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.
A
S
M
E
H
INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.
62403558 R02 November 14, 2012
Save this manual for future reference.
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.
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
- Do not store or use gasoline or other
flammable vapors and liquids in the
vicinity of this or any other appliance.
- 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.
- 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.
- 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
- Installation and service must be performed
by a qualified installer, service agency or
the gas supplier.
- L’installation et l’entretien doivent être
assurés par un installateur ou un service
d’entretien qualifié ou par le fournisseur
de gaz.
2
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.
 Installer: Read all instructions,
including this manual, before
installing. Perform steps in the order
given.
 User: Refer to the User’s
Information Section for your
reference.
 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.
 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!
 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.
 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.
 Local approval: of the flue system
and the condensate connection to
the public sewer system may be
required.
4
 Local approval: The local building
regulations stipulating the installation
rules at the time of installation.
 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.
 Installation location: The boiler
must not be installed on carpeting.
 Air intake and outlets: Do not
restrict or seal any air intake or outlet
openings.
 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.
 Defects: If you find any defects,
you must inform the owner of
the system of the defect and the
associated hazard in writing.
 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.
 When servicing boiler, to
avoid electric shock, disconnect
electrical supply before performing
maintenance.
SAFETY INSTRUCTIONS
 When servicing boiler, to avoid
severe burns, allow boiler to cool
before performing maintenance.
 Electrical: Label all wires prior
to disconnection when servicing
controls. Wiring errors can cause
improper and dangerous operation.
Verify proper operation after
servicing.
 ATTENTION: Au moment de
l’entretien des commandes,
étiquetez tous les 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.
 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.

En cas de surchauffe ou si
l’alimentation de gaz ne peut être
coupée, ne pas couper ni débranch
l’alimentation électrique de la
ponpe. Fermer plutôt le robinet
d’admission de gaz à l’extérieur de
l’appareil
 Do not use this appliance if
any part has been under water.
Immediately call a 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.
5
 Ensure the boiler and its controls
are protected from dripping or
spraying water during normal
operation or service.
 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!
 When calling or writing about
the boiler – Please have the boiler
model and serial number from the
boiler rating plate.
 Any claims for damage or
shortage in shipment must be
filed immediately against the
transportation company by the
consignee.
 Factory warranty (shipped with
unit) does not apply to units
improperly installed or improperly
operated.
 Only use the boiler in the
combinations and with the
accessories and spares listed in
this manual.
 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
 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
6
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
7
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
8
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.
9
1 - INSTALLATION - CODE REQUIREMENTS
1.2- Commonwealth
of Massachusetts
Installation
Requirements
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.
In the Commonwealth of
2. APPROVED CARBON MONOXIDE
Massachusetts, the installation must be
DETECTORS. Each carbon monoxide
performed by a licensed plumber or gas
detector as required in accordance with
fitter. WARNING!!!
the above provisions shall comply with
NFPA 720 and be ANSI/UL 2034 listed
WARNING!!!
and IAS certified.
Improper
venting can result in excessive 3. SIGNAGE. A metal or plastic
identification plate shall be permanently
levels of carbon monoxide
mounted to the exterior of the building
which can cause severe
at a minimum height of eight (8) feet
personal injury or death!
above grade directly in line with the
exhaust vent terminal for the horizontally
(a) For all side wall horizontally vented
vented gas fueled heating appliance
gas fueled equipment installed in
or equipment. The sign shall read, in
every dwelling, building or structure
print size no less than one-half (1/2)
used in whole or in part for residential
inch in size, “GAS VENT DIRECTLY
purposes, including those owned
BELOW. KEEP CLEAR OF ALL
or operated by the commonwealth
OBSTRUCTIONS”.
and where the side wall exhaust vent
4. INSPECTION. The state or local gas
termination is less than seven (7) feet
inspector of the side wall horizontally
above finished grade, in the area of
vented gas fueled equipment shall not
the venting, including but not limited
approve the installation unless, upon
to decks and porches, the following
inspection, the inspector observes
requirements shall be satisfied:
carbon monoxide detectors and
1. INSTALLATION OF CARBON
signage installed in accordance with
MONOXIDE DETECTORS. At the time
the provisions of 248 CMR 5.08(2)(a)1
of installation of the side wall horizontal
through 4.
vented gas fueled equipment, the
installing plumber or gasfitter shall
(b) Exemptions
observe that a hard wired carbon
The following equipment is exempt from
monoxide detector with an alarm and
248 CMR 5.08(2)(a) 1 through 4:
battery back-up is installed on the floor
1. The equipment listed in Chapter 10
level where the gas equipment is to
entitled “Equipment Not Required To Be
be installed. In addition, the installing
Vented” in the most current edition of
plumber or gasfitter shall observe that a
NFPA 54 as adopted by the Board; and
battery operated or hard wired carbon
2. Product Approved side wall horizontally
monoxide detector with an alarm is
vented gas fueled equipment installed
installed on each additional level of the
in a room or structure separate from the
dwelling, building or structure served
dwelling, building or structure used in
by the side wall horizontal vented
whole or in part for residential purposes.
gas fueled equip-ment. It shall be the
responsibility of the property owner to
(c) MANUFACTURER REQUIREMENTS
secure the services of qualified licensed - GAS EQUIPMENT - VENTING SYSTEM
professionals for the installation of hard PROVIDED.
wired carbon monoxide detectors.
When the manufacturer of Product
a. In the event that the side wall
Approved side wall horizontally vented
horizontally vented gas fueled
gas equipment provides a venting system
equipment is installed in a crawl
design or venting system components with
space or an attic, the hard wired
the equipment, the instructions provided
carbon monoxide detector with alarm by the manufacturer for installation of the
and battery back-up may be installed equipment and the venting system shall
on the next adjacent floor level.
include:
b. In the event that the requirements of
1. Detailed instructions for the installation of
this subdivision can not be met at the
the venting system design or the venting
time of completion of installation, the
system components; and
10
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!!!
WARNING!!!
Failure to follow
these indications can causing
an explosion, extensive property
damage, severe personal injury or
death!
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
11
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
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)
Figure 3-1 Main components (continued)
12
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)
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
Figure 3-1 Main components
13
4 - FUNCTION OVERVIEW
Figure 4-1 160-B Hydronic functional schematic
Figure 4-2 - 160-C Hydronic functional schematic
14
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
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:
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. Using this boiler model, you can
create a system for the production of
instantaneous domestic hot water and
Figure 4-3 Outdoor reset control to optimize the efficiency
15
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.
5 - INSTALLATION - Location
5.1 - Choosing the
installation location
WARNING!!!
WARNING!!!
Do not store
any flammable materials
or liquids in the immediate
vicinity of the boiler. A fire or
explosion can result, causing
severe personal injury, death,
or substantial property
damage.
WARNING!!!
WARNING!!!
If the boiler is
installed on a wall, this must be
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
damage.
WARNING!!!
WARNING!!!
WARNING!!!
WARNING!!!
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.
Do not install
the boiler on carpeting. Fire
can result, causing severe
personal injury, death, or
substantial property damage.
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!!! Do not allow too
Figure 5-1 Recommended minimum clearance
distances for proper installation and servicing
16
much dust to collect on the
boiler.
5 - INSTALLATION - Location
When locating the boiler the following NOTE: Service clearances are not
mandatory, but are recommended to
factors must be considered:
ease of service should it be
 the location of vent/air intake ensure
required.
terminals;
 connection to the gas supply;
5.1.3 - Clearances from
 connection to the water supply;
combustible material
 connection to the heating system; This boiler may be installed directly onto
 connection to the domestic hot water a wall of combustible material with the
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.
5.1.1 - Closet and alcove
installations
following clearance:
- Ceiling:
2 inches (51 mm)
- Front:
2 inches (51 mm)
- Rear:
0 inches (0 mm)
- Sides:
2 inches (51 mm)
- Floor:
2 inches (51 mm)
- 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)
5.1.4 - Vent and air piping
This boiler requires a special vent
system, designed for pressurized
It is possible to install the boiler in
venting.
a closet or alcove structure, but
The boiler is to be used for either direct
you must to consider a minimum
vent installation or for installation using
clearances for serviceability as per
room combustion air. When room air is
section 5.1.2 and a minimum volume
considered, see Section 10-10.
of 48 cubic feet.
Vent and air may be vented vertically
WARNING!!!
through the roof or out a side wall,
unless otherwise specified. You may
WARNING!!!
It is forbidden use any of the vent/air piping methods
the use of PVC vent piping material covered in Section 10. Do not attempt
to install the boiler using any other
in a closet or alcove structure due
means.
to elevate temperature. Failure to
Be sure to locate the boiler such that
follow this warning could result in
the vent and air piping can be routed
fire, personal injury, or death.
through the building and properly
WARNING!!!
terminated.
WARNING!!!
The vent/air piping lengths, routing and
Provide
termination method must all comply
two ventilating air openings of
with the methods and limits given in
160 sq. inch each. One located
Section 10.
at 6 inch from the top and one
located at 6 inch from the bottom
of the structure. Failure to follow
5.1.5 - Prevent
this warning could result in fire,
combustion air
personal injury, or death.
contamination
Install air inlet piping for the boiler
as described in Section 10. Do not
terminate vent/air in locations that can
Figure 5-1 shows the minimum allow contamination of combustion air.
clearances required for installation Refer to Section 10.2, for products and
and servicing.
areas which may cause contaminated
combustion air.
5.1.2 - Clearances for
installation and servicing
17
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!!!
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
6 - INSTALLATION - Mounting the boiler
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
wall studs;
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 6-1 Wall bracket installation
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
Figure 6-2 Dimensions
18
7 - INSTALLATION - Water connection
7.1 - Water connections
The boiler comes with the fittings shown in Figure 7-1.
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
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”)
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.
Figure 7-1 Fittings supplied with the boiler
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!!! Do not use the boiler
to directly heat swimming pool or
spa water.
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.
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.
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
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
solution in the system piping.
WARNING!!!
WARNING!!!
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).
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!!! To protect the radiant
WARNING!!!
CAUTION!!! Risk of system
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.
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
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
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.
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
10. Indirect water heaters: field
supplied. Full port ball valves are
supplied. This boiler may be piped
required. Failure to use full port ball
to an indirect water heater to heat
valves could result in a restricted
domestic hot water with the space
flow rate through the boiler.
heat transfer medium. There are
5. Back flow preventer: Field supplied.
two options when utilizing an
Back flow preventer valves are
indirect water heater:
recommended for installation as
A. The space heating piping will
shown in Figures 7-6 and 7-7.
branch off to flow the space heat
Failure to install these valves could
transfer medium through a single
result in a reverse flow condition
wall heat exchanger coil inside
during pump(s) off cycle.
the indirect water heater.
6. Domestic indirect hot water isolation
B. The indirect water heater is
valves: Field supplied. Full port ball
connected to the system supply
valves are required. Failure to use
piping. A pump controlled by the
full port ball valves could result in
boiler’s control will regulate the
a restricted flow rate through the
flow of water through the indirect
boiler.
water heater. The indirect water
7. Anti-scald mixing valve: Field
heater’s temperature will be
supplied. An anti-scald mixing valve
regulated by the boiler’s control.
is recommended (see Figure 7-6).
The boiler is pre-configured to
It is recommended also when an
control the operation of the DHW
indirect water heater is present.
pump with Domestic Hot Water
8. Unions: Field supplied.
Prioritization programming.
Recommended for unit
serviceability.
CAUTION!!! It is up to the
9. Pressure relief valve: Factory
installer to ensure the minimum
installed. The pressure relief valve
system flow is not less than 5
is sized to ASME specifications.
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.
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!!!
Failure
to properly pipe the relief
valve discharge can result in
scalding of individuals and
animals. Never install any type
of valve between the boiler and
the relief valve or an explosion
causing extensive property
damage, severe personal injury
or death may occur!
WARNING!!!
A = 3/4” pipe extension (not provided)
B = Discharge device open to the
atmosphere (not provided)
C = Condensate discharge pipe
Figure 7-2 Relief valve discharge piping
21
WARNING!!!
Never block
the outlet of the safety relief
valve or an explosion causing
extensive property damage,
severe personal injury or death
may occur!
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.
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.
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!!! 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
CAUTION!!! It is up to the
160-B boiler model. Refer to Figure
installer to ensure the minimum 9-1 to wire the indirect water heater
pump, the system pump and the
system flow is not less than 5
heating pump (if present).
GPM at any time.
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
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.
Figure 7-3 Available Head for heating circuit for models “160-C”
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
Figure 7-4 Internal Boiler Head Loss for model “160-B”
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
water heater is present.
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
g
Heatin
m
e
syst
supply
g
Heatin
m
e
t
sys
return
Gas inlet
Cold
water p
u
make-
stic
Dome er
t
a
hot w
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
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
Figure 7-6 Piping of the boiler model 160-C
24
7 - INSTALLATION - Water connections
g
Heatin
m
syste
supply
g
Heatin
m
e
t
sys
return
to a
Supply direct
in
DHW eater
h
water ed)
d
e
e
(if n
Cold
water p
u
make-
Gas inlet
from a
Return direct
in
DHW eater (if
h
r
e
t
a
w
d)
e
need
1 = Boiler
2 = Air separator
3 = Ball valve
4 = Drain cocks
5 = Filling valve
6 = Expansion tank
7 = Filter
8 = Back flow preventer
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
Figure 7-7 Piping of the boiler 160-B
25
7 - INSTALLATION - Water connections
7.5 - Condensate
disposal
be installed in such a way so as to
avoid the freezing of the liquid;
WARNING!!!
never discharge into gutters or rain
WARNING!!!
be properly pitched towards the
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:
collectors;
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.
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.
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
Condensate
trap and drain
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);
Figure 7-8 Condensate trap and drain connection
26
8 - INSTALLATION - Electrical connections
8.1 - Electrical connections:
overview
WARNING!!!
WARNING!!!
ELECTRICAL SHOCK HAZARD
– For your safety, turn off electrical power supply
before making any electrical connections to avoid
possible electric shock hazard. Failure to do so
can cause severe personal injury or death.
WARNING!!!
WARNING!!!
Label all wires prior to
disconnection when servicing controls. Wiring
errors can cause improper and dangerous
operation!
WARNING!!!
ATTENTION!!!
Au moment de l’entretien des
commandes, étiquetez tous les fils avant de les
débrancher. Des erreurs de câblage peuvent
entraîner un fonction-nement inadéquat et
dangereux. S’assurer que l’appareil fonctionne
adéquatement une fois l’entretien terminé.
WARNING!!!
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
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
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
System pump (see
piping diagram of
Figure7-6)
120Vac LINE (HOT)
NEUTRAL
GROUND
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
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.
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 NOTICE! If the boiler is not properly
grounded, the boiler will block,
and 8-2:
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
NOTICE! the maximum room thermostat 2. use a two conductor cable with a
cable length permitted is 32 ft (10 m).
minimum cross section of # 18 AWG
than 1 hp or 1 amps, you must
For longer lengths, up to 300ft (100 m) a
between the boiler and the outdoor
isolate with a relay.
shielded cable, with the shield connected
temperature sensor.
to the ground, must be used.
6. Connect the electrical supply cable
WARNING!!!
NOTICE! the maximum outdoor
to the electrical connections into
temperature sensor cable length
WARNING!!!
the pump. Follow manufacturer’s
Since the room permitted is 32 ft (10 m). For longer
instruction of the pump.
thermostat wires conduct 24 Vac, lengths, up to 300 ft (100 m) a shielded
cable, with the shield connected to the
they must never be run through
NOTICE! If the 120 volt power wires
ground, must be used;
conduits containing 120Vac
are inverted, the boiler will lock-out,
WARNING!!!
power wires or an electrical
displaying error code L05.
shock hazard will exist.
WARNING!!!
Since the
outdoor
temperature
sensor
8.1.3 - Thermostat wiring
8.1.4 - Installing the
wires conduct 24 Vac, they must
Install the room thermostat in a part of
outdoor temperature
never be run through conduits
the house where the temperature is as
containing 120 Vac power wires
near to average as possible. Avoid areas sensor
or an electrical shock hazard will
subject to sudden temperature changes
The outdoor temperature sensor is
exist.
such as outside windows or doors, above supplied with the boiler. Install the
radiation elements, near lamps, etc.,
outdoor temperature sensor, on an
3. connect the outdoor temperature
(see Figure 8-3).
exterior wall of the building facing
sensor cable leads to terminals “13”
NORTH or NORTH-EAST, at a height
and “14” as shown in Figure 8-2;
Connect the room thermostat to the
of between 4 ft (1.2 m) and 6 ft (1.8 m)
4. connect the outdoor temperature
boiler by following the steps below:
from the ground level. On multi story
sensor cable leads to the ends of the
1. remove the boiler casing according to buildings, install the sensor near the
external temperature sensor.
the instructions given in Section 14.2
upper half of the second floor. Do not
and open the junction box cover;
install the sensor above doors, windows
Set the boiler so that it detects the
2. use a two conductor cable with a
or ventilation outlets nor directly under
outdoor temperature sensor, as follows:
minimum cross section of #18 AWG
balconies or gutter pipes. Do not shield
between the boiler and the room
the outdoor temperature sensor. Do
1. press down the
button for
thermostat;
not install the sensor on walls without
12
seconds
until
the
display
starts
3. route the cable through an empty
overhangs, or not protected from rain. To
cable clamp “E” in the junction box;
connect the outdoor temperature sensor
blinking and shows
;
4. connect the cable leads to the “9” and to the boiler proceed as follows:
“10” terminals as shown in Figure 8-2. 1. remove the boiler casing according to 2. then press and release the
the instructions given in Section 14.2
button several times until the following
and open the junction box;
parameter appears;
CAUTION!!! If the pump is larger
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.
8.1.5 - Alarm output
6ft (
Figure 8-3 Room thermostat location
29
)
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.
9 - INSTALLATION - Connecting to an indirect water heater
WARNING!!!
9.1 - Connecting
the boiler to an
indirect water
heater
5. move switch #1, item “D” to its “ON”
WARNING!!!
position as marked on the control
Since the
board;
indirect water heater temperature
6. move switch #5 in the OFF position;
sensor wires conduct 24 Vac,
7. on model 160-C, on the rear side
they must never be run through
of the electrical junction box board,
conduits containing 120 Vac
if present, disconnect the plug with
power wires or an electrical
This boiler, can be connected to
two wires, item “E”, corresponding
shock hazard will exist.
an indirect water heater. The water
to wires #44 and #45.
WARNING!!!
connection must be made per figure
8. on model 160-C, on the rear side
7-7. Heating pump item “9” of Figure
of the electrical box, disconnect
WARNING!!!
Once the
7-7 is mandatory for boiler model 160the electrical plug from the diverter
boiler
is
connected
to an indirect
B. The electrical connections must be
valve (see Figure 3-1, item “35”).
water
heater,
it
will
perform
a
made per figure 9-1. To change the
When you disconnect the plug you
weekly
antilegionella
cycle.
This
logic of the boiler, to drive and load an
must insure that the boiler is in the
cycle raises the water heater
indirect water heater, follow the steps
heating mode. If you are not sure,
temperature to 140°F one time
below while refering to Figure 9-2:
light the boiler ON, wait the display
per week.
1. disconnect the boiler from the
show “F” and then light-off the
electrical supply;
boiler. Now you can disconnect the
NOTE! A few cable conduit holes are
2. remove the boiler casing according
plug from the diverter valve.
provided on the bottom right side of
to the instructions given in section
9. use a # 18 AWG two wire cable to
the boiler
14.2;
connect the indirect water heater
3. push the plastic spring tabs “B”;
temperature sensor to terminals
CAUTION!!! If the pump is larger
4. open the front half of the electrical
“15” and “16”, as per Figure 9-1
box in the “C” direction;
10. insert the probe of the indirect
than 1 hp or 2 amps, you must
water heater sensor into the socket
isolate with a relay.
of the indirect water heater.
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
(DHW Priority)
is set with the
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.
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
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;
10 - INSTALLATION - Vent and combustion air
10.1 - Removing
of a boiler from a
common venting
system
(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
WARNING!!!
main burner operation. Use the
flame of a match or candle, or
WARNING!!!
smoke from a cigarette, cigar or
DO NOT
pipe.
connect this boiler or any other
appliance using a positive
(f) Alter it has been determined
pressure, in a common vent
that each appliance remaining
system! Failure to comply with
connected to the common venting
this WARNING could result in
system properly vents when tested
the accumulation of carbon
as outlined above, return doors,
monoxide gas which can cause
windows, exhaust fans, fireplace
severe personal injury or
dampers and any other gasdeath!
burning appliance to their previous
condition of use.
When an existing boiler is removed
from a common venting system, the
(g) Any improper operation of the
common venting system is likely to
common venting system should
be too large for proper venting of
be corrected so the installation
the appliances remaining connected
conforms with the National Fuel
to it. At the time of removal of an
Gas Code, ANSI Z223.1 /NFPA 54
existing boiler, the following steps
and/or CAN/CSA B149.1, Natural
shall be followed with each appliance
Gas and Propane Installation
remaining connected to the common
Code. When resizing any portion
venting system placed in operation,
of the common venting system,
while the other appliances remaining
the common venting system
connected to the common venting
should be resized to approach
system are not in operation.
the minimum size as determined
using the appropriate Annex G of
(a) Seal any unused openings in the
the National Fuel Gas Code, ANSI
common venting system.
Z223.1 /NFPA 54 and/or CAN/CSA
B149. 1, Natural Gas and Propane
(b) Visually inspect the venting system
Installation Code.
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.
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
10.3 - Venting and
air piping systems
venting.
You must install air piping from
outside to the boiler air intake. The
resultant installation is Direct Vent
WARNING!!!
(sealed combustion).
WARNING!!!
The boiler is to be used for either
Install air inlet piping as described
The vent
Direct Vent installation or for
in this Section 10. You must pipe
installation must be in
installation using room combustion
combustion air to the boiler air intake.
accordance with part Venting
air. When room air is considered, see
Do not terminate vent/air in locations
of Appliances, of the latest
Section 10-10.
that can allow contamination of
edition of the National Fuel Gas
Vent and air must terminate near one
combustion air.
Code, ANSI Z223.1/NFPA 54 or
another and may be vented vertically
WARNING!!!
section, Venting Systems and
through the roof or out a side wall,
Air Supply for Appliances, of
WARNING!!!
unless otherwise specified. You may
Contaminate
the CAN/CSA B149.1, Natural
use any of the vent/air piping methods
combustion air will damage
Gas and Propane Installation
from Figure 10-1 to Figure 10-6. Do
the boiler, resulting in possible
code or applicable provisions
not attempt to install this boiler using
severe personal injury, death or
of the local building codes.
any other means.
substantial property damage.
Improper venting can result
WARNING!!!
in excessive levels of carbon
Ensure that the combustion air
monoxide which can result
WARNING!!!
DO NOT mix
will not contain any of the follow
in severe personal injury or
components from different
contaminants.
death!
systems. The vent system
could fail, causing leakage of
Products that may contaminated the
NOTICE! All vent pipes must
flue products into the living
air combustion:
be mechanically fixed, properly
space. Use only approved
- Permanent wave solutions;
supported, and the exhaust must
materials listed on Tables 10-1
- Chlorinated waxes/cleaners;
be pitched a minimum of a 1/4 inch
and 10-2. Improper materials
- Chlorine-based swimming pool
per foot back to the boiler (to allow
or mixing materials can result
chemicals;
drainage of condensate).
in excessive levels of carbon
- Calcium chloride used for thawing;
monoxide which can result
- Sodium chloride used for water
NOTICE! The vent system shall
in severe personal injury or
softening;
be installed so as to prevent the
death!
- Refrigerant leaks;
accumulation of condensate.
- Paint or varnish removers;
- Hydrochloric acid/muriatic acid;
NOTICE! Due to the high efficiency of Be sure to locate the boiler such that
- Cements and glues;
the boiler it may discharge what looks the vent and air piping can be routed
through the building and properly
- Antistatic fabric softeners used in
like white smoke especially when the
clothes dryers;
outside air temperature is cold. This is terminated.
- Chlorine-type bleaches, detergents, a simply water vapor, a purely natural The vent/air piping lengths, routing
and termination method must all
and cleaning solvents found in
phenomenon and not a reason for
comply with the methods and limits
household laundry rooms;
concern.
given in Section 10.4
- Adhesives used to fasten building
WARNING!!!
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.
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
33
10 - INSTALLATION - Vent and combustion air
Figure 10-2 Vertical two pipes Figure 10-3 Side wall air
(Direct Venting).
intake, vertical vent (Direct
venting).
Air
intake
Figure 10-1 Side wall two
pipes (Direct venting).
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 /
10.5 - Install vent
Maximum allowable and combustion air
combustion air and piping
WARNING!!!
vent piping lengths
WARNING!!!
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.
This
boiler must be vented and
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
personal injury or death.
WARNING!!!
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!!!
Never use
cellular (foam) core pipe in
vent pipe line and fittings.
Failure to comply could result
in severe personal injury,
death, or substantial property
damage.
WARNING!!!
WARNING!!!
Increasing or
decreasing combustion air or
vent piping is not authorized.
Failure to comply could result
in severe personal injury,
death, or substantial property
damage.
WARNING!!!
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
Vent pipe and fittings
Pipe cement/primer
Standard for installation
in USA
Material
PVC schedule 40, 80
ANSI/ASTM D1785
CPVC schedule 40/80
ANSI/ASTM F441
Polypropylene
ULC-S636
Stainless steel AL29-4C
UL1738
PVC
ANSI/ASTM D2564
CPVC
ANSI/ASTM F493
Standard for installation
in CANADA
ULC-S636
Table 10-1 Approved vent materials
Approved vent manufacturers and items
Item
Material
Manufacturer/supplier
Manufacturer/supplier
Part Number
Concentric roof or wall terminal
PVC
IPEX (System 636)
196006
Two pipes wall terminal
PVC
IPEX (System 636)
081219 or 196985
Single pipe wall terminal (90° elbow)
PVC
IPEX (System 636)
196025
Boiler adapter (80mm to 3” PVC)
Polypropylene
COSMOGAS
62617303
Bird screen
PVC
IPEX (System 636)
196051
Two pipes roof terminal
Polypropylene
Cosmogas
62617306 and 61302003
Two pipes wall terminal
Polypropylene
Cosmogas
61302004 and 61302003
Single pipe roof terminal
Polypropylene
Cosmogas
62617306
Single pipe wall terminal
Polypropylene
Cosmogas
61302004
Two or single pipe boiler adapter (80mm to Polypropylene
80mm Polypropylene)
Cosmogas
62617286
Bird screen
Polypropylene
Cosmogas
61302003
Concentric boiler adapter
Polypropylene
Cosmogas
62617224
Concentric roof terminal
Polypropylene
Cosmogas
62617304
Concentric wall terminal
Polypropylene
Cosmogas
62617232
Single pipe wall or roof terminal
Polypropylene
Centrotherm (Innoflue System)
ISEP0339
Two pipes wall or roof terminal
Polypropylene
Centrotherm (Innoflue System)
ISEP0339 and ISEL0387UV
Bird screen
Polypropylene
Centrotherm (Innoflue System)
IASPP03
Single pipe wall or roof terminal
Polypropylene
Duravent (PolyPro)
3PPS36B
Two pipes wall or roof terminal
Polypropylene
Duravent (PolyPro)
3PPS36B and 3PPS-E90B
Bird screen
Polypropylene
Duravent (PolyPro)
3PPS-BG
Single pipe wall or roof terminal
Stainless steel
Duravent (FasNSeal)
FSVL3603
Two pipes wall or roof terminal
Stainless steel
Duravent (FasNSeal)
FSVL3603 and FSELB8803
Boiler adapter (80mm to 3” stainless steel)
Stainless steel
Duravent (FasNSeal)
FSA-80MM3
Bird screen
Stainless steel
Duravent (FasNSeal)
FSBS3
Single pipe wall or roof terminal
Stainless steel
Heat Fab (SGV)
SGV03L36
Two pipes wall or roof terminal
Stainless steel
Heat Fab (SGV)
SGV03L36 and SGV03E90
Boiler adapter (80mm to 3” stainless steel)
Stainless steel
Heat Fab (SGV)
SGV03AD80
Bird screen
Stainless steel
Heat Fab (SGV)
SGV03TM
Table 10-2 Approved vent manufacturers and items
36
10 - INSTALLATION - Vent and combustion air
10.6 - Air inlet pipe
materials:
WARNING!!!
10.6.1 - Sealing of Type
“B” double-wall or
galvanized air inlet pipe
material
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
Sealing of Type “B” double-wall or
The air
galvanized air inlet pipe material used pipe manufacturer’s recommended
inlet pipe(s) must be sealed.
solvents and standard commercial
for air inlet piping on a sidewall or
Improper sealed can result
vertical rooftop Combustion Air Supply pipe cement for the material used.
in excessive levels of carbon
The PVC, CPVC, ABS Dryer Vent or
System:
monoxide which can result
Flex Duct air inlet pipe should use a
a. Seal all joints and seams of the air
in severe personal injury or
silicone sealant to ensure a proper
inlet pipe using either Aluminum
death!
seal at the appliance connection and
Foil Duct Tape meeting UL
the air inlet cap connection. Dryer
Standard 723 or 181A-P or a high
Choose acceptable combustion air
vent or Flex Duct should use a screw
quality UL Listed silicone sealant.
inlet pipe materials from the following
b. Do not install seams of vent pipe on type clamp to seal the pipe to the
list:
appliance air inlet and the air inlet
the bottom of horizontal runs.
- PVC, CPVC or ABS Dryer Vent
cap. Proper sealing of the air inlet
c. Secure all joints with a minimum
or Sealed Flexible Duct (not
pipe ensures that combustion air will
of three sheet metal screws or
recommended for rooftop air inlet)
be free of contaminants and supplied
pop rivets. Apply Aluminum Foil
- Galvanized steel vent pipe with joints
in proper volume.
Duct Tape or silicone sealant to
and seams sealed as specified in
When a sidewall or vertical rooftop
all screws or rivets installed in the
this section.
combustion air supply system is
pipe.
- Type “B” double-wall vent with joints
disconnected for any reason, the air
d. Ensure that the air inlet pipes are
and seams sealed as specified in
inlet pipe must be resealed to ensure
properly supported.
this section.
that combustion air will be free of
WARNING!!!
- AL29-4C, stainless steel material
contaminants and supplied in proper
to be sealed to specification of its
volume.
WARNING!!!
manufacturer.
Failure to
WARNING!!!
- Polypropylene material to be sealed
properly seal all joints and
to specification of its manufacturer.
seams as required in the air
WARNING!!!
Failure to
inlet piping may result in flue
properly
seal
all
joints
and
NOTICE! PVC, CPVC, ABS Dryer
gas recirculation, spillage
seams
as
required
in
the
air
Vent and stainless steel pipe may
of flue products and carbon
inlet
piping
may
result
in
flue
require an adapter (not provided)
monoxide emissions causing
gas
recirculation,
spillage
to transition between the air inlet
severe personal injury or
of flue products and carbon
connection on the appliance and the
death.
monoxide emissions causing
air inlet pipe
severe personal injury or
WARNING!!!
death.
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.
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
WARNING!!!
WARNING!!!
Use only
the materials listed in Tables
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
property damage.
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.
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
WARNING!!!
instructions supplied with the vent
This appliance
system.
requires a special venting
system. The field provided vent
NOTICE The installer must use a
fittings must be connected to
specific vent starter adapter at the
the boiler following Section
flue collar connection, supplied by the
10.7.1. Use only the vent
vent manufacturer to adapt to its vent
materials, primer, and cement
system. See Table 10-2 for approved
specified in this manual to make
vent adapters.
the vent connections. Failure to
follow this warning could result
in fire, personal injury, or death. 10.7.1 - Installing PVC/
WARNING!!!
WARNING!!!
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!
WARNING!!!
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
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.
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:
1. install boiler adapter “A” above
boiler. Rotate boiler adapter “A” so
as air intake and vent connections
are in the desired left or right side.
Check stamped arrow to understand
which is the vent and air intake
connection.
WARNING!!!
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!
10 - INSTALLATION - Vent and combustion air
and half clamp on the adapter “E”.
2. insert the clamp “D” into convertor
Tight the clamps with a tork of 1.5 - 2
“A” in the “C” side.
lbf ft (2-3 Nm).
3. insert the adapter “E” into connection 5. insert the clamp “F” into convertor
“C” of the convertor “A”;
“E”.
4. use the precedent clamp “D” to
6. insert the air inlet PVC/CPVC pipe,
mechanically secure the adapter “E”
for 2” into the adapter “E”;
to the adapter “A”. To do this tighten 7. use the precedent clamp “F” to
the half clamp on the adapter “A”
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:
1. install boiler adapter “A” above
boiler. Rotate boiler adapter “A” so
as air intake and vent connections
are in the desired left or right side.
Check stamped arrow to understand
which is the vent and air intake
connection.
WARNING!!!
WARNING!!!
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!
WARNING!!!
WARNING!!!
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
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!
Figure 10-8 PVC/CPVC Venting connection
39
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).
10 - INSTALLATION - Vent and combustion air
10.8 - Stainless
steel vent piping
materials
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!!!
This
appliance requires a special
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
injury, or death.
WARNING!!!
WARNING!!!
Improper
installation of Stainless steel
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).
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
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.
Figure 10-9 Stainless Steel Venting connection
40
10 - INSTALLATION - Vent and combustion air
10.8.1 - Stainless steel air Vent connection (Figure
intake/vent connections 10-9 item “A”) is used to provide
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.
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
connection.
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!!!
WARNING!!!
Use only
the materials listed in Tables
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
property damage.
WARNING!!!
WARNING!!!
This appliance
requires a special venting
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
injury, or death.
WARNING!!!
WARNING!!!
Improper
installation of Polypropylene
systems may result in injury or
death.
Figure 10-10 Polypropylene boiler adaptor
42
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.
10 - INSTALLATION - Vent and combustion air
10.9.1 - Polypropylene
two pipes air intake/vent
connections
systems. Figure 10-10 shows fitting
into hole “M” of boiler adapter “A”
“A” that can freely turn 360 degrees
3. Insert vent pipe “N” into boiler
for optimum installation versatility (see
adapter “A”
section 10.9.2 for P/N of “A” fitting).
4. Tight the two Band Clamps “O” to
mechanically secure vent pipe “N”
Combustion air piping and vent piping Tork screws “D” at 2 lbf ft (3 Nm).
to boiler adapter “A”. Tight band
must be supported per guidelines
Pipes or elbows connected directly
clamps with a tork of 1.5 - 2 lbf ft
listed in the National Mechanical
(2-3 Nm).
Code, Section 305, Table 305.4 or as to the boiler, must be mechanically
secure. Follow these instructions to
local codes dictate.
connect pipes to the boiler (make
The vent system must be both gas
reference to Figure 10-11):
tight and watertight. All seams and
The boiler is not supplied with the
joints must be joined and sealed in
fittings needed for separate vent and 1. Prepare the two collars “G” with
Band Clamps “E” and “F”;
accordance with the vent system
combustion air systems. A special kit
manufacturer’s instructions.
must be ordered to connect the boiler 2. Insert the end of Band Clamp “L”
WARNING!!!
to separate vent and combustion air
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!
Mechanically secure each joint
Figure 10-11 Polypropylene Venting connection
Figure 10-12 Connecting extensions and elbows
43
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).
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
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
(3 Nm)
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!
B = Connection flange
C = Fasten clip
D = Fasten clip screw
F = Coaxial vertical adaptor
Figure 10-14 Installation of the coaxial fitting
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
62617232
46
10 - INSTALLATION - Vent and combustion air
10.10 - Single pipe
vent (not sealed
combustion)
WARNING!!!
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.
WARNING!!!
WARNING!!!
Fire danger
due to flammable materials or
liquids. Do not store flammable
materials and liquids in the
immediate vicinity of the boiler.
WARNING!!!
WARNING!!!
Boiler
must be clear and free from
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
formation and build-up.
10.10.1 - Combustion Air
and Ventilation openings
WARNING!!!
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)
WARNING!!!
Where exhaust of the top and one commencing within
fans, clothes dryers, and kitchen 12 in. (300 mm) of the bottom, of the
ventilation systems interfere
room shall be provided. The openings
with the operation of appliances, shall communicate directly, or by ducts,
makeup air shall be provided.
with the outdoors or spaces that freely
WARNING!!!
communicate with the outdoors, as
NOTICE Installation must comply with
follows:
WARNING!!!
The
local requirements and with the National
1. Where directly communicating with the
equipment room MUST be
Fuel Gas Code, ANSI Z223.1 for U.S.
outdoors or where communicating to
provided with properly sized
installations or CSA B149.1 for Canadian
the outdoors through vertical ducts,
openings to assure adequate
installations.
each opening shall have a minimum
combustion air from outside.
free area of 1 in2 each 4000 Btu/hr
Failure to comply could result in
For installation in Canada, vent pipe
(550 mm2/kW) of total input rating of
severe personal injury, death, or
system must be certified to ULC-S636 (see
all appliances located in the room.
substantial property damage.
Table 10-1).
2. Where communicating with the
outdoors through horizontal ducts,
• There will be a noticeable increase
NOTICE All vent pipes connections
each opening shall have a minimum
in the noise level during normal
must be secured following manufacturer
free area of 1 in2 each 2000 Btu/hr
operation from the inlet air opening. instruction, properly supported, and the
(1100 mm2/kW) of total input rating of
• Vent system and terminations must
exhaust must be pitched a minimum of a
all appliances located in the room.
comply with the venting instructions 1/4 inch per foot back to the boiler (to allow
set forth in sections 10.1, 10.2,
drainage of condensate).
One Permanent Opening Method. One
10.3, 10.4, 10.5, 10.7, 10.8 and
permanent opening, commencing within
10.9.
12 in. (300 mm) of the top of the room,
WARNING!!!
shall be provided. The appliances shall
have clearances of at least 1 in. (25 mm)
WARNING!!!
Use only the
from the sides and back and 6 in. (150
materials, vent systems, and
mm) from the front of the appliance.
terminations listed in Tables
The opening shall directIy communicate
10-1 and 10-2. DO NOT mix vent
with the outdoors or shall communicate
systems of different types or
through a vertical or horizontal duct
manufacturers, unless listed in
to the outdoors or spaces that freely
this manual. Failure to comply
communicate with the outdoors and shall
could result in severe personal
have a minimum free area of 1 in2 each
injury, death, or substantial
3000 Btu/hr (700 mm2 /kW) of the total
property damage.
input rating of all appliances located in
the room
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
must be followed.
WARNING!!!
47
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
5. Maintain clearances as shown in
where wind eddies could affect
Figure 10-11 (get references to
performance or cause recirculation,
“Mechanical draft vent terminal”
such as inside building corners,
only). Also maintain the following:
near adjacent buildings or surfaces,
a. Vent must terminate:
window wells, stairwells, alcoves,
• At least 6 feet from adjacent walls.
courtyards, or other recessed
• No closer than 12 inches below
areas.
roof overhang.
f. Do not terminate above any door or
• At least 7 feet above any public
window. Condensate can freeze,
walkway.
causing ice formations.
• At least 3 feet above any forced
g. Locate or guard vent to prevent
air intake within 10 feet.
condensate damage to exterior
• No closer than 4 feet below or
finishes.
horizontally from any door or
4. The vent piping must terminate in an
window or any other gravity air
elbow pointed outward as shown in
inlet.
Figure 10-12 or 10.13.
b. Do not terminate closer than 4
WARNING!!!
feet horizontally from any electric
meter, gas meter, regulator, relief
WARNING!!!
valve, or other equipment. Never
Do not
terminate above or below any of
exceed the maximum lengths
these within 4 feet horizontally.Item
of the outside vent piping
unique to CANADA: vent system
shown in Figures 10-12 or 10-13.
shall terminate at least 6 ft from
Excessive length exposed to the
electrical and gas meters.
outside could cause freezing
6. Locate termination so it is not likely to
of condensate in the vent pipe,
be damaged by foreign objects, such as
resulting in potential boiler
stones or balls, or subject to buildup of
shutdown.
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
10.11.2 - 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
10.11.1 - Vent/air
in the Section 10.4.
2.
You
must consider the surroundings
termination
when terminating the vent and air:
WARNING!!!
a. Position the vent termination
WARNING!!!
where vapors will not damage
A gas vent
nearby shrubs, plants or air
extending through an exterior
conditioning equipment or be
wall shall not terminate
objectionable.
adjacent to a wall or below
b. The flue products will form
building extensions such as
a noticeable plume as they
eaves, parapets, balconies, or
condense in cold air. Avoid areas
decks. Failure to comply could
where the plume could obstruct
result in severe personal injury,
window views.
death, or substantial property
c. Prevailing winds could cause
damage.
freezing of condensate and
WARNING!!!
water/ice buildup where flue
products impinge on building
WARNING!!!
Do not
surfaces or plants.
connect any other appliance
d. Avoid possibility of accidental
to the vent pipe or multiple
contact of flue products with
boilers to a common vent
people or animals.
pipe. Failure to comply could
e. Do not locate the terminations
result in severe personal injury,
where wind eddies could
death, or substantial property
affect performance or cause
damage.
recirculation, such as inside
building corners, near adjacent
NOTICE Installation must comply
buildings or surfaces, window
with local requirements and with the
wells, stairwells, alcoves,
National Fuel Gas Code, ANSI Z223.1
courtyards, or other recessed
for U.S. installations or CSA B149.1
areas.
for Canadian installations.
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
Flu
Air
ee
xha
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
Figures 10-17 and 10-18.
inta
ke
ust
WARNING!!!
WARNING!!!
Do not
exceed the maximum lengths
of the outside vent piping
shown in Figures 10-17 and 1018. Excessive length exposed
to the outside could cause
freezing of condensate in the
vent pipe, resulting in potential
boiler shutdown.
Termination
template
Bird screen
w
no
/S
de
el
lev
a
Gr
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 10-17 Two pipes sidewall termination
of air and vent
Air
Flu
inta
ee
ke
xha
ust
Bird screen
n
e/S
ad
Gr
ow
el
lev
Figure 10-18 Two pipes sidewall termination of
air and vent (if space permits)
50
10 - INSTALLATION - Vent and combustion air
10.11.3 - Prepare wall
penetrations
Flu
ee
Air
xha
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.
inta
ke
ust
Metal thimble
Termination
template
Bird screen
10.11.4 - Termination and
fittings
Figure 10-19 Two pipes sidewall termination
assembly
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.
Vent terminals
10.11.5 - Multiple vent/air
terminations
1. When terminating multiple boilers terminate
each vent/air connection as shown in Figure
10-20.
WARNING!!!
WARNING!!!
Air intake
All vent pipes and air
inlets must terminate at the same height
to avoid possibility of severe personal
injury, death, or substantial property
damage.
between edge
of each air
intake pipe
Same distance
for vent
terminal
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.
NOTE: keep the air intake at min. 12” from grade or
snow line. Provide vent and air intake with bird screen
Figure 10-20 Two pipes multiple boilers vent
terminations
51
10 - INSTALLATION - Vent and combustion air
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
r
go
n
rha
e
Ov
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.
f
roo
Vent
Combustion air
intake
e/
ad
Gr
w
o
sn
e
lin
NOTICE Ensure termination location
clearance dimensions are as shown in
Figure 10-21.
Figure 10-21 Concentric sidewall
termination clearances
52
10 - INSTALLATION - Vent and combustion air
10.12.3 - Multiventing
sidewall terminations
CAUTION!!! DO NOT use fieldsupplied couplings to extend
pipes. Airflow restriction
will occur and may cause
intermittent operation.
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.
6. Operate the appliance one (1) heat
cycle to ensure combustion air and
vent pipes are properly connected
to the concentric vent termination
connections.
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
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
Vent
10 - INSTALLATION - Vent and combustion air
10.13 - Vertical
termination - Two
pipes
10.13.1 - Determine
location
Locate the vent/air terminations using
the following guidelines:
1. The total length of piping for vent or
WARNING!!!
air must not exceed the limits given
in the Section 10-4.
WARNING!!!
Follow
2. The vent must terminate at least
instructions below when
3 feet above the highest place in
determining vent location to
which the vent penetrates the roof
avoid possibility of severe
and at least 2 feet above any part
personal injury, death or
of a building within 10 horizontal
substantial property damage.
feet.
WARNING!!!
3. The air piping must terminate in a
down-turned 180° return pipe no
WARNING!!!
Do not
further than 2 feet from the center
connect any oher appliance
of the vent pipe. This placement
to the vent pipe or multiple
avoids recirculation of flue products
boilers to a common vent
into the combustion air stream.
pipe. Failure to comply could
4. The vent piping must terminate at
result in severe personal injury,
least 1 foot above the air intake.
death, or substantial property
The air inlet pipe and vent pipe can
damage.
be located in any desired position
on the roof, but must always be no
Installation must comply with local
further than 2 feet apart and with
requirements and with the National
the vent termination at least 1 foot
Fuel Gas Code, ANSI Z223.1 for
above the air intake.
U.S. installations or CSA B149.1 for
5. Locate terminations so they are
Canadian installations.
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
above roof or
snow line
Figure 10-23 Two pipes vertical terminations
of air and vent
54
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.
10 - INSTALLATION - Vent and combustion air
10.13.4 - Multiple vent/air
terminations
Air intake
Vent
Air intake
Vent
vertically from
vent outlet to
any air inlet
from edge of
air intake pipe
to adjacent
vent pipe from
another boiler
NOTE: keep the terminals at min. 12” from grade or
snow line. Provide vent and air intake with bird screen.
Figure 10-24 Two pipes Multiple boilers vertical
terminations
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
1. When terminating multiple boilers,
terminate each vent/air connection
as shown in Figures 10-24 and 1025.
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.
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.
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.
Vent
Combustion
Air
(18” for Canada)
Minimum
clearance above
highest anticipated
snow level.
Maximum of 24”
above roof.
Roof boot /
flashing
(field supplied)
Vent
Support
(field supplied)
Combustion
Air
Vent
Combustion
air intake
Combustion
Air
Minimum clearance above snow
level (18” for Canada) Maximum
24” above roof or snow level)
Figure 10-26 Concentric vertical termination
56
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
individually vented (see Figure 10-27).
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
10.14.5 - Alternate vertical
concentric venting
Flue exhaust
Combustion
air intake
Combustion
air inlet with
screen
This appliance may be installed with a concentric
vent arrangement where the vent pipe is routed
through an existing unused venting system; or by
using the existing unused venting system as a
chase for vent and combustion air routing.
Concentric Venting Arrangement
The venting is to be vertical through the roof.
The annular space between the O.D. of the vent
pipe and the I.D. of the existing unused venting
system is utilized for the combustion air source.
The minimum size of the existing vent system
required to achieve enough annular space for
combustion air is 7 inches.
The upper and lower termination as well as any
other unsealed joints in the existing vent system
must be sealed to ensure that all combustion air
is drawn from under the vent cap as shown in
Figures 10-28 and 10-29.
Existing
Sealed
cap
Seal
Flue
outlet
Seal
Combustion
air intake
Flue exhaust
Combustion
air intake
Combustion
air inlet with
screen
Seal
Existing
Figure 10-28 Alternate concentric
vertical venting (Example n°2)
Seal
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.
Sealed
cap
Flue outlet
Figure 10-29 Alternate concentric
vertical venting (Example n°1)
58
10 - INSTALLATION - Vent and combustion air
10.15 - Existing
vent as a chase
Follow all existing termination and
clearance requirements of section 1013.
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
11.1 - Gas supply
piping
WARNING!!!
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!
INSTAL MANUAL SHUT-OFF
VALVE 5 FT (1.5m) ABOVE
FLOOR WHERE REQUIRED BY
LOCAL CODES
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
the boiler or its accessories.
WARNING!!!
GROUND JOINT UNION
TO BOILER
SEDIMENT TRAP OR DRIP LEG
Figure 11-1 Gas supply
piping
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
11-1
11-2
60
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
before placing it in operation.
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!
6. Use pipe sealing compound
compatible with propane gas. Apply
sparingly only to male threads of the
pipe joints so that pipe dope does
not block gas flow.
WARNING!!!
WARNING!!!
Failure to
apply pipe sealing compound
can result in severe personal
injury, death, or substantial
property damage.
WARNING!!!
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 - INSTALLATION - Gas supply
11.2 - Pipe sizing for 11.4 - Check inlet
natural gas
gas supply
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.
11.3 - Propane Gas
WARNING!!!
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
(verify during high fire).
WARNING!!!
WARNING!!!
Ensure that
the high gas pressure regulator
is at least 6 - 10 ft upstream of
the appliance.
WARNING!!!
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.
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
the gas valve will be damaged!
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
11.5 - 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).
11 - INSTALLATION - Gas supply
11.6 - Convert the
boiler from Natural
Gas to Propane gas
or viceversa
WARNING!!!
stamping on the orifice matches the
gas type (See Table 11-3).
- 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;
WARNING!!!
The gas
conversion shall be performed
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
specified in this instructions.
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
WARNING!!!
WARNING!!!
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
occur.
WARNING!!!
WARNING!!!
The CO
(carbon monoxide) level should
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
substantial property damage.
and
to:
- 61 to convert the boiler from LP
GAS to NATURAL GAS
or
- 62 to convert the boiler from
NATURAL GAS to LP GAS,
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.
8 - push
new value;
WARNING!!!
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.
button to save the
9 - turn off power to the boiler;
Contents:
10 - Move switch #7 (see Figure 9-2)
The conversion kit (supplied with the
from ON position to OFF position;
boiler) is composed of the following
elements, which are necessary for the
11 - Replace the orifice item “C” of
gas change:
Figure 11-2 for the correct one for
- a label rating the new gas setting;
the type of gas used. Verify that the
Gas Type
TY value
setting
Min.
supply
pressure
Max.
supply
pressure
Orifice
CO2
content at
high fire
CO2
content at
low fire
O2
content at
high fire
O2 content
at low fire
CO content at
high and low fire
/
/
in.W.C.
in.W.C.
Stamping
%
%
%
%
ppm
Natural gas
61
3
13
9.1
9.2 ± 0.1
8.7 ± 0.3
4.5 ± 0.1
5.4 ± 0.3
less than 150
LP gas
62
3
13
5.7
9.5 ± 0.2
9.5 ± 0.3
6.4 ± 0.2
6.4 ± 0.3
less than 250
Table 11-3 Settings of the boiler for NATURAL GAS and LP GAS
62
11 - INSTALLATION - Gas supply
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 = Fixing nut
B = Gasket
C = Orifice
D = Brass fitting
E = CO2 / O2 regulator
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 11-4 Label for LP gas boiler
Figure 11-3 Label for Natural gas boiler
63
12 - START-UP
12.1 - Operating
Make sure that the user
12.1.1 - User instructions
Make sure that the user knows
Before starting the boiler, the following
must be done.
The user must be correctly instructed
by the installer, on how to operate the
boiler, in particular:
Make sure that the user
understands that combustion air
and ventilation openings must not be
restricted/closed/ or mdified in any
way.
understands never to tamper
with gas control settings and the
risk of CO poisoning should an
unauthorized individual do so.
how to adjust temperatures,
controls and the room thermostats
for maximum efficiency.
12.1.2 - Filling the
condensate trap
The condensate trap is positioned
inside the boiler as shown in Figure
Make sure that the user is informed 3-1, item “46”. It must be filled with
water to prevent the leakage of flue
of all the special measures to be
gases from the condensate drainpipe,
taken for combustion air inlet and
item “41” in Figure 3-1. To fill the
discharging flue gases, and that
condensate trap proceed as follows:
these must not be modified in any
1. unscrew “E” screw (Figure 12-1);
way.
flange “D” and O-Rings “C”
Make sure that the user keeps this 2. remove
(Figure 12-1);
manual and all other documentation
included with the boiler.
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!!!
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 12.1.5 – Auto-purging the
chemical substances, such as
anti-freeze, must be carried
out according to the product
instructions.
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
To fill the heating system, proceed as process involves the turning the pump
on and off in order to remove any air
follows:
1. open the automatic air vent, shown trapped in the heating system. Before
as item “1” in Figure 3-1, two turns; starting the auto-purging cycle the
2. open the fill valve located under the automatic air vent, item “1” shown in
boiler and proceed to fill the heating Figure 3-1 must be opened.
system and boiler until the pressure
gauge, item “13” in Figure 13-1,
12.1.6 – Delay to light-on
reads 20 psi (1.5 bar) and “FILL”
Each time the on/off power switch,
disappears from the display;
item “12” in Figure 13-1, is switched
3. check that there is no water leaking on, a delay timing sequence of 3
from the fittings. If there is, the
minutes begin.
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).
12.1.4 - 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
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
12.6 - Ignition
control testing
If the gas available at the installation
site is not the type the boiler is
configured to use, the boiler must be
That the gas supply system is
converted. Special conversion kits are
provided with all the safety devices available for this purpose inside the
and controls required under current boiler. Follow instruction on Section
national and local codes.
11.6.
WARNING!!!
That the vent and combustion
air terminals are free from any
WARNING!!!
blockages.
Conversion
of the boiler to use another
That the condensate drain tube is
type of gas must be carried
properly connected.
out by a qualified technician.
WARNING!!!
Improper conversion of the
WARNING!!!
boiler could result in a fire or
an explosion causing severe
If you smell gas:
personal injury or death!
 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
1. Open the manual gas shut off valve
supplier from a neighbor’s
(Figure 11-1),.
phone. Follow the gas
2. Switch the on/off power switch, item
supplier’s instructions.
“12” in Figure 13-1, to “on”.
 If you cannot reach your gas
3. Upon start-up, an
is shown for
supplier, call the fire depart3
minutes
while
the
boiler
goes
ment.
through
its
heating
system
purge
Failure to follow the above steps
cycle. To by-pass this stage, press
can result in a fire or explosion
causing property damage, personal
the
and
keys together
injury or loss of life!
until a blinking
appears.
type of fuel that it is configured to
use. Read Sections 11.
12.5 - Start-up of
the boiler
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).
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.
66
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
must be zero.
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!
12 - START-UP
12.7 - Gas supply
pressure checking
WARNING!!!
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.
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;
and
keys
8. press the
at the same time for more than
10 seconds, the display will show
;
9. press the
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
key until the
. Now the
display shows
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).
If the gas supply pressure does not
fall within 3 and 13 in.W.C. adjust the
67
upstream gas pressure regulator to
bring the gas supply pressure within
the above values.
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.
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
the gas valve will be damaged!
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!
12 - START-UP
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:
Figure 12-4 Combustion air pressure probes
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
is displayed;
than 10 seconds, until a blinking
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
68
12 - START-UP
12.9 - Checking and
adjusting CO2 levels
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
Table 11-3 lists the correct CO2 ranges
“E” screw of Figure 12-3. Use a
for a boiler running at normal operating
2.5mm Allen Wrench to turn the
conditions at an altitude below 2000
screw (clockwise to reduce the CO2
ft (600m). CO2 values outside of the
level, counter-clockwise to increase
ranges given in Table 11-3 may lead to
the CO2 level) in small increments
malfunctioning of the boiler and cause
and wait for the CO2 to stabilize to
it to prematurely fail. To check the CO2
prevent overshooting the desired
value, carry out a combustion analysis
value;
as follows while referencing Figure 12-6:
9.
When
CO2 level match the value of
WARNING!!!
Table 11-3, seal screw “E” with red
WARNING!!!
paint or nail polish to discourage
During this
tampering.
procedure compare also CO
(carbon monoxide) reading, with 10. press the
key until the
the value given in Table 11-3. If
if a call for heat
display shows
this is higher, STOP the boiler
and call the Factory service
has been generated or until
department (see phone number
is
displayed if a domestic hot water
on the last cover page). Failure
demand
has been generated. The
to comply with this requirement
boiler
will
now run for 10 minutes at
could result in severe personal
low fire input;
injury, death or substantial
11. wait 2 to 3 minutes for the CO2 to
property damage.
stabilize;
12.
compare the CO2 reading with the
NOTE: During the 10 minutes
low fire range given in Table 11-3,
override mode, if the demand on
making sure to use the range for the
the boiler is low causing the flue
gas type in use. The CO2 reading
gas temperature to increase rapidly,
must be inside the specified range;
boiler will go into lock out code L06.
If not, STOP the boiler and call the
Factory service department (see
To reactivate it, press
button.
phone number on the last cover
page).
1. carefully remove items “E”, “D” and
“C” from the combustion air/ vent
13. press the
button to return the
fitting:
boiler
to
its
normal
operating mode.
2. generate a call for heat; and wait up
14.
close
flue
and
air
probe
“A” and “B”
the boiler is light-on;
of Figure 12-6.
4. press the
and
keys for 15. turn knob “7” and “11” of Figure
13-1 to the OFF position.
more than 10 seconds, the display
will show a blinking
5. press the
shows
A = air probe
B = flue exhaust probe
C = O-ring gaskets
D = cap
E = fixing screw
Figure 12-6 Combustion
analysis probes
;
key until the display
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,
69
12 - START-UP
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
“P” parameter
value
value.
Correspondent
heat input
(btu/hr)
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
70
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,
to indicate that it
shows
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
several times during the first month of
operations to remove any air bubbles
present.
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 131) 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
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).
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.
button in order to
Press the
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.
72
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).
13 - USE
13.7 - Adjusting the 13.9 - Heating
domestic hot water system type
temperature
selection
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
13-1, 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.
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
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
The boiler provides hot water to the
is required):
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. While in the “Installers’ Menu”, set the
To maximize the boilers’ performance,
parameter to 01. In this mode
temperature knob “7”, should be set at
a value that is just sufficient to maintain the heating supply water temperature,
the desired temperature of the rooms. As calculated temperature in Figures 13-2
the weather gets colder, progressively and 13-3, will be adjusted automatically
increase the water temperature by based on the input from the outdoor
adjusting knob “7”. When the weather temperature sensor. The relationship
gets milder turn the water temperature between the outdoor temperature
down. This extremely simple method and the supply water temperature,
is suitable for the following types of corresponds with the graphs shown
in Figures 13-2 and 13-3. In order to
systems:
A - small systems with radiators where change the relationship between the
the thermostat is installed in a room supply water temperature and the
whose temperature is characteristic outdoor temperature, all the parameters
listed in the sections below must be set.
of all the other rooms;
B - large systems with radiators, where
each zone is controlled by its own 13.10.1 - Outdoor reset
room thermostat. Where zone valves
are used the boiler pump is shutdown applications
only when all the room thermostats Outdoor reset is a sophisticated way to
maximize comfort and boiler efficiency.
are satisfied.
C - large systems with low temperature It is suitable for the following system
radiant panels , where each zone is types:
controlled by its own room thermostat. A - small systems, with radiators where
the thermostat is installed in a room
Where zone valves are used the boiler
whose temperature is characteristic
pump is shutdown only when all the
of all the other rooms. The room
room thermostats are satisfied.
thermostat is used to turn the boiler
13.8 - Heating
system temperature
adjustment
13.10 - Outdoor
reset adjustment
73
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).
13 - USE
13.10.3 - Outdoor reset: 13.10.4 - Outdoor reset:
setting parameters
zone adjustments
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;
= “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:
-
= 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.
74
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,
, to obtain
adjust the parameter
a calculated temperature of 176 °F (80
°C) for the typical design outside winter
temperature, see Figure 13-2.
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.
13 - USE
13.10.6 – Outdoor reset
with room compensation
While in the “Installers’ Menu” (section
parameter to 02.
13.17) set the
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.
Calculated temperature (°F)
parameter can range
The
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
Outside temperature (°F)
Calculated temperature (°F)
Figure 13-2 - Graph of the outdoor reset adjustment
(influence of parameters “br”, “OA”, “Ob” and “Oc”)
Outside temperature (°F)
Figure 13-3 - Graphs of the outdoor reset adjustment
(influence of parameter “b”)
75
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.
OA = Slope of the line
Ob = Minimum heating
temperature
Oc = Maximum heating
temperature
br = “Fix point” of the angle
fulcrum of the line
b = parallel shift of the line
(adjusted by the heating
knob, item “7” of 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.
SWITCH
1
2
3
4
5
6
7
8
Position
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
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.
Description
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.
76
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.
13 - USE
13.15 - Display
in energy saving
mode
If desired, the display, item “1” and
“2” in Figure 13-1, can be switched
permanently off, with the exception
of when it displays errors or settings.
To switch the display off, access the
“Installers’ Menu”, in section 13.17
and set the
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.
PARAMETER
DESCRIPTION
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;
to save the parameter
4. press
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
button
2. press and release the
button, will be lost.
using the
several times until the desired
parameter is displayed;
The table below lists each “Users’
menu” parameter, what it affects and
3. use the
or
keys, to
its adjustment range.
change the value of the selected
parameter;
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.
Setting range: 0,1 to 5,0
Adjustment of the “Minimum heating
temperature” as shown in Figure 13-2 when
outdoor reset is active per section 13.9.
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.
Setting range: see section 13.10.3
Adjustment of the parallel shift of the curve as
shown in Figure 13-3 when outdoor reset is
active per section 13.9.
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).
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.
Temperature display only, with a range between 68
°F (20 °C) and 189 °F (87 °C).
Display of the domestic hot water temperature
when set by knob “11” shown in Figure 13-1.
Display of last error code registered, Section
13.18.2
Temperature display only with a range between 104
°F (40 °C) and 158 °F (70 °C), see section 13.7.
Error code display per section 13.18.2
Lockout code per section 13.18.1
Display of last lockout occurred, Section
13.18.1
77
13 - USE
13.17 - “Installer’s
menu”
button
1. press and hold the
down for 12 seconds until the
parameter is displayed;
CAUTION!!! Changing these
button
2. press and release the
parameters could cause the
to scroll through the list of the
boiler and therefore the system
parameters;
to malfunction. For this reason,
3. once the parameter has been
only a qualified technician who
displayed, it can be changed using
has in-depth knowledge of the
boiler should change them.
the
or
keys;
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):
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.
4. press and release the
button
to confirm the amended data before
moving to the next parameter.
When the last parameter has been
reached and the
button
pressed, the display will stop blinking
indicating the exit from the menu.
DESCRIPTION
INFORMATION ON DISPLAY ITEM “2” OF FIGURE 13-1
Boiler temperature, measured by U1
sensor
Value in °F (cannot be changed)
DHW temperature, measured by U2
sensor
Value in °F (cannot be changed)
Domestic cold water (or ind. water heater)
temperature , measured by U3 sensor
Value in °F (cannot be changed)
Outdoor temperature, measured by U4
sensor
Value in °F (cannot be changed) (displayed only if outdoor reset is
active, as per section 13.9)
Ionization current value
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
Value in °F (cannot be changed)
Flue gas temperature, measured by U7
sensor
Value in °F (cannot be changed)
Heating return temperature, measured
by U8 sensor
Value in °F (cannot be changed)
Type of basic setting of control board
Can be changed in accordance with Section 11.6
Status of room thermostat contact
00 = contact open (heating service off)
01 = contact closed (heating service on)
Measurement of fan speed rotation
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
13 - USE
Continued
PARAMETER
DESCRIPTION
INFORMATION ON DISPLAY ITEM “2” OF FIGURE 13-1
Heating service functioning mode
Can be changed (see Section 13.9):
00 = thermostatic adjustment;
01 = outdoor reset;
02 = outdoor reset with room compensation;
Reaction to external temperature
Keep always at value of 1
Angle fulcrum of climatic adjustment
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.
Reduction of temperature generated by
the opening of the room thermostat
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.
Boiler knobs’ status
Can be changed:
01 = knobs presents;
00 = knobs absent.
Display “1” and “2” as per figure 13-1
energy saver
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
Must be maintained at 20 value
Integral of the heating PID modulation
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
Can be changed between 1 and 54. Default value is 18 (180 sec).
Can be modified only in conjunction with factory technicians.
Indirect water heater priority selection:
Value expressed in minutes.
Can be changed between 00 (function disabled) and 99 minutes.
Default value is 00 (See also section 9.1.1).
79
13 - USE
13.18 Diagnostics
During the normal operation of the
boiler, the display, of Figure 13-1,
continually shows the operating
status of the boiler as shown below
(see also section 17):
PARAMETER
PARAMETER REFERENCE
DISPLAY READ OUT (ITEM “2”, FIGURE 13-1)
Boiler in stand-by mode or pause (no request for heating or
domestic hot water)
Boiler temperature (°F)
Anti-freeze function active
Boiler temperature (°F)
Boiler not in lock-out mode but in Attention mode.
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
System pressure too low, system must be filled. See section 13.1.
No display
Domestic hot water service active
Domestic hot water temperature (°F)
Heating service active
Heating temperature (°F)
Boiler in lock-out mode. To reset it, press the
button. If
the lock-out occurs frequently, contact a professionally qualified
technician.
Lock-out code (see section 13.18.1 for
decodification).
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).
Boiler in Anti-legionella functioning (see section 13.12)
80
Error code (see section 13.18.2 for
decodification).
Boiler temperature (°F)
Storage tank temperature (°F)
13 - USE
13.18.1 - Diagnostics: “L” lock-outs
Lock-out
“L”
Code description
Checks to make
Solutions
L01
No flame detected after
three ignition attempts.
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.
L02
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.
L03
Boiler temperature is over
203° F (95°C).
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.
L04
a-Check that the circulator pump is
working;
b-Check if the water flow is not less than
5 GPM
Gas valve command relay
Replace the power control board
L05
Safety relay
Check for correct polarity of the wires to
the pump. Try to switch the wires.
L06
Flue gas sensor over
210°F (99°C)
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%
L07
Electrical circuit of flue
gas sensor is interrupted
Check that the electrical resistance of
If the sensor resistance does not correspond with the correct
the flue gas sensor corresponds with the values, replace it;
graph in section 14.13;
L08
L09
L10
L12
L13
L14
L15
L16
Spark generator relay
Replace the power control board
RAM memory
Replace the power control board
E2prom memory damaged
Replace the power control board
E2prom memory damaged
Replace the power control board
Program error
Replace the power control board
Program error
Replace the power control board
Program error
Replace the power control board
L17
Program error
The temperature
difference between the
U1 and U6 sensors is too
great
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
Replace the power control board
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.
81
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.
13 - USE
13.18.1 - Diagnostics: “L” lock-outs (continued)
Lock-out
“L”
Code description
Solutions
Controls
L18
Program error
Replace the power control board
L19
Flame sensed for 10
seconds, after the closure
of the gas valve
Call technical service
L20
Flame sensed before
opening of the gas valve.
Call technical service
L21
Boiler in blocking state for
more than 20 hours
L25
U1 or U6 sensor increase
its temperature too fast
L32
Program error
L33
Fan rotation error
L45
Heating circuit filling time
longer than 10 minutes.
L46
Filling of heating circuit
repeated 16 times in 24
hours
Flue pressure switch
open time longer than 60
minutes
L47
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.
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 a -If the heating pressure switch is not correctly set, it must be
the pressure drops below 8.7 psi
replaced;
(0,6 bar), and disappears when the
b - if the system has a leak, it must be fixed.
pressure rises above 22 psi (1.5
bar);
b - check that there are no water leaks
in the heating system.
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.
82
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
13 - USE
13.18.2 - Diagnostics: “E” blocking errors
Blocking
“E”
Code description
E01
E02
E04
E07
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
Check that the electrical resistance of
U2 domestic hot water
temperature sensor circuit the sensor corresponds with the graph in
section 14.13;
interrupted.
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
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
Check that the electrical resistance of
U3 cold water or indirect
water heater sensor circuit the sensor corresponds with the graph in
section 14.13;
interrupted
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
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
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
Check that the electrical resistance of
U2 domestic hot water
temperature sensor circuit the sensor corresponds with the graph in
section 14.13;
short-circuited
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
U8 return temperature
sensor circuit interrupted
U6 boiler temperature
sensor circuit interrupted.
E11
U1 boiler temperature
sensor circuit shortcircuited.
E13
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
U1 boiler temperature
sensor circuit interrupted.
E08
E12
Checks to make
83
13 - USE
13.18.2 - Diagnostics: “E” blocking errors (continued)
Blocking
“E”
Code description
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
E14
U8 return temperature
sensor short-circuited
E15
U4 outside sensor shortcircuited
E16
Erroneous temperature
reading.
E17
U3 cold water temperature
or indirect water heater
temperature sensor circuit
shorted
E18
U6 boiler temperature
sensor circuit shorted
E19
E2prom memory damaged
Replace the command and control board
E20
Flame presence with gas
valve closed
Replace the gas valve
E21
Phase and neutral inverted Invert phase and neutral
If phase and neutral are correctly wired, replace the power and
control board
E22
Electrical supply frequency Check the electrical frequency of the
system.
other than 60Hz
Check if CS parameter is at 03 (see
section 17)
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.
E23
Ground connection is
absent
if the boiler is properly grounded, replace the power control
board
E30
Erroneous temperature
reading.
Replace the power control board
E31
Erroneous temperature
reading.
Replace the power control board
E32
Erroneous temperature
reading.
Replace the power control board
E33
Erroneous temperature
reading.
Replace the power control board
E42
Program error
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
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
Check if the boiler is properly grounded
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
Move ON switches 7 an set again the
correct tY value (see section 17)
If tY value is correct, change the power control board
E50
Error in the boiler tY
parameter selection
E51
Reset button pressed too
often in a short period time
E52
Heating flow switch
closed
Check if the heating pump is running.
Check if the flow switch contact is stuck
The pump should not run and the contanct should open
The contact must be open
E53
Heating flow switch
open
Check if the heating pump is running.
Check if the flow switch contact is
broken
The pump should run and the contact should closed
The contact must be closed
84
14 - MAINTENANCE
14.1 - Care and
maintenance
A trained and qualified service technician
should perform the inspection listed in these
instructions before each heating season and
This section must be brought to the attention at regular intervals.
WARNING!!!
of the user by the installer so that the user
can make the necessary arrangements with
WARNING!!!
Servicing,
a qualified service agency for the periodic
inspection and adjustment must
care and maintenance of the boiler. User
be done by a trained technician
must check its boiler follow Table 14-1
in accordance with all applicable
column “User maintenance”.
local and national codes. Improper
The installer must also inform the user that
servicing or adjustment could
the lack of proper care and maintenance of
damage the boiler! Failure to
this boiler and any fuel burning equipment
comply with this warning can
may result in a hazardous condition.
result in a fire or explosion
Installer should discuss contents of the
causing property damage,
Section 13 (User’s section) with the user.
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
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)
User maintenance
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:
- Shut boiler down (unless boiler used for domestic
hot water) (Follow section 14.1.18);
Table 14-1 - Service and Maintenance Schedules
85
14 - MAINTENANCE
WARNING!!!
3. Check for gas leaks: using soap
14.1.6 - Check ignition and
solution, check for gas leaks from
Never
meter to boiler including all pipes and flame sense electrodes
obstruct the flow of combustion
1. Remove the fan-burner assembly
fittings and boier connections. Use
and ventilation air. Failure to
unit (see section 14.3)
liquid soap solution for all gas testing.
provide adequate combustion
2. Remove any deposits accumulated
WARNING!!!
air for this boiler can result
on the ignition/flame sense electrode
in excessive levels of carbon
WARNING!!!
using sand paper.
Do not
monoxide which can result in
3. Check electrodes positioning meet
check for gas leaks with an
severe personal injury or death!
Section 14.4
open flame. Use the bubble
WARNING!!!
test. Failure to use the bubble
WARNING!!!
14.1.7 - Check wiring and
test or check for gas leaks
If
with an open flame can cause
connections
maintenance is performed on
explosion,
severe
personal
Inspect all boiler wiring, making
the vent-air intake system it
injury, death, or substantial
sure wires are in good condition and
must be properly reassembled
property damage.
securely attached.
and sealed. Failure to properly
maintain the vent-air system
14.1.3 - Verify flue and air 14.1.8 - Perform
can result in excessive levels
of carbon monoxide which can lines in good condition
performance verification.
result in severe personal injury and sealed tight;
1. Start boiler and perform a
or death!
1. Check for obstruction, condensation,
combustion test as per section 12.9.
WARNING!!!
corrosion and physical damage,
2. Verify cold fill pressure is correct and
water stains, any signs of rust, other
WARNING!!!
that operating pressure does not go
Before
corrosions or separation of the vent
too high (could be a problem on the
performing any maintenance
and air intake piping.
expansion tank).
operations, shut the boiler
2. Check outside terminations. Screens
off, close the manual gas
and louvers should be free of any
14.1.9 - Flame inspection
shut-off valve (Figure 11-1)
debris and must be cleaned as
1. Inspect flame through observation
and shut off electrical power
required.
window.
to the boiler. Follow the
2. If the flame is unsatisfactory at either
Operating Instructions outlined
14.1.4 - Check system
high fire or low fire, clean the burner
in the section “SAFETY
following section 14.3.
INSTRUCTIONS” (Beginning of water pressure/system
the manual).
piping/expansion tank;
14.1.10 - Check flame
1. Check water piping and accessories
for
leaks.
Slightest
leaks
should
be
14.1.1 - Address reported
signal
corrected.
1. Follow section 14.12.4 to check the
problems
2. Check the system to be full of water
flame signal.
Inspect any problems reported by the
and pressure to remain stable at
2. At high fire and low fire the flame
owner and correct before proceeding.
correct setting on gauge.
signal shown on the display should
be within values given in Section 15,
14.1.2 - Check all piping
header “ionisation current”. A lower
14.1.5 - Check control
for leaks
flame signal may indicate a fouled or
settings
damaged flame sense electrode. If
1. Thermostat Test (control knobs items
cleaning the flame sense electrode
CAUTION!!! Eliminate all system
“7” and “11”, Figure 13-1): Set knobs
does not improve, ground wiring
setting to low enough to end call for
or boiler leaks. Continual fresh
is in good condition, and ground
heat. Gas valve should close and
makeup water will reduce boiler
continuity is satisfactory, replace the
burner should stop firing. Fan go into
life. Minerals can build up in
flame sense electrode.
a post purge, then shuts off.
sections, reducing heat transfer,
2. Control Safety Shutdown test: with
overheating heat exchanger,
the burner firing, close the manual
14.1.11 - Check relief valve
and causing heat exchanger
gas shut off valve (Figure 11-1) .
Inspect the relief valve and lift the lever
failure. Leaking water may also
Gas valve should close and burner
to verify flow. Before operating any
cause severe property damage.
should stop firing. The boiler will try
relief valve, ensure that it is piped with
for ignition three times after this,
its discharge in a safe area to avoid
1. Inspect all water and gas piping and
then should lock out with an “L 01”
severe scald potential. Read Section
verify to be leak free.
error shown on the display. Open the 7.2.2 before proceeding further. Relief
2. Look for signs of leaking lines and
manual gas shut-off valve, and press vavle should be re-inspected at least
correct any problems found.
the “Reset” button to return to normal once every three years, by a licensed
operation.
WARNING!!!
86
14 - MAINTENANCE
plumbing contractor or authorized
2. Air contaminants -- Products
14.1.16 - Check
inspection agency, to ensure that
containing chlorine or fluorine,
condensate drain system
the product has not been affected
if allowed to contaminate the
1. Inspect the condensate drain line,
by corrosive water conditions and to
boiler intake air, will cause acidic
condensate fittings and condensate
ensure that the valve and discharge line
condensate in the boiler. This will
trap for signs of weeping or leakage.
have not been altered or tampered with
cause significant damage to the
2. If you detect signs of leakage,
illegally.
boiler if allowed to continue. Read
immediately contact your qualified
Certain naturally occurring conditions
the list of potential materials listed in
service technician to inspect the
may corrode the valve or its
Section 10.2. If any of these products
boiler and system.
components over time, rendering the
are in the room from which the boiler
valve inoperative. Such conditions are
takes its combustion air, they must
not detectable unless the valve and its
be removed immediately or the boiler 14.1.17 - Check boiler
components are physically removed
combustion air (and vent termination)
piping (gas and water)
and inspected. This inspection must
must be relocated to another area.
1. If gas odor or leak is detected,
only be conducted by a plumbing
immediately shut down the boiler
contractor or authorized inspection
14.1.13 - Check pressure
following the procedures on page 3.
agency – not by the user.
Call a qualified service technician.
WARNING!!!
gauge
2.
Visually
inspect for leaks around
1. Make sure the pressure reading
WARNING!!!
water
piping.
Also inspect the
on the boiler pressure gauge does
Failure to
circulators,
relief
valve, and fittings.
not
exceed
25
psi.
Higher
pressure
re-inspect the boiler relief valve
Immediately
call
a
qualified service
may indicate a problem with the
as directed could result in unsafe
technician
to
repair
any leaks.
expansion tank.
pressure buildup, which can result
WARNING!!!
2. Contact a qualified service technician
in severe personal injury, death, or
if problem persists.
substantial property damage.
WARNING!!!
Have leaks
fixed at once by a qualified
14.1.12 - Check boiler area 14.1.14 - Check vent
service technician. Failure to
WARNING!!!
piping
comply could result in severe
1. Visually inspect the flue gas vent
personal injury, death, or
WARNING!!!
To prevent
piping for any signs of blockage,
substantial property damage.
potential of severe personal
leakage, or deterioration of the
injury, death, or substantial
piping. Notify your qualified service
14.1.18 - Shut boiler down
property damage, eliminate
technician at once if you find any
(unless boiler is used for
all materials discussed below
problems.
from the boiler vicinity and the
WARNING!!!
Domestic Water)
vicinity of the boiler combustion
1. Follow “To Turn Off Gas to Appliance”
WARNING!!!
air inlet.
Failure
on page 3 of this manual.
to inspect the vent system
2. Do not drain the system unless
If contaminants are found:
as noted above and have it
exposure to freezing temperatures
Remove products immediately
repaired by a qualified service
will occur.
from the area. If they have
technician can result in vent
3. Do not drain the system if it is filled
been there for an extended
system failure, causing severe
with an antifreeze solution.
period, call a qualified service
personal injury or death.
4. DO NOT shut down boilers used for
technician to inspect the boiler
domestic water heating, they must
for possible damage from acid
operate year-round.
14.1.15
Check
air
piping
corrosion.
1. Visually inspect the air inlet
termination to be sure it is
If products cannot be removed,
unobstructed. Inspect the entire
immediately call a qualified
length of air piping to ensure piping
service technician to re-pipe
is intact and all joints are properly
vent and air piping and locate
sealed.
vent termination/air intake away
2. Call your qualified service technician
from contaminated areas.
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
and around the electrodes;
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!
Figure 14-2 Remove the fan-burner assembly unit
89
11. using only water, wash the inside
of the combustion chamber, detail
“H” in Figure 14-2. The water, will
drain into the condensate drain.
Clean the condensate trap (see
Section 14.6) before reassembling
components;
12. reassemble the components by
proceeding in reverse order;
13. open the manual gas shutoff
valve;
14. restore electrical power to the
boiler;
15. check that there are no gas leaks.
WARNING!!!
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!
14 - MAINTENANCE
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.
A = Left ignition electrode
B = Right ignition electrode
C = Flame detection electrode
Figure 14-3 Positioning electrodes on burner
(Use a hand caliper to verify the distances of the
electrodes)
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
WARNING!!!
2. press the
and
keys
together for more than 10 seconds,
The condensate trap must be checked
until a blinking
is displayed;
every year and cleaned if required.
3. the combustion blower will run at
Follow the steps below to properly
maximum speed for 10 minutes.
clean the condensate trap and its
During this time the burner will not
associated components while referring
light. This will minimize the amount
to Figure 14-4:
of liquid present in the trap, item
“A”;
1. turn the power switch to on, item
“12” in Figure 13-1;
4. press the
button
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;
18. check that there are no gas leaks.
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
14.7 - Circulator
pump motor
replacement (only
for 160-C model)
Figure 14-5 Replacing the pump motor (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
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 14-6 Supply fittings removal (only for
160-C model)
Figure 14-7 3-way valve servomotor removal
93
14 - MAINTENANCE
14.10 - Draining the 14.11 - Draining the
heating side of the domestic hot water
boiler
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;
To drain the domestic hot water side
of the boiler follow the steps below:
1. turn off the boiler;
2. close the valve in the water main
supplying the DHW system;
3. open all the hot and cold faucets in
the building;
4. if there isn’t a faucet or drain valve
below the boiler level, disconnect
DHW connections “10” and “12” in
Figure 3-1.
14.12 – Overrides
To carry out specific checks covered
in the manual, it is possible to override
the control logic of the boiler. See the
following sections:
14.12.1 - Auto-purging
To reset the auto-purging procedure
press the
and
keys
together for 10 seconds. When the
appears on the display,
blinking
press
.
14.12.2 - Fan
To run just the fan at full speed press
- for domestic hot water turn
knob “11” in Figure 13-1 to its
maximum and fully open a hot
water faucet;
and
keys
2. press the
together for more than 10 seconds,
until a blinking
the display;
appears on
key until the
3. press the
display shows:
-
for minimum heating
output;
-
for maximum heating
output adjusted by P parameter,
see section 12.10;
-
for maximum heating
output;
-
for minimum DHW output;
-
for maximum DHW output;
key in order to
4. press the
restore the boiler to normal running
conditions.
14.12.4 – Checking the
flame current
While running at the minimum and
maximum output described in Section
and
keys together
the
14.12.3, the display will show the
for 10 seconds, until the blinking
letter of the mode checked. In the
appears on the display. The fan second part of the display the value
will run at full speed for 10 minutes. To of the ionization current will be
NOTICE: The boiler cannot be
shut the fan off before the 10 minutes shown. 30 corresponds to a current
drained completely of water without
of 1 uA, 99 to a current of 5.5 uA.
purging the unit with an air pressure
is up press the
key.
The flame current must always be at
of 15 psi.
the correspondent value as shown
WARNING!!!
in Section 15, header “ionisation
14.12.3 – Minimum and
current”. If the value is not within the
WARNING!!!
maximum output
Do not
above values, check:
The boiler can be run at its minimum
recover and/or re-use water
a - positioning of the flame sensor
or maximum output in both the
drained from the heating
electrod as per section 14.4;
heating and domestic hot water
circuit for any purpose as it
b - CO2 content as per section 12.9;
could be contaminated. Failure modes by following the steps below:
c - combustion air pressure as per
to comply with this warning
section 12.8.
1. generate a demand for the mode to
can cause extensive property
be overridden:
damage, severe personal injury
- for heating turn up the room
or death!
thermostat and turn knob “7” in
Figure 13-1 to its maximum;
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!!!
WARNING!!!
Label all wires prior
to disconnection when servicing
controls. Wiring errors can cause
improper and dangerous operation!
Verify proper operation after
servicing Failure to comply with
this warning can cause extensive
property damage, severe personal
injury
or death!
WARNING!!!
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!!!
WARNING!!!
Label all
wires prior to disconnection
when servicing controls. Wiring
errors can cause improper and
dangerous operation! Verify proper
operation after servicing Failure
to comply with this warning can
cause extensive property damage,
severe personal injury or death!
WARNING!!!
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
XX-160-B; XX-160-C;
Country of destination
Type of boiler
Category of discharge chimney
CSA certificate N°
Maximum Heat input Btu/hr
Minimum heat input
Btu/hr
Efficiency at maximum heat input (160°F/140°F)
%
Maximum Heat output (160°F/140°F)
Btu/hr
Efficiency at minimum heat input (122°F/86°F)
%
Minimum heat output (122°F/86°F)
Btu/hr
Certified AFUE rate
%
Gas flow rate
Natural gas
ft3/hr
LP Gas
gal/hr
Gas supply pressure Natural gas
In.W.C.
LP Gas
In.W.C.
Minimum gas supply pressure
Natural gas
In.W.C.
LP Gas
In.W.C.
Maximum gas supply pressure
Natural gas
In.W.C.
LP Gas
In.W.C.
Combustion air pressure with min. length
Natural gas
In.W.C.
LP Gas
In.W.C.
Combustion air pressure with max. length
Natural gas
In.W.C.
LP Gas
In.W.C.
Instantaneous d.h.w production [rise 75°F (42°C)]
gal/min
Maximum heating temperature
°F
Minimum heating temperature
°F
Maximum heating pressure
PSI
Minimum heating pressure
PSI
Maximum pressure of domestic hot water circuit
PSI
Minimum pressure of domestic hot water circuit
PSI
Capacity of expansion tank (160-C model only)
gal
Supply voltage Absorbed electric power
W
Flue gas pipes diameter (split)
“ (mm) Max. length flue gas pipes (split)
ft
Flue gas pipes diameter (coaxial)
“ (mm)
Max. length flue gas pipes (coaxial)
ft
Equivalent length of one elbow
ft
CO (Carbon monoxide) with natural gas ppm
CO (Carbon monoxide) with LP gas
ppm
NOx (0% O2 with natural gas)
ppm
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
°F
Flue gas mass-flow
lb/hr
Head pressure available for flue vent/air intake line
In.W.C.
Maximum condensation flow rate
gal/hr
Average acidity of condensation
PH
Boiler weight (empty of water) (160-C model)
lb
Boiler weight (empty of water) (160-B model)
lb
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
100
16 - SPARE PARTS
101
16 - SPARE PARTS
102
16 - SPARE PARTS
103
16 - SPARE PARTS
Bottom side of the 160-B model
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
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
104
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
106
Domestic hot water
Boiler in stand-by
Read out in normal
operating condition
(see section 13.18 )
User’s menu, with
thermostatic CH
settings to 00 (see
section 13.16)
User’s menu, with outdoor
reset, CH settings to 01 or
02 (see section 13.16)
Installer’s menu
(see section 13.17)
Overrides menu (see
section 14.12)
Push and release the RESET
key
Push and hold the RESET
key for a time, in seconds,
indicated by the number
Last lock out error
Last blocking error
D.H.W. temp.
setting
Central heating
temp. setting
D.H.W. temp.
setting
Calculated heat.
temp.
Room
therm.
state
Basic
setting
Return
temp.
Flue
temp.
High limit
temp.
Max.
heat.
temp.
Parallel shift
Ionisation
current
Outdoor
temp.
D.C.W.
temp./ tank
temp.
D.H.W.
temp.
Supply
temp.
Min.
heat.
temp.
Curve
angle
Push and release the + key
Push and release the - key
Push and hold together the + and keys, for a time, in seconds, indicated
by the number
Domestic
at high
fire
Domestic
at high
fire
Domestic
at low
fire
Heating
at high
fire
Heating
at regul.
fire
Heating
at low
fire
Only fan
in run
17 - READ OUT FLOW CHART
Anti legionella protection
D.H.W. active more than
120 min.
Blocking error
Lock-out
Anti Freeze protection
Central heating
Last lock out error
Last blocking error
Fan speed
rpm/100
107
DHW priority selection
Anty cicling during
central heating
Heating integral band
setting
Heating proportional
band setting
Minimum domestic
stpoint in sleep mode
Domestic sensitivity
regulator parameter
Disabled
parameter
Energy
saver
display
State of the
knobs
Heat. temp.
reduction by
open RT
Angle
fulcrum
Reaction
to outdoor
temp.
Heating
service
mode
Setting
output for
heating
17 - READ OUT FLOW CHART
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.
if readable, may assume the follow values:
00 = Flow Switch disabled;
01 = Flow Switch enabled;
if readable, may assume the follow values:
00 = Outdoor minimum temperature of 14°F;
01 = Outdoor minimum temperature of -39°F; (add a 68 kohm
1/4W resistor in parallel with the outdoor sensor).
If readable, may assume the follow values:
00, 01, 02, 03, 04, 05, 06, 07 and 08. Must be always at
00.
108
NOTE
109
COSMOGAS s.r.l.
Via L. da Vinci 16, 47014 MELDOLA (FC) ITALY
TEL +39 543 498383
info@cosmogas.com
www.cosmogas.com
COSMOGAS Noth America
TEL 860-833-8375
Cosmogas.USA@gmail.com
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