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14 - MAINTENANCE
Figure 14-6 Supply fittings removal (only for
160-C model)
14.9 - 3-way valve removal (only for
160-C model)
The 3-way valve, details “M” and “Q” in Figures 14-6 and 14-7, directs hot water produced by the primary heat exchanger to the heating circuit or to the secondary heat exchanger for the production of D.H.W. To replace or clean it, follow the steps below while referring to Figures 14-6 and 14-7:
1. follow the steps in Section 14.10 and 14-11 to isolate and drain the water from the boiler;
2. follow the steps in Section 14.2, to gain access the internal components;
3. disconnect fittings “A”;
4. remove screws “C”;
5. rotate “D” flange in the direction of the black arrow (See particular fig.
1);
6. remove the bracket “E”;
5. remove fitting “F”;
6. remove fitting “L”;
7. remove fitting “M” and check its state.
8. remove spring “N”;
9. remove servomotor “O”;
10. remove the fitting “P”
11. remove the spring “Q” and check for any dirt.
Figure 14-7 3-way valve servomotor removal
93
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Table of contents
- 2 SAFETY INSTRUCTIONS
- 6 TABLE OF CONTENTS
- 9 1 - INSTALLATION - CODE REQUIREMENTS
- 9 1.1 - Regulations and guidelines
- 10 1 - INSTALLATION - CODE REQUIREMENTS
- 10 1.2- Commonwealth of Massachusetts Installation Requirements
- 11 2 - GENERAL INFORMATION
- 11 2.1 - Key to symbols used
- 11 2.2 - Description of model
- 12 3 - MAIN COMPONENTS
- 14 4 - FUNCTION OVERVIEW
- 15 4.1 - Intended use and functions of the boiler
- 15 4.2 - Efficiency up to 98%
- 16 5 - INSTALLATION - Location
- 16 5.1 - Choosing the installation location
- 17 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
- 18 6 - INSTALLATION - Mounting the boiler
- 18 6.1 - Mounting the boiler
- 19 7 - INSTALLATION - Water connection
- 19 7.1 - Water connections
- 19 7.2 - Supply and return piping
- 20 7.2.1 - Near boiler heating piping components
- 21 7.2.2 - Relief valve
- 22 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
- 23 7.4 - Domestic hot and cold water (only for 160-C model)
- 26 7.5 - Condensate disposal
- 27 8 - INSTALLATION - Electrical connections
- 27 8.1 - Electrical connections: overview
- 28 8.1.1 - Connecting the power supply cable
- 28 8.1.2 - Wiring the heating pump for 160-B model
- 29 8.1.3 - Thermostat wiring
- 29 8.1.4 - Installing the outdoor temperature sensor
- 29 8.1.5 - Alarm output
- 30 9 - INSTALLATION - Connecting to an indirect water heater
- 30 9.1 - Connecting the boiler to an indirect water heater
- 31 9.1.1 Indirect water heater priority selection
- 31 9.2 - Opening the instrument panel
- 32 10 - INSTALLATION - Vent and combustion air
- 32 10.1 - Removing of a boiler from a common venting system
- 33 10.2 - Prevent combustion air contamination
- 33 10.3 - Venting and air piping systems
- 35 10.4 - Minimum / Maximum allowable combustion air and vent piping lengths
- 35 10.5 - Install vent and combustion air piping
- 37 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
- 38 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
- 40 10.8 - Stainless steel vent piping materials
- 41 10.8.1 - Stainless steel air intake/vent connections
- 42 10.9 - Polypropylene vent piping materials
- 43 10.9.1 - Polypropylene two pipes air intake/vent connections
- 44 10.9.2 - Polypropylene two pipes system components
- 45 10.9.3 - Polypropylene concentric system
- 46 10.9.4 - Polypropylene concentric system components
- 47 10.10 - Single pipe vent (not sealed combustion)
- 47 10.10.1 - Combustion Air and Ventilation openings
- 48 10.10.2 - Determine location
- 49 10.11 - Sidewall termination - Two pipes
- 49 10.11.1 - Vent/air termination
- 49 10.11.2 - Determine location
- 51 10.11.3 - Prepare wall penetrations
- 51 10.11.4 - Termination and fittings
- 51 10.11.5 - Multiple vent/air terminations
- 52 10.12 - Sidewall termination – Concentric vent
- 52 10.12.1 - Description and usage
- 52 10.12.2 - Sidewall termination installation
- 53 10.12.3 - Multiventing sidewall terminations
- 54 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
- 55 10.13.4 - Multiple vent/air terminations
- 56 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
- 57 10.14.4 - Multiventing vertical terminations
- 58 10.14.5 - Alternate vertical concentric venting
- 59 10.15 - Existing vent as a chase
- 60 11 - INSTALLATION - Gas supply
- 60 11.1 - Gas supply piping
- 61 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
- 62 11.6 - Convert the boiler from Natural Gas to Propane gas or viceversa
- 64 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
- 65 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
- 66 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
- 67 12.7 - Gas supply pressure checking
- 68 12.8 - Check the combustion air pressure
- 69 12.9 - Checking and adjusting CO2 levels
- 70 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
- 71 13 - USE
- 71 13.1 - Check heating system pressure
- 71 13.2 - Overview
- 71 13.3 - Displays
- 72 13.4 - Start-up procedure
- 72 13.5 - Summer mode
- 72 13.6 - Winter mode
- 73 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
- 74 13.10.3 - Outdoor reset: setting parameters
- 74 13.10.4 - Outdoor reset: zone adjustments
- 74 13.10.5 - Outdoor reset activation
- 75 13.10.6 – Outdoor reset with room compensation
- 76 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
- 77 13.15 - Display in energy saving mode
- 77 13.16 - “Users’ menu
- 78 13.17 - “Installer’s menu
- 80 13.18 - Diagnostics
- 81 13.18.1 - Diagnostics: “L” lock-outs
- 83 13.18.2 - Diagnostics: “E” blocking errors
- 85 14 - MAINTENANCE
- 85 14.1 - Care and maintenance
- 86 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
- 87 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)
- 88 14.2 - Removing the casing
- 89 14.3 - Cleaning the burner and primary heat exchanger, flue gas side
- 90 14.4 - Correct positioning of the ignition and flame detection electrodes
- 90 14.5 - Domestic hot water heat exchanger (only for 160-C model)
- 91 14.6 - Condensate trap cleaning
- 92 14.7 - Circulator pump motor replacement (only for 160-C model)
- 92 14.8 - Expansion tank pressure (only for 160-C model)
- 93 14.9 - 3-way valve removal (only for 160-C model)
- 94 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
- 95 14.13 - Water and flue temperature sensor
- 95 14.14 - Outdoor temperature sensor (optional)
- 96 14.15 - Functional wiring diagram
- 98 14.16 - Multiwire wiring diagram
- 100 15 - TECHNICAL DATA
- 101 16 - SPARE PARTS
- 106 17 - READ OUT FLOW CHART