Installation and maintenance instructions for gas-fired condensing hot water boilers model:

CSG 160

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

Save this manual for future reference.

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S

M

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

SAFETY INSTRUCTIONS

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

- Do not store or use gasoline or other flammable 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 fire department.

- Installation and service must be performed by a qualified 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 inflammables 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 qualifié ou par le fournisseur de gaz.

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SAFETY INSTRUCTIONS

3

SAFETY INSTRUCTIONS

WARNING!!!

WARNING!!!

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

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Installer: Read all instructions, including this manual, before installing. Perform steps in the order given.

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User: Refer to the User’s

Information Section for your reference.

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Local approval: The local building regulations stipulating the installation rules at the time of installation.

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Installation location: The boiler must be located in an area where leakage of the tank or connections will not result in damage to the area adjacent to the boiler or to lower floors of the structure. When such locations cannot be avoided, it is recommended that a suitable drain pan, adequately drained, be installed under the boiler. The pan must not restrict combustion air flow.

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Installation location: The boiler must not be installed on carpeting.

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Qualified installer: Qualified installer is an individual with specific, technical training in space heating systems, domestic hot water systems, fuel gas systems and electrical systems. This individual must have the legally required qualifications.

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Installation and Alterations: Only a Qualified installer must carry out the installation and calibration of the boiler. Never modify the boiler or its flue gas carrying components in any way. This boiler must be properly vented. Failure to follow these instructions could result in personal injury or death!

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Air intake and outlets: Do not restrict or seal any air intake or outlet openings.

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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.

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Defects: If you find any defects, you must inform the owner of the system of the defect and the associated hazard in writing.

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Flue gas/air intake: You are only permitted to operate the condensing gas boiler with the combustion air/ flue gas system that has been specifically designed and approved for this type of boiler.

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Flue gas/air intake: If boiler installation is provided as replacement heater, DO NOT connect new boiler venting to an existing vent system, if it is shared with other appliances.

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Local approval: of the flue system and the condensate connection to the public sewer system may be required.

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Maintenance: at least once a year the user must call a Qualified installer for routine maintenance.

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 Qualified installer using original spare parts. Failure to comply with this requirement may compromise the safety of the unit and void its warranty.

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When servicing boiler, to

avoid electric shock, disconnect electrical supply before performing maintenance.

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SAFETY INSTRUCTIONS



When servicing boiler, to avoid

severe burns, allow boiler to cool before performing maintenance.

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

Verify proper operation after servicing.



Ensure the boiler and its controls are protected from dripping or

spraying water during normal operation or service.

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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!

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ATTENTION: Au moment de





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



l’entretien des commandes,

étiquetez tous les fils 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.

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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, turn off the manual gas shut-off valve external to the appliance.

Do not use this appliance if

any part has been under water.

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



N’utilisez pas cet appareil s’il a été plongé dans l’eau, même

partiellement. Faites inspecter l’appareil par un tecnicien qualifié et remplacez toute partie du système de contrôle et toute commande qui ont été plongés dans l’eau.

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When calling or writing about

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

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Any claims for damage or

shortage in shipment must be filed immediately against the transportation company by the consignee.

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Factory warranty (shipped with

unit) does not apply to units improperly installed or improperly operated.

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Only use the boiler in the combinations and with the accessories and spares listed in this manual.

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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

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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.

TABLE OF CONTENTS

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

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

TABLE OF CONTENTS ......................................................................................................................................................................... 8

1 - INSTALLATION - CODE REQUIREMENTS ..................................................................................................................................... 9

1.1 - Regulations and guidelines ...................................................................................................................................................... 9

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

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

2 - GENERAL INFORMATION ............................................................................................................................................................. 11

2.1 - Key to symbols used .............................................................................................................................................................. 11

2.2 - Description of model: .............................................................................................................................................................. 11

3 - MAIN COMPONENTS .................................................................................................................................................................... 12

4 - FUNCTION OVERVIEW ................................................................................................................................................................. 14

4.1 - Intended use and functions of the boiler ................................................................................................................................. 15

4.2 - Efficiency up to 98% ............................................................................................................................................................... 15

5 - INSTALLATION - Location ............................................................................................................................................................ 16

5.1 - Choosing the installation location ........................................................................................................................................... 16

5.1.1 - Closet and alcove installations ................................................................................................................................. 17

5.1.2 - Clearances for installation and servicing .................................................................................................................. 17

5.1.3 - Clearances from combustible material ..................................................................................................................... 17

5.1.4 - Vent and air piping.................................................................................................................................................... 17

5.1.5 - Prevent combustion air contamination ..................................................................................................................... 17

5.2 - Transporting the boiler ............................................................................................................................................................ 17

6 - INSTALLATION - Mounting the boiler .......................................................................................................................................... 18

6.1 - Mounting the boiler ................................................................................................................................................................. 18

7 - INSTALLATION - Water connection ............................................................................................................................................. 19

7.1 - Water connections .................................................................................................................................................................. 19

7.2 - Supply and return piping ......................................................................................................................................................... 19

7.2.1 - Near boiler heating piping components .................................................................................................................... 20

7.2.2 - Relief valve ............................................................................................................................................................... 21

7.2.3 - Expansion Tank and Makeup Water ......................................................................................................................... 22

7.2.4 - Heating pump ........................................................................................................................................................... 22

7.2.5 - Sizing heating system .............................................................................................................................................. 22

7.2.6 - Domestic Hot Water System Piping when using an indirect water heater ............................................................... 22

7.3 - Converting a combi boiler into a heating only boiler ............................................................................................................... 22

7.4 - Domestic hot and cold water (only for 160-C model) ............................................................................................................. 23

7.5 - Condensate disposal .............................................................................................................................................................. 26

8 - INSTALLATION - Electrical connections ..................................................................................................................................... 27

8.1 - Electrical connections: overview ............................................................................................................................................. 27

8.1.1 - Connecting the power supply cable ......................................................................................................................... 28

8.1.2 - Wiring the heating pump for 160-B model ................................................................................................................ 28

8.1.3 - Thermostat wiring ..................................................................................................................................................... 29

8.1.4 - Installing the outdoor temperature sensor ................................................................................................................ 29

8.1.5 - Alarm output ............................................................................................................................................................. 29

9 - INSTALLATION - Connecting to an indirect water heater .......................................................................................................... 30

9.1 - Connecting the boiler to an indirect water heater ................................................................................................................... 30

9.1.1 Indirect water heater priority selection ........................................................................................................................ 31

9.2 - Opening the instrument panel ................................................................................................................................................ 31

10 - INSTALLATION - Vent and combustion air ............................................................................................................................... 32

10.1 - Removing of a boiler from a common venting system .......................................................................................................... 32

10.2 - Prevent combustion air contamination ................................................................................................................................. 33

10.3 - Venting and air piping systems ............................................................................................................................................. 33

10.4 - Minimum / Maximum allowable combustion air and vent piping lengths .............................................................................. 35

10.5 - Install vent and combustion air piping .................................................................................................................................. 35

10.6 - Air inlet pipe materials: ......................................................................................................................................................... 37

10.6.1 - Sealing of Type “B” double-wall or galvanized air inlet pipe material ..................................................................... 37

10.6.2 - Sealing of PVC, CPVC or ABS air inlet pipe .......................................................................................................... 37

10.7 - PVC/CPVC vent piping materials ......................................................................................................................................... 38

10.7.1 - Installing PVC/CPVC vent and air piping ............................................................................................................... 38

10.7.2 - PVC/CPVC air intake/vent connections ................................................................................................................. 38

10.8 - Stainless steel vent piping materials .................................................................................................................................... 40

10.8.1 - Stainless steel air intake/vent connections ............................................................................................................ 41

10.9 - Polypropylene vent piping materials ..................................................................................................................................... 42

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TABLE OF CONTENTS

10.9.1 - Polypropylene two pipes air intake/vent connections ............................................................................................. 43

10.9.2 - Polypropylene two pipes system components ....................................................................................................... 44

10.9.3 - Polypropylene concentric system ........................................................................................................................... 45

10.9.4 - Polypropylene concentric system components ...................................................................................................... 46

10.10 - Single pipe vent (not sealed combustion) ........................................................................................................................... 47

10.10.1 - Combustion Air and Ventilation openings ............................................................................................................. 47

10.10.2 - Determine location ............................................................................................................................................... 48

10.11 - Sidewall termination - Two pipes ........................................................................................................................................ 49

10.11.1 - Vent/air termination ............................................................................................................................................... 49

10.11.2 - Determine location ................................................................................................................................................ 49

10.11.3 - Prepare wall penetrations ..................................................................................................................................... 51

10.11.4 - Termination and fittings ......................................................................................................................................... 51

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

10.12 - Sidewall termination – Concentric vent .............................................................................................................................. 52

10.12.1 - Description and usage.......................................................................................................................................... 52

10.12.2 - Sidewall termination installation ........................................................................................................................... 52

10.12.3 - Multiventing sidewall terminations ........................................................................................................................ 53

10.13 - Vertical termination - Two pipes .......................................................................................................................................... 54

10.13.1 - Determine location ............................................................................................................................................... 54

10.13.2 - Prepare roof penetrations..................................................................................................................................... 54

10.13.3 - Termination and fittings ........................................................................................................................................ 54

10.13.4 - Multiple vent/air terminations................................................................................................................................ 55

10.14 - Vertical termination – Concentric vent ................................................................................................................................ 56

10.14.1 - Description and usage.......................................................................................................................................... 56

10.14.2 - Determine location ............................................................................................................................................... 56

10.14.3 - Vertical termination installation ............................................................................................................................. 56

10.14.4 - Multiventing vertical terminations ......................................................................................................................... 57

10.14.5 - Alternate vertical concentric venting ..................................................................................................................... 58

10.15 - Existing vent as a chase ..................................................................................................................................................... 59

11 - INSTALLATION - Gas supply ..................................................................................................................................................... 60

11.1 - Gas supply piping ................................................................................................................................................................. 60

11.2 - Pipe sizing for natural gas..................................................................................................................................................... 61

11.3 - Propane Gas ......................................................................................................................................................................... 61

11.4 - Check inlet gas supply .......................................................................................................................................................... 61

11.5 - Operating at high altitudes .................................................................................................................................................... 61

11.6 - Convert the boiler from Natural Gas to Propane gas or viceversa ....................................................................................... 62

12 - START-UP ..................................................................................................................................................................................... 64

12.1 - Operating .............................................................................................................................................................................. 64

12.1.1 - User instructions..................................................................................................................................................... 64

12.1.2 - Filling the condensate trap ..................................................................................................................................... 64

12.1.3 - Filling the heating system ....................................................................................................................................... 64

12.1.4 - Filling the domestic hot water heat exchanger (160-C model only) ....................................................................... 65

12.1.5 – Auto-purging the heating system ........................................................................................................................... 65

12.1.6 – Delay to light-on..................................................................................................................................................... 65

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

12.3 - Confirming the boiler’s gas type ........................................................................................................................................... 66

12.4 - Gas type conversion ............................................................................................................................................................. 66

12.5 - Start-up of the boiler ............................................................................................................................................................. 66

12.6 - Ignition control testing ........................................................................................................................................................... 66

12.7 - Gas supply pressure checking ............................................................................................................................................. 67

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

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

12.10 - Adjusting the heating capacity ............................................................................................................................................ 70

12.11 - Domestic hot water flow rate adjustment (160-C model only) ............................................................................................ 70

12.12 - Cold start boiler .................................................................................................................................................................. 70

13 - USE ............................................................................................................................................................................................... 71

13.1 - Check heating system pressure ........................................................................................................................................... 71

13.2 - Overview ............................................................................................................................................................................... 71

13.3 - Displays ................................................................................................................................................................................ 71

13.4 - Start-up procedure ................................................................................................................................................................ 72

13.5 - Summer mode ...................................................................................................................................................................... 72

13.6 - Winter mode ......................................................................................................................................................................... 72

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TABLE OF CONTENTS

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

13.8 - Heating system temperature adjustment .............................................................................................................................. 73

13.9 - Heating system type selection .............................................................................................................................................. 73

13.10 - Outdoor reset adjustment ................................................................................................................................................... 73

13.10.1 - Outdoor reset applications ................................................................................................................................... 73

13.10.2 - Outdoor reset adjustment precautions ................................................................................................................. 73

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

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

13.10.5 - Outdoor reset activation ....................................................................................................................................... 74

13.10.6 – Outdoor reset with room compensation............................................................................................................... 75

13.11 - Boiler switch settings .......................................................................................................................................................... 76

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

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

13.14 - Boiler’s Freeze protection ................................................................................................................................................... 76

13.15 - Display in energy saving mode .......................................................................................................................................... 77

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

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

13.18 - Diagnostics ......................................................................................................................................................................... 80

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

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

14 - MAINTENANCE ............................................................................................................................................................................ 85

14.1 - Care and maintenance ......................................................................................................................................................... 85

14.1.1 - Address reported problems .................................................................................................................................... 86

14.1.2 - Check all piping for leaks ....................................................................................................................................... 86

14.1.3 - Verify flue and air lines in good condition and sealed tight; ................................................................................... 86

14.1.4 - Check system water pressure/system piping/expansion tank; ............................................................................... 86

14.1.5 - Check control settings ............................................................................................................................................ 86

14.1.6 - Check ignition and flame sense electrodes ............................................................................................................ 86

14.1.7 - Check wiring and connections................................................................................................................................ 86

14.1.8 - Perform performance verification. .......................................................................................................................... 86

14.1.9 - Flame inspection .................................................................................................................................................... 86

14.1.10 - Check flame signal ............................................................................................................................................... 86

14.1.11 - Check relief valve ................................................................................................................................................. 86

14.1.12 - Check boiler area ................................................................................................................................................. 87

14.1.13 - Check pressure gauge ......................................................................................................................................... 87

14.1.14 - Check vent piping ................................................................................................................................................. 87

14.1.15 - Check air piping.................................................................................................................................................... 87

14.1.16 - Check condensate drain system .......................................................................................................................... 87

14.1.17 - Check boiler piping (gas and water) ..................................................................................................................... 87

14.1.18 - Shut boiler down (unless boiler is used for Domestic Water) ............................................................................... 87

14.2 - Removing the casing ............................................................................................................................................................. 88

14.3 - Cleaning the burner and primary heat exchanger, flue gas side .......................................................................................... 89

14.4 - Correct positioning of the ignition and flame detection electrodes ...................................................................................... 90

14.5 - Domestic hot water heat exchanger (only for 160-C model) ................................................................................................ 90

14.6 - Condensate trap cleaning ..................................................................................................................................................... 91

14.7 - Circulator pump motor replacement (only for 160-C model) ................................................................................................ 92

14.8 - Expansion tank pressure (only for 160-C model) ................................................................................................................. 92

14.9 - 3-way valve removal (only for 160-C model) ........................................................................................................................ 93

14.10 - Draining the heating side of the boiler ................................................................................................................................ 94

14.11 - Draining the domestic hot water side of the boiler .............................................................................................................. 94

14.12 – Overrides ........................................................................................................................................................................... 94

14.12.1 - Auto-purging ......................................................................................................................................................... 94

14.12.2 - Fan ....................................................................................................................................................................... 94

14.12.3 – Minimum and maximum output ........................................................................................................................... 94

14.12.4 – Checking the flame current.................................................................................................................................. 94

14.13 - Water and flue temperature sensor .................................................................................................................................... 95

14.14 - Outdoor temperature sensor (optional) .............................................................................................................................. 95

14.15 - Functional wiring diagram ................................................................................................................................................... 96

14.16 - Multiwire wiring diagram ..................................................................................................................................................... 98

15 - TECHNICAL DATA ..................................................................................................................................................................... 100

16 - SPARE PARTS ........................................................................................................................................................................... 101

17 - READ OUT FLOW CHART ........................................................................................................................................................ 106

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1 - INSTALLATION - CODE REQUIREMENTS

1.1 - Regulations and guidelines

- 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;

- the latest edition of the

National Electric

Code ANSI/NFPA 70 and or Canadian

Electrical Code Part 1 CSA C22.1.

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

Controls and Safety

Devices for Automatically Fired Boilers,

ANSI/ASME CSD-1

NOTICE! Install CO detectors per local regulations.

NOTICE

This boiler meet the safe and other performance requirements as specified in

ANSI Z21.13 standard.

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

IMPORTANT

In accordance with Section 325 (f)(3) of the energy policy and conservation

Act, this boiler is equipped with a feature that saves energy by reducing the boiler water temperature has the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of en external energy menagement system that serves the same function. THIS OVERRIDE MUST NOT BE

USED UNLESS AT LEAST ONE OF THE

FOLLOWING CONDITIONS IS TRUE:



An external energy menagement system is installed that reduces the boiler water temperature at the heating load decreases.



This boiler is not used for any space heating.



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



This boiler is equipped with a tankless coil.

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1 - INSTALLATION - CODE REQUIREMENTS

1.2- Commonwealth of Massachusetts

Installation

Requirements

In the Commonwealth of

Massachusetts, the installation must be performed by a licensed plumber or gas fitter.

WARNING!!!

WARNING!!!

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

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

1. INSTALLATION OF CARBON

MONOXIDE DETECTORS. At the time of installation of the side wall horizontal vented gas fueled equipment, the installing plumber or gasfitter shall observe that a hard wired carbon monoxide detector with an alarm and battery back-up is installed on the floor level where the gas equipment is to be installed. In addition, the installing plumber or gasfitter shall observe that a battery operated or hard wired carbon monoxide detector with an alarm is installed on each additional level of the dwelling, building or structure served by the side wall horizontal vented gas fueled equip-ment. It shall be the responsibility of the property owner to secure the services of qualified licensed professionals for the installation of hard wired carbon monoxide detectors.

a. In the event that the side wall horizontally vented gas fueled equipment is installed in a crawl space or an attic, the hard wired carbon monoxide detector with alarm and battery back-up may be installed on the next adjacent floor level.

b. In the event that the requirements of this subdivision can not be met at the time of completion of installation, the owner shall have a period of thirty

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

2. APPROVED CARBON MONOXIDE

DETECTORS. Each carbon monoxide detector as required in accordance with the above provisions shall comply with

NFPA 720 and be ANSI/UL 2034 listed and IAS certified.

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

“GAS VENT DIRECTLY

BELOW. KEEP CLEAR OF ALL

OBSTRUCTIONS”.

4. INSPECTION. The state or local gas inspector of the side wall horizontally vented gas fueled equipment shall not approve the installation unless, upon inspection, the inspector observes carbon monoxide detectors and signage installed in accordance with the provisions of 248 CMR 5.08(2)(a)1 through 4.

(b) Exemptions

The following equipment is exempt from

248 CMR 5.08(2)(a) 1 through 4:

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be

Vented” in the most current edition of

NFPA 54 as adopted by the Board; and

2. Product Approved side wall horizontally vented gas fueled equipment installed in a room or structure separate from the dwelling, building or structure used in whole or in part for residential purposes.

(c) MANUFACTURER REQUIREMENTS

- GAS EQUIPMENT - VENTING SYSTEM

PROVIDED.

When the manufacturer of Product

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

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

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

(d) MANUFACTURER REQUIREMENTS

– GAS EQUIPMENT - VENTING SYSTEM

NOT PROVIDED.

When the manufacturer of a Product

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

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

2. The “special venting systems” shall be

Product Approved by the Board, and the instructions for that system shall include a parts list and detailed installation instructions.

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

2 - GENERAL INFORMATION

2.1 - Key to symbols used

WARNING!!!

an explosion, extensive property damage, severe personal injury or death!

Failure to follow these indications can causing

CAUTION!!!

Failure to observe this indication may compromise the smooth running of the appliance or cause serious damage to individuals, animals or property.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not related to personal injury or property damage.



Important indication symbol

2.2 - Description of model:

XX - 160 - X

B = heating only version, for inside installation

C = combi version (space heating and instantaneous D.H.W. production), for inside installation.

160 = Fully modulating gas-fired, condensing hot water boiler, with maximum power input of 160,000 Btu/hr (47 kW) and minimum power input of 30,000 Btu/hr (9 kW)

Manufacturer’s reference

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3 - MAIN COMPONENTS

1 - Automatic air vent

2 - Air intake and flue gas discharge fitting (venting system)

3 - U7 flue gas temp. sensor and flue safety switch

4 - Expansion tank (not present on 160-B model)

5 - Inlet air plenum

6 - Air/gas mixer device

7 - U2 d.h.w. temp. sensor (not present on 160-B model)

8 - Heating pressure switch (low water cut-off)

9 - Heating supply connection

10 - DHW connection (not present on 160-B model)

11 - Gas inlet connection

12 - Cold water connection (not present on 160-B model)

13 - Heating return connection

14 - Power Control Board

Figure 3-1 Main components (continued)

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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 (in some customized models may be not present)

3 - MAIN COMPONENTS

22 - Combustion analysis tap

23 - U1 supply temperature sensor

24 - Burner window

25 - Air/gas manifold

26 - U6 high temperature limit sensor

27 - Flue gas back flow 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 (not present on 160-B model)

36 - U3 domestic cold water temp. sensor (not present on 160-B model)

Figure 3-1 Main components

37 - Cable clamp

38 - ASME Safety relief valve

39 - U8 return temperature sensor

40 - By-pass pipe (not present on 160-B model)

41 - Condensation discharge pipe

42 - Secondary heat exchanger for domestic hot water production

(not present on 160-B model) (For P/N see Section 15)

43 - Expansion tank connection pipe (not present on 160-B model)

44 - Circulator pump screw (not present on 160-B model)

45 - Circulator pump (not present on 160-B model)

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

13

4 - FUNCTION OVERVIEW

Figure 4-1 160-B Hydronic functional schematic

Key to figures 4-1 and 4-2:

1 = boiler

2 = automatic air vent

3 = air intake

4 = flue 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 = flue 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 = flue pressure switch

Figure 4-2 - 160-C Hydronic functional schematic

14

4 - FUNCTION OVERVIEW

4.1 - Intended use and functions of the boiler

This gas-fired 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 specific procedure in section

13.7 for the adjustment of the domestic hot water temperature.

This boiler can be installed with a Direct

Venting system or with a one pipe vent system and getting combustion air from room.

The quality of the system water is very important. Poor water quality can damage heating systems due to scale formation and corrosion.

This boiler can be connected to an indirect storage tank for the production of domestic hot water (Section 9).

Depending on the model choosen, the following system types can be created:

160-C. Using this boiler model, 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 176°F (80°C).

The boiler can also function directly with a radiant floor panel, see section 7.2.

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

Figure 7-3. The same verification must be done for the domestic installation, see Figure 7-5.

160-B. Using this boiler model, you can create a system with heating elements functioning at temperatures ranging between 68°F (20°C) and 176°F (80°C) can be configured.

The boiler can also function directly with a radiant floor panel, see section 7.2.

The 160-B model is not equipped with the components required for the production of domestic hot water. Also not included is the expansion tank and circulator pump, see Figure 4.2.

To connect the boiler to the heating system, the installer must consider the loss of pressure generated by the boiler

(see Figure 7-4), and choose a pump capable of overcoming the head loss of both the boiler and the heating system.

160-C and 160-B models can be connected to a room thermostat,

Section 8.1.3.

An outdoor air temperature sensor can also be connected to the boiler for an outdoor reset supply temperature control for maximum fuel efficiency and comfort (see Section 8.1.4). In this configuration 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 13.10.



The boiler must be connected to a heating system and a domestic hot water supply with compatible specifications, performance and power rating.

4.2 - Efficiency up to

98%

When the outdoor reset is activated

(an outside sensor is connected), this boiler is designed to always work at the maximum efficiency (see Section

13.10). It will automatically change the supply temperature in relation with the outdoor temperature (Outdoor reset).

The graph in Figure 4-3 shows an example on how it can work.

This graph represents 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 efficiency. 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 4-3 Outdoor reset control to optimize the efficiency

15

5 - INSTALLATION - Location

5.1 - Choosing the installation location

WARNING!!!

or liquids in the immediate vicinity of the boiler. A fire or explosion can result, causing severe personal injury, death, or substantial property

WARNING!!!

Do not store any flammable materials

WARNING!!!

vertical and constructed to bear the boiler’s weight or the boiler and building may be damaged causing severe personal injury, death, or substantial property

WARNING!!!

If the boiler is installed on a wall, this must be

WARNING!!!

Do not install the boiler on carpeting. Fire can result, causing severe personal injury, death, or substantial property damage.

WARNING!!!

WARNING!!!

Provisions for combustion air and ventilation of the boiler room are always required, regardless whether the combustion air is taken from the outside (Direct Vent, sealed combustion) or inside

(room air for combustion).

Insufficient ventilation of the boiler room can lead to high air temperatures. Make sure that intake and exhaust openings are sufficiently sized and no reduction or closure of openings takes place. When the problem is not resolved, do not operate the boiler. Please note these restrictions and its dangers to the operator of the boiler. Failure to comply with this provisions could result in severe personal injury, death, or substantial property damage.

Figure 5-1 Recommended minimum clearance distances for proper installation and servicing

16

WARNING!!!

WARNING!!!

LIQUEFIED

PETROLEUM (L.P.) PROPANE

GAS-FIRED BOILER LOCATION

REQUIRES SPECIAL

ATTENTION: 1994 UNIFORM

MECHANICAL CODE, section

304.6: “LPG Appliances.

Liquefied petroleum gasburning appliances shall not be installed in a pit, basement or similar location where heavierthan-air-gas might collect.

Appliances so fueled shall not be installed in an abovegrade under-floor space or basement unless such location is provided with an approved means for removal of unburned gas.” Failure to comply with this provision could result in severe personal injury, death, or substantial property damage.

CAUTION!!!

This boiler is not designed for direct outdoor installation. If installed outside of the structure, 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 or temperature that exceed 100°F (38°C). Failure to properly locate this boiler can result in premature failure voiding the warranty.

CAUTION!!!

This boiler should be installed in a location so that any water leaking from the boiler or piping connections or relief valve openings will not cause damage to the area surrounding the unit or any lower floors in the structure.

CAUTION!!!

When installed in a room with thin walls or a thin floor, resonating noise may occur. Install noise reducing parts if required.

CAUTION!!!

boiler.

Do not allow too much dust to collect on the

5 - INSTALLATION - Location

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 or equivalent device;



piping of the safety relief valve discharge;



possible connection of the outdoor temperature sensor;



possible connection of an indirect water heater.

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

5.1.3 - Clearances from combustible material

This boiler may be installed directly onto a wall of combustible material with the following clearance:

- Ceiling:

- Front:

- Rear:

- Sides:

- Floor:

2 inches (51 mm)

2 inches (51 mm)

0 inches (0 mm)

2 inches (51 mm)

2 inches (51 mm)

- Concentric vent: 0 inches (0 mm)

- Split vent (two pipes), first 3ft from the boiler: 1 inch (25 mm)

- Split vent (two pipes), after 3ft from the boiler: 0 inches (0 mm)

- Boiler piping: 1/4 inch (7 mm)

5.1.1 - Closet and alcove installations

It is possible to install the boiler in a closet or alcove structure, but you must to consider a minimum clearances for serviceability as per section 5.1.2 and a minimum volume

WARNING!!!

WARNING!!!

in a closet or alcove structure due to elevate temperature. Failure to follow this warning could result in

WARNING!!!

It is forbidden the use of PVC vent piping material

WARNING!!!

Provide two ventilating air openings of

160 sq. inch each. One located at 6 inch from the top and one located at 6 inch from the bottom of the structure. Failure to follow this warning could result in fire, personal injury, or death.

5.1.2 - Clearances for installation and servicing

Figure 5-1 shows the minimum clearances required for installation and servicing.

5.1.4 - Vent and air piping

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

The boiler is to be used for either direct vent installation or for installation using room combustion air. When room air is considered, see Section 10-10.

Vent and air may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods covered in Section 10. Do not attempt to install the boiler using any other means.

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated.

The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in

Section 10.

5.1.5 - Prevent combustion air contamination

Install air inlet piping for the boiler as described in Section 10. Do not terminate vent/air in locations that can allow contamination of combustion air.

Refer to Section 10.2, for products and areas which may cause contaminated combustion air.

WARNING!!!

WARNING!!!

Ensure that the combustion air will not contain any of the contaminants listed in Section 10.2.

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

5.2 - Transporting the boiler

WARNING!!!

Always lift and carry the boiler with a hand truck or special equipment Failure to comply with this provisions could result in severe personal injury or death.

CAUTION!!!

The boiler may be damaged when it is improperly secured and transported.

CAUTION!!!

The unpacked boiler may be damaged when not protected against contamination



Only transport the boiler using the right transportation equipment, such as a hand truck with a fastening belt or special equipment for maneuvering steps.



During transportation the boiler must be secured on the transportation equipment to prevent it from falling off.



Protect all parts against impacts if they are to be transported.



Observe the transportation markings on the packaging.



Leave the protective covers on the connections.



Cover the flue gas and air intake connections at the top of the boiler with plastic film

17

6 - INSTALLATION - Mounting the boiler

Figure 6-1 Wall bracket installation

6.1 - Mounting the boiler

Refer to Figure 6-1:

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

WARNING!!!

WARNING!!!

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 causing severe personal injury, death, or substantial property damage.

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 6-2 Dimensions

1 = Area for power supply cable

2 = Heating supply connection (3/4”)

3 = Domestic hot water connection (3/4”) (absent on 160-B model)

4 = Gas connection (3/4”)

5 = Domestic cold water connection (3/4”) (absent on 160-B model)

6 = heating return connection (3/4”)

7 = positions for boiler support

8 = Flue discharge/air intake connection

18

7 - INSTALLATION - Water connection

7.1 - Water connections

The boiler comes with the fittings shown in Figure 7-1.

A = heating system supply (3/4”)

B = domestic hot water supply (3/4”)

(Absent on 160-B model)

C = Inlet gas connection (3/4”)

D = domestic cold water (3/4”) (Absent on

160-B model)

E = heating system return (3/4”)

Figure 7-1 Fittings supplied with the boiler

7.2 - 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.

CAUTION!!!

This boiler must have adequate water flowing of 5 GPM 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 flushed to remove sediment, flux, filings 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!!!

Any dirt or foreign matter which is present in the heating circuit , might accumulate inside the secondary domestic heat exchanger, limiting the heat exchange and reducing the production of domestic hot water

CAUTION!!!

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

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!!!

Continual fresh make-up water will reduce boiler life. Mineral buildup in the heat exchanger reduces heat transfer, overheats the stainless steel heat exchanger, and causes failure. Addition of oxygen carried in by makeup water can cause internal corrosion in system components. Leaks in boiler or piping must be repaired at once to prevent makeup water entering the boiler.

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.

19

7 - INSTALLATION - Water connections

CAUTION!!!

Risk of system damage due to unsuitable heating system water. If oxygen-permeable pipes are used, e.g. for under floor heating systems, the systems must be separated from one another by plate heat exchangers. Unsuitable heating system water promotes sludge and corrosion formation. This can result in heat exchanger damage and malfunction, which is not covered by warranty.

CAUTION!!!

spa water.

Do not use the boiler to directly heat swimming pool or

System water piping methods

This boiler is designed to function in a closed loop pressurized system not less than 8 psi (0,5 bar). A pressure gauge is included to monitor system pressure. It is important to note that the boiler version 160-B has a minimal amount of pressure drop

(see Figure 7-4) and must be figured in when sizing the circulators. Each boiler installation must have an air elimination device, which will remove air from the system. Install the boiler so the gas ignition system components are protected from water (dripping, spraying, etc.) during appliance operation for basic service of circulator replacement, valves, and others.

Observe a minimum of 1/4” (7mm) clearance around all un-insulated hot water pipes when openings around the pipes are not protected by noncombustible materials.

tested at least once a year and as recommended by the producer of the glycol solution. Allowance should be made for the expansion of the glycol

WARNING!!!

WARNING!!!

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

WARNING!!!

Never use non-approved additives or toxic

WARNING!!!

Use only inhibited propylene glycol solutions, which are specifically formulated for hydronic systems. Ethylene glycol is toxic and can attack gaskets and seals used in hydronic systems.

CAUTION!!!

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.

Low water cutoff device

On a boiler installed above radiation level, some states and local codes require a low water cutoff device at the time of installation.

CAUTION!!!

This boiler is capable of servicing multiple temperature loop systems.

It is the responsibility of the installer to protect the loops with lower temperature requirements from higher temperatures that may be required by other loops

Freeze protection

Freeze protection for new or existing systems must use glycol that is specially formulated for this purpose.

This includes inhibitors, which prevent the glycol from attacking the metallic system components. Make certain to check that the system fluid is correct for the glycol concentration and inhibitor level. The system should be

Floor radiant heating systems

With switch #6 in Figure 9-2, 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).

20

CAUTION!!!

If the boiler is installed in a low temperature system, the switch #6 in

Figure 9-2 must be placed in the ON position to prevent the supply water temperature from exceeding 113°F (45°C) or damage to the low temperature system components could occur

(see section 5.9).

CAUTION!!!

To protect the radiant floor panel against over heating you must install a safety device that shuts-off the boiler before it reaches the floor panel’s limit temperature.

CAUTION!!!

Risk of system damage due to unsuitable heating system water. If oxygen-permeable pipes are used, e.g. for under floor heating systems, the systems must be separated from one another by plate heat exchangers. Unsuitable heating system water promotes sludge and corrosion formation. This can result in heat exchanger damage and malfunction, which is not covered by warranty.

7.2.1 - Near boiler heating piping components

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

2. Boiler system pump: field supplied for 160-B model. Factory installed for 160-C model. Circulators MUST be sized to meet the specified minimum flow requirements of 5

GPM.

3. Indirect water heater circulating pump: Field supplied. The pump MUST be sized to meet the specified minimum flow requirements of 5 GPM.

Consult the indirect water heater operating guide to determine flow characteristics for the selected product used.

7 - INSTALLATION - Water connections

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

5. Back flow preventer: Field supplied.

Back flow preventer valves are recommended for installation as shown in Figures 7-6 and 7-7.

Failure to install these valves could result in a reverse flow condition during pump(s) off cycle.

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

7. Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is recommended (see Figure 7-6).

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

8. Unions: Field supplied.

Recommended for unit serviceability.

9. Pressure relief valve: Factory installed. The pressure relief valve is sized to ASME specifications.

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

A. The space heating piping will branch off to flow the space heat transfer medium through a single wall heat exchanger coil inside the indirect water heater.

B. The indirect water heater is connected to the system supply piping. A pump controlled by the boiler’s control will regulate the flow of water through the indirect water heater. The indirect water heater’s temperature will be regulated by the boiler’s control.

The boiler is pre-configured to control the operation of the DHW pump with Domestic Hot Water

Prioritization programming.

CAUTION!!!

It is up to the installer to ensure the minimum system flow is not less than 5

GPM at any time.

WARNING!!!

WARNING!!!

The National

Standard Plumbing Code, the National Plumbing Code of Canada and the Uniform

Plumbing Code limit the pressure of the heat transfer fluid to less than the minimum working pressure of the potable water system up to

30 psi maximum. Also, the heat transfer fluid must be water or other non-toxic fluid having a toxicity of Class 1, as listed in Clinical Toxicology of Commercial Products, 5th

Edition

11. Filter: Field supplied. A filter or equivalent multipurpose strainer is recommended at the return pipe of the boiler to remove system particles from older hydronic systems and protect newer systems.

A = 3/4” pipe extension (not provided)

B = Discharge device open to the atmosphere (not provided)

C = Condensate discharge pipe

7.2.2 - Relief valve

This 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.

Pipe the discharge to a drain (See

Figure 7-2). Provide piping that is the same size as the safety relief valve outlet

WARNING!!!

WARNING!!!

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

WARNING!!!

Failure to properly pipe the relief

WARNING!!!

Never block the outlet of the safety relief valve or an explosion causing extensive property damage, severe personal injury or death may occur!

Figure 7-2 Relief valve discharge piping

21

7 - INSTALLATION - Water connections

7.2.3 - Expansion Tank and Makeup Water

Boiler model 160-C is factory equipped with its expansion tank with

2 gals volume. Ensure this volume is sufficient for the heating system you are designing. If not, install an additional external expansion tank.

For boiler model 160-B, ensure the expansion tank is properly sized for the boiler volume (1,5 gallons

[6 litres]) and the system volume, temperature and pressure.

To connect a system pump on the secondary looping see Figure 7-6 and electrically connect the pump follow

Figure 8-2

160-B boiler is not fitted with an internal pump. The installer needs to install an external heating pump as illustrated in Figure 7-7. To size the pump, together the system head loss, consider also the graph in Figure

7-4. The minimum allowable flow rate through the boiler is 5 gpm (1,135 l/h).

CAUTION!!!

Undersized expansion tanks will cause system water to be lost through the pressure relief valve and cause additional makeup water to be added to the system. Eventual boiler heat exchanger failure can result due to this excessive makeup water addition, compromising the functionality of the unit and void its warranty.

For model 160-B (and for 160-C if needed), the expansion tank must be located as shown in Figures

7-6 and 7-7 when using a primary/ secondary piping arrangement or as per recognized design methods. Refer to the expansion tank manufacturer instructions for additional installation details.

Connect the expansion tank to an air separator only if the air separator is located on the suction side (inlet) of the system circulator.

Always locate and install the system fill connection at the same location as the expansion tank connection to the system.

7.2.4 - Heating pump

160-C boiler is fitted with a circulator pump. The head available to supply flow through the heating system at the boiler connections is shown in graph form in Figure 7-3. The internal pump is sufficient to run the water into the primary looping.

CAUTION!!!

It is up to the installer to ensure the minimum system flow is not less than 5

GPM at any time.

CAUTION!!!

It is up to the installer to ensure the minimum system flow is not less than 5

GPM at any time.

To wire the heating pump to the boiler, refer to Section 9.1. Because the pump is normally used in conjunction with an indirect water heater, see

Figure 7-7 which shows a typical installation with a typical rise of 35°F and using the follow heating pump:

- GRUNDFOS model UPS15-58FC

- TACO model 008/0010

- B&G model NRF-36

- Armstrong model Astro 30

For different installations, size the pump using recognized design methods.

7.2.5 - Sizing heating system

Size the piping and system components required in the space heating system, using recognized design methods.

7.2.6 - Domestic Hot

Water System Piping when using an indirect water heater

See Figure 7-7 , for recommended piping to an indirect water heater. This recommended piping configuration ensures priority is given to the production and recovery of DHW.

Install the heating pump (item “9”,

Figure 7-7) only if you are using a

160-B boiler model. Refer to Figure

9-1 to wire the indirect water heater pump, the system pump and the heating pump (if present).

22

7.3 - Converting a combi boiler into a heating only boiler

If you are in possession of a combi boiler

(160-C) you can use it as a heat only boiler without using the domestic hot water circuit. To do so, simply plug the two fittings, items “3” and “5” of Figure 6-2, and move switch N°5 (see Figure 9-1) from OFF position to ON position. Now knob “11” of Figure 13-1 is disabled.

7 - INSTALLATION - Water connections

Figure 7-3 Available Head for heating circuit for models “160-C”

Figure 7-4 Internal Boiler Head Loss for model “160-B”

7.4 - Domestic hot and cold water

(only for 160-C model)

160-C boiler, offers resistance to the passage of domestic water (see graph flow/pressure of Figure 7-5).

The installer or the engineer must take account of this in order to ensure the correct domestic water flow to the utilities.

CAUTION!!!

If the domestic water hardness is greater than 9 gr/gal (150 mg/l) we recommend installing a water softener with filter. Failure to comply with this requirement may compromise the functionality of the unit and void its warranty.



Figure 11 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 flow, install an adjustable flow restrictor upstream the cold water inlet (see Figure 7-6 item “17”)



160-C boiler can be used as heat only boiler (see Section 7-3).

Anti-scald mixing valve: Field supplied. An anti-scald mixing valve is recommended (see Figure 7-6). It is recommended also when an indirect

WARNING!!!

WARNING!!!

Install an anti scald mixing valve downstream domestic hot water piping.

Failure to comply with this provision can result in scalding of individuals and animals causing, severe personal injury or death!

Figure 7-5 Domestic Water Coil Head Loss for model “160-C”

23

7 - INSTALLATION - Water connections

Heating system return

Cold water make-up

Heating system supply

Domestic hot water

1 = Boiler

2 = Air separator

3 = Ball valve

4 = Drain cocks

5 = Filling valve

6 = Expansion tank (If needed)

7 = Filter

11 = Relief valve drain

Figure 7-6 Piping of the boiler model 160-C

24

12 = Gas shut-off valve (Install manual shut-off valve 5 ft

(1.5m) above floor).

13 = Ground joint union

14 = Condensate drain (see also Figure 7-8)

16 = System pump

17 = Flow restrictor

18 = Mixing valve

7 - INSTALLATION - Water connections

Heating system return

Cold water make-up

Heating system supply

Supply to a

DHW indirect water heater

(if needed)

Return from a

DHW indirect water heater (if needed)

1 = Boiler

2 = Air separator

3 = Ball valve

4 = Drain cocks

5 = Filling valve

6 = Expansion tank

7 = Filter

8 = Back flow preventer

Figure 7-7 Piping of the boiler 160-B

9 = Heating pump

11 = Relief valve drain

12 = Gas shut-off valve (Install manual shut-off valve 5 ft

(1.5m) above floor)

13 = Ground joint union

14 = Condensate drain (see also Figure 7-8)

15 = Indirect water heater pump (if needed)

16 = System pump

25

7 - INSTALLATION - Water connections

7.5 - 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, Figure 3-1, item “46”, for the evacuation of condensate and to prevent the leakage of combustion products. The condensate trap drains through pipe shown in Figure 7-2 item “C”. The condensation disposal system must:

 be connected by means of an appropriate trap capable of preventing the pressurization of the condensate system and the return of sewer gas (see figure 7-8);

 slope condensate tubing down and away from the boiler into a drain or condensate neutralizing filter.

Condensate from the boiler will be slightly acidic (around pH 4). Install a neutralizing filter if required by local codes.

 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.

A condensate removal pump is required if the boiler is below the drain. When installing a condensate pump, select one approved for use with condensing boilers and furnaces.

The pump should have an overflow switch to prevent property damage from condensate spillage.

COMMONWEALTH OF

MASSACHUSETTS SPECIAL

REQUIREMENT

When the boiler is installed and used in the Commonwealth of

Massachusetts, a neutralization unit MUST be installed in the condensate removal system.

CAUTION!!!

Use materials approved by the authority having jurisdiction. In the absence of other authority,

PVC and CPVC pipe must comply with ASTM D1785 or

D2845. Cement and primer must comply with ASME D2564 or F493. For Canada use CSA or ULC certified PVC or CPVC pipe, fittings, and cement.

CAUTION!!!

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

 comply with national and/or local codes for condensate neutralizer between pipe “C” of figure 7-2 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);

Condensate trap and drain

Figure 7-8 Condensate trap and drain connection

26

8 - INSTALLATION - Electrical connections

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

M = Indirect water heater temperature sensor terminals

N = Remote command cable (optional)

Figure 8-1 Junction box

8.1 - Electrical connections: overview

WARNING!!!

before making any electrical connections to avoid possible electric shock hazard. Failure to do so

WARNING!!!

ELECTRICAL SHOCK HAZARD

– For your safety, turn off electrical power supply

WARNING!!!

errors can cause improper and dangerous operation!

WARNING!!!

Label all wires prior to disconnection when servicing controls. Wiring

ATTENTION!!!

débrancher. Des erreurs de câblage peuvent entraîner un fonction-nement inadéquat et dangereux. S’assurer que l’appareil fonctionne

WARNING!!!

Au moment de l’entretien des commandes, étiquetez tous les fils avant de les

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/NFPA 70 and/or the Canadian Electrical Code Part I, CSA C22.1,

Electrical Code.

NOTICE! Wiring must be N.E.C. Class 1. Use only type

105°C wire or equivalent.

Installation must comply with:

1. National Electrical Code and any other national, state,provincial, or local codes, or regulations.

2. In Canada, CSA C22.1 Canadian Electrical Code Part 1, and any local codes.



Check that the electrical system is adequate for the power consumption indicated on the rating plate.



Line voltage field 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, (0.3

mm).



A properly rated shut-off switch shall be located nearest to the boiler.



Ensure that the polarity between live and neutral wires is maintained when connecting the boiler.

27

8 - INSTALLATION - Electrical connections

Outdoor sensor

Room thermostat

Neutral

120Vac hot central heating

120Vac LINE (HOT)

NEUTRAL

GROUND

System pump (see piping diagram of

Figure7-6)

Figure 8-2 Electrical connections for 160-C model (Refere to Figure 7-6)

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.

8.1.1 - Connecting the power supply cable

Provide and install a fused disconnect or service switch (15 amp recommended) as required by the code. To connect the electrical power supply cable, follow the steps below while referring to Figures 8-1 and 8-2:

1. remove the boiler casing following the instructions given in Section 14.2 and open the junction box cover;

2. press the two plastic springs tabs labeled “B” on the bottom side;

3. open panel “A” in the “C” direction;

4. remove the three screws labeled “D”;

5. open door “E” in the “F” direction;

6. install the power supply wires, “G” as shown;

7. strip the power supply wires being careful to leave the ground wire 1in

(25 mm) longer than the other two;

8. connect the ground wire to the ground terminal;

9. connect the 120 volt hot wire to terminal “L1”;

10. 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

28

8.1.2 - Wiring the heating pump for 160-B model

On 160-B model the heating pump is not supplied with the boiler. Install the heating pump following Section 7.2.4. If the boiler is not connected to an indirect water heater, wire the heating pump to the boiler following the steps below while refering to Figures 8-1 and 8-2:

1. remove the boiler casing according to the instructions given in section 14.2 and open the junction box cover;

2. use a three wire cable with a minimum cross section of # 14 AWG between the boiler and the circulator pump;

3. route the circulator cable through an empty cable clamp in the junction box;

4. connect the Hot and Neutral cable wires respectively to the “4 and 5” terminals in the junction box;

5. connect the Ground wire to an empty

“Ground” connection inside the junction box.

8 - INSTALLATION - Electrical connections

CAUTION!!!

If the pump is larger than 1 hp or 1 amps, you must isolate with a relay.

6. Connect the electrical supply cable to the electrical connections into the pump. Follow manufacturer’s instruction of the pump.

NOTICE! If the 120 volt power wires are inverted, the boiler will lock-out,

displaying error code L05.

8.1.3 - 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 Figure 8-3).

Connect the room thermostat to the boiler by following the steps below:

1. remove the boiler casing according to the instructions given in Section 14.2 and open the junction box cover;

2. use a two conductor cable with a minimum cross section of #18 AWG between the boiler and the room thermostat;

3. route the cable through an empty cable clamp “E” in the junction box;

4. connect the cable leads to the “9” and

“10” terminals as shown in Figure 8-2.

NOTICE! the maximum room thermostat cable length permitted is 32 ft (10 m).

For longer lengths, up to 300ft (100 m) a shielded cable, with the shield connected

WARNING!!!

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.

8.1.4 - Installing the outdoor temperature sensor

The outdoor temperature sensor is supplied with the boiler. Install the outdoor temperature sensor, on an exterior wall of the building facing

NORTH or NORTH-EAST, 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 floor. 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 14.2 and open the junction box;

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 32 ft (10 m). For longer lengths, up to 300 ft (100 m) a shielded cable, with the shield connected to the

WARNING!!!

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 “13” and “14” as shown in Figure 8-2;

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 climatic heat adjustment desired as explained in Section 13.10;

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

6ft ( )

8.1.5 - Alarm output

Inside the electrical box (see Figure 9-2) 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, indirectly, any kind of external signal to devices such an audible alarm, phone, or other devices.

Figure 8-3 Room thermostat location

29

9 - INSTALLATION - Connecting to an indirect water heater

9.1 - Connecting the boiler to an indirect water heater

This boiler, can be connected to an indirect water heater. The water connection must be made per figure

7-7. Heating pump item “9” of Figure

7-7 is mandatory for boiler model 160-

B. The electrical connections must be made per figure 9-1. To change the logic of the boiler, to drive and load an indirect water heater, follow the steps below while refering to Figure 9-2:

1. disconnect the boiler from the electrical supply;

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

14.2;

3. push the plastic spring tabs “B”;

4. open the front half of the electrical box in the “C” direction;

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

6. move switch #5 in the OFF position;

7. on model 160-C, on the rear side of the electrical junction box board, if present, disconnect the plug with two wires, item “E”, corresponding to wires #44 and #45.

8. on model 160-C, on the rear side of the electrical box, disconnect the electrical plug from the diverter valve (see Figure 3-1, item “35”).

When you disconnect the plug you must insure that the boiler is in the heating mode. 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 water heater temperature sensor to terminals

“15” and “16”, as per Figure 9-1

10. insert the probe of the indirect water heater sensor into the socket of the indirect water heater.

WARNING!!!

WARNING!!!

sensor wires conduct 24 Vac, they must never be run through conduits containing 120 Vac power wires or an electrical

WARNING!!!

Since the indirect water heater temperature

WARNING!!!

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

NOTE! A few cable conduit holes are provided on the bottom right side of the boiler

CAUTION!!!

If the pump is larger than 1 hp or 2 amps, you must isolate with a relay.

11. reinstall all dismounted parts.

Indirect water heater sensor (optional)

Outdoor sensor

Room thermostat

Isolation relay

Heating pump (see piping diagram of

Figure 7-7)

120Vac hot

Neutral

120Vac hot

120Vac LINE (HOT)

NEUTRAL

GROUND

Indirect water heater pump (see piping diagram of Figure 7-7)

System pump (see piping diagram of

Figure 7-7)

Figure 9-1 Electrical connections for 160-B model (see Figure 7-7)

30

9 - INSTALLATION - Connecting to an indirect water heater

9.1.1 Indirect water heater priority selection

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

Once the indirect water heater is satisfied the boiler will automatically return to central heating.

Priority selection is a functionality that toggles between CH and DHW demand when they are both active at the same time. The priority selection is set with the (DHW Priority) parameter in the “Installer menu” (see

Section 13.17).

Each value set into the parameter will correspond to the minutes delay boiler toggles between

Central Heating and DHW demand.

9.2 - Opening the instrument panel

To open the instrument panel and gain access to the boiler control board, follow this procedure:

1. disconnect the boiler from the electrical supply;

2. remove the boiler casing according to the instructions given in Section

14.2;

3. push the plastic spring tabs “B” shown in Figure 9-2;

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

Figure 9-2;

A = Front cover of the electrical box

B = Plastic spring to open the electrical box

C = Direction to open the electrical box

D = Switches for the functional setting of the boiler

Figure 9-2 Control board and unit electrical box details

31

10 - INSTALLATION - Vent and combustion air

10.1 - Removing of a boiler from a common venting system

WARNING!!!

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

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

(a) Seal any unused openings in the common venting system.

(b) Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction, leakage, corrosion and other deficiencies which could cause an unsafe condition.

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

Close fireplace dampers.

(d) Place in operation the appliance being inspected. Follow the lighting instructions. Adjust thermostat so appliance will operate continuously.

(e) Test for spillage at the draft hood relief opening after 5 minutes of main burner operation. Use the flame of a match or candle, or smoke from a cigarette, cigar or pipe.

(f) Alter it has been determined that each appliance remaining connected to the common venting system properly vents when tested as outlined above, return doors, windows, exhaust fans, fireplace dampers and any other gasburning appliance to their previous condition of use.

(g) Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel

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

Gas and Propane Installation

Code. When resizing any portion of the common venting system, the common venting system should be resized to approach the minimum size as determined using the appropriate Annex G of the National Fuel Gas Code, ANSI

Z223.1 /NFPA 54 and/or CAN/CSA

B149. 1, Natural Gas and Propane

Installation Code.

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

(a) Sceller toutes les ouvertures non utilisées du système d’évacuation.

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

32

(c) Dans la mesure du possible, fermer toutes les portes et les fenêtres du bâtiment et toutes les portes entre l’espace où les appareils toujours raccordés du système d’évacuation sont installés et les autres espaces du bâtiment.

Mettre en marche les sécheuses, tous les appareils non raccordés au système d’évacuation commun et tous les ventilateurs d’extraction comme les hottes de cuisinère et les ventilateurs des salles de bain.

S’assurer que ces ventilateurs fonctionnent à la vitesse maximale.

Ne pas faire fonctionner les ventilateurs d’été. Fermer les registres des cheminées.

(d) Mettre l’appareil inspecté en marche. Suivre les instructions d’allumage. Régler le thermostat de façon que l’appareil fonctionne de façon continue.

(e) Faire fonctionner le brûleur principal pendant 5 min ensuite, déterminer si le coupe-tirage déborde à l’ouverture de décharge.

Utiliser la flamme d’une allunette ou d’une chandelle ou la fumée d’une cigarette, d’un cigare ou d’une pipe.

(f) Une fois qu’il a été déterminé, selon la métode indiquée ci-dessus, que chaque appareil raccordé au système d’évacuation est mis

à l’air libre de façor adéquate.

Remettre les portes et les fenêtres, les ventilateurs, les registres de cheminées et les appareils au gaz

à leur position originale.

(g) Tout mauvais fonctionnement du systéme d’évacution commun devrait étré corrigé de façon que l’installation soit conforme au

National Fuel Gas Code, ANSI

Z223.1/NFPA 54 et (ou) aux codes d’installation CSA-B149.1. Si la grosseur d’une section du système d’ évacuation doit étré modifiée, le système devrait étré modifié pour respecter les valeurs minimales des tableaux pertinents de l’appendice

G du National Fuel Gas Code,

ANSI Z223.1/ NFPA 54 et (ou) des codes d’installation CSA-B149.1.

10 - INSTALLATION - Vent and combustion air

10.2 - Prevent combustion air contamination

Install air inlet piping as described in this Section 10. You must pipe combustion air to the boiler air intake.

Do not terminate vent/air in locations that can allow contamination of

WARNING!!!

WARNING!!!

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

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

Products that may contaminated the air combustion:

- Permanent wave solutions;

- Chlorinated waxes/cleaners;

- Chlorine-based swimming pool chemicals;

- Calcium chloride used for thawing;

- Sodium chloride used for water softening;

- Refrigerant leaks;

- Paint or varnish removers;

- Hydrochloric acid/muriatic acid;

- Cements and glues;

- Antistatic fabric softeners used in clothes dryers;

- Chlorine-type bleaches, detergents, and cleaning solvents found in household laundry rooms;

- Adhesives used to fasten building products and other similar products;

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

-Dry cleaning/laundry areas and establishments;

- Swimming pools;

- Metal fabrication plants;

- Beauty shops;

- Refrigeration repair shops;

- Photo processing plants;

- Auto body shops;

- Plastic manufacturing plants;

- Furniture refinishing areas and establishments;

- Remodeling areas;

- Garages with workshops.

10.3 - Venting and air piping systems

WARNING!!!

The vent installation must be in accordance with part Venting

of Appliances, of the latest edition of the National Fuel Gas

Code, ANSI Z223.1/NFPA 54 or section, Venting Systems and

Air Supply for Appliances, of the CAN/CSA B149.1, Natural

Gas and Propane Installation code or applicable provisions of the local building codes.

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

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

NOTICE! The vent system shall be installed so as to prevent the accumulation of condensate.

NOTICE! Due to the high efficiency of the boiler it may discharge what looks like white smoke especially when the outside air temperature is cold. This is a simply water vapor, a purely natural phenomenon and not a reason for

WARNING!!!

WARNING!!!

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

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

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

(sealed combustion).

The boiler is to be used for either

Direct Vent installation or for installation using room combustion air. When room air is considered, see

Section 10-10.

Vent and air must terminate near one another and may be vented vertically through the roof or out a side wall, unless otherwise specified. You may use any of the vent/air piping methods from Figure 10-1 to Figure 10-6. Do not attempt to install this boiler using

WARNING!!!

WARNING!!!

DO NOT mix components from different systems. The vent system could fail, causing leakage of flue products into the living space. Use only approved materials listed on Tables 10-1 and 10-2. Improper materials or mixing materials can result in excessive levels of carbon monoxide which can result in severe personal injury or death!

Be sure to locate the boiler such that the vent and air piping can be routed through the building and properly terminated.

The vent/air piping lengths, routing and termination method must all comply with the methods and limits given in Section 10.4

33

10 - INSTALLATION - Vent and combustion air

Figure 10-1 Side wall two pipes (Direct venting).

Figure 10-2 Vertical two pipes

(Direct Venting).

Figure 10-3 Side wall air intake, vertical vent (Direct venting).

Air intake

Figure 10-4 Vertical concentric (Direct venting).

Figure 10-5 Side wall concentric (Direct venting).

34

Figure 10-6 Side wall one pipe venting, combustion air from room (not Direct venting).

10 - INSTALLATION - Vent and combustion air

10.4 - Minimum /

Maximum allowable combustion air and vent piping lengths

This boiler can be fitted with a very long venting system. However there is a relationship between the length of the venting system and the power input of the boiler. Figure 10-7 shows this relation which an installer must consider when in the designing stage of the venting.

The maximum length of the two pipes vent system is 300 equivalent ft (Air intake plus flue exhuast). However, each single pipe can’t be longer than

150 ft.

The maximum length of the concentric system is 70 ft.

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

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

The minimum length of the venting sytem (Two pipes or concentric) is 1 ft

(357 mm) with one elbow.

10.5 - Install vent and combustion air

WARNING!!!

supplied with combustion and ventilation air as described in this section. Ensure the vent and air piping and the combustion air supply comply with these instructions regarding vent system, air system, and combustion air quality. See also Section 10.2 of this manual. Inspect finished vent and air piping thoroughly to ensure all are airtight and comply with the instructions provided and with all requirements of all applicable codes. Failure to provide a properly installed vent and air system will cause severe

WARNING!!!

This boiler must be vented and

WARNING!!!

Using vent materials other than those listed in Table 10-1 and Table

10-2, failure to properly seal all seams and joints, mixing of venting materials or failure to follow vent pipe and fittings manufacturer’s instructions can result in personal injury, death or property damage.

WARNING!!!

WARNING!!!

vent pipe line and fittings.

Failure to comply could result in severe personal injury, death, or substantial property

WARNING!!!

Never use cellular (foam) core pipe in

WARNING!!!

vent piping is not authorized.

Failure to comply could result in severe personal injury, death, or substantial property

WARNING!!!

Increasing or decreasing combustion air or

WARNING!!!

Use only the materials listed in Tables

10-1 and 10-2 for vent pipe, and fittings. Failure to comply could result in severe personal injury, death, or substantial property damage.

NOTICE Installation must comply with local requirements and with the

National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For installation in Canada, vent pipe system must be certified to ULC-S636

(see Table 10-1).

Figure 10-7 Relation between Power input and Vent system length

35

10 - INSTALLATION - Vent and combustion air

Vent pipe materials and fittings must comply with the following standards

Item Material

Standard for installation in USA

Standard for installation in CANADA

PVC schedule 40, 80 ANSI/ASTM D1785

Vent pipe and fittings

Pipe cement/primer

CPVC schedule 40/80

Polypropylene

Stainless steel AL29-4C

PVC

CPVC

ANSI/ASTM F441

ULC-S636

UL1738

ANSI/ASTM D2564

ANSI/ASTM F493

ULC-S636

Table 10-1 Approved vent materials

Item

Approved vent manufacturers and items

Material Manufacturer/supplier

Concentric roof or wall terminal

Two pipes wall terminal

Single pipe wall terminal (90° elbow)

Boiler adapter (80mm to 3” PVC)

Bird screen

Two pipes roof terminal

Two pipes wall terminal

Single pipe roof terminal

Single pipe wall terminal

Two or single pipe boiler adapter (80mm to

80mm Polypropylene)

Bird screen

Concentric boiler adapter

Concentric roof terminal

Concentric wall terminal

Single pipe wall or roof terminal

Two pipes wall or roof terminal

Bird screen

Single pipe wall or roof terminal

Two pipes wall or roof terminal

Bird screen

PVC

PVC

PVC

Polypropylene

PVC

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Polypropylene

Single pipe wall or roof terminal

Two pipes wall or roof terminal

Stainless steel

Stainless steel

Boiler adapter (80mm to 3” stainless steel) Stainless steel

Bird screen Stainless steel

Single pipe wall or roof terminal

Two pipes wall or roof terminal

Stainless steel

Stainless steel

Boiler adapter (80mm to 3” stainless steel) Stainless steel

Bird screen Stainless steel

IPEX (System 636)

IPEX (System 636)

IPEX (System 636)

COSMOGAS

IPEX (System 636)

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Cosmogas

Centrotherm (Innoflue System)

Centrotherm (Innoflue System)

Centrotherm (Innoflue System)

Duravent (PolyPro)

Duravent (PolyPro)

Duravent (PolyPro)

Duravent (FasNSeal)

Duravent (FasNSeal)

Duravent (FasNSeal)

Duravent (FasNSeal)

Heat Fab (SGV)

Heat Fab (SGV)

Heat Fab (SGV)

Heat Fab (SGV)

Table 10-2 Approved vent manufacturers and items

36

Manufacturer/supplier

Part Number

196006

081219 or 196985

196025

62617303

196051

62617306 and 61302003

61302004 and 61302003

62617306

61302004

62617286

61302003

62617224

62617304

62617232

ISEP0339

ISEP0339 and ISEL0387UV

IASPP03

3PPS36B

3PPS36B and 3PPS-E90B

3PPS-BG

FSVL3603

FSVL3603 and FSELB8803

FSA-80MM3

FSBS3

SGV03L36

SGV03L36 and SGV03E90

SGV03AD80

SGV03TM

10 - INSTALLATION - Vent and combustion air

10.6 - Air inlet pipe materials:

WARNING!!!

The air inlet pipe(s) must be sealed.

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

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

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

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

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

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

- Polypropylene material to be sealed to specification of its manufacturer.

NOTICE! PVC, CPVC, ABS Dryer

Vent and stainless steel pipe may require an adapter (not provided) to transition between the air inlet connection on the appliance and the

WARNING!!!

WARNING!!!

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

10.6.1 - Sealing of Type

“B” double-wall or galvanized air inlet pipe material

Sealing of Type “B” double-wall or galvanized air inlet pipe material used for air inlet piping on a sidewall or vertical rooftop Combustion Air Supply

System: a. Seal all joints and seams of the air inlet pipe using either Aluminum

Foil Duct Tape meeting UL

Standard 723 or 181A-P or a high quality UL Listed silicone sealant.

b. Do not install seams of vent pipe on the bottom of horizontal runs.

c. Secure all joints with a minimum of three sheet metal screws or pop rivets. Apply Aluminum Foil

Duct Tape or silicone sealant to all screws or rivets installed in the pipe.

d. Ensure that the air inlet pipes are

WARNING!!!

WARNING!!!

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

10.6.2 - Sealing of PVC,

CPVC or ABS air inlet pipe

The PVC, CPVC, or ABS air inlet pipe should be cleaned and sealed with the pipe manufacturer’s recommended solvents and standard commercial pipe cement for the material used.

The PVC, CPVC, ABS Dryer Vent or

Flex Duct air inlet pipe should use a silicone sealant to ensure a proper seal at the appliance connection and the air inlet cap connection. Dryer vent or Flex Duct should use a screw type clamp to seal the pipe to the appliance air inlet and the air inlet cap. Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume.

When a sidewall or vertical rooftop combustion air supply system is disconnected for any reason, the air inlet pipe must be resealed to ensure that combustion air will be free of contaminants and supplied in proper

WARNING!!!

WARNING!!!

Failure to properly seal all joints and seams as required in the air inlet piping may result in flue gas recirculation, spillage of flue products and carbon monoxide emissions causing severe personal injury or death.

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

37

10 - INSTALLATION - Vent and combustion air

10.7 - PVC/CPVC vent piping materials

specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 10-2 for approved vent adapters.

WARNING!!!

10-1 and 10-2 for vent pipe, and fittings. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial

WARNING!!!

Use only the materials listed in Tables

WARNING!!!

system. The field provided vent fittings must be connected to the boiler following Section

10.7.1. Use only the vent materials, primer, and cement specified in this manual to make the vent connections. Failure to follow this warning could result

WARNING!!!

This appliance requires a special venting

WARNING!!!

pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury

WARNING!!!

Do not insulate PVC/CPVC exhaust

WARNING!!!

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

NOTICE Installation must comply with local requirements and with the

National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for

Canadian installations.

NOTICE The installer must use a

For installation in Canada, vent pipe system must be certified to ULC-S636

(see Table 10-1).

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

NOTICE Installation of a PVC/CPVC vent system should adhere to the PVC/

CPVC vent manufacturer’s installation instructions supplied with the vent system.

NOTICE The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 10-2 for approved vent adapters.

10.7.1 - Installing PVC/

CPVC vent and air piping

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

1. Work from the boiler to vent or air termination. Do not exceed the lengths given in Section 10-4.

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

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

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

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

6. Priming and Cementing: a. Handle fittings and pipes carefully to prevent contamination of surfaces.

1. install boiler adapter “A” above boiler. Rotate boiler adapter “A” so as air intake and vent connections are in the desired left or right side.

Check stamped arrow to understand which is the vent and air intake

WARNING!!!

WARNING!!!

Check stamped arrow on boiler adapter for the correct side of air intake.

Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

38

b. Apply a liberal even coat of primer to the fitting socket.

c. Apply a liberal even coat of primer to the pipe end to approximately

1/2” beyond the socket depth.

d. Apply a second primer coat to the fitting socket.

e. While primer is still wet, apply an even coat of approved cement to the pipe equal to the depth of the fitting socket.

f. While primer is still wet, apply an even coat of approved cement to the fitting socket.

g. Apply a second coat of cement to the pipe.

h. While the cement is still wet, insert the pipe into the fitting, if possible twist the pipe a 1/4 turn as you insert it. NOTE: If voids are present, sufficient cement was not applied and joint could be defective.

i. Wipe excess cement from the joint removing ring or beads as it will needlessly soften the pipe.

10.7.2 - PVC/CPVC air intake/vent connections

Combustion Air Intake connection (see Figure 10-8

Item “C”).

This connection is used to provide combustion air directly to the boiler from outdoors. Combustion air piping must be supported per guidelines listed in the National

Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

To connect a PVC/CPVC pipe to the air intake connection proceed as follow while referring to Figure 10-8:

10 - INSTALLATION - Vent and combustion air

2. insert the clamp “D” into convertor

“A” in the “C” side.

3. insert the adapter “E” into connection

“C” of the convertor “A”;

4. use the precedent clamp “D” to mechanically secure the adapter “E” to the adapter “A”. To do this tighten the half clamp on the adapter “A” and half clamp on the adapter “E”.

Tight the clamps with a tork of 1.5 - 2 lbf ft (2-3 Nm).

5. insert the clamp “F” into convertor

“E”.

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

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

(2-3 Nm).

Vent connection (see Figure

10-8 Item “B”)

. This connection is used to provide a passageway for conveying combustion gas to the outside. Vent piping must be supported per the National Building Code, Section

305, Table 305.4 or as local codes dictate.

To connect a PVC/CPVC pipe to the vent connection proceed as follow while referring to Figure 10-8:

A = Two pipes boiler adapter

B = Flue exhaust connection

C = Air intake connection

D = Fixing clamp

E = PVC/CPVC adapter

F = Fixing clamp

G = PVC/CPVC pipe

H = 90° elbow

WARNING!!!

WARNING!!!

correct side of flue exhaust and air intake. Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe

WARNING!!!

Check stamped arrow on boiler adapter for the

WARNING!!!

Do not insulate

PVC/CPVC exhaust pipe nor install into an enclosure, closet, alcove or any other obstruction thereby preventing the cooling of the exhaust pipe. Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

1. install boiler adapter “A” above boiler. Rotate boiler adapter “A” so as air intake and vent connections are in the desired left or right side.

Check stamped arrow to understand which is the vent and air intake

WARNING!!!

WARNING!!!

Check stamped arrow on boiler adapter for the correct side of vent.

Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

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

C).

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

4. Use clamp “D” to mechanically secure adapter “E” to boiler adapter

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

5. Insert clamp “F” into adapter “E”.

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

7. Use clamp “F” to mechanically secure pipe “G” to adapter “E”. To do this, tighten one side of clamp “F” onto pipe “G” and the other side of clamp “F” to the adapter “E”. Tight the clamps with a tork of 1.5 - 2 lbf ft

(2-3 Nm).

Figure 10-8 PVC/CPVC Venting connection

39

10 - INSTALLATION - Vent and combustion air

10.8 - Stainless steel vent piping materials

WARNING!!!

Use only the materials, vent systems, and terminations listed in Tables

10-1 and 10-2. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING!!!

WARNING!!!

venting system. The field provided vent fittings must be connected to the boiler following Section 10.8.1.

Failure to follow this warning could result in fire, personal

WARNING!!!

This appliance requires a special

WARNING!!!

systems may result in injury or

WARNING!!!

Improper installation of Stainless steel

WARNING!!!

Use only water-based lubricants on joints.

Never use hydrocarbons-based lubricants because they would destroy gaskets. Failure to follow this warning could result in excessive levels of carbon monoxide, which can result in severe personal injury or death!

NOTICE Installation must comply with local requirements and with the National

Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

WARNING!!!

WARNING!!!

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

A = Flue exhaust connection

B = Combustion air intake connection

C = Fixing clamp

D = Stainless steel elbow

E = Stainless steel adaptor

F = Stainless steel extension

G = Air intake pipe

Figure 10-9 Stainless Steel Venting connection

40

For installation in Canada, vent pipe system must be certified to ULC-S636

(see Table 10-1).

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

NOTICE Installation of a stainless steel vent system should adhere to the stainless steel vent manufacturer’s installation instructions supplied with the vent system.

NOTICE The installer must use a specific vent starter adapter at the flue collar connection, supplied by the vent manufacturer to adapt to its vent system. See Table 10-2 for approved vent adapters.

10 - INSTALLATION - Vent and combustion air

10.8.1 - Stainless steel air intake/vent connections

Combustion Air Intake connection (see Figure 10-9

Item “C”).

This connection is used to provide combustion air directly to the boiler from outdoors. Combustion air piping must be supported per guidelines listed in the National

Mechanical Code, Section 305, Table

305.4 or as local codes dictate.

To connect a PVC/CPVC pipe to the air intake connection follow section

10.7.2.

Vent connection (Figure

10-9 item “A”)

is used to provide a passageway for conveying combustion gases to the outside. Vent piping must be supported per the

National Building Code, Section 305,

Table 305.4 or as local codes dictate.

To connect a stainless steel pipe to the vent connection proceed as follow: while referring to Figure 10-9:

1. install boiler adapter “A” above boiler. Rotate boiler adapter “A” so as air intake and vent connections are in the desired left or right side.

Check stamped arrow to understand which is the vent and air intake

WARNING!!!

WARNING!!!

Check stamped arrow on boiler adapter for the correct side of vent.

Failure to follow this warning could result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

2. Insert clamp “D” onto side “B” of boiler adapter “A” .

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

4. Use clamp “D” to mechanically secure adapter “E” to boiler adapter

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

5. Insert vent pipe “G”, into adapter

“E”, following instruction of stainless steel pipe manufacturer.

41

10 - INSTALLATION - Vent and combustion air

10.9 - Polypropylene vent piping materials

WARNING!!!

10-1 and 10-2 for vent pipe, and fittings. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial

WARNING!!!

Use only the materials listed in Tables

WARNING!!!

system. The field provided vent fittings must be connected to the boiler following Section 10.9.1.

Failure to follow this warning could result in fire, personal

WARNING!!!

This appliance requires a special venting

WARNING!!!

Improper installation of Polypropylene systems may result in injury or death.

WARNING!!!

WARNING!!!

Use only water-based lubricants on joints.

Never use hydrocarbons-based lubricants because they would destroy gaskets. Failure to follow this warning could result in excessive levels of carbon monoxide, which can result in severe personal injury or death!

NOTICE Installation must comply with local requirements and with the National

Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For installation in Canada, vent pipe system must be certified to ULC-S636

(see Table 10-1).

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

NOTICE Installation of a

Polypropylene vent system should adhere to the polypropylene vent manufacturer’s installation instructions supplied with the vent system.

Figure 10-10 Polypropylene boiler adaptor

42

10 - INSTALLATION - Vent and combustion air

10.9.1 - Polypropylene two pipes air intake/vent connections

Combustion air piping and vent piping must be supported per guidelines listed in the National Mechanical

Code, Section 305, Table 305.4 or as local codes dictate.

The boiler is not supplied with the fittings needed for separate vent and combustion air systems. A special kit must be ordered to connect the boiler to separate vent and combustion air systems. Figure 10-10 shows fitting

“A” that can freely turn 360 degrees for optimum installation versatility (see section 10.9.2 for P/N of “A” fitting).

Tork screws “D” at 2 lbf ft (3 Nm).

into hole “M” of boiler adapter “A”

3. Insert vent pipe “N” into boiler adapter “A”

4. Tight the two Band Clamps “O” to mechanically secure vent pipe “N” to boiler adapter “A”. Tight band clamps with a tork of 1.5 - 2 lbf ft

(2-3 Nm).

Pipes or elbows connected directly to the boiler, must be mechanically secure. Follow these instructions to connect pipes to the boiler (make reference to Figure 10-11):

1. Prepare the two collars “G” with

Band Clamps “E” and “F”;

2. Insert the end of Band Clamp “L”

The vent system must be both gas tight and watertight. All seams and joints must be joined and sealed in accordance with the vent system

WARNING!!!

WARNING!!!

Carefully follow the installation steps below for the assembling the two pipes venting system

(elbows and extensions), as illustrated in Figure 10-12. it is necessary to properly insert the male side onto the female side and mechanically secure them by using the proper clamps. Improper venting can result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

Figure 10-11 Polypropylene Venting connection



Mechanically secure each joint with the supplied band clamps as shown in Figure 10-12. Follow this procedure:

1. Insert the Male side (“B”) of a vent pipe into the Female side “A” of another;

2. Use Band Clamp “C” to keep the two pipes together;

3. Use screws “E” to tighten the Band

Clamp onto both pipes. Tight band clamps with a tork of 1.5 - 2 lbf ft

(2-3 Nm).

Figure 10-12 Connecting extensions and elbows

43

10 - INSTALLATION - Vent and combustion air

10.9.2 - Polypropylene two pipes system components

Some of the most commonly used components for installing the two pipes polypropylene vent and combustion air systems are listed below:

P/N 62617286 - Two pipes adaptor 80/80 PP

P/N 62617236 - 3ft PP M/F extension

P/N 62617240 - 60 ft PP flexible extension

P/N 62617241 - Spacer for PP flexible extension

P/N 62617244 - 90° PP M/F in line elbow

P/N 62617246 - 45° PP M/F in line elbow

P/N 62617249 - Secure clamp for PP extensions

P/N 62617306 - Split vertical terminal

P/N 61302003 - Air intake grid

P/N 61302004 - Flue exhaust grid

Figure 10-13 Dimensions of two pipes system

61302003

COD. 62617306

61302004

44

10 - INSTALLATION - Vent and combustion air

B = Connection flange

C = Fasten clip

D = Fasten clip screw

F = Coaxial vertical adaptor

Figure 10-14 Installation of the coaxial fitting

10.9.3 - Polypropylene concentric system

The boiler is not supplied with the fittings needed for connecting a coaxial vent/combustion air system.

A special kit must be ordered to connect the boiler with the Coaxial polypropylene vent. Figure 10-14 shows how to install the Coaxial fitting above the boiler. Tight the screws “D” of Figure 10-14 with a tork of 2 lbf ft

WARNING!!!

WARNING!!!

Carefully follow installation steps below, for the coaxial pipe assembly

(elbows and extensions), as illustrated in Figure 10-15. It is necessary to properly insert the internal and external pipe and mechanically secure them by using a stainless steel self tapping screw. Improper venting can result in excessive levels of carbon monoxide or a fire, which can result in severe personal injury or death!

In particular:

1. slip-fit the extension “1” and “2”

(see Figure 10-15) together;

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

“4” (see Figure 10-15) in a position where the two pipes “1” and “2” are overlapped;

3. insert a suitable stainless steel self tapping screw “5” and tight it with a screwdriver “6”



It is recommended that wall sleeve be used when installing the coaxial system through an exterior wall.

This will allow the system to be easily slipped out for access during routine maintenance.



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

Figure 10-15 Securing extensions and elbows together

45

10 - INSTALLATION - Vent and combustion air

10.9.4 - Polypropylene concentric system components

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

P/N 62617234 - In line 90° PP coaxial M/F elbow

P/N 62617252 - In line 45° PP coaxial M/F elbow

P/N 62617231 - 3ft (1m) PP coaxial extension

P/N 62617304 - PP coaxial roof end piece

P/N 62617232 - PP Coaxial wall end piece

P/N 62617224 - PP straight coaxial adaptor

46

62617232

10 - INSTALLATION - Vent and combustion air

10.10 - Single pipe vent (not sealed combustion)

WARNING!!!

When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for

Combustion and Ventilation, of the latest edition of the National

Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of

CGA Standard B149 Installation

Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.

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

WARNING!!!

WARNING!!!

The equipment room MUST be provided with properly sized openings to assure adequate combustion air from outside.

Failure to comply could result in severe personal injury, death, or substantial property damage.

• There will be a noticeable increase in the noise level during normal operation from the inlet air opening.

• Vent system and terminations must comply with the venting instructions set forth in sections 10.1, 10.2,

10.3, 10.4, 10.5, 10.7, 10.8 and

WARNING!!!

WARNING!!!

Use only the materials, vent systems, and terminations listed in Tables

10-1 and 10-2. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage.

WARNING!!!

WARNING!!!

liquids. Do not store flammable materials and liquids in the

WARNING!!!

Fire danger due to flammable materials or

WARNING!!!

combustible materials, gasoline and other flammable vapors and liquids, and corrosive liquids and vapors. Never use chlorine and hydrocarbon containing chemicals (such as spray chemicals, solution and cleaning agents, paints, glues etc.) in the vicinity of the boiler. Do not store and use these chemicals in the boiler room. Avoid excessive dust

WARNING!!!

Boiler must be clear and free from

WARNING!!!

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

NOTICE Installation must comply with local requirements and with the National

Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

For installation in Canada, vent pipe system must be certified to ULC-S636 (see

Table 10-1).

NOTICE All vent pipes connections must be secured following manufacturer instruction, properly supported, and the exhaust must be pitched a minimum of a

1/4 inch per foot back to the boiler (to allow drainage of condensate).

47

10.10.1 - Combustion Air and Ventilation openings

WARNING!!!

Make sure that combustion air and ventilation openings are sufficiently sized and no reduction or closure of openings takes place. Please note these restrictions and its dangers to the operator of the boiler and to the homeowner.

Failure to comply could result in severe personal injury, death, or substantial property damage.

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

Two Permanent Openings Method.

Two permanent openings, one commencing within 12 in. (300 mm) of the top and one commencing within

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

1. Where directly communicating with the outdoors or where communicating to the outdoors through vertical ducts, each opening shall have a minimum free area of 1 in2 each 4000 Btu/hr

(550 mm2/kW) of total input rating of all appliances located in the room.

2. Where communicating with the outdoors through horizontal ducts, each opening shall have a minimum free area of 1 in2 each 2000 Btu/hr

(1100 mm2/kW) of total input rating of all appliances located in the room.

One Permanent Opening Method. One permanent opening, commencing within

12 in. (300 mm) of the top of the room, shall be provided. The appliances shall have clearances of at least 1 in. (25 mm) from the sides and back and 6 in. (150 mm) from the front of the appliance.

The opening shall directIy communicate with the outdoors or shall communicate through a vertical or horizontal duct to the outdoors or spaces that freely communicate with the outdoors and shall have a minimum free area of 1 in2 each

3000 Btu/hr (700 mm2 /kW) of the total input rating of all appliances located in the room

10 - INSTALLATION - Vent and combustion air

10.10.2 - Determine location

Locate the vent termination using the following guidelines:

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

Section 10.4.

2. You must consider the surroundings when terminating the vent: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate and water/ ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue products with people or animals.

e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

f. Do not terminate above any door or window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage to exterior finishes.

4. The vent piping must terminate in an elbow pointed outward as shown in

WARNING!!!

WARNING!!!

Do not exceed the maximum lengths of the outside vent piping shown in Figures 10-12 or 10-13.

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

5. Maintain clearances as shown in

Figure 10-11

(get references to

“Mechanical draft vent terminal”

only). Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

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

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

b. Do not terminate closer than 4 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 4 feet horizontally.

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

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

CAUTION!!!

Increase the grade clearances of the snow line quote

Figure 10-16 Vent position of a Direct vent boiler and of a Mechanical draft boiler (not sealed)

48

10 - INSTALLATION - Vent and combustion air

10.11 - Sidewall termination - Two pipes

10.11.1 - Vent/air termination

WARNING!!!

wall shall not terminate adjacent to a wall or below building extensions such as eaves, parapets, balconies, or decks. Failure to comply could result in severe personal injury, death, or substantial property

WARNING!!!

A gas vent extending through an exterior

WARNING!!!

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

NOTICE Installation must comply with local requirements and with the

National Fuel Gas Code, ANSI Z223.1 for U.S. installations or CSA B149.1 for Canadian installations.

10.11.2 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the Section 10.4.

2. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue products with people or animals.

e. Do not locate the terminations where wind eddies could affect performance or cause recirculation, such as inside building corners, near adjacent buildings or surfaces, window wells, stairwells, alcoves, courtyards, or other recessed areas.

f. Do not terminate above any door or window. Condensate can freeze, causing ice formations.

g. Locate or guard vent to prevent condensate damage to exterior finishes.

49

10 - INSTALLATION - Vent and combustion air

Air intake

Flue exhaust

Figure 10-17 Two pipes sidewall termination of air and vent

Air intake

Flue exhaust

Termination template

Bird screen

Bird screen

Grade/Snow level

Grade/Snow level

3. The air piping must terminate in a down-turned elbow as shown in Figures 10-17 and 10-18. This arrangement avoids recirculation of flue products into the combustion air stream.

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

WARNING!!!

WARNING!!!

Do not exceed the maximum lengths of the outside vent piping shown in Figures 10-17 and 10-

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

5. Maintain clearances as shown in

Figures 10-17 and 10-18. Also maintain the following: a. Vent must terminate:

• At least 6 feet from adjacent walls.

• No closer than 12 inches below roof overhang.

• At least 7 feet above any public walkway.

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

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

b. Air inlet must terminate at least

12 inches above grade or snow line; at least 12 inches below the vent termination; c. Do not terminate closer than 6 feet horizontally from any electric meter, gas meter, regulator, relief valve, or other equipment. Never terminate above or below any of these within 6 feet horizontally.

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

Figure 10-18 Two pipes sidewall termination of air and vent (if space permits)

50

10 - INSTALLATION - Vent and combustion air

Air intake

Flue exhaust

Metal thimble

Termination template

Bird screen

Figure 10-19 Two pipes sidewall termination assembly

Vent terminals between edge of each air intake pipe

Same distance for vent terminal

Air intake

NOTE: keep the air intake at min. 12” from grade or snow line. Provide vent and air intake with bird screen

10.11.3 - Prepare wall penetrations

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

2. Vent pipe penetration: a. Cut a hole for the vent pipe. For either combustible or noncombustible construction, size the vent pipe hole with at least a 1/2 inch clearance around the vent pipe outer diameter (4½ inch hole for 3 inch vent pipe) b. Insert a galvanized metal thimble in the vent pipe hole as shown in Figure 10-19.

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

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

5. Seal exterior openings thoroughly with exterior caulk.

10.11.4 - Termination and fittings

1. The air termination coupling must be oriented at least 12 inches above grade or snow line as shown in Figures 10-17 and 10-18.

2. Maintain the required dimensions of the finished termination piping as shown in

Figures 10-17 and 10-18.

3. Do not extend exposed vent pipe outside of the building more than what is shown in

Figures 10-17 and 10-18. Condensate could freeze and block vent pipe.

10.11.5 - Multiple vent/air terminations

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

WARNING!!!

WARNING!!!

to avoid possibility of severe personal injury, death, or substantial property damage.

All vent pipes and air inlets must terminate at the same height

2. Place wall penetrations to obtain minimum clearance of 12 inches between edge of air inlet and adjacent vent outlet, as shown in Figure 10-20 for U.S. installations. For

Canadian installations, provide clearances required by CSA B149.1 Installation Code.

3. The air inlet is part of a direct vent connection.

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

Figure 10-20 Two pipes multiple boilers vent terminations

51

10 - INSTALLATION - Vent and combustion air

Combustion air intake

Grade / snow line

Overhang or roof

Vent

Figure 10-21 Concentric sidewall termination clearances

10.12 - Sidewall termination –

Concentric vent

10.12.1 - Description and usage

The termination kit must terminate outside the structure and must be installed as shown in Figure 10-21.

The required concentric termination kit as well as combustion air and vent pipe materials are listed in Tables

10-1 and 10-2.

10.12.2 - Sidewall termination installation

1. Determine the best location for the termination kit (see Figure 10-21).

2. The total length of piping for vent or air must not exceed the limits given in Section 10-4.

3. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue products with people or animals e. Do not terminate above any door or window. Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent condensate damage to exterior finishes.

4. Cut one (1) hole 5 inch diameter into the structure to install the termination kit.

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

NOTICE Ensure termination location clearance dimensions are as shown in

Figure 10-21.

52

10 - INSTALLATION - Vent and combustion air

CAUTION!!!

DO NOT use fieldsupplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

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

10.12.3 - Multiventing sidewall terminations

When two or more direct vent appliances are vented near each other, each appliance must be individually vented and vent terminations may be installed as shown in Figure 10-22. It is important that vent terminations be made as shown to avoid recirculation of flue gas.

WARNING!!!

WARNING!!!

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

Combustion air intake

Vent

NOTE: keep the terminals horizontally in the same line and at min. 12” from grade or snow line.

Figure 10-22 Concentric sidewall multiple boilers terminations

53

10 - INSTALLATION - Vent and combustion air

10.13 - Vertical termination - Two pipes

WARNING!!!

determining vent location to avoid possibility of severe personal injury, death or

WARNING!!!

Follow instructions below when

WARNING!!!

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

Installation must comply with local requirements and with the National

Fuel Gas Code, ANSI Z223.1 for

U.S. installations or CSA B149.1 for

Canadian installations.

10.13.1 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in the Section 10-4.

2. The vent must terminate at least

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

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

4. The vent piping must terminate at least 1 foot above the air intake.

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

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

Screen

Vent above air inlet and above roof or snow line

Alternate air intake location: air intake terminal may be located anywhere within

24” of vent terminal

Combustion air intake

10.13.2 - Prepare roof penetrations

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

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

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

3. Space the air and vent holes to provide the minimum spacing shown in Figure 10-23 and listed in section 10.13.1.

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

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

10.13.3 - Termination and fittings

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

10-23) by inserting bird screens.

2. The air piping must terminate in a down-turned 180° return bend as shown in Figure 10-23. Locate the air inlet pipe no further than 2 feet from the center of the vent pipe.

This placement avoids recirculation of flue products into the combustion air stream.

3. Maintain the required dimensions of the finished termination piping as shown in Figure 10-23.

4. Do not extend exposed vent pipe outside of building more than shown in Figure 10-23. Condensate could freeze and block vent pipe.

above roof or snow line

Figure 10-23 Two pipes vertical terminations of air and vent

54

10 - INSTALLATION - Vent and combustion air

Air intake

Vent Air intake

Vent

NOTE: keep the terminals at min. 12” from grade or snow line. Provide vent and air intake with bird screen.

vertically from vent outlet to any air inlet from edge of air intake pipe to adjacent vent pipe from another boiler

Figure 10-24 Two pipes Multiple boilers vertical terminations

10.13.4 - Multiple vent/air terminations

1. When terminating multiple boilers, terminate each vent/air connection as shown in Figures 10-24 and 10-

25.

WARNING!!!

WARNING!!!

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

2. Place roof penetrations to obtain minimum clearance of 12 inches between edge of air intake elbow and adjacent vent pipe of another boiler for U.S. installations (see

Figure 10-24). For Canadian installations, provide clearances required by CSA B149.1 Installation

Code.

3. The air inlet is part of a direct vent connection. It is not classified as a forced air intake with regard to spacing from adjacent boiler vents.

Vent

Air intake

Vent

Air intake vertically from vent outlet to any air inlet

NOTE: keep the terminals at min. 12” from grade or snow line. Provide vent and air intake with bird screen.

Figure 10-25 Alternate vertical terminations with multiple boilers

55

10 - INSTALLATION - Vent and combustion air

10.14 - Vertical termination –

Concentric vent

10.14.1 - Description and usage

Both combustion air and vent pipes must attach to the termination kit. The termination kit must terminate outside the structure and must be installed as shown in Figure 10-26.

10.14.2 - Determine location

Locate the vent/air terminations using the following guidelines:

1. The total length of piping for vent or air must not exceed the limits given in Section 10-4.

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

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

Vent

10.14.3 - Vertical termination installation

1. Determine the best location for the termination kit (see Figure 10-26).

2. The total length of piping for vent or air must not exceed the limits given in Section 10-4.

3. You must consider the surroundings when terminating the vent and air: a. Position the vent termination where vapors will not damage nearby shrubs, plants or air conditioning equipment or be objectionable.

b. The flue products will form a noticeable plume as they condense in cold air. Avoid areas where the plume could obstruct window views.

c. Prevailing winds could cause freezing of condensate and water/ice buildup where flue products impinge on building surfaces or plants.

d. Avoid possibility of accidental contact of flue products with people or animals e. Do not terminate above any door or window. Condensate can freeze, causing ice formations.

f. Locate or guard vent to prevent condensate damage to exterior finishes.

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

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

NOTICE Ensure termination location clearance dimensions are as shown in

Figure 10-26.

NOTICE Ensure termination height is above the roof surface or anticipated snow level (12 inches in U.S.A. or

18 inches in Canada) as shown in

Figures 10-26.

CAUTION!!!

DO NOT use fieldsupplied couplings to extend pipes. Airflow restriction will occur and may cause intermittent operation.

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

Combustion

Air

Roof boot / flashing

(field supplied)

(18” for Canada)

Minimum clearance above highest anticipated snow level.

Maximum of 24” above roof.

Support

(field supplied)

Vent

Combustion air intake

Combustion

Air

Vent

Combustion

Air

Figure 10-26 Concentric vertical termination

56

Minimum clearance above snow level (18” for Canada) Maximum

24” above roof or snow level)

10 - INSTALLATION - Vent and combustion air

10.14.4 - Multiventing vertical terminations

When two (2) or more direct vent appliances are vented near each other, each appliance must be

WARNING!!!

WARNING!!!

NEVER common vent or breach vent this appliance to avoid possibility of severe personal injury, death, or substantial property damage.

When two or more direct vent appliances are vented near each other, two vent terminations may be installed as shown in Figure 10-27. It is important that vent terminations be made as shown to avoid recirculation of flue gases.

Minimum clearance above snow level (18” for Canada)

Maximum 24” above roof or snow level)

Combustion air intake

Figure 10-27 Concentric multiple boilers vertical terminations

57

10 - INSTALLATION - Vent and combustion air

Seal

Combustion air intake

Flue exhaust

Combustion air intake

10.14.5 - Alternate vertical concentric venting

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

Combustion air inlet with screen

Existing

Sealed cap

Seal

Concentric Venting Arrangement

The venting is to be vertical through the roof.

The annular space between the O.D. of the vent pipe and the I.D. of the existing unused venting system is utilized for the combustion air source.

The minimum size of the existing vent system required to achieve enough annular space for combustion air is 7 inches.

The upper and lower termination as well as any other unsealed joints in the existing vent system must be sealed to ensure that all combustion air is drawn from under the vent cap as shown in

Figures 10-28 and 10-29.

Flue outlet

Flue exhaust

Combustion air intake

Combustion air intake

Combustion air inlet with screen

Seal

Figure 10-28 Alternate concentric vertical venting (Example n°2)

Approved venting materials must be used as specified in Tables 10-1 and 10-2.

Follow all vent / air termination and clearance requirements per this section to the appropriate example. Installation must comply with local requirements and with the National Fuel Gas Code.

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from Section 10-4.

If an existing unused venting system is converted for use with this method of concentric venting, the installer must ensure that the existing venting system is clean and free from particulate contamination that will harm this appliance and cause increased nuisance calls or maintenance.

See Section 10.2 for a list of corrosive contaminants and sources.

Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in

Figures 10-28 and 10-29.

58

Figure 10-29 Alternate concentric vertical venting (Example n°1)

Seal

Existing

Sealed cap

Flue outlet

10 - INSTALLATION - Vent and combustion air

10.15 - Existing vent as a chase

Follow all existing termination and clearance requirements of section 10-

13.

The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from Section 10-4.

Use only approved venting materials listed in Tables 10-1 and 10-2.

Combustion air intake

Flue exhaust

Seal

Existing

Sealed cap

Seal

Flue outlet

Figure 10-30 Alternate concentric vertical venting (Example n°3)

59

11 - INSTALLATION - Gas supply

Figure 11-1 Gas supply piping

11-1

INSTAL MANUAL SHUT-OFF

VALVE 5 FT (1.5m) ABOVE

FLOOR WHERE REQUIRED BY

LOCAL CODES

GROUND JOINT UNION

TO BOILER

SEDIMENT TRAP OR DRIP LEG

11.1 - 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 fire or explosion causing extensive property damage, severe personal injury or death!

supply piping system during any pressure testing of that system at a test pressure in excess of 1/2

PSIG (3.5 kPa).

b. The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than 1/2 PSIG (3.5 kPa).

c. The appliance and its gas connection must be leak tested

WARNING!!!

WARNING!!!

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

Connecting gas supply piping:

1. Refere to Figure 11-1 to pipe gas to the boiler.

a. Install ground joint union for servicing, when required.

b. Install a manual shutoff valve in the gas supply piping, outside boiler jacket c. Manual main shutoff valves, must be identified by the installer.

2. Install sediment trap / drip leg. (see

Figure 11-1).

3. Support piping with hangers, not by

WARNING!!!

WARNING!!!

Do not attempt to support the weight of the piping with the boiler or its accessories. Failure to comply could result in severe personal injury, death, or substantial property damage.

4. Purge all air from the gas supply piping.

5. Before placing the boiler in operation, check the boiler and its gas connection for leaks.

a. The appliance must be disconnected from the gas

6. Use pipe sealing compound compatible with propane gas. Apply sparingly only to male threads of the pipe joints so that pipe dope does

WARNING!!!

WARNING!!!

can result in severe personal injury, death, or substantial

WARNING!!!

Failure to apply pipe sealing compound

WARNING!!!

This boiler is typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP following instruction on

Section 11.6. Failure to comply could result in severe personal injury, death, or substantial property damage.

11-2

60

11 - INSTALLATION - Gas supply

11.2 - Pipe sizing for natural gas

Refer to Tables 11-1 and 11-2 for pipe length and diameter. Based on rated boiler input (divide by 1,000 to obtain ft3/hr). For additional gas pipe sizing information, refer to ANSI Z223.1 (or

B149.1 for Canadian installations).

Natural gas supply pressure requirements

1. Pressure required at the gas valve inlet pressure port:

• Maximum 13”W.C. with no flow

(lockup) or with boiler on.

• Minimum 3”W.C. with gas flowing

(verify during high fire).

2. Install 100% lockup gas pressure regulator in supply line if inlet pressure can exceed 13”W.C. at any time. Adjust lockup regulator for

13”W.C. maximum.

WARNING!!!

These boilers are typically shipped ready to fire on natural gas. Check boiler rating plate to determine which fuel the boiler is set for. If set to natural gas, it may be converted to LP by following instruction on

Section 11-6. Failure to comply could result in severe personal injury, death, or substantial property damage.

Pipe sizing for propane gas

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

Propane supply pressure requirements:

1. Adjust propane supply regulator provided by the gas supplier for

13”W.C. maximum pressure.

2. Pressure required at gas valve inlet pressure port:

• Maximum 13”W.C. with no flow

(lockup) or with boiler on.

• Minimum 3”W.C. with gas flowing

WARNING!!!

WARNING!!!

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

11.4 - Check inlet gas supply

WARNING!!!

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

11.5 - 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, and check and adjust the

CO2 level following Section 12-9.

For installations in Canada, the boiler is rated for installations up to 2,000 ft (609 m).

The gas piping must be sized for the proper flow and length of pipe, to avoid excessive pressure drop. Both the gas meter and the gas regulator must be properly sized for the total gas load.

If you experience a pressure drop greater than 1”W.C., the meter, regulator, or gas line is undersized or in need of service.

1. Follow Section 12.7 to check the inlet gas supply pressure.

2. If gas supply pressure is within normal range and no adjustments are needed, proceed on to step 4.

3. If the gas pressure is out of range, contact the gas utility, gas supplier, qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the boiler.

4. Turn the power switch to the “OFF” position.

5. Shut off the gas supply at the manual gas valve in the gas piping to the appliance.

6. After verifying the correct gas pressures disconnect the manometer, turn the screw in pressure connection

“D” in Figure 12-3, clockwise until snug and check for any gas leaks.

CAUTION!!!

Never force the pressure connection screw or

WARNING!!!

WARNING!!!

Never use an open flame to check for gas leaks, a fire or an explosion could result causing severe personal injury or death!

61

11 - INSTALLATION - Gas supply

11.6 - Convert the boiler from Natural

Gas to Propane gas or viceversa

WARNING!!!

by a qualified service agency in accordance with this instructions and all applicable codes and requirements of the authority having jurisdiction.

The information in these instructions must be followed to minimize the risk of fire or explosion or to prevent property damage, personal injury or death. The qualified service agency is responsible for the proper conversion of the boiler. The installation is not proper and complete until the operation of the converted appliance is checked as

WARNING!!!

The gas conversion shall be performed

WARNING!!!

The conversion shall be carried out in accordance with the requirements of the provincial authorities having jurisdition and in accordance with the requirements of the

CAN-B149.1 and CAN1-B149.2

installation code.

- an instruction sheet;

- an orifice;

Installing:

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

1 - turn off power to the boiler;

2 - open the boiler’s casing (Follow

Section 14.2);

3 - open the instrument panel (Follow

Section 9.2);

4 - Move switch #7 (see Figure 9-2) from OFF position to ON position;

5 - turn on power to the boiler;

6 - on the boiler’s display you’ll see

followed by a number;

7 - using the push buttons set the input

- 61 to convert the boiler from LP

GAS to NATURAL GAS

or

- 62 to convert the boiler from

NATURAL GAS to LP GAS,

8 - push new value;

to:

9 - turn off power to the boiler;

and

button to save the

Contents:

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

- a label rating the new gas setting;

10 - Move switch #7 (see Figure 9-2) from ON position to OFF position;

11 - Replace the orifice item “C” of

Figure 11-2 for the correct one for the type of gas used. Verify that the stamping on the orifice matches the gas type (See Table 11-3).

11 - turn on power to the boiler;

12 - Turn completely counter clockwise the screw E of Figure

11-2;

13 - Checking gas supply pressure following Section 12.7.

The Gas supply pressure must be between the maximum and minimum value as stated in Table 11-3.

14 - Verifying the CO2 rate and its eventual adjustment following

Section 12-9: The boiler during its normal operation, within a maximum altitude of 2000 ft, has a CO2 exhaust rate as shown in

Table 11-3. If not within range of value shown, malfunctions will

WARNING!!!

WARNING!!!

not exceed values given in

Table 11-3, when combustion is correct. Failure to comply with this requirement could result in severe personal injury, death or

WARNING!!!

The CO

(carbon monoxide) level should

WARNING!!!

All combustion measurements must be performed with calibrated equipment to ensure proper reading and accuracy.

Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

Gas Type TY value setting

/

Natural gas

LP gas

/

61

62

Min. supply pressure in.W.C.

3

3

Max. supply pressure

Orifice in.W.C.

Stamping

13 9.1

13 5.7

CO2 content at high fire

CO2 content at low fire

O2 content at high fire

O2 content at low fire

% % % %

9.2 ± 0.1

8.7 ± 0.3

4.5 ± 0.1

5.4 ± 0.3

9.5 ± 0.2

9.5 ± 0.3

6.4 ± 0.2

6.4 ± 0.3

Table 11-3 Settings of the boiler for NATURAL GAS and LP GAS

62

CO content at high and low fire ppm less than 150 less than 250

11 - INSTALLATION - Gas supply

A = Fixing nut

B = Gasket

C = Orifice

D = Brass fitting

E = CO2 / O2 regulator

WARNING!!!

WARNING!!!

If the combustion levels are not within the range given in Table

11-3 for the firing rate, shut the boiler down and contact your distributor or the boiler manufacturer (see reference in the last cover page). Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

15 - Attach to the front of the boiler the appropriate conversion label, found in the conversion kit (see

Figure 11-3 or Figure 11-4), stating the new type of gas adjustment of the boiler.

a - Apply the label in Figure 11-4 if the boiler has been converted to

LP GAS; b - Apply the label in Figure 11-3 if the boiler has been converted to

NATURAL GAS.

Figure 11-2 Gas valve

Figure 11-3 Label for Natural gas boiler

63

Figure 11-4 Label for LP gas boiler

12 - START-UP

12.1 - Operating

Before starting the boiler, the following must be done.

12.1.1 - User instructions

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



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



Make sure that the user knows how to adjust temperatures, controls and the room thermostats for maximum efficiency.



Make sure that the user understands that combustion air and ventilation openings must not be restricted/closed/ or mdified in any way.



Make sure that the user is informed of all the special measures to be taken for combustion air inlet and discharging flue gases, and that these must not be modified in any way.



Make sure that the user keeps this manual and all other documentation included with the boiler.

12.1.2 - Filling the condensate trap

The condensate trap is positioned inside the boiler as shown in Figure

3-1, item “46”. It must be filled with water to prevent the leakage of flue gases from the condensate drainpipe, item “41” in Figure 3-1. To fill the condensate trap proceed as follows:

1. unscrew “E” screw (Figure 12-1);

2. remove flange “D” and O-Rings “C”

(Figure 12-1);

3. With a rubber tube and a funnel, slowly pour approximately 4 oz.

(100 ml), of water into the “B” opening - DO NOT put water into the “A” opening (Figure 12-1);

4. re-install flange “D” and O-Rings

“C” and reinstall screw “E” (Figure

12-1);

WARNING!!!

WARNING!!!

If boiler stays off for more than 3 months, repeat the above operation to again fill the condensate trap.

Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

12.1.3 - Filling the heating system

WARNING!!!

Never use non-approved 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.

CAUTION!!!

The heating system must be filled with clean water from the domestic water system. Contaminated water can damage the boiler voiding its warranty.

A = Combustion air probe

B = Flue exhaust probe

C = Gaskets

D = Probe cap

E = Screw

Figure 12-1 Filling the condensate trap

A = Purging valve for the domestic hot water heat exchanger

Figure 12-2 Domestic heat exchanger

64

12 - START-UP

CAUTION!!!

The addition of any chemical substances, such as anti-freeze, must be carried out according to the product instructions.

To fill the heating system, proceed as follows:

1. open the automatic air vent, shown as item “1” in Figure 3-1, two turns;

2. open the fill valve located under the boiler and proceed to fill the heating system and boiler until the pressure gauge, item “13” in Figure 13-1, reads 20 psi (1.5 bar) and “FILL” disappears from the display;

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

4. close the fill valve;

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

12.1.5 – Auto-purging the heating system

Each time the on/off power switch, item “12” in Figure 13-1, is switched on, an auto-purging cycle lasting 3 minutes begins. The auto-purging process involves the turning the pump on and off in order to remove any air trapped in the heating system. Before starting the auto-purging cycle the automatic air vent, item “1” shown in

Figure 3-1 must be opened.

12.1.6 – Delay to light-on

Each time the on/off power switch, item “12” in Figure 13-1, is switched on, a delay timing sequence of 3 minutes begin.

12.1.4 - Filling the domestic hot water heat exchanger (160-C model only)

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

1. connect a rubber tube to the air purging cock “A” shown in Figure

12-2 and place the end in an empty bucket or sink;

2. open the cock “A” shown in

Figure 12-2 until air can be heard escaping;

3. once the water runs clear of air bubbles close the cock “A” shown in Figure 12-2;

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

65

12 - START-UP

12.2 - General warnings concerning gas supply

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



That the boiler is supplied with the type of fuel that it is configured to use. Read Sections 11.



That the gas supply system is provided with all the safety devices and controls required under current national and local codes.



That the vent and combustion air terminals are free from any blockages.



That the condensate drain tube is

WARNING!!!

If you smell gas:



Do not try to light any appliance.



Do not touch any electrical switch. Do not use any phone in your building.



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



If you cannot reach your gas supplier, call the fire department.

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

12.3 - Confirming the boiler’s gas type

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

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

NATURAL GAS

Maximum supply pressure = 13 in.W.C. (33.0 mbar).

Minimum supply pressure = 3 in.W.C.

(7.6 mbar).

LP Gas

Maximum supply pressure = 13 in.W.C. (33.0 mbar).

Minimum supply pressure = 3 in.W.C.

(7.6 mbar).

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

12.4 - Gas type conversion

If the gas available at the installation site is not the type the boiler is configured to use, the boiler must be converted. Special conversion kits are available for this purpose inside the boiler. Follow instruction on Section

11.6.

WARNING!!!

WARNING!!!

Conversion of the boiler to use another type of gas must be carried out by a qualified technician.

Improper conversion of the boiler could result in a fire or an explosion causing severe personal injury or death!

12.5 - Start-up of the boiler

1. Open the manual gas shut off valve

(Figure 11-1),.

2. Switch the on/off power switch, item

“12” in Figure 13-1, to “on”.

3. Upon start-up, an is shown for

3 minutes while the boiler goes through its heating system purge cycle. To by-pass this stage, press the and until a blinking

keys together

appears.

12.6 - Ignition control testing

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

1. turn the power switch (item “12” in

Figure 13-1) to on;

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

3. turn knobs “7” and “11” in Figure

13-1 to their maximum position;

4. wait a few minutes for the burner to light-up as indicated when light

“3” shown in Figure 13-1 stays illuminated.

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

6. after 2 minutes, the display must show L01;

7. open the manual gas shutoff valve, see Figure 11-1;

8. verify your gas meter, gas flow

WARNING!!!

WARNING!!!

If gas flow occurs, close the manual gas shutoff valve and troubleshoot the system to determine why there is gas flow when the gas valve should be deenergized.

Do not operate the boiler until the problem is resolved or a fire or explosion causing property damage, personal injury or loss of life may occur!

Then press the button.

4. The boiler will fire only when the room thermostat calls for heat.

Connect the external temperature sensor, check that the temperature calculated is higher than the minimum running temperature as explained in Section 13.10.

5. Rotate knobs “7” and “11” shown in Figure 13-1 to the desired temperature.

6. If the pump indicator is illuminated, item “6” in Figure 13-1, but the pump is not running, it may be stuck. If this is the case, shut-off the boiler and release the pump.

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12 - START-UP

C -

Service pressure probe

D - Inlet gas pressure probe

E - CO2 adjusting screw

F - Factory adjusted regulator

(Should never be touched)

Figure 12-3 Gas valve

12.7 - Gas supply pressure checking

WARNING!!!

DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

upstream gas pressure regulator to bring the gas supply pressure within

WARNING!!!

WARNING!!!

DO NOT adjust the screws “E” and/or

“F” (Figure 12-3). These screws are factory-set for the correct gas flow and outlet pressure.

Attempting to alter the gas valve setting could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage.

Check the gas supply pressure by following the steps below:

1. close the manual gas shut-off valve, Figure 11-1;

2. follow the steps in Section 14.2 to remove the front cover;

3. turn the screw in pressure port “D” shown in Figure 12-3 three turns counterclockwise;

4. connect a manometer with graduations of at least 0.1 in.W.C.

(0.25 mbar) to the inlet gas port “D” shown in Figure 12-3;

5. open the manual gas shut off valve,

Figure 11-1;

6. check that the gas supply pressure does not exceed 13 in.W.C.;

7. turn the power switch to on and generate a heat demand by turning knob “7” shown in Figure 13-1 to its maximum setting. Also ensure that the room thermostat is calling for heat;

8. press the and keys at the same time for more than

10 seconds, the display will show

;

9. press the key until the display shows . Now the boiler will run for 10 minutes at maximum input;

10. check the manometer to make sure the gas supply pressure does not drop below 3 in.W.C. (7.6 mbar).

After verifying the correct gas pressures:

1. close the manual gas shut-off valve, Figure 11-1;

2. disconnect the manometer;

3. turn the screw in pressure connection “D” in Figure 12-3, clockwise until snug;

4 check for any gas leaks.

CAUTION!!!

Never force the pressure connection screw or

WARNING!!!

WARNING!!!

Never use an open flame to check for gas leaks, a fire or an explosion could result causing severe personal injury or death!

If the gas supply pressure does not fall within 3 and 13 in.W.C. adjust the

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12 - START-UP

Figure 12-4 Combustion air pressure probes

12.8 - Check the combustion air pressure

The boiler has a factory-set air/gas ratio. The pressure of the gas at the burner is indirectly controlled by the blower. The combustion air pressure must be checked as follows while refering to Figures 12-4 and 12-5:

1. use a differential manometer with a precision of at least 0.1 in.W.C.

(0.25 mbar);

2. close the manual gas shut off valve, Figure 11-1;

4. open the boiler casing following Section 14.2;

5. remove plug “B”;

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

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

12-5;

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

9. the manometer connections must be made as shown in Figure 12-5, to get the correct pressure reading;

10. replace panel “H” of Figure 14-1 and latch it closed.

If panel “H” is not properly in place the manometer reading will not be accurate;

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

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

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

14. compare the pressure on the manometer with the table in Section 15, raw “Combustion air pressure”.

15. if the combustion air pressure is too low, check that there are no obstructions in the combustion air and vent systems and check that the flue and air intake length meet with the rules of Section 10.4.;

16. if the combustion air pressure is within tolerance press the

button to return the boiler to its normal running mode;

17. once the combustion air pressure check has been performed, disconnect the manometer, close pressure probe screw “C”, re-install everything like on Figure 12-4. Close the boiler casing and turn the manual gas shut off valve on.

Figure 12-5 Differential pressure gauge connections to checking the combustion air pressure

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12 - START-UP

A = air probe

B = flue exhaust probe

C = O-ring gaskets

D = cap

E = fixing screw

Figure 12-6 Combustion analysis probes

12.9 - Checking and adjusting CO2 levels

Table 11-3 lists the correct CO2 ranges for a boiler running at normal operating conditions at an altitude below 2000 ft (600m). CO2 values outside of the ranges given in Table 11-3 may lead to malfunctioning of the boiler and cause it to prematurely fail. To check the CO2 value, carry out a combustion analysis

WARNING!!!

WARNING!!!

During this procedure compare also CO

(carbon monoxide) reading, with the value given in Table 11-3. If this is higher, STOP the boiler and call the Factory service department (see phone number on the last cover page). Failure to comply with this requirement could result in severe personal injury, death or substantial property damage.

NOTE: During the 10 minutes override mode, if the demand on the boiler is low causing the flue gas temperature to increase rapidly, boiler will go into lock out code L06.

To reactivate it, press button.

1. carefully remove items “E”, “D” and

“C” from the combustion air/ vent fitting:

2. generate a call for heat; and wait up the boiler is light-on;

4. press the and keys for more than 10 seconds, the display will show a blinking ;

5. press the key until the display shows if a call for heat has been generated or until

is displayed if a domestic hot water demand has been generated.

The boiler will now run for 10 minutes at high fire input;

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

7. insert the probe of a calibrated combustion analyzer into port “B” and take a flue gas sample;

8. compare the CO2 reading with the high fire range given in Table 11-3, making sure to use the range for the gas type in use. If the CO2 reading is outside the specified range, it must be adjusted operating on the

“E” screw of Figure 12-3. Use a

2.5mm Allen Wrench to turn the screw (clockwise to reduce the CO2 level, counter-clockwise to increase the CO2 level) in small increments and wait for the CO2 to stabilize to prevent overshooting the desired value;

9. When CO2 level match the value of

Table 11-3, seal screw “E” with red paint or nail polish to discourage tampering.

10. press the display shows

key until the

if a call for heat has been generated or until is displayed if a domestic hot water demand has been generated. The boiler will now run for 10 minutes at low fire input;

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

12. compare the CO2 reading with the low fire range given in Table 11-3, making sure to use the range for the gas type in use. The CO2 reading must be inside the specified range;

If not, STOP the boiler and call the

Factory service department (see phone number on the last cover page).

13. press the button to return the boiler to its normal operating mode.

14. close flue and air probe “A” and “B” of Figure 12-6.

15. turn knob “7” and “11” of Figure

13-1 to the OFF position.

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12 - START-UP

“P” parameter value

Correspondent heat input

(btu/hr)

12.10 - Adjusting the heating capacity

This boiler has been engineered with an “intelligent” micro-processor control that will adjust the heating output to match the system demand.

To maximize the effectiveness of the system, the parameters found in the “Installer’s menu”, in

Section 13.17, can be adjusted set the maximum heating output to the effective maximum load necessary for the system. The parameter can be adjusted from 100 (factory set value), to 1. The correspondence between value and heating output is given by table in Figure 12-1.

NOTE: This setting, adjusts the heating input only. The domestic output is always 160,000 btu/hr for every value.

12.11 - Domestic hot water flow rate adjustment (160-C model only)

The volume of domestic hot water that the boiler can produce, depends on the flow rate of the domestic water system. If the flow rate is too high, the water will move through the heat exchanger without being adequately heated. It is therefore advisable to carry out the following adjustments:

1. switch the on/off power switch, item

“12” in figure 13-1, to “on”;

2. adjust control “11” as shown in

Figure 13-1, to 130 °F (50 °C);

3. fully open a hot water faucet. If a mixing type faucet with single lever is opened, the position must be fully to HOT;

4. set the domestic hot water mixing valve (field installed), to its maximum value);

5. wait 5 minutes for the temperature to stabilize;

6. if the water temperature is too low, reduce the water flow using a flow restrictor (Field installed) until reaching the desired temperature

(turn the flow restrictor in small increments and wait for the temperature to stabilize to prevent overshooting the desired value).

NOTE: Water flow should generally be regulated according to the values given in Section 15, under the heading “instantaneous d.h.w. production [rise 75 °F (42 °C)]”.

12.12 - Cold start boiler

The boiler has a “cold start” working mode. Any time the room thermostat opens (no call for heat), the burner stops immediately. However even with the room thermostat contact open, the boiler will run for freeze protection as described in Section 13.14.

Table 12-1 Correspondence table to set space heating input

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13 - USE

1 - Display of the parameters

2 - Display of the paramenters value.

3 - Light indicates the burner state: Light-on = Burner ON; Blinking = Burner OFF.

4 - Light indicating DHW service: Light-on = DHW service ON; Light-off = DHW service OFF.

5 - Light indicates the decimal.

6 - Light indicates CH service: Light-on = CH service in function; Light-off = CH service out of function.

7 - Heating temperature control.

8 - Key for decreasing parameter values.

9 - Key for resetting shutdowns and for scrolling the list of parameters.

10 - Key for increasing parameter values.

11 - Domestic hot water temperature control.

12 - On/off power switch.

13 - Heating circuit pressure gauge.

Figure 13-1 Instrument panel

13.1 - Check heating system pressure

If the pressure inside the heating circuit falls below 7psi (0,5 bar), the appliance switches off and the display “1” as per Figure 13-1, several times during the first month of operations to remove any air bubbles present.

is off (blinking);

- the indicator “4” displays whether the domestic hot water service is on or off;

- the indicator “6” displays whether a heating service request is active (on) or nor (off).

shows to indicate that it is necessary to restore the correct pressure. Open the filling cock and check the pressure on the pressure gauge “13” of Figure 13-1, it must reach a pressure of 20 psi (1,5 bar) and the indication must disappear; close the filling cock.

CAUTION!!!

During normal operations, the filling cock must always remain in the closed position.

If, with time, the pressure drops, restore the correct value. This operation may have to be repeated

13.2 - Overview

The boiler is pre-set with standard parameters. However, it is possible to make a number of changes or consult the parameters by means of using the

“Users’ Menu” (see Section 13.16).

During functioning display “1” of

Figure 13-1, displays the status of the boiler and display “2” (see Figure 13-

1) shows the value of the parameters.

The various operating statuses are shown in Section 13.18.

Within the “Users’ Menu” (see Section

13.16) it is possible to check the last lock-out or error which have occurred.

In addition to the operating modes, the instrument panel provides important information on the current functioning of the boiler, via the indicators “3”, “4”, “5” and “6” of Figure

13-1. In particular:

- the indicator “3” displays whether the burner is functioning (on) or whether it

71

13.3 - Displays

During normal operations, the parameters’ display “1” and the values’ display “2” (see Figure 13-1) remain permanently on, if the ”Energy

Saving” mode has not be activated

(See Section 13.15).

The parameters which can be displayed are shown with their meaning in the table shown in Section

13.18.

13 - USE

13.4 - Start-up procedure

1. Open the manual shutoff gas valve;

2. switch on electric power to the boiler;

3. If the display shows code E21, it means that the polarity has not been observed between phase and neutral (Call service department, do not attempt to repair it);

4. on initial start-up, the appliance carries out a light-on delay lasting

3 minutes. This is indicated by the appearance of on the display;

5. wait 3 minutes until the end of the

;

6. turn knob “7” of Figure 13-1 until it reaches the heating temperature desired. Turn knob “11” of Figure

13-1 until it reaches the domestic water temperature desired.

The flame control appliance will startup the burner.

If the burner fails to ignite within 15 seconds, the boiler will automatically attempt ignition another two times, after which if it fails to start-up, it will shut down and the display will show

01.

Press the button in order to re-set normal operating conditions.

The boiler will automatically attempt another start-up.

CAUTION!!!

If the appliance frequently shuts down, contact a qualified technician to restore normal running conditions.

Now the boiler will continue to operate in relation to the service requested and will indicate the following on display “1”:

- if a domestic water request is active (Load of an indirect water heater);

- if a heating request is active;

- if there is no domestic water or heating request active.

13.5 - Summer mode

To disable the heating functions for a prolonged period, leaving only the domestic hot water function, switch OFF the heating temperature, until the wording OFF appears, by turning knob “7” of Figure 13-1 to the minimum.

13.6 - Winter mode

In Winter mode, by means of the pump, the boiler sends the water to the system at the temperature set using knob “7” of Figure 13-1.

When the temperature inside the boiler reaches the temperature set, the burner starts to modulate the flame so as to reduce the output to a minimum. If the temperature rises further, the burner shuts down.

Simultaneously, the pump which sends the water to the system is switched on and off by the room thermostat. This can be noted, because indicator “6” of Figure 13-1 switches on and off in correspondence with the on and off of the pump.

At first the pump may make a noise.

This is due to the presence of residual air in the hydraulic system which will soon disappear on its own.

We recommend keeping the temperature set using knob “7” at the point shown by the symbols on the panel for a rational use of the boiler.

If it is a particularly cold Winter and it is difficult to maintain the desired room temperature, turn knob “7” to gradually higher values.

CAUTION!!!

do not demandate the antifreeze protection of your house to the boiler.

Because the boiler’s function depends from the electrical supply and from the gas supply and because a trouble can stops the boiler, if you live your house, it is mandatory install a safety device that alarm the user in a case the house will reach a temperature near 50°F (10°C).

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13 - USE

13.7 - Adjusting the domestic hot water temperature

The domestic hot water temperature is adjusted by turning knob “11” shown in Figure 13-1. When the knob is turned, the display, item “1” in Figure

13.9 - Heating system type selection

The boiler is factory set for wall stat control as per Section 13.8.

The heating system type can be changed by going to the “Installers’

Menu” in Section 13.17 and changing

13-1, shows a flashing and the temperature being selected. The range within which the domestic hot water can be set is 104°F (40°C) to 140°F (60°C) or from 104°F (40°C) to 158°F (70°C) when an indirect storage tank is used.

13.8 - Heating system temperature adjustment

The boiler provides hot water to the heating system at the temperature set by adjusting knob “7” as shown in Figure 13-1. The room thermostat turns the boiler’s circulator pump on in order to satisfy the heat demand of the rooms controlled by the thermostat.

To maximize the boilers’ performance, temperature knob “7”, should be set at a value that is just sufficient to maintain the desired temperature of the rooms. As the weather gets colder, progressively increase the water temperature by adjusting knob “7”. When the weather gets milder turn the water temperature down. This extremely simple method is suitable for the following types of systems:

A - small systems with radiators where the thermostat is installed in a room whose temperature is characteristic of all the other rooms;

B - large systems with radiators, where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisfied.

C - large systems with low temperature radiant panels , where each zone is controlled by its own room thermostat.

Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisfied.

the parameter. One of the three following heating modes can be selected:

-CH = 00 “Wall stat control”: follow

Section 13.8;

-CH = 01 “Outdoor reset control”: follow Section 13.10 (an outdoor temperature sensor is required);

-CH = 02 “Outdoor reset control with room compensation control”: follow Section 13.10.1 to 13.10.6

(an outdoor temperature sensor is required):

13.10 - Outdoor reset adjustment

While in the “Installers’ Menu”, set the

parameter to 01. In this mode the heating supply water temperature, calculated temperature in Figures 13-2 and 13-3, will be adjusted automatically based on the input from the outdoor temperature sensor. The relationship between the outdoor temperature and the supply water temperature, corresponds with the graphs shown in Figures 13-2 and 13-3. In order to change the relationship between the supply water temperature and the outdoor temperature, all the parameters listed in the sections below must be set.

13.10.1 - Outdoor reset applications

Outdoor reset is a sophisticated way to maximize comfort and boiler efficiency.

It is suitable for the following system types:

A - small systems, with radiators where the thermostat is installed in a room whose temperature is characteristic of all the other rooms. The room thermostat is used to turn the boiler on and off.

B - Iarge systems, with radiators, where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisfied (see to an appropriate electrical system).

C - small systems, with low temperature radiant panels where the thermostat is installed in a room whose temperature is characteristic of all the other rooms. The room thermostat is used to turn the boiler on and off. In this type of system it is necessary to consider that the radiant panel systems sometimes have long lag times.

D - Iarge systems with low temperature radiant where each zone is controlled by its own room thermostat. Where zone valves are used the boiler pump is shutdown only when all the room thermostats are satisfied.

13.10.2 - Outdoor reset adjustment precautions

When making adjustments to change the supply temperature, it is advisable to first set the suggested default values for the desired curves shown in figures

13-2 and 13-3. If these default values do not produce a satisfactory result, then proceed to make the appropriate adjustments bearing in mind that:

A - each parameter must be very gradually;

B - after each parameter change, wait at least 24 hours in order to see the result;

C - the closer the adjustment curve matches the actual load of the building, the greater the comfort and the energy savings will be;

D - knob “7” in Figure 13-1 can be used to make the small line shifts,

“b”, shown in Figure 13-3. These shifts will change the supply water temperature up to 18 °F (10 °C).

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13 - USE

13.10.3 - Outdoor reset: setting parameters

Refer to Section 13.16 and set:

- = “The angle of the curve”, which can be adjusted between

0.1 and 5.0. Suggested starting values are: 0.6 for “low temperature” systems; 1.6 for

“high temperature” systems;

13.10.4 - Outdoor reset: zone adjustments

The default values previously suggested are for boilers using an outdoor temperature sensor installed in dwellings with average heat loss in areas where the design outside winter temperature is 23 °F (-5°C). In the event that the climatic zone is different,

- adjust the parameter , to obtain a calculated temperature of 176 °F (80

°C) for the typical design outside winter temperature, see Figure 13-2.

-

= “Minimum heating temperature”. When the calculated temperature drops below this value the heating service stops.

The range of adjustment is between 68 °F (20 °C) and

140 °F (60 °C). The suggested starting values are: 86 °F

(30 °C) for “low temperature” systems; 104 °F (40 °C) for

“high temperature” systems;

= “Maximum heating temperature”. This parameter is the high limit of the supply heating temperature. Its range of adjustment is between 86

°F (30 °C) and 194 °F (90 °C).

The suggested starting values are: 113 °F (45 °C) for “low temperature” systems or 176 °F

(80 °C) for “high temperature” systems.

Refer to Section 13.17 and set:

13.10.5 - Outdoor reset activation

Once selected, reset adjustment is completely automatic and will switch off at the end of the heating season and switch back on at the beginning of the heating season. When the

“Calculated temperature” is lower than the “Minimum heating temperature”,

(parameter ) , the heating service switches off. When the “Calculated temperature” exceeds the “Minimum heating temperature” (parameter

) , the heating service switches back on.

If for some reason the heating service doesn’t match the load, use knob “7” in Figure 13-1, to raise or lower the calculated temperature and match the

“Minimum heating temperature” on an advanced or delayed basis.

- = This parameter must always be at value of 1.

- = “Fix point” is the heating calculated temperature, when the outdoor temperature is

68 °F (20 °C). It is called “Fix

Point” because it is also the angle fulcrum of the curve.

The suggested starting values are: 92 °F (33 °C) for “low temperature” systems 122 °F

(50 °C) for “high temperature” systems.

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13 - USE

Outside temperature (°F)

Figure 13-2 - Graph of th e outdoor reset adj ustment

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

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

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

Climatic adjustment with room compensation can be used in all the systems described in Section 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.

Outside temperature (°F)

Figure 13-3 - Graphs of th e outdoor reset adj ustment

(influence of parameter “b”)

75

OA = Slope of the line

Ob = Minimum heating temperature

Oc = Maximum heating temperature br = “Fix point” of the angle fulcrum of the line b = parallel shift of the lin e

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

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 configured to match the application.

The table below lists each switch and its corresponding funtions.

CAUTION!!!

Improper setting of these switches could cause the boiler to malfunction resulting in improper system performance.

Only a qualified technician, with an in-depth knowledge of the boilers’ control system, should change them.

SWITCH Position Description

1

8

6

7

4

5

2

3

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

OFF

ON

Boiler without production of D.H.W

Boiler with production of D.H.W. via storage tank

Boiler with production of instantaneous D.H.W.

Position not available for this serie of boilers

Heating pressure switch, disabled

Heating pressure switch, enabled

EBM PAPST brand fan

Position not available for this serie of boilers

Combination boiler for heating and D.H.W.

Boiler for heating only

High temperature heating service, 86°F (30°C) to 176°F (80°C)

Low temperature heating service, 68°F (20°C) to 113°F (45°C)

Boiler configuration change, disabled

Boiler configuration change, enabled

Maximum heating supply water temperature of 176°F (80°C)

Position not available for this kind of boilers

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 satisfied, the circulator pump continues to run for 1 minute; b - DHW delay: each time the domestic hot water demand is satisfied, a 2 minutes delay must pass before the heating service is allowed to restart; c - Protection against legionnaires bacteria: if the boiler is connected to a DHW storage tank the boiler will increase the tank temperature to 140 °F (60 °C) every seven days, prevent the formation of legionnaires bacteria. This function is displayed by .

d - DHW alarm: if the call for domestic hot water lasts for longer than two hours, an 01 alarm is generated.

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

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!!!

For the freeze 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.

CAUTION!!!

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

CAUTION!!!

Because the 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.

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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 parameter at a value other than zero. Keep in mind that each value will correspond to a delay in minutes until the display goes into

Energy Saving mode.

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;

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.

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

Adjustment of the curve angel as shown in

Figure 13-2 when outdoor reset is active per section 13.9.

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

Setting range: 0,1 to 5,0

Setting range: see section 13.10.3

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.

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.

Display of last error code registered, Section

13.18.2

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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13.17 - “Installer’s menu”

CAUTION!!!

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

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 confirm the amended data before moving to the next parameter.

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 lost.

button, will be

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

The boiler’s micro-processor makes this menu of parameters available to the qualified 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):

When the last parameter has been reached and the button pressed, the display will stop blinking indicating the exit from the menu.

PARAMETER DESCRIPTION

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

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

Value in °F (cannot be changed)

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)

High limit temperature, measured by U6 sensor

Flue gas temperature, measured by U7 sensor

Heating return temperature, measured by U8 sensor

Value in °F (cannot be changed)

Value in °F (cannot be changed)

Value in °F (cannot be changed)

Type of basic setting of control board

Status of room thermostat contact

Measurement of fan speed rotation

Can be changed in accordance with Section 11.6

00 = contact open (heating service off)

01 = contact closed (heating service on)

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

BTU input for heating service

Adjustable according to the instructions of section 12.10

Continue

78

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Continued

PARAMETER DESCRIPTION

Heating service functioning mode

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

Can be changed (see Section 13.9):

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 figure 13-1 energy saver

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)

Parameter disabled for this kind of boiler

Domestic sensitivity setting

No influence in this kind of boiler

Minimum domestic setpoint during sleep mode

No influence in this kind of boiler

Proportional band of the heating PID modulation

Integral of the heating PID modulation

Must be maintained at 20 value

Must be maintained at 40 value

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.

Can be changed between 1 and 54. Default value is 18 (180 sec).

Can be modified 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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13.18 -

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 filled. See section 13.1.

Domestic hot water service active

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 service active

Heating temperature (°F)

Boiler in lock-out mode. To reset it, press the technician

.

button. If the lock-out occurs frequently, contact a professionally qualified

Blocking error. Contact a professionally qualified technician. Blocking errors automatically reset if the condition causing the block disappears

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

Lock-out code (see section 13.18.1 for decodification).

Error code (see section 13.18.2 for decodification).

Boiler temperature (°F)

Boiler in Anti-legionella functioning (see section 13.12)

Storage tank temperature (°F)

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13 - USE

13.18.1 - Diagnostics: “L” lock-outs

“L”

Code

L01

Lock-out description

No flame detected after three ignition attempts.

Checks to make Solutions

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) 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, confirm that the the CO2 content is adjusted properly (see section

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

L08

L09

L10

L12

L13

L14

L15

L16

L17

L02

L03

L04

L05

L06

L07

Flame extinguishes three times.

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-If the ionization current is not greater than 60, confirm that the the CO2 content is adjusted properly (see section

12.9). Check the flame detection electrode (section 14.4) and if necessary replace it, check the integrity of the flame detection electrode electrical wires. b-Following procedure as per Section 14.12.4, check few times if passing from low fire to high fire the flame estinguish. If estinguish, change the gas valve.

Boiler temperature is over

203° F (95°C).

a-Check that the circulator pump is working; b-Check if the water flow is not less than

5 GPM

Gas valve command relay

Safety relay

Flue gas sensor over

210°F (99°C)

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

Check: a - that the electrical resistance of the flue gas sensor complies with the graph in Section 14.13; b - that the efficiency of the boiler is over 86% a-If the circulator pump is bad, replace it, if is good, replace the power control board. b-If the water flow 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 flue gas sensor resistance does not correspond with the correct values, replace it; b-if the boiler efficiency 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

Electrical circuit of flue gas sensor is interrupted

Check that the electrical resistance of the flue gas sensor corresponds with the graph in section 14.13;

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

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

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

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 flow rate is too low. The heating water flow rate must be corrected.

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

“L”

Code

Lock-out description

Controls

Solutions

L18

Program error

Replace the power control board

L19

L20

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

Flame sensed before opening of the gas valve.

Call technical service

Call technical service

L21

L25

L32

L33

L45

L46

L47

Boiler in blocking state for more than 20 hours

U1 or U6 sensor increase its temperature too fast

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

Section 13.18.2

Check: a - that the heating water flow is not too low; b - that the circulator pump is working a - If temperature difference between U1 and U8 is higher than

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

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

Program error

Fan rotation error

Heating circuit filling time longer than 10 minutes.

Filling of heating circuit repeated 16 times in 24 hours

Flue pressure switch open time longer than 60 minutes

Replace the power control board

Check that the voltage to the fan is

163(±10)Vdc.

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

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.

a -If the heating pressure switch is not correctly set, it must be replaced; b - if the system has a leak, it must be fixed.

Check: a - that no obstructions are in the flue discharge/air intake line b - check the flue pressure switch setting point, setting is 4.5 in.W.C

c - check that the electrical resistance of the flue gas sensor corresponds with the graph in section 14.13; d - check that the electrical connection cables between the flue pressure switch, the flue sensor and the power control board.

a -If ther’is an obstruction, it must be removed; b - If the flue pressure switch is not correctly set, it must be replaced; c - If the flue 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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13.18.2 - Diagnostics: “E” blocking errors

“E”

Code

E01

E02

E04

Blocking description

Checks to make

U1 boiler temperature sensor circuit interrupted.

U2 domestic hot water temperature sensor circuit interrupted.

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 14.13; check that the electrical connection cables between the sensor and the power control board have continuity and carry current

U8 return temperature sensor circuit interrupted

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

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

E07

U3 cold water or indirect water heater sensor circuit interrupted

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

E08

U6 boiler temperature sensor circuit interrupted.

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

E11

U1 boiler temperature sensor circuit shortcircuited.

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

E12

E13

U2 domestic hot water temperature sensor circuit short-circuited

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

Erroneous temperature reading.

Replace the power control board

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E32

E33

E42

E50

E51

E52

E53

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

“E”

Code

E14

E15

E16

E17

E18

Blocking description

U8 return temperature sensor short-circuited

U4 outside sensor shortcircuited

Checks to make

Solutions

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

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 power control board

Erroneous temperature reading.

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

U6 boiler temperature sensor circuit shorted

E2prom memory damaged

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 14.13; 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

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

E19

E20

E21

E22

E23

E30

Flame presence with gas valve closed

Phase and neutral inverted Invert phase and neutral

Electrical supply frequency other than 60Hz

Check the electrical frequency of the system.

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

Ground connection is absent

Erroneous temperature reading.

Check if the boiler is properly grounded

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

Erroneous temperature reading.

Replace the power control board

Erroneous temperature reading.

Erroneous temperature reading.

Program error

Error in the boiler tY parameter selection

Reset button pressed too often in a short period time

Heating flow switch closed

Heating flow 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 flow switch contact is stuck

Check if the heating pump is running.

Check if the flow switch contact is broken

84

Replace the power control board

Replace the power control board

Replace the power control board

If tY value is correct, change the power control board

The pump should not run and the 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 qualified 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.

A trained and qualified service technician should perform the inspection listed in these instructions before each heating season and

WARNING!!!

WARNING!!!

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

WARNING!!!

WARNING!!!

Never store combustible materials, gasoline or any product containing flammable 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!

Service and maintenance schedules

Service Technician User maintenance

Annual Startup:

- Address reported problems (Follow section 14.1.1);

- Check all piping for leaks (Follow section 14.1.2)

- Verify flue 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 flame sense electrodes (Follow section 14.1.6);

- Check wiring and connections (Follow section

14.1.7);

- Perform performance verification (Follow section

14.1.8);

- Flame inspection (Follow section 14.1.9);

- Check flame signal (Follow section 14.1.10);

- Clean the heat exchanger if flue 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)

Daily:

- 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:

Table 14-1 - Service and Maintenance Schedules

85

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

14 - MAINTENANCE

WARNING!!!

WARNING!!!

and ventilation air. Failure to provide adequate combustion air for this boiler can result in excessive levels of carbon monoxide which can result in

WARNING!!!

Never obstruct the flow of combustion

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

WARNING!!!

WARNING!!!

Do not check for gas leaks with an open flame. Use the bubble test. Failure to use the bubble test or check for gas leaks with an open flame can cause explosion, severe personal injury, death, or substantial property damage.

WARNING!!!

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

WARNING!!!

If maintenance is performed on

WARNING!!!

Before 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).

14.1.1 - Address reported problems

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

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.

14.1.2 - Check all piping for leaks

CAUTION!!!

Eliminate all system 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.

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 firing. Fan go into a post purge, then shuts off.

2. Control Safety Shutdown test: with the burner firing, close the manual gas shut off valve (Figure 11-1) .

Gas valve should close and burner should stop firing. 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.

86

14.1.6 - Check ignition and flame sense electrodes

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

2. Remove any deposits accumulated on the ignition/flame 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 verification.

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

2. Verify cold fill 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 flame through observation window.

2. If the flame is unsatisfactory at either high fire or low fire, clean the burner following section 14.3.

14.1.10 - Check flame signal

1. Follow section 14.12.4 to check the flame signal.

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

14.1.11 - Check relief valve

Inspect the relief valve and lift the lever to verify flow. 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

WARNING!!!

WARNING!!!

Failure to 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.

WARNING!!!

To prevent 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 qualified service technician to inspect the boiler for possible damage from acid corrosion.

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

2. Air contaminants -- Products containing chlorine or fluorine, if allowed to contaminate the boiler intake air, will cause acidic condensate in the boiler. This will cause significant 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.

14.1.16 - Check condensate drain system

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

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

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 qualified service technician if problem persists.

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 qualified service technician.

2. Visually inspect for leaks around water piping. Also inspect the circulators, relief valve, and fittings.

Immediately call a qualified service

WARNING!!!

WARNING!!!

Have leaks fixed at once by a qualified service technician. Failure to comply could result in severe personal injury, death, or substantial property damage.

14.1.14 - Check vent piping

1. Visually inspect the flue gas vent piping for any signs of blockage, leakage, or deterioration of the piping. Notify your qualified service technician at once if you find any

WARNING!!!

WARNING!!!

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

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 filled with an antifreeze solution.

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

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 qualified service technician if you notice any problems.

1. Combustible/flammable materials --

Do not store combustible materials, gasoline or any other flammable vapors or liquids near the boiler.

Remove immediately if found.

87

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

88

14 - MAINTENANCE

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

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

WARNING!!!

WARNING!!!

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

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 flame 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;

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 figure

14-2;

10. using the same vacuum cleaner, clean the surfaces of the burner

WARNING!!!

WARNING!!!

while 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!

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;

WARNING!!!

WARNING!!!

Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Figure 14-2 Remove the fan-burner assembly unit

89

14 - MAINTENANCE

A = Left ignition electrode

B = Right ignition electrode

C = Flame detection electrode

Fi gure 14-3 Positioning electrodes on burner

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

14.4 - Correct positioning of the ignition and flame 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 flame detection electrode to the burner surface must be between 0.23 in (6.0 mm), and 0.27 in (7.0 mm).

NOTE: To insure correct functioning of boiler the distances listed above shall be verified 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 efficiency over time, it may be necessary to clean or replace it.

90

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!!!

WARNING!!!

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

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. refill the condensate trap per

Section 12.1.2.

16. open the manual gas shutoff valve;

17. restore electrical power to the boiler;

WARNING!!!

WARNING!!!

Never use an open flame to test for gas leaks. Always use an approved leak detection method. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

Figure 14-4 Removing the condensing trap

91

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 fill 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

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.

92

14 - MAINTENANCE

Figure 14-6 Supply fittings 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 fittings “A”;

4. remove screws “C”;

5. rotate “D” flange in the direction of the black arrow (See particular fig.

1);

6. remove the bracket “E”;

5. remove fitting “F”;

6. remove fitting “L”;

7. remove fitting “M” and check its state.

8. remove spring “N”;

9. remove servomotor “O”;

10. remove the fitting “P”

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

Figure 14-7 3-way valve servomotor removal

93

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 fill 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

WARNING!!!

WARNING!!!

Do not recover and/or re-use water drained from the heating circuit for any purpose as it could be contaminated. Failure to comply with this warning can cause extensive property damage, severe personal injury or death!

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.

- 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 the display;

appears on

3. press the display shows:

key until the

for minimum heating output;

14.12 – Overrides

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

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

for maximum heating output; press the and keys together for 10 seconds. When the blinking appears on the display,

for minimum DHW output;

14.12.1 - Auto-purging

To reset the auto-purging procedure

- for maximum DHW output;

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

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;

14.12.4 – Checking the flame 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 flame 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 flame sensor electrod as per section 14.4; b - CO2 content as per section 12.9; c - combustion air pressure as per section 12.8.

94

14 - MAINTENANCE

14.13 - Water and flue 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

95

14 - MAINTENANCE

14.15 - Functional wiring diagram

WARNING!!!

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

WARNING!!!

Label all wires prior to disconnection when servicing

ATTENTION!!!

Au moment de l’entretien des commandes,

étiquetez tous les fils 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

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

14 - MAINTENANCE

14.16 - Multiwire wiring diagram

WARNING!!!

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!

WARNING!!!

Label all wires prior to disconnection

ATTENTION!!!

Au moment de l’entretien des commandes,

étiquetez tous les fils 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 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

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

98

14 - MAINTENANCE

99

15 - TECHNICAL DATA

MODEL

Country of destination

Type of boiler

Category of discharge chimney

CSA certificate N°

Maximum Heat input

Minimum heat input

Efficiency at maximum heat input (160°F/140°F)

Maximum Heat output (160°F/140°F)

Efficiency at minimum heat input (122°F/86°F)

Minimum heat output (122°F/86°F)

Certified AFUE rate

Gas flow rate

Gas supply pressure

Minimum gas supply pressure

Maximum gas supply pressure

Maximum heating temperature

Minimum heating temperature

Maximum heating pressure

Minimum heating pressure

Maximum pressure of domestic hot water circuit

Minimum pressure of domestic hot water circuit

Capacity of expansion tank (160-C model only)

Supply voltage

Absorbed electric power

Flue gas pipes diameter (split)

Max. length flue gas pipes (split)

Flue gas pipes diameter (coaxial)

Max. length flue gas pipes (coaxial)

Equivalent length of one elbow

CO (Carbon monoxide) with natural gas

CO (Carbon monoxide) with LP gas

NOx (0% O2 with natural gas)

CO2 (Carbon dioxide) for Natural gas at high fire

CO2 (Carbon dioxide) for Natural gas at low fire

CO2 (Carbon dioxide) for LP gas at high fire

CO2 (Carbon dioxide) for LP gas at low fire

O2 (Oxygen) for Natural gas at high fire

O2 (Oxygen) for Natural gas at low fire

O2 (Oxygen) for LP gas at high fire

O2 (Oxygen) for LP gas at low fire

Ionisation current

Maximum flue gas temperature

Natural gas

LP Gas

Natural gas

LP Gas

Flue gas mass-flow

Head pressure available for flue vent/air intake line

Maximum condensation flow rate

Average acidity of condensation

Boiler weight (empty of water) (160-C model)

Boiler weight (empty of water) (160-B model) ft

“ (mm) ft ft ppm ppm ppm

%

%

%

%

%

%

%

%

°F lb/hr

In.W.C. gal/hr

PH lb lb

Natural gas

Btu/hr

Btu/hr

%

Btu/hr

%

Btu/hr

% ft3/hr gal/hr

In.W.C.

In.W.C.

In.W.C.

Combustion air pressure with min. length

LP Gas In.W.C.

Natural gas In.W.C.

LP Gas In.W.C.

Natural gas In.W.C.

Combustion air pressure with max. length

LP Gas In.W.C.

Natural gas In.W.C.

LP Gas

Instantaneous d.h.w production [rise 75°F (42°C)]

In.W.C. gal/min

°F

°F

PSI

PSI

PSI

PSI gal

W

“ (mm)

100

XX-160-B; XX-160-C;

USA and Canada

Direct Vent and room combustion air

IV

2045300 (114696)

160,000

30,000

93

148,800

97

29,100

93

156

1.75

7

11

3

3

13

13

2.5 to 3.1

2.1 to 2.7

2.1 to 2.7

1.8 to 2.4

4.32

189

68

30

8

150

1

2.64

120Vac - 60Hz

170

3.15” (80)

300

2.36/3.94 (60/100)

70

45° elbow = 3ft, 90° elbow = 5ft

<150

<250

<30

9.1 to 9.3

8.4 to 9

9.3 to 9.7

9.2 to 9.8

4.4 to 4.6

5.1 to 5.7

5.7 to 5.9

6.1 to 6.7

71 to 90

210

160

3.6

1.32

4

125

93

16 - SPARE PARTS

101

16 - SPARE PARTS

102

16 - SPARE PARTS

103

16 - SPARE PARTS

Spare parts list

1 – 60504206 CABLE UL IGNITOR CONN 90° L155

2 – 60802005 NUT ZINC COATED 6MA

3 – 60320001 SILICONE PIPE D 4X8

4 – 61405036 TEE FOR DRY WATER CONDENSATION

5 – 60510022 SPARK GENERATOR NO CABLE UL

6 – 62111016 SENSOR NTC 10 KOHM A KLIP DIAM.22

7 – 62622011 COPPER PIPE D22 M/F 3/4”G-1”G

8 – 60802018 3/4” RING NUT

9 – 60702030 O-RING NBR 2,62 X 20,63

10 – 62649004 PRIMARY HEAT EXCHANGER C.R.R ASME

11 – 60702047 GASKET EPDM X OSSIDO D84 H7

12 – 62111017 SENSOR NTC 10 KOHM 1/8”

13 – 60803027 GASKET COPPER 1/8” SP.1,5

14 – 61405025 SILICONE TAP

15 – 60801116 SCREW 6X35 ZINC TC-CR

16 – 60803011 WASHER 6X18X1,5 PIA-ZIN-LAR UNI6593

17 – 60406074 BRACKET SIPHON L84 H130 P32

Bottom side of the 160-B model

104

18 – 60702055 O-RING 134 EPDM 3,53 X 25,8

19 – 60801043 SCREW SELFTAPPING 3.9 X 9.5 CROSS HEAD

20 – 62630136 SIPHON

21 – 60801100 SCREW SELFTAPPING 2.9 X 6.5 CROSS HEAD

22 – 60806020 SPRING 28,7

23 – 62113041 PRESSURE SWITCH ON 4,5 INWC

24 – 60406092 BRACKET PRESSURE SWITCH

25 – 60322012 POLIETYLENE PIPE L=1000

26 – 60402037 SEALING CHAMBER DOOR

27 – 60701001 1”G GASKET

28 – 62301031 PUMP GRUNDFOS UP 15/58U BRUTE USA

29 – 62622012 COPPER PIPE D22 RETURN SEALING CHAMBER

30 – 62111015 SENSOR NTC 10K BAIO

31 – 62110067 OUTDOOR SENSOR

32 – 60801132 SCREW 4,8X19 ZINC AF TC-CR UNI6954

33 – 61405164 PLUG FOR FLUE AIR FITTING

34 – 60702052 O-RING 2050 EPDM 1,78 X 12,42

35 – 61405160 DISCHARGE RACCORD PP

36 – 60702035 GASKET ROUND SPONGE D.3,5 MM IP44 S3

37 – 61206001 AUTOMATIC AIR VENT

16 - SPARE PARTS

38 – 60101119 3/8G MALE to 1/8NPT FEMALE BUSHING

39 – 60703033 GASKET EPDM D38 F20 SP6

40 – 60411085 45xx WALL MOUNTING BRACKET

41 – 60801097 SCREW SELFTAPPING 5X50 WOOD

42 – 62201005 EXP TANK LT. 8 561X203X80 RETT.

43 – 60815012 GLASS WINDOW WITH GASKET

44 – 60701005 3/8” G GASKET

45 – 61102006 FAIRLEAD 6 POLES SILICONE

46 – 62625064 EXP TANK PIPE

47 – 61405219 PLASTIC CAP TPP 8.5

48 – 62110071 TANK SENSOR

49 – 62610067 EXTERNAL JACKET 500X840X245

50 – 61405167 DOOR SUPPORT

51 – 62610065 DOOR ABS

52 – 62630167 LP TO NATURAL CONVERSION KIT FOR 160 GENERIC

53 – 62630166 NATURAL TO LP CONVERSION KIT FOR 160 GENERIC

54 – 62417004 160 USER’S INSTRUCTIONS

55 – 62403558 160 GENERIC INSTALLER’S INSTRUCTIONS

56 – 62629036 BURNER HEAD

57 – 61504029 EXTRUSION L.25MM

58 – 60909008 THERM. INSULATION VERMICULITE D117 F74 SP21,5

59 – 60703032 GASKET. SIL. D157 F145 H6,7

60 – 61404108 BASE MANIFOLD AIR ALUMINUM

61 – 60703030 GASKET SIL.MANIFOLD FAN D83 SP3,5

62 – 60801136 SCREW SELFTAPPING 4X12 TC S-TT UNI-8112

63 – 62651016 MANIFOLD AIR CUTTED

64 – 61404114 MIXER AIR/GAS “COSMOMIX”

65 – 60702049 O-RING 3350 NBR 2,62 X 88,57

66 – 60702048 O-RING 3200 NBR 2,62 X 50,47

67 – 60408261 DIAPHRAGM COSMOMIX 9 HOLES D.10

68 – 60702056 O-RING 165 NBR 3,53 X 61,91

69 – 61901029 FAN 45 KW USA

70 – 61405174 BACK FLUE-GASES PREVENTER

71 – 60702051 O-RING 3825 SIL 2,62 X 209,22

72 – 61404109 COVER MANIFOLD AIR ALUMINUM

73 – 60801080 SCREW SELFTAPPING 4X10 TC S-TT UNI-8112

74 – 60801111 SELFTAPPING BOLT 6.3X38

75 – 60701013 GASKET FRIZITE D15,5 F11,5 SP1,5

76 – 60815011 GLASS PIREX D15,5 SP3,3

77 – 60404253 FLANGE L21,2 H34

78 – 60801081 SCREW SELFTAPPING 4X8 TC S-TT UNI-8112

79 – 60505022 LEFT IGNITION ELECTRODE FOR NOVADENS

80 – 60505023 RIGHT IGNITION ELECTRODE FOR NOVADENS

81 – 60505024 DETECTION ELECTRODE FOR NOVADENS

82 – 60801102 SCREW 5X12 EXAGONAL HEAD

83 – 60406069 SPRING MIXER

84 – 60702050 O-RING 3056 NBR (118) 2,62X13,95

85 – 62624125 GAS PIPE (SIT) USA

86 – 60701006 GASKET 3/4P 24X15X2 KLINSIL

87 – 60801014 SCREW 4X10 ZINC TC-CR

88 – 60101224 FLANGE GAS 32X32 3/4P

89 – 60702029 O-RING 130 2,62 X 22,22

90 – 61201040 GAS VALVE SIGMA848 120V

91 – 60801021 BOLT 5X12 CROSS HEAD

92 – 62623249 PIPE D18 F/F 3/4P-3/4P SIT USA

93 – 62103009 CONTROL KNOB S3

94 – 60702041 O-RING NBR 1,6 X 11,1

95 – 61405203 FRONT INTERFACE

96 – 61405151 TREE POTMETER-KNOB

97 – 61405190 KEYS RUBBER 3 POSITIONS

98 – 62102009 PRESSURE GAUGE DIAM.38 - 1/4” PSI

99 – 60506019 GAS VALVE SERVICE SWITCH

100 – 61405184 BASE ELECTRICAL BOX

101 – 61405186 FAIRLEAD SX

102 – 61405188 FAIRLEAD DX

103 – 62110076 POWER CONTROL BOARD PHC 120V

104 – 60801138 SCREW 4X8 ZINC TC-CR DIN4042

105 – 60507056 JUNCTION BOARD 45

106 – 62118015 INTERFACE OPENTERM

107 – 61405185 COVER ELECTRICAL BOX

108 – 61103011 FAIRLEAD 7 EXIT

109 – 61405189 COVER JUNCTION BOX

110 – 62622034 COPPER PIPE D.22 SUPPLY SEALING CHAMBER

111 – 61203015 3 WAY VALVE MOTOR 120V

112 – 61202024 PLUG PISTON BODY OT.

113 – 60808002 SPRING FORCK 3V

114 – 61202027 UPPER PISTON

115 – 61408005 HYDRONIC SUPPLY GROUP.

116 – 62113034 HEATING PRESSURE SWITCH

117 – 60704003 GASKET COPPER 1/4P

118 – 60801134 SCREW 5X18 ZINC TC-ES-INC UNI5931

119 – 61205010 ASME SAFETY RELIEF VALVE

120 – 60110003 1”-3/4” BRASS NIPPLE

121 – 61202025 COVER PISTON HEATING

122 – 61202028 PISTON HEATING SIDE

123 – 60107005 PLUG BRASS 1/4P M WITH O-RING

124 – 60110028 NIPPLE OT 1”-22X1,5 MM

125 – 60702036 O-RING 2075 EPDM 1,78 X 18,77

126 – 61408007 HYDRONIC RETURN GROUP

127 – 61202026 BY-PASS VALVE

128 – 60107006 3/8” MALE CAP

129 – 62653003 DOMESTIC HEAT EXCHANGER “ACQUAJET”

130 – 62110052 SENSOR NTC 10 KOHM KLIP WITH SCREW

131 – 60802008 NUT ZINC COATED 4MA

132 – 60702053 O-RING 3037 EPDM 2,62 X 9,19

133 – 62628001 PURGING PIPE

134 – 61206011 PURGING VALVE M10X1

135 – 60808003 FORCK BY-PASS PIPE

136 – 60305073 BY-PASS PIPE

137 – 60702054 O-RING 4075 EPDM 3,53 X 18,64

138 – 60901022 FRONT THERM. INSULATION “ACQUAJET”

139 – 60901023 REAR THERM. INSULATION “ACQUAJET”

140 – 60440008 BRACKET EXAGONAL HOLES SHORT

141 – 60440009 BRACKET EXAGONAL HOLES LONG

142 – 60110025 3/4”NPT-3/4”BSP BRASS NIPPLE

143 – 60411117 BRACKET EXAGONAL HOLE SMALL

144 – 60701004 1/2” GASKET

145 – 61101001 FAIRLEAD PA 107 SCREW HILO 3,5X14,5

146 – 60101011 CONNECTION BRASS 3/4P TO 1P

147 – 60101225 CONNECTION BRASS 1/2P TO 1P

148 – 60802018 3/4” NUT

149 – 60801135 6X8 TC-CR DIN7985 ZINC. SCREW

150 – 60310002 1”-3/4” COPPER PIPE

151 – 61407001 3/4” BRASS FEMALE TEE

152 – 61408012 HYDRONIC SUPPLY GROUP ONLY HEAT

153 – 60101124 1/2” CAP

154 – 60101193 1/2”-1/4” FF BRASS FITTING

155 – 60107014 3/4” F BRASS PLUG

156 – 60101168 3/4” MF BRASS ELBOW

157 – 60113003 3/4” NUT

158 – 60107015 3/8” FEMALE PLUG BRASS

159 – 61408009 HYDRONIC RETURN GROUP ONLY HEATING

160 – 60703039 GASKET EPDM INTERNAL D60

161 – 62606030 PLASTIC EXTERNAL JACKET

162 – 60107019 1/2” BRASS MALE CAP

163a – 60111051 9.1MM NATURAL GAS INJECTOR

163b – 60111052 5.7MM LP GAS INJECTOR

164 – 60702071 2.62X13.10 NBR O-RING

165 – 60101255 Ø6/4-1/4”FEMALE FITTING

166 – 61206007 1/4” TAP

167 – 60101254 Ø6/4-Ø6/4-1/8”MALE TEE FITTING

168 – 60322013 4X6 PTFE FLEXIBLE PIPE

169 – 60418036 24X17X2 AISI316L WASHER

170 – 60432009 24X17X1.5 AISI316L WASHER

171 – 60101256 1/2”-1/4” MF BRASS FITTING

172 – 60101257 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 identification and replacement should be attempted only by a qualified technician.

Relief/Safety valves must be ASME rated for the pressure and gross output of the boiler.

105

17 - READ OUT FLOW CHART

Only fan in run Heating at low fire Heating at regul. fire Heating at high fire at low fire at high fire at high fire

Supply temp.

temp./ tank temp.

Outdoor temp.

Ionisation current High limit temp.

Flue temp.

Return temp.

Basic setting

Room therm. state

Curve angle Min. heat. temp.

Max. heat. temp.

Calculated heat. temp.

Push and hold together the + and - keys, for a time, in seconds, indicated by the number

Central heating temp. setting key for a time, in seconds, indicated by the number

Overrides menu (see section 14.12) reset, CH settings to 01 or 02 (see section 13.16) thermostatic CH settings to 00 (see section 13.16)

Read out in normal operating condition (see

106

17 - READ OUT FLOW CHART

Fan speed rpm/100

Setting output for heating

Heating service mode Reaction to outdoor temp.

Angle fulcrum Heat. temp. reduction by open R 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

107

17 - READ OUT FLOW CHART

CAUTION!!!

Changing these parameters could cause the boiler and therefore the system to malfunction. For this reason, only a qualified 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 qualified 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.

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;

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 configuration. Must be always at 00.

Rotating selection in a module configuration.

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)

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.

If readable, may assume the follow values:

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

00.

108

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).

NOTE

109

COSMOGAS s.r.l.

Via L. da Vinci 16, 47014 MELDOLA (FC) ITALY

TEL +39 543 498383 [email protected]

www.cosmogas.com

COSMOGAS Noth America

TEL 860-833-8375

[email protected]