, contains a series of switches that allow the boiler to be conﬁ gured to match the application. The table below lists each switch and its corresponding funtions.

SWITCH Position Description

1 OFF Boiler without production of D.H.W ON Boiler with production of D.H.W. via storage tank 2 OFF Boiler with production of instantaneous D.H.W. ON Position not available for this serie of boilers 3 OFF Heating pressure switch, disabled ON Heating pressure switch, enabled 4 OFF EBM PAPST brand fan ON Position not available for this serie of boilers 5 OFF Combination boiler for heating and D.H.W. ON Boiler for heating only 6 OFF High temperature heating service, 86°F (30°C) to 176°F (80°C) ON Low temperature heating service, 68°F (20°C) to 113°F (45°C) 7 OFF Boiler conﬁ guration change, disabled ON Boiler conﬁ guration change, enabled 8 OFF Maximum heating supply water temperature of 176°F (80°C) ON Position not available for this kind of boilers

CAUTION!!!

of these switches could cause the boiler to malfunction resulting in improper system performance. Only a qualiﬁ ed technician, with an in-depth knowledge of the boilers’ control system, should change them.

Improper setting

13.12 - Delays, alarms and protective actions

To protect the life of the appliance, improve comfort, and maximize energy savings, the following timings have been incorporated into the control logic: a - Pump delay: each time the room

thermostat is satisﬁ ed, the circulator pump continues to run for 1 minute;

b - DHW delay: each time the domestic

hot water demand is satisﬁ ed, a 2 minutes delay must pass before the heating service is allowed to restart;

c - Protection against legionnaires

bacteria: if the boiler is connected to a DHW storage tank the boiler will increase the tank temperature to 140 °F (60 °C) every seven days, prevent the formation of legionnaires bacteria. This function is displayed

by

d - DHW alarm: if the call for domestic

hot water lasts for longer than two hours, an

This function is only for boilers set up to provide instantaneous DHW.

.

01 alarm is generated.

e - Time delay in restarting the burner:

in its normal functioning state, except when providing domestic water, every time the burner stops, there is a delay time of 3 minutes before the boiler restarts again.

13.13 - Circulator pump and three way valve protection

During the summer months, the circulator is run once a day for around 15 seconds to prevent it from seizing. At the same time, the three way valve (if present) is activated for the same reason.

13.14 - Boiler’s Freeze protection

CAUTION!!!

protection function to work, the boiler must remain connected to the electrical and gas supplies with knobs “7” and “11” in Figure 13-1, in the OFF position.

For the freeze

CAUTION!!!

protection function is conceived to protect the boiler only, not the heating system.

CAUTION!!!

boiler’s freeze protection function depends from the electrical supply and from the gas supply, it is mandatory install a safety device that alarm the user in a case the boiler room will reach a temperature near 35°F (2°C)

Once the boiler has reached a temperature of 45 °F (7 °C), the heating pump will automatically comes on. If the temperature falls below 35 °F (2 °C), the burner will light to prevent the boiler from freezing. If the boiler will not be used for long time it should be drained per Sections

14.10 and 14.11.

This freeze

Because the

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13 - USE

13.15 - Display in energy saving mode

If desired, the display, item “1” and “2” in Figure 13-1, can be switched permanently off, with the exception of when it displays errors or settings. To switch the display off, access the “Installers’ Menu”, in section 13.17

and set the other than zero. Keep in mind that each value will correspond to a delay in minutes until the display goes into Energy Saving mode.

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” of Figure 13-1

parameter at a value

Adjustment of the curve angel as shown in Figure 13-2 when outdoor reset is active per section 13.9.

13.16 - “Users’ menu”

When entering the “Users’ menu”, the display, item “1” in Figure 13-1, will start blinking indicating that a change of mode has taken place. To access the “Users’ menu” (see also Section 17 to better understand the several menus):

1. press the button for 2 seconds until the display starts blinking;

2. press and release the button several times until the desired parameter is displayed;

3. use the or keys, to change the value of the selected parameter;

Setting range: 0,1 to 5,0

4. press to save the parameter change before going to the next parameter.

When the last parameter has been reached and the button

pressed, the display will stop blinking indicating exit from the menu.

NOTE: If no key is pressed for more than 60 seconds, the control automatically exits the “Users’ menu”. Any parameter change not saved

using the button, will be lost. The table below lists each “Users’

menu” parameter, what it affects and its adjustment range.

Adjustment of the “Minimum heating temperature” as shown in Figure 13-2 when outdoor reset is active per section 13.9.

Adjustment of the “Maximum heating temperature” as shown in Figure 13-2 when outdoor reset is active per section 13.9.

Adjustment of the parallel shift of the curve as shown in Figure 13-3 when outdoor reset is active per section 13.9.

Display of the calculated heating temperature when outdoor reset is active per section 13.9, or display of the temperature set by knob “7” shown in Figure 13-1.

Display of the domestic hot water temperature when set by knob “11” shown in Figure 13-1.

Display of last error code registered, Section

13.18.2

Setting range: see section 13.10.3

The adjustment is made by turning knob “7” shown in Figure 13-1. The selected curve can be shifted up or down by 36 °F (20 °C).

Temperature display only, with a range between 68 °F (20 °C) and 189 °F (87 °C).

Temperature display only with a range between 104 °F (40 °C) and 158 °F (70 °C), see section 13.7.

Error code display per section 13.18.2

Display of last lockout occurred, Section

13.18.1

Lockout code per section 13.18.1

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13 - USE

13.17 - “Installer’s menu”

CAUTION!!!

parameters could cause the boiler and therefore the system to malfunction. For this reason, only a qualiﬁ ed technician who has in-depth knowledge of the boiler should change them.

The boiler’s micro-processor makes this menu of parameters available to the qualiﬁ ed technician for the analysis of the functioning and adjustment of the appliance to the system. When entering the “Installers’ Menu”, the display item “1” in Figure 13-1, will start to blink indicating that a change of mode has taken place. To access the “Installers’ Menu” just (see also Section 17 to better understand the several menus):

Changing these

1. press and hold the button down for 12 seconds until the

parameter is displayed;

2. press and release the button to scroll through the list of the parameters;

3. once the parameter has been displayed, it can be changed using

the or keys;

4. press and release the button to conﬁ rm the amended data before moving to the next parameter.

When the last parameter has been reached and the button

pressed, the display will stop blinking indicating the exit from the menu.

NOTE: If no key is pressed for more than 60 seconds, the control automatically exits the “Installers’ menu”. Any parameter change not

saved using the button, will be lost.

The next table lists each “Installers’ menu” parameter, what it affects and its adjustment range.

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” OF FIGURE 13-1

Boiler temperature, measured by U1 sensor

DHW temperature, measured by U2 sensor

Domestic cold water (or ind. water heater) temperature , measured by U3 sensor

Outdoor temperature, measured by U4 sensor

Ionization current value

High limit temperature, measured by U6 sensor

Flue gas temperature, measured by U7 sensor

Heating return temperature, measured by U8 sensor

Type of basic setting of control board

Status of room thermostat contact

Value in °F (cannot be changed)

Value in °F (cannot be changed) Value in °F (cannot be changed) (displayed only if outdoor reset is

active, as per section 13.9) Value from 0 to 99 (cannot be changed)

(30 corresponds to a current of 1uA) (99 corresponds to a current of 5.5 uA)

Value in °F (cannot be changed)

Can be changed in accordance with Section 11.6 00 = contact open (heating service off)

01 = contact closed (heating service on)

Measurement of fan speed rotation

BTU input for heating service

Value in g/1’/100 (rpm/100) (cannot be changed)

Adjustable according to the instructions of section 12.10

Continue

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13 - USE

Continued

PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM “2” OF FIGURE 13-1

Can be changed (see Section 13.9):

Heating service functioning mode

00 = thermostatic adjustment; 01 = outdoor reset; 02 = outdoor reset with room compensation;

Reaction to external temperature

Angle fulcrum of climatic adjustment

Reduction of temperature generated by the opening of the room thermostat

Boiler knobs’ status

Display “1” and “2” as per ﬁ gure 13-1 energy saver

Parameter disabled for this kind of boiler

Domestic sensitivity setting

Minimum domestic setpoint during sleep mode

Proportional band of the heating PID modulation

Keep always at value of 1 Can be changed from 16°F (-9°C) to 149°F (65°C) (active only with

outdoor reset). See section 13.10.3 for its adjustment.

Can be changed: from 1°F (1°C) to 36°F (20°C) (active only with outdoor reset featuring room compensation) See section 13.10.6 for its adjustment.

Can be changed: 01 = knobs presents; 00 = knobs absent.

Can be changed: 00 = display always on; any other value, corresponds to a delay in the switching off of the display, expressed in minutes (see also Section 13.15)

No inﬂ uence in this kind of boiler

Must be maintained at 20 value

Integral of the heating PID modulation

Burner Anticycling: minimum delay from a burner light-off to the sequent light-on. Value expressed in sec x 10

Indirect water heater priority selection: Value expressed in minutes.

Must be maintained at 40 value

Can be changed between 1 and 54. Default value is 18 (180 sec). Can be modiﬁ ed only in conjunction with factory technicians.

Can be changed between 00 (function disabled) and 99 minutes. Default value is 00 (See also section 9.1.1).

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13 - USE

13.18 Diagnostics

During the normal operation of the boiler, the display, of Figure 13-1, continually shows the operating status of the boiler as shown below (see also section 17):

PARAMETER

PARAMETER REFERENCE DISPLAY READ OUT (ITEM “2”, FIGURE 13-1)

Boiler in stand-by mode or pause (no request for heating or domestic hot water)

Anti-freeze function active

Boiler not in lock-out mode but in Attention mode.

System pressure too low, system must be ﬁ lled. See section 13.1.

Domestic hot water service active

Heating service active

Boiler in lock-out mode. To reset it, press the the lock-out occurs frequently, contact a professionally qualiﬁ ed

technician Blocking error. Contact a professionally qualiﬁ ed technician. Blocking

errors automatically reset if the condition causing the block disappears

.

button. If

Boiler temperature (°F)

Boiler temperature (°F) 01 = Boiler temperature (°F) Domestic hot

water service active for more than 120 minutes. Turn domestic hot water to OFF position to reinstate heating. 02 = Data connection interrupted between cascade boilers

No display Domestic hot water temperature (°F)

Heating temperature (°F)

Lock-out code (see section 13.18.1 for decodiﬁ cation).

Error code (see section 13.18.2 for decodiﬁ cation).

Auto-purging procedure that last 3 minutes in progress (see section 13.4).

Boiler in Anti-legionella functioning (see section 13.12)

78

Boiler temperature (°F)

Storage tank temperature (°F)

13 - USE

13.18.1 - Diagnostics: “L” lock-outs

“L” Code

L01

L02

L03

L04 L05

L06

Lock-out description

No ﬂ ame detected after three ignition attempts.

Flame extinguishes three times.

Boiler temperature is over 203° F (95°C).

Gas valve command relay Safety relay

Flue gas sensor over 210°F (99°C)

Checks to make

Check: a-correct gas supply pressure (see

section 12.7); b-ignition spark (see section 14.4); c-correct combustion air pressure (see

section 12.8); d-120Vac at the gas valve; e-resistance of the two gas valve coils

should be 0.18 kohm and 1.1 kohm; f- If the burner lights, but goes out at the

end of the ignition attempt, check: that

the ionization current is set at a value

greater than 60 (follow procedure in

section 14.12.4)

Check: a-that the ionization current is set

at a value greater than 60 (follow

procedure in section 14.12.4); b-check that gas valve open fast

enough;

a-Check that the circulator pump is working; b-Check if the water ﬂ ow is not less than 5 GPM

Check for correct polarity of the wires to the pump. Try to switch the wires.

Check: a - that the electrical resistance of the ﬂ ue gas sensor complies with the graph in Section 14.13; b - that the efﬁ ciency of the boiler is over 86%

Solutions

a-If the gas supply pressure is incorrect, it must be adjusted to

the correct pressure;

b-If spark is not present, check for correct ignition ectrode

position and gap as per section 14.4; If position is correct, check for 120Vac at the supply of the spark generator.

c-if the combustion air pressure is incorrect, inspect the vent

system and eliminate any obstructions;

d-if the voltage to the gas valve is not 120Vac the power control

board must be replaced;

e-if the resitance of the gas valve coils is not 0.18 kohm and/or

1.10 kohm, the gas valve must be replaced.

f-If the ionization current is not greater than 60, conﬁ rm that

the the CO2 content is adjusted properly (see section

12.9). Check the ﬂ ame detection electrode (section 14.4) and if necessary replace it, check the integrity of the ﬂ ame detection electrode electrical wires.

a-If the ionization current is not greater than 60, conﬁ rm that

the the CO2 content is adjusted properly (see section

12.9). Check the ﬂ ame detection electrode (section 14.4) and if necessary replace it, check the integrity of the ﬂ ame detection electrode electrical wires.

b-Following procedure as per Section 14.12.4, check few times

if passing from low ﬁ re to high ﬁ re the ﬂ ame estinguish. If estinguish, change the gas valve.

a-If the circulator pump is bad, replace it, if is good, replace the power control board. b-If the water ﬂ ow is less than 5 GPM check for any zone

valves that must be opened. Replace the power control board

If the pump won’t run replace it. If the pump is good try to replace the power control board.

a-If the ﬂ ue gas sensor resistance does not correspond with the

correct values, replace it;

b-if the boiler efﬁ ciency is less than 86% and the CO2 content

is correct, the primary heat exchanger has to be replaced and proper water treatment methods employed to prevent mineral build up on the water side

L07

L08 L09

L10 L12 L13 L14 L15 L16

L17

Electrical circuit of ﬂ ue gas sensor is interrupted

Spark generator relay

RAM memory E2prom memory damaged

E2prom memory damaged Program error Program error Program error Program error The temperature

difference between the U1 and U6 sensors is too great

Check that the electrical resistance of the ﬂ ue gas sensor corresponds with the

graph in section 14.13;

Check that: a - the electrical resistance of the two sensors corresponds with the graph in section 14.13; b -check that the heating water ﬂ ow is not too low.

79

If the sensor resistance does not correspond with the correct values, replace it;

Replace the power control board Replace the power control board

Replace the power control board Replace the power control board Replace the power control board Replace the power control board a-If one or both sensors does not have the correct resistance

value, it must be replaced;

b-If temperature difference between U1 and U8 is higher than

55°F at maximum input, the heating water ﬂ ow rate is too low. The heating water ﬂ ow rate must be corrected.

13 - USE

13.18.1 - Diagnostics: “L” lock-outs (continued)

“L” Code

L18

L19

L20

L21

L25

L32 L33

L45

L46

Lock-out description

Program error

Flame sensed for 10 seconds, after the closure of the gas valve

Flame sensed before opening of the gas valve.

Boiler in blocking state for more than 20 hours

U1 or U6 sensor increase its temperature too fast

Program error Fan rotation error

Heating circuit ﬁ lling time longer than 10 minutes.

Filling of heating circuit repeated 16 times in 24 hours

Controls

Check: a - that the heating water ﬂ ow is not too

low;

b - that the circulator pump is working

Check that the voltage to the fan is 163(±10)Vdc.

Check: a - that the heating pressure switch

setting pressure, FILL appears when the pressure drops below 8.7 psi (0,6 bar), and disappears when the pressure rises above 22 psi (1.5 bar);

b - check that there are no water leaks

in the heating system.

Solutions

Replace the power control board

Call technical service

Press RESET button and check the blocking error “E” on Section 13.18.2

a - If temperature difference between U1 and U8 is higher than

55°F (31°C), at maximum input, the heating water ﬂ ow rate is too low. The heating water ﬂ ow rate must be corrected.

b - If the pump works, replace the power control board.

Replace the power control board

If the fan is powered with 163Vdc, replace the fan. If the voltage to the fan is not 163 Vdc, replace the board.

a -If the heating pressure switch is not correctly set, it must be

replaced;

b - if the system has a leak, it must be ﬁ xed.

L47

Flue pressure switch open time longer than 60 minutes

Check: a - that no obstructions are in the ﬂ ue

discharge/air intake line

b - check the ﬂ ue pressure switch

setting point, setting is 4.5 in.W.C

c - check that the electrical resistance of

the ﬂ ue gas sensor corresponds with the graph in section 14.13;

d - check that the electrical connection

cables between the ﬂ ue pressure switch, the ﬂ ue sensor and the power control board.

a -If ther’is an obstruction, it must be removed; b - If the ﬂ ue pressure switch is not correctly set, it must be

replaced;

c - If the ﬂ ue sensor resistance does not correspond, it must be

replaced;

d - if the electrical circuit is damaged, it must be repaired; if the previous four cases do not apply, replace the power

control board

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13 - USE

13.18.2 - Diagnostics: “E” blocking errors “E”

Code

E01

E02

E04

E07

Blocking description

U1 boiler temperature sensor circuit interrupted.

U2 domestic hot water temperature sensor circuit interrupted.

U8 return temperature sensor circuit interrupted

U3 cold water or indirect water heater sensor circuit interrupted

Checks to make

Check that the electrical resistance of the sensor corresponds with the graph in section 14.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

Solutions

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

E08

E11

E12

E13

U6 boiler temperature sensor circuit interrupted.

U1 boiler temperature sensor circuit shortcircuited.

U2 domestic hot water temperature sensor circuit short-circuited

Erroneous temperature reading.

Check that the electrical resistance of the sensor corresponds with the graph in section 14.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the power control board

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13.18.2 - Diagnostics: “E” blocking errors (continued)

“E” Code

E14

E15

E16 E17

E18

E19 E20

E21 E22

E23

E30

Blocking description

U8 return temperature sensor short-circuited

U4 outside sensor shortcircuited

Erroneous temperature reading.

U3 cold water temperature or indirect water heater temperature sensor circuit shorted

U6 boiler temperature sensor circuit shorted

E2prom memory damaged

Flame presence with gas valve closed

Phase and neutral inverted

Electrical supply frequency other than 60Hz

Ground connection is absent

Erroneous temperature reading.

Checks to make

Check that the electrical resistance of the sensor corresponds with the graph in section 14.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current Check that the electrical resistance of the sensor corresponds with the graph in section 14.14; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

Check that the electrical resistance of the sensor corresponds with the graph in section 14.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

Invert phase and neutral Check the electrical frequency of the

system. Check if CS parameter is at 03 (see section 17)

Check if the boiler is properly grounded

Solutions

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the power control board If the sensor resistance does not correspond, it must be

replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

If the sensor resistance does not correspond, it must be replaced; if the electrical circuit is damaged, it must be repaired; if the previous two cases do not apply, replace the power control board

Replace the command and control board

Replace the gas valve

If phase and neutral are correctly wired, replace the power and control board

If the electrical supply frequency is other than 60Hz, contact the electric company; if the mains frequency is 60Hz, replace the command and control board. Make sure that the CS parameter is at 03.

if the boiler is properly grounded, replace the power control board

Replace the power control board

E31

E32 E33

E42 E50

E51

E52 E53

Erroneous temperature reading.

Program error

Error in the boiler tY parameter selection

Reset button pressed too often in a short period time

Heating ﬂ ow switch closed

Heating ﬂ ow switch open

Move ON switches 7 an set again the correct tY value (see section 17)

Check if the heating pump is running. Check if the ﬂ ow switch contact is stuck

Check if the heating pump is running. Check if the ﬂ ow switch contact is broken

82

Replace the power control board

If tY value is correct, change the power control board

The pump should not run and the contanct should open The contact must be open

The pump should run and the contact should closed The contact must be closed

14 - MAINTENANCE

14.1 - Care and maintenance

This section must be brought to the attention of the user by the installer so that the user can make the necessary arrangements with a qualiﬁ ed service agency for the periodic care and maintenance of the boiler. User must check its boiler follow Table 14-1 column “User maintenance”. The installer must also inform the user that the lack of proper care and maintenance of this boiler and any fuel burning equipment may result in a hazardous condition. Installer should discuss contents of the Section 13 (User’s section) with the user.

Service and maintenance schedules

Service Technician User maintenance

Annual Startup:

A trained and qualiﬁ ed service technician should perform the inspection listed in these instructions before each heating season and at regular intervals.

WARNING!!!

inspection and adjustment must be done by a trained technician in accordance with all applicable local and national codes. Improper servicing or adjustment could damage the boiler! Failure to comply with this warning can result in a ﬁ re or explosion causing property damage, personal injury or loss of life!

Servicing,

Daily:

WARNING!!!

combustible materials, gasoline or any product containing ﬂ ammable vapors and liquids in the vicinity of the boiler. Failure to comply with this warning can result in extensive property damage, severe personal injury or death!

Never store

- Address reported problems (Follow section 14.1.1);

- Check all piping for leaks (Follow section 14.1.2)

- Verify ﬂ ue and air lines in good condition and sealed tight (Follow section 14.1.3);

- Check system water pressure/system piping/ expansion tank (Follow section 14.1.4);

- Check control settings (Follow section 14.1.5);

- Check ignition and ﬂ ame sense electrodes (Follow section 14.1.6);

- Check wiring and connections (Follow section

14.1.7);

- Perform performance veriﬁ cation (Follow section

14.1.8);

- Flame inspection (Follow section 14.1.9);

- Check ﬂ ame signal (Follow section 14.1.10);

- Clean the heat exchanger if ﬂ ue temperature is more than 72°F (40°C) above return water temperature (Follow section 14.3).

- Clean condensate trap (Follow section 14.5).

- Check combustion air pressure (Follow section

12.8).

- Check relief valve (Follow section 14.1.11);

- Check for any air inside the domestic heat exchanger (Follow section 12.1.4);

- Check any domestic water softener if need any maintenance (follow softener’s manufacturer instructions)

- Check boiler area (Follow section 14.1.12);

- Check pressure gauge (Follow section 14.1.13);

Monthly:

- Check vent piping (Follow section 14.1.14);

- Check air piping (Follow section 14.1.15);

- Check condensate drain system (Follow section

14.1.16);

Every six month:

- Check boiler piping (gas and water) for leaks (Follow section 14.1.17);

End of season months:

- Shut boiler down (unless boiler used for domestic hot water) (Follow section 14.1.18);

Table 14-1 - Service and Maintenance Schedules

83

14 - MAINTENANCE

WARNING!!!

obstruct the ﬂ ow of combustion and ventilation air. Failure to provide adequate combustion air for this boiler can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

maintenance is performed on the vent-air intake system it must be properly reassembled and sealed. Failure to properly maintain the vent-air system can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

WARNING!!!

performing any maintenance operations, shut the boiler off, close the manual gas shut-off valve (Figure 11-1) and shut off electrical power to the boiler. Follow the Operating Instructions outlined in the section “SAFETY INSTRUCTIONS” (Beginning of the manual).

Never

If

Before

14.1.1 - Address reported problems

Inspect any problems reported by the owner and correct before proceeding.

14.1.2 - Check all piping for leaks

CAUTION!!!

or boiler leaks. Continual fresh makeup water will reduce boiler life. Minerals can build up in sections, reducing heat transfer, overheating heat exchanger, and causing heat exchanger failure. Leaking water may also cause severe property damage.

1. Inspect all water and gas piping and verify to be leak free.

2. Look for signs of leaking lines and correct any problems found.

Eliminate all system

3. Check for gas leaks: using soap solution, check for gas leaks from meter to boiler including all pipes and ﬁ ttings and boier connections. Use liquid soap solution for all gas testing.

WARNING!!!

check for gas leaks with an open ﬂ ame. Use the bubble test. Failure to use the bubble test or check for gas leaks with an open ﬂ ame can cause explosion, severe personal injury, death, or substantial property damage.

Do not

14.1.3 - Verify ﬂ ue and air

lines in good condition and sealed tight;

1. Check for obstruction, condensation, corrosion and physical damage, water stains, any signs of rust, other corrosions or separation of the vent and air intake piping.

2. Check outside terminations. Screens and louvers should be free of any debris and must be cleaned as required.

14.1.4 - Check system

water pressure/system piping/expansion tank;

1. Check water piping and accessories for leaks. Slightest leaks should be corrected.

2. Check the system to be full of water and pressure to remain stable at correct setting on gauge.

14.1.5 - Check control

settings

1. Thermostat Test (control knobs items “7” and “11”, Figure 13-1): Set knobs setting to low enough to end call for heat. Gas valve should close and burner should stop ﬁ ring. Fan go into a post purge, then shuts off.

2. Control Safety Shutdown test: with the burner ﬁ ring, close the manual gas shut off valve (Figure 11-1) . Gas valve should close and burner should stop ﬁ ring. The boiler will try for ignition three times after this, then should lock out with an “L 01” error shown on the display. Open the manual gas shut-off valve, and press the “Reset” button to return to normal operation.

84

14.1.6 - Check ignition and ﬂ ame sense electrodes

1. Remove the fan-burner assembly unit (see section 14.3)

2. Remove any deposits accumulated on the ignition/ﬂ ame sense electrode using sand paper.

3. Check electrodes positioning meet Section 14.4

14.1.7 - Check wiring and

connections

Inspect all boiler wiring, making sure wires are in good condition and securely attached.

14.1.8 - Perform

performance veriﬁ cation.

1. Start boiler and perform a combustion test as per section 12.9.

2. Verify cold ﬁ ll pressure is correct and that operating pressure does not go too high (could be a problem on the expansion tank).

14.1.9 - Flame inspection

1. Inspect ﬂ ame through observation window.

2. If the ﬂ ame is unsatisfactory at either high ﬁ re or low ﬁ re, clean the burner following section 14.3.

14.1.10 - Check ﬂ ame

signal

1. Follow section 14.12.4 to check the ﬂ ame signal.

2. At high ﬁ re and low ﬁ re the ﬂ ame signal shown on the display should be within values given in Section 15, header “ionisation current”. A lower ﬂ ame signal may indicate a fouled or damaged ﬂ ame sense electrode. If cleaning the ﬂ ame sense electrode does not improve, ground wiring is in good condition, and ground continuity is satisfactory, replace the ﬂ ame sense electrode.

14.1.11 - Check relief valve

Inspect the relief valve and lift the lever to verify ﬂ ow. Before operating any relief valve, ensure that it is piped with its discharge in a safe area to avoid severe scald potential. Read Section

7.2.2 before proceeding further. Relief

vavle should be re-inspected at least once every three years, by a licensed

14 - MAINTENANCE

plumbing contractor or authorized inspection agency, to ensure that the product has not been affected by corrosive water conditions and to ensure that the valve and discharge line have not been altered or tampered with illegally. Certain naturally occurring conditions may corrode the valve or its components over time, rendering the valve inoperative. Such conditions are not detectable unless the valve and its components are physically removed and inspected. This inspection must only be conducted by a plumbing contractor or authorized inspection agency – not by the user.

WARNING!!!

re-inspect the boiler relief valve as directed could result in unsafe pressure buildup, which can result in severe personal injury, death, or substantial property damage.

Failure to

14.1.12 - Check boiler area

WARNING!!!

potential of severe personal injury, death, or substantial property damage, eliminate all materials discussed below from the boiler vicinity and the vicinity of the boiler combustion air inlet.

If contaminants are found: Remove products immediately from the area. If they have been there for an extended period, call a qualiﬁ ed service technician to inspect the boiler for possible damage from acid corrosion.

If products cannot be removed, immediately call a qualiﬁ ed service technician to re-pipe vent and air piping and locate vent termination/air intake away from contaminated areas.

1. Combustible/ﬂ ammable materials -- Do not store combustible materials, gasoline or any other ﬂ ammable vapors or liquids near the boiler. Remove immediately if found.

To prevent

2. Air contaminants -- Products containing chlorine or ﬂ uorine, if allowed to contaminate the boiler intake air, will cause acidic condensate in the boiler. This will cause signiﬁ cant damage to the boiler if allowed to continue. Read the list of potential materials listed in Section 10.2. If any of these products are in the room from which the boiler takes its combustion air, they must be removed immediately or the boiler combustion air (and vent termination) must be relocated to another area.

14.1.13 - Check pressure

gauge

1. Make sure the pressure reading on the boiler pressure gauge does not exceed 25 psi. Higher pressure may indicate a problem with the expansion tank.

2. Contact a qualiﬁ ed service technician if problem persists.

14.1.14 - Check vent

piping

1. Visually inspect the ﬂ ue gas vent piping for any signs of blockage, leakage, or deterioration of the piping. Notify your qualiﬁ ed service technician at once if you ﬁ nd any problems.

WARNING!!!

to inspect the vent system as noted above and have it repaired by a qualiﬁ ed service technician can result in vent system failure, causing severe personal injury or death.

Failure

14.1.15 - Check air piping

1. Visually inspect the air inlet termination to be sure it is unobstructed. Inspect the entire length of air piping to ensure piping is intact and all joints are properly sealed.

2. Call your qualiﬁ ed service technician if you notice any problems.

14.1.16 - Check condensate drain system

1. Inspect the condensate drain line, condensate ﬁ ttings and condensate trap for signs of weeping or leakage.

2. If you detect signs of leakage, immediately contact your qualiﬁ ed service technician to inspect the boiler and system.

14.1.17 - Check boiler

piping (gas and water)

1. If gas odor or leak is detected, immediately shut down the boiler following the procedures on page 3. Call a qualiﬁ ed service technician.

2. Visually inspect for leaks around water piping. Also inspect the circulators, relief valve, and ﬁ ttings. Immediately call a qualiﬁ ed service technician to repair any leaks.

WARNING!!!

ﬁ xed at once by a qualiﬁ ed service technician. Failure to comply could result in severe personal injury, death, or substantial property damage.

Have leaks

14.1.18 - Shut boiler down

(unless boiler is used for Domestic Water)

1. Follow “To Turn Off Gas to Appliance” on page 3 of this manual.

2. Do not drain the system unless exposure to freezing temperatures will occur.

3. Do not drain the system if it is ﬁ lled with an antifreeze solution.

4. DO NOT shut down boilers used for domestic water heating, they must operate year-round.

85

14 - MAINTENANCE

14.2 - Removing the

casing

In order to remove the casing, follow the steps below while refering to Figure 14-1:

1. remove screws “A”;

2. raise latch “C”;

3. remove the front cover;

4. press the two plastic springs, item “L”, down;

5. lower the electrical box;

6. lift latch “G”;

7. pull the bottom of cover “H” out by around 4 in (10 cm);

8. lift cover “H” up by around 1in (2 cm) and remove it.

Figure 14-1 Removing the casing

86

14 - MAINTENANCE

14.3 - Cleaning the burner and primary heat exchanger, ﬂ ue gas side

Burner and primary heat exchanger must be checked every year and cleaned if required. To correctly clean the burner and the ﬂ ue gas side of the heat exchanger follow the steps below:

WARNING!!!

proceeding to the next step, verify that the electrical supply to the boiler, and any other electrical supply near the boiler, is off. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

1. follow the steps in Section 14.2 to gain access to the sealing chamber;

2. unscrew nut “D” (Figure 14-2) from the gas valve (taking care not to lose gasket “E” in Figure 14-4);

3. disconnect the two wires from the ignition electrodes and the wire from the ﬂ ame detection electrode, Figure 3-1, details “47” and “50”;

4. disconnect the wire from safety sensor “F” in Figure 14-2;

5. unscrew the four nuts “C” in Figure 14-2;

Before

6. prepare a suitable cover for the gas valve outlet under nut “D” so that no dirt, water, or other foreign objects can fall into the gas valve during cleaning;

7. remove the entire fan - burner assembly, detail “A” in Figure 14-2;

8. use a cylindrical brush with plastic bristles to clean the inside of the combustion chamber, detail “H” in Figure 14-2;

9. use a vacuum cleaner to remove any unburned residue from the combustion chamber “H” in ﬁ gure 14-2;

10. using the same vacuum cleaner, clean the surfaces of the burner and around the electrodes;

WARNING!!!

performing the next step, carefully wash only the inside of the combustion chamber “H” of Figure 14-2, and do not get water on the outside of the combustion chamber opening. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

while

11. using only water, wash the inside of the combustion chamber, detail “H” in Figure 14-2. The water, will drain into the condensate drain. Clean the condensate trap (see Section 14.6) before reassembling components;

12. reassemble the components by proceeding in reverse order;

13. open the manual gas shutoff valve;

14. restore electrical power to the boiler;

15. check that there are no gas leaks.

WARNING!!!

an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Never use

Figure 14-2 Remove the fan-burner assembly unit

87

14 - MAINTENANCE

14.4 - Correct

positioning of the ignition and ﬂ ame detection electrodes

For the boiler to work properly the electrodes must be positioned as shown in Figure 14-3:

the distance between the ignition

electrodes “A” and “B”, must be between 0.08 in (2 mm), and 0.10 in (2.5 mm);

the distance of the ignition

electrodes to the burner surface must be between 0.20 in (5.0 mm), and 0.22 in (5.5 mm);

the distance of the ﬂ ame detection

electrode to the burner surface must be between 0.23 in (6.0 mm), and 0.27 in (7.0 mm).

A = Left ignition electrode B = Right ignition electrode C = Flame detection electrode

Figure 14-3 Positioning electrodes on burner

(Use a hand caliper to verify the distances of the electrodes)

NOTE: To insure correct functioning of boiler the distances listed above shall be veriﬁ ed with a hand caliper.

14.5 - Domestic

hot water heat exchanger (only for 160-C model)

The production of DHW takes place in the secondary heat exchanger, detail “42” in Figure 3-1. If this heat exchanger loses efﬁ ciency over time, it may be necessary to clean or replace it.

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14 - MAINTENANCE

14.6 - Condensate trap cleaning

The condensate trap must be checked every year and cleaned if required. Follow the steps below to properly clean the condensate trap and its associated components while referring to Figure 14-4:

1. turn the power switch to on, item “12” in Figure 13-1;

2. press the and keys together for more than 10 seconds,

until a blinking is displayed;

3. the combustion blower will run at maximum speed for 10 minutes. During this time the burner will not light. This will minimize the amount of liquid present in the trap, item “A”;

4. press the button

WARNING!!!

proceeding to the next step, verify that the electrical supply to the boiler, and any other electrical supply near the boiler, is off. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

5. follow the steps in Section 14.2 to gain access the internal components;

6. carefully cover the electrical panel “B” with a waterproof material to prevent water from entering the electrical system;

7. grip spring clamp “G” with a pair of pliers and slide it downwards;

8. pull the condensation trap hose “H” off the trap;

9. remove the fan-burner assembly unit, follow steps of section 14.3;

10. cover the gas valve outlet to ensure that no objects or condensate water enters the gas valve;

11. disconnect the condensate hose “O” from the condensate trap “A”.

12. unscrew nut “I” from the bottom of the trap, “A”, and pull it upwards, taking care not to spill the condensation;

13. open the condensate trap taking care not to lose o ring “L” and clean the inside “M”;

14. re-assemble everything in reverse order, taking care that oring “L” is placed in the proper location;

15. reﬁ ll the condensate trap per Section 12.1.2.

16. open the manual gas shutoff valve;

17. restore electrical power to the boiler;

18. check that there are no gas leaks.

Before

Figure 14-4 Removing the condensing trap

89

WARNING!!!

an open ﬂ ame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Never use

14 - MAINTENANCE

Figure 14-5 Replacing the pump motor (only for 160-C model)

14.7 - Circulator

pump motor replacement (only for 160-C model)

To replace the circulator pump follow the steps below while, refering to Figure 14-5:

1. follow the steps in Section 14.10 to isolate and drain the water from the boiler;

2. follow the steps in Section 14.2 to gain access the internal components;

3. remove screws “B”;

4. remove the circulator pump motor “A”;

5. label the electrical wires of the circulator pump motor, phase and neutral must be respected;

6. disconnect the electrical wires from the circulator pump motor

7. install the new circulator pump motor and reassemble the boiler

8. open the heating system isolation valves and heating system ﬁ ll valve

9. follow the steps in Section 12.1.3 to bleed the air from the heating system.

NOTE: If display shows L05 reverse polarity (phase and neutral) to the pump

90

14.8 - Expansion

tank pressure (only for 160-C model)

To check the expansion tank pressure follow the steps below:

1. follow the steps in Section 14.10 to isolate and drain the water from the boiler

2. follow the steps in Section 14.2, to gain access the internal components;

3. check the pressure of the expansion tank, item “4” of Figure 3-1 (The air inlet probe is on the top of the expansion tank). It must be 14 psi (1 bar). If the pressure is lower recharge the expansion tank while letting the water run out of the heating system drain valve.

14 - MAINTENANCE

Figure 14-6 Supply ﬁ ttings removal (only for 160-C model)

14.9 - 3-way valve

removal (only for 160-C model)

The 3-way valve, details “M” and “Q” in Figures 14-6 and 14-7, directs hot water produced by the primary heat exchanger to the heating circuit or to the secondary heat exchanger for the production of D.H.W. To replace or clean it, follow the steps below while referring to Figures 14-6 and 14-7:

1. follow the steps in Section 14.10 and 14-11 to isolate and drain the water from the boiler;

2. follow the steps in Section 14.2, to gain access the internal components;

3. disconnect ﬁ ttings “A”;

4. remove screws “C”;

5. rotate “D” ﬂ ange in the direction of the black arrow (See particular ﬁ g.

1);

6. remove the bracket “E”;

5. remove ﬁ tting “F”;

6. remove ﬁ tting “L”;

7. remove ﬁ tting “M” and check its state.

8. remove spring “N”;

9. remove servomotor “O”;

10. remove the ﬁ tting “P”

11. remove the spring “Q” and check for any dirt.

Figure 14-7 3-way valve servomotor removal

91

14 - MAINTENANCE

14.10 - Draining the heating side of the boiler

To drain the heating side of the boiler follow the steps below:

1. cool boiler turning knob “7” in Figure 13-1 to 114°F (45°C). Wait until the display, item “1” in Figure 13-1, shows a temperature less than 114°F (45°C);

2. turn off the boiler;

3. shut off electrical power to the boiler;

4. close the manual gas shutoff valve, Figure 11-1;

5. close the boiler isolation valves, in the heating system. If isolation valves haven’t been installed, the entire heating system will have to be drained.

6. close the heating system ﬁ ll valve;

7. follow the steps in Section 14.2, to gain access the internal components;

8. connect a hose to the boiler drain valve intem “4” in Figure 7-6 and 7-7, and place the other end in a sink or some other suitable drain;

9. open the boiler drain valve and drain the boiler;

10. if boiler isolation valves have not been installed in the heating system open any bleed valves at the highest point of the system;

11. after draining out all the water, close the bleed valves and the boiler drain valve;

NOTICE: The boiler cannot be drained completely of water without purging the unit with an air pressure of 15 psi.

WARNING!!!

recover and/or re-use water drained from the heating circuit for any purpose as it could be contaminated. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Do not

14.11 - Draining the domestic hot water side of the boiler

To drain the domestic hot water side of the boiler follow the steps below:

1. turn off the boiler;

2. close the valve in the water main supplying the DHW system;

3. open all the hot and cold faucets in the building;

4. if there isn’t a faucet or drain valve below the boiler level, disconnect DHW connections “10” and “12” in Figure 3-1.

14.12 – Overrides

To carry out speciﬁ c checks covered in the manual, it is possible to override the control logic of the boiler. See the following sections:

14.12.1 - Auto-purging

To reset the auto-purging procedure press the and keys

together for 10 seconds. When the blinking appears on the display,

press .

14.12.2 - Fan

To run just the fan at full speed press the and keys together

for 10 seconds, until the blinking

appears on the display. The fan will run at full speed for 10 minutes. To shut the fan off before the 10 minutes

is up press the

14.12.3 – Minimum and maximum output

The boiler can be run at its minimum or maximum output in both the heating and domestic hot water modes by following the steps below:

1. generate a demand for the mode to

be overridden:

- for heating turn up the room thermostat and turn knob “7” in Figure 13-1 to its maximum;

key.

- for domestic hot water turn knob “11” in Figure 13-1 to its maximum and fully open a hot water faucet;

2. press the and keys together for more than 10 seconds,

until a blinking appears on the display;

3. press the key until the display shows:

- for minimum heating output;

- for maximum heating output adjusted by P parameter, see section 12.10;

- for maximum heating output;

- for minimum DHW output;

- for maximum DHW output;

4. press the key in order to restore the boiler to normal running conditions.

14.12.4 – Checking the

ﬂ ame current

While running at the minimum and maximum output described in Section

14.12.3, the display will show the

letter of the mode checked. In the second part of the display the value of the ionization current will be shown. 30 corresponds to a current of 1 uA, 99 to a current of 5.5 uA. The ﬂ ame current must always be at the correspondent value as shown in Section 15, header “ionisation current”. If the value is not within the above values, check: a - positioning of the ﬂ ame sensor

electrod as per section 14.4;

b - CO2 content as per section 12.9; c - combustion air pressure as per

section 12.8.

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14 - MAINTENANCE

14.13 - Water and

ﬂ ue temperature sensor

The boiler has a number of sensors that measure temperature. The electrical resistance between the sensor wires must correspond with the values shown in Figure 14-8.

The temperature sensors are: U1; U2, U3, U5, U6, U7 and U8. The location of each sensor can be found in Figure 3-1 and Section 14.15 and 14.16.

Figure 14-8 Water temperature sensors’ curve

14.14 - Outdoor

temperature sensor (optional)

An outdoor temperature sensor can be connected to the boiler (see section 8.1.4). The electrical resistance existing between the sensor wires must correspond with the values shown in Figure 14-9.

Figure 14-9 Outdoor temperature sensor curve

93

WARNING!!!

14 - MAINTENANCE

14.15 - Functional wiring diagram

WARNING!!!

Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

ATTENTION!!!

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

LEGEND: ALA - Alarm output

CM - Power control board CR - Remote command (only for outdoor models) EA - Ignition electrode ER - Flame detection electrode EPO - External pump (REQUIRED FOR MODEL 160-B) EV3V - External three way valve (optional) F1 - Fuse 2Amps FPS - Flue pressure switch GS - Spark generator IG - Main electrical switch J1 - Six poles connector J2 - Four poles connector J3 - Twelve poles connector J4 - Four poles connector J5 - Sixteen poles connector J10 - Ten poles connector J18 - Height poles connector U1 - Supply temperature sensor U2 - Domestic hot water temperature sensor U3 - Domestic cold water temperature sensor U3 TANK - Storage tank temperature sensor (optional) U4 - Outside temperature sensor (optional) U6 - Heating Safety high limit temperature sensor U7 - Flue gases temperature sensor with integrated safety

high limit switch U8 - Return temperature sensor PO1 - Heating pump PR - Heating pressure switch SDC - Electrical connection board RT1 - Room thermostat connection RT2 - Room thermostat connection on remote control

“CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

94

14 - MAINTENANCE

95

WARNING!!!

14 - MAINTENANCE

14.16 - Multiwire wiring diagram

WARNING!!!

wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

ATTENTION!!!

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

Label all

Au moment

LEGEND: ALA - Alarm output

CM - Power control board CR - Remote command (only for outdoor models) EA - Ignition electrode ER - Flame detection electrode EPO - External pump (REQUIRED FOR 160-B model) EV3V - External three way valve (optional) F1 - Fuse 2Amps FPS - Flue pressure switch GS - Spark generator IG - Main electrical switch J1 - Six poles connector J2 - Four poles connector J3 - Twelve poles connector J4 - Four poles connector J5 - Sixteen poles connector J10 - Ten poles connector J18 - Height poles connector U1 - Supply temperature sensor U2 - Domestic hot water temperature sensor U3 - Domestic cold water temperature sensor U3 TANK - Storage tank temperature sensor (optional) U4 - Outside temperature sensor (optional) U6 - Heating Safety high limit temperature sensor U7 - Flue gases temperature sensor with integrated safety high limit switch U8 - Return temperature sensor PO1 - Heating pump PR - Heating pressure switch SDC - Electrical connection board RT1 - Room thermostat connection RT2 - Room thermostat connection on remote control “CR” (optional) VE - Fan VG1 - Gas valve V3V - Three way valve

96

14 - MAINTENANCE

97

15 - TECHNICAL DATA

MODEL VSL-160-B; VSL-160-C;

Country of destination USA and Canada Type of boiler Direct Vent and room combustion air Category of discharge chimney IV CSA certiﬁ cate N° 2045300 (114696) Maximum Heat input Btu/hr 160,000 Minimum heat input Btu/hr 30,000 Efﬁ ciency at maximum heat input (160°F/140°F) % 93 Maximum Heat output (160°F/140°F) Btu/hr 148,800 Efﬁ ciency at minimum heat input (122°F/86°F) % 97 Minimum heat output (122°F/86°F) Btu/hr 29,100 Certiﬁ ed AFUE rate % 91.5 Gas ﬂ ow rate Natural gas ft3/hr 156 LP Gas gal/hr 1.75 Gas supply pressure Natural gas In.W.C. 7 LP Gas In.W.C. 11 Minimum gas supply pressure Natural gas In.W.C. 3 LP Gas In.W.C. 3 Maximum gas supply pressure Natural gas In.W.C. 13 LP Gas In.W.C. 13 Combustion air pressure with min. length Natural gas In.W.C. 2.5 to 3.1 LP Gas In.W.C. 2.1 to 2.7 Combustion air pressure with max. length Natural gas In.W.C. 2.1 to 2.7 LP Gas In.W.C. 1.8 to 2.4 Instantaneous d.h.w production [rise 75°F (42°C)] gal/min 4.32 Maximum heating temperature °F 189 Minimum heating temperature °F 68 Maximum heating pressure PSI 30 Minimum heating pressure PSI 8 Maximum pressure of domestic hot water circuit PSI 150 Minimum pressure of domestic hot water circuit PSI 1 Capacity of expansion tank (160-C model only) gal 2.64 Supply voltage 120Vac - 60Hz Absorbed electric power W 170 Flue gas pipes diameter (split) “ (mm) 3.15” (80) Max. length ﬂ ue gas pipes (split) ft 300 Flue gas pipes diameter (coaxial) “ (mm) 2.36/3.94 (60/100) Max. length ﬂ ue gas pipes (coaxial) ft 70 Equivalent length of one elbow ft 45° elbow = 3ft, 90° elbow = 5ft CO (Carbon monoxide) with natural gas ppm <150 CO (Carbon monoxide) with LP gas ppm <250 NOx (0% O2 with natural gas) ppm <30

CO2 (Carbon dioxide) for Natural gas at high ﬁ re % 9.1 to 9.3 CO2 (Carbon dioxide) for Natural gas at low ﬁ re % 8.4 to 9 CO2 (Carbon dioxide) for LP gas at high ﬁ re % 9.3 to 9.7 CO2 (Carbon dioxide) for LP gas at low ﬁ re % 9.2 to 9.8 O2 (Oxygen) for Natural gas at high ﬁ re % 4.4 to 4.6 O2 (Oxygen) for Natural gas at low ﬁ re % 5.1 to 5.7 O2 (Oxygen) for LP gas at high ﬁ re % 5.7 to 5.9 O2 (Oxygen) for LP gas at low ﬁ re % 6.1 to 6.7 Ionisation current 71 to 90

Maximum ﬂ ue gas temperature °F 210 Flue gas mass-ﬂ ow lb/hr 160 Head pressure available for ﬂ ue vent/air intake line In.W.C. 3.6 Maximum condensation ﬂ ow rate gal/hr 1.32 Average acidity of condensation PH 4 Boiler weight (empty of water) (160-C model) lb 125 Boiler weight (empty of water) (160-B model) lb 93

98

16 - SPARE PARTS

99

16 - SPARE PARTS

100

16 - SPARE PARTS

101

16 - SPARE PARTS

Bottom side of the 160-B model

Spare parts list

1 - 81 9010 000 - CABLE UL IGNITOR CONN 90° L155 2 - 81 9011 000 - NUT ZINC COATED 6MA 3 - 81 9012 000 - SILICONE PIPE D 4X8 4 - 81 9013 000 - TEE FOR DRY WATER CONDENSATION 5 - 81 9014 000 - SPARK GENERATOR NO CABLE UL 6 - 81 9015 000 - SENSOR NTC 10 KOHM A KLIP DIAM.22 7 - 81 9016 000 - COPPER PIPE D22 M/F 3/4”G-1”G 8 - 81 9017 000 - 3/4” RING NUT 9 - 81 9018 000 - O-RING NBR 2,62 X 20,63 10 - 81 9019 000 - PRIMARY HEAT EXCHANGER C.R.R ASME 11 - 81 9020 000 - GASKET EPDM X OSSIDO D84 H7 12 - 81 9021 000 - SENSOR NTC 10 KOHM 1/8” 13 - 81 9022 000 - GASKET COPPER 1/8” SP.1,5 14 - 81 9023 000 - SILICONE TAP 15 - 81 9024 000 - SCREW 6X35 ZINC TC-CR 16 - 81 9025 000 - WASHER 6X18X1,5 PIA-ZIN-LAR UNI6593 17 - 81 9026 000 - BRACKET SIPHON L84 H130 P32

18 - 81 9027 000 - O-RING 134 EPDM 3,53 X 25,8 19 - 81 9028 000 - SCREW SELFTAPPING 3.9 X 9.5 CROSS HEAD 20 - 81 9029 000 - SIPHON 21 - 81 9030 000 - SCREW SELFTAPPING 2.9 X 6.5 CROSS HEAD 22 - 81 9031 000 - SPRING 28,7 23 - 81 9032 000 - PRESSURE SWITCH ON 4,5 INWC 24 - 81 9033 000 - BRACKET PRESSURE SWITCH 25 - 81 9034 000 - POLIETYLENE PIPE L=1000 26 - 81 9035 000 - SEALING CHAMBER DOOR 27 - 81 9036 000 - 1P GASKET 28 - 81 9006 000 - PUMP GRUNDFOS UP 15/58U BRUTE USA 29 - 81 9038 000 - COPPER PIPE D22 RETURN SEALING CHAMBER 30 - 81 9039 000 - SENSOR NTC 10K BAIO 31 - 81 9040 000 - OUTDOOR SENSOR 32 - 81 9041 000 - SCREW 4,8X19 ZINC AF TC-CR UNI6954 33 - 81 9042 000 - PLUG FOR FLUE AIR FITTING 34 - 81 9043 000 - O-RING 2050 EPDM 1,78 X 12,42 35 - 81 9044 000 - DISCHARGE RACCORD PP 36 - 81 9045 000 - GASKET ROUND SPONGE D.3,5 MM IP44 S3 37 - 81 9046 000 - AUTOMATIC AIR VENT

102

16 - SPARE PARTS

38 - 81 9047 000 - 3/8G MALE to 1/8NPT FEMALE BUSHING 39 - 81 9048 000 - GASKET EPDM D38 F20 SP6 40 - 81 9049 000 - 45xx WALL MOUNTING BRACKET 41 - 81 9050 000 - SCREW SELFTAPPING 5X50 WOOD 42 - 81 9051 000 - EXP TANK LT. 8 561X203X80 RETT. 43 - 81 9052 000 - GLASS WINDOW WITH GASKET 44 - 81 9053 000 - 3/8” G GASKET 45 - 81 9054 000 - FAIRLEAD 6 POLES SILICONE 46 - 81 9055 000 - EXP TANK PIPE 47 - 81 9056 000 - PLASTIC CAP TPP 8.5 48 - 81 9057 000 - TANK SENSOR 49a - 81 9058 000 - EXTERNAL JACKET 500X840X245 WITHOUT DOOR 50 - not used 51 - not used 52a - 81 9191 000 - VSL 160 LP TO NATURAL CONVERSION KIT 53a - 81 9190 000 - VSL 160 NATURAL TO LP CONVERSION KIT 54a - 81 9063 000 - VSL 160 USER’S INSTRUCTIONS 55a - 81 9506 000 - VSL 160 INSTALLER’S INSTRUCTIONS FROM S/N 12130000 56 - 81 9065 000 - BURNER HEAD 57 - 81 9066 000 - EXTRUSION L.25MM 58 - 81 9067 000 - THERM. INSULATION VERMICULITE D117 F74 SP21,5 59 - 81 9068 000 - GASKET. SIL. D157 F145 H6,7 60 - 81 9069 000 - BASE MANIFOLD AIR ALUMINUM 61 - 81 9070 000 - GASKET SIL.MANIFOLD FAN D83 SP3,5 62 - 81 9071 000 - SCREW SELFTAPPING 4X12 TC S-TT UNI-8112 63 - 81 9072 000 - MANIFOLD AIR CUTTED 64 - 81 9073 000 - MIXER AIR/GAS “COSMOMIX” 65 - 81 9074 000 - O-RING 3350 NBR 2,62 X 88,57 66 - 81 9075 000 - O-RING 3200 NBR 2,62 X 50,47 67 - 81 9076 000 - DIAPHRAGM COSMOMIX 9 HOLES D.10 68 - 81 9077 000 - O-RING 165 NBR 3,53 X 61,91 69 - 81 9078 000 - FAN 45 KW USA 70 - 81 9079 000 - BACK FLUE-GASES PREVENTER 71 - 81 9080 000 - O-RING 3825 SIL 2,62 X 209,22 72 - 81 9081 000 - COVER MANIFOLD AIR ALUMINUM 73 - 81 9082 000 - SCREW SELFTAPPING 4X10 TC S-TT UNI-8112 74 - 81 9083 000 - SELFTAPPING BOLT 6.3X38 75 - 81 9084 000 - GASKET FRIZITE D15,5 F11,5 SP1,5 76 - 81 9085 000 - GLASS PIREX D15,5 SP3,3 77 - 81 9086 000 - FLANGE L21,2 H34 78 - 81 9087 000 - SCREW SELFTAPPING 4X8 TC S-TT NI-8112 79 - 81 9088 000 - LEFT IGNITION ELECTRODE 80 - 81 9089 000 - RIGHT IGNITION ELECTRODE 81 - 81 9090 000 - DETECTION ELECTRODE 82 - 81 9091 000 - SCREW 5X12 EXAGONAL HEAD 83 - 81 9092 000 - SPRING MIXER 84 - 81 9093 000 - O-RING 3056 NBR (118) 2,62X13,95 85 - 81 9094 000 - GAS PIPE (SIT) USA 86 - 81 9095 000 - GASKET 3/4P 24X15X2 KLINSIL 87 - 81 9096 000 - SCREW 4X10 ZINC TC-CR 88 - 81 9097 000 - FLANGE GAS 32X32 3/4P 89 - 81 9098 000 - O-RING 130 2,62 X 22,22 90 - 81 9099 000 - GAS VALVE SIGMA848 120V 91 - 81 9100 000 - BOLT 5X12 CROSS HEAD 92 - 81 9101 000 - PIPE D18 F/F 3/4P-3/4P SIT USA 93 - 81 9102 000 - CONTROL KNOB S3 94 - 81 9103 000 - O-RING NBR 1,6 X 11,1 95 - 81 9104 000 - FRONT INTERFACE 96 - 81 9105 000 - TREE POTMETER-KNOB 97 - 81 9106 000 - KEYS RUBBER 3 POSITIONS 98 - 81 9107 000 - PRESSURE GAUGE DIAM.38 - 1/4” PSI 99 - 81 9108 000 - MAIN SWITCH 100 - 81 9109 000 - BASE ELECTRICAL BOX 101 - 81 9110 000 - FAIRLEAD SX 102 - 81 9111 000 - FAIRLEAD DX 103 - 81 9112 000 - POWER CONTROL BOARD PHC 120V 104 - 81 9113 000 - SCREW 4X8 ZINC TC-CR DIN4042 105 - 81 9114 000 - JUNCTION BOARD 45 106 - 81 9115 000 - INTERFACE OPENTERM 107 - 81 9116 000 - COVER ELECTRICAL BOX 108 - 81 9117 000 - FAIRLEAD 7 EXIT 109 - 81 9118 000 - COVER JUNCTION BOX 110 - 81 9119 000 - COPPER PIPE D.22 SUPPLY SEALING CHAMBER 111 - 81 9120 000 - 3 WAY VALVE MOTOR 120V 112 - 81 9121 000 - PLUG PISTON BODY OT. 113 - 81 9122 000 - SPRING FORCK 3V

114 - 81 9123 000 - UPPER PISTON 115 - 81 9124 000 - HYDRONIC SUPPLY GROUP. 116 - 81 9125 000 - HEATING PRESSURE SWITCH 117 - 81 9126 000 - GASKET COPPER 1/4P 118 - 81 9127 000 - SCREW 5X18 ZINC TC-ES-INC UNI5931 119 - 81 9128 000 - ASME SAFETY RELIEF VALVE 120 - 81 9129 000 - BRASS NIPPLE 1” - 3/4” 121 - 81 9130 000 - COVER PISTON HEATING 122 - 81 9131 000 - PISTON HEATING SIDE 123 - 81 9132 000 - PLUG BRASS 1/4P M WITH O-RING 124 - 81 9133 000 - NIPPLE OT 1”-22X1,5 MM 125 - 81 9134 000 - O-RING 2075 EPDM 1,78 X 18,77 126 - 81 9135 000 - HYDRONIC RETURN GROUP 127 - 81 9136 000 - BY-PASS VALVE 128 - 81 9137 000 - 3/8” MALE CAP 129 - 81 9138 000 - DOMESTIC HEAT EXCHANGER “ACQUAJET” 130 - 81 9139 000 - SENSOR NTC 10 KOHM KLIP WITH SCREW 131 - 81 9140 000 - NUT ZINC COATED 4MA 132 - 81 9141 000 - O-RING 3037 EPDM 2,62 X 9,19 133 - 81 9142 000 - PURGING PIPE 134 - 81 9143 000 - PURGING VALVE M10X1 135 - 81 9144 000 - FORCK BY-PASS PIPE 136 - 81 9145 000 - BY-PASS PIPE 137 - 81 9146 000 - O-RING 4075 EPDM 3,53 X 18,64 138 - 81 9147 000 - FRONT THERM. INSULATION “ACQUAJET” 139 - 81 9148 000 - REAR THERM. INSULATION “ACQUAJET” 140 - 81 9149 000 - BRACKET EXAGONAL HOLES SHORT 141 - 81 9150 000 - BRACKET EXAGONAL HOLES LONG 142 - 81 9151 000 - NIPPLE OTT 3/4NPT-3/4P USA 143 - 81 9152 000 - BRACKET EXAGONAL HOLE SMALL 144 - 81 9153 000 - 1/2” G GASKET 145 - 81 9154 000 - FAIRLEAD PA 107 SCREW HILO 3,5X14,5 146 - 81 9155 000 - CONNECTION BRASS 3/4P TO 1P 147 - 81 9156 000 - CONNECTION BRASS 1/2P TO 1P 148 - 81 9157 000 - 3/4” NUT 149 - 81 9158 000 - SCREW 6X8 ZINC TC-CR DIN7985 150 - 81 9159 000 - COPPER PIPE 1P TO 3/4P 151 - 81 9160 000 - BRASS 3/4P FEMALE TEE 152 - 81 9161 000 - HYDRONIC SUPPLY GROUP ONLY HEAT 153 - 81 9162 000 - 1/2P CAP 154 - 81 9163 000 - 1/2”-1/4” FF BRASS FITTING 155 - 81 9164 000 - PLUG BRASS 3/4P F 156 - 81 9165 000 - BRASS ELBOW 3/4P MF 157 - 81 9166 000 - 3/4 NUT 158 - 81 9167 000 - PLUG BRASS 3/8P F 159 - 81 9168 000 - HYDRONIC RETURN GROUP ONLY HEATING 162 - 81 9169 000 - BRASS 1/2P MALE CAP 163a – 81 9188 000 - 9.1MM NATURAL GAS INJECTOR 163b – 81 9189 000 - 5.7MM LP GAS INJECTOR 164 - 81 9200 000 - 2.62X13.10 NBR O-RING 165 – 81 9192 000 - Ø6/4-1/4”FEMALE FITTING 166 – 81 9193 000 - 1/4” TAP 167 – 81 9194 000 - Ø6/4-Ø6/4-1/8”MALE TEE FITTING 168 – 81 9195 000 - 4X6 PTFE FLEXIBLE PIPE 169 – 81 9196 000 - 24X17X2 AISI316L WASHER 170 – 81 9197 000 - 24X17X1.5 AISI316L WASHER 171 – 81 9198 000 - 1/2”-1/4” MF BRASS FITTING 172 – 81 9199 000 - Ø6/4-1/4”MALE BRASS ELBOW FITTING (WITH VITON O-RING)

If replacement parts are needed

When parts are needed, refer to boiler model and serial number shown on the boiler name/rating plate. Control identiﬁ cation and replacement should be attempted only by a qualiﬁ ed technician. Relief/Safety valves must be ASME rated for the pressure and gross output of the boiler.

103

17 - READ OUT FLOW CHART

Only fan

in run

Heating

at low

ﬁ re

Heating

at regul.

ﬁ re

Heating

at high

Supply

temp.

D.H.W.

temp.

D.C.W.

ﬁ re

Domestic

at low

temp./ tank

temp.

ﬁ re

Domestic

Outdoor

temp.

Curve

angle

at high

ﬁ re

Ionisation

current

Min.

heat.

Domestic

at high

ﬁ re

High limit

temp.

Max.

temp.

heat.

temp.

Flue

temp.

Return

temp.

Basic

setting

Room

therm.

state

Push and hold together the + and -

keys, for a time, in seconds, indicated

Push and hold the RESET

key for a time, in seconds,

Push and release the - key

by the number

indicated by the number

Push and release the + key

Push and release the RESET

key

Overrides menu (see

section 14.12)

Installer’s menu

(see section 13.17)

Parallel shift

Central heating

temp. setting

D.H.W. temp.

setting

Calculated heat.

temp.

D.H.W. temp.

setting

Last blocking error

Last lock out error

User’s menu, with outdoor

reset, CH settings to 01 or

02 (see section 13.16)

User’s menu, with

104

thermostatic CH

settings to 00 (see

section 13.16)

Boiler in stand-by

Read out in normal

operating condition

(see section 13.18 )

Domestic hot water

17 - READ OUT FLOW CHART

Setting

output for

Fan speed

rpm/100

heating

Heating

service

mode

Reaction

to outdoor

temp.

Angle

fulcrum

Heat. temp.

reduction by

open RT

State of the

knobs

Energy

saver

display

Disabled

parameter

Domestic sensitivity

regulator parameter

Minimum domestic

stpoint in sleep mode

Heating proportional

band setting

Heating integral band

setting

Anty cicling during

central heating

DHW priority selection

Last blocking error

Last lock out error

Central heating

Anti Freeze protection

Lock-out

Blocking error

D.H.W. active more than

120 min.

Anti legionella protection

105

17 - READ OUT FLOW CHART

CAUTION!!!

Changing these parameters could cause the boiler and therefore the system to malfunction. For this reason, only a qualiﬁ ed technician who has in-depth knowledge of the boiler should change them.

The boiler’s micro-processor makes this menu of parameters available to the qualiﬁ ed technician for the setting of the appliance . To enter this menu you must:

1. turn the main electrical supply Off;

2. move the switch #7 (see Figure 9-2, item “D”) to the ON position;

3. turn the main electrical supply On.

Basic functionalities selection and Speed blower selection (see below for more explications)

Main electrical supply and temperature unit selection (see below for more explications)

Domestic functionalities selection. Must be always at 00

Master or slave selection in a module conﬁ guration. Must be always at 00.

Rotating selection in a module conﬁ guration. Must be always at 00.

Now “ty” is displayed. Use plus and minus keys to change the value; use RESET key to save the value and swap to the next parameter. To exit this menu you must:

1. turn the main electrical supply Off;

2. move the switch # 7 (see Figure 9-2, item “D”) to the Off position;

may assume the follow values: 61 - for boilers at NATURAL gas; 62 - for boilers at LP gas;

may assume the follow values: 00 - 230Vac, 50Hz, °C; 01 - 230Vac, 50Hz, °F; 02 - 120Vac, 60Hz, °C; 03 - 120Vac, 60Hz, °F

may assume the follow values: 00, 01 and 02. Must be always at 00.

Heating Water Flow Switch. (Function present only for certain boilers) (See below for more explications)

Outdoor temperature sensor range (See below for more explications)

If readable, may assume the follow values:

00, 01, 02, 03, 04, 05, 06, 07 and 08. Must be always at

00.

if readable, may assume the follow values:

00 = Flow Switch disabled; 01 = Flow Switch enabled;

if readable, may assume the follow values: 00 = Outdoor minimum temperature of 14°F; 01 = Outdoor minimum temperature of -39°F; (add a 68 kohm 1/4W resistor in parallel with the outdoor sensor).

If readable, may assume the follow values:

00, 01, 02, 03, 04, 05, 06, 07 and 08. Must be always at

00.

106

NOTE

107

62403559 R00 May 03, 2012

SLANT/FIN CORPORATION, Greenvale, N.Y. 11548 • Phone: (516) 484-2600

FAX: (516) 484-5921 • Canada: Slant/Fin LTD/LTEE, Mississauga, Ontario

www.slantfin.com

Slant/Fin VSL-160C User Manual Part C

Specifications and Main Features

Frequently Asked Questions

User Manual