Part No.
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.
SAFETY INSTRUCTIONS 3
SAFETY INSTRUCTIONS WARNING!!! These instructions must be read prior to installation. If the information in these instructions is not followed exactly, a 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.
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.
TABLE OF CONTENTS SAFETY INSTRUCTIONS .................................................................................................................2 TABLE OF CONTENTS .....................................................................................................................6 1 - INSTALLATION - CODE REQUIREMENTS .................................................................................8 1.1 - Regulations and guidelines .....................................................................
TABLE OF CONTENTS 12 - START-UP.................................................................................................................................62 12.1 - Operating ......................................................................................................................................................... 62 12.2 - General warnings concerning gas supply ........................................................................................................ 64 12.
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.
2 - GENERAL INFORMATION 2.1 - Key to symbols used WARNING!!! Failure to follow these indications can causing an explosion, extensive property damage, severe personal injury or death! CAUTION!!! 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.
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.
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.
4 - FUNCTION OVERVIEW Figure 4-1 160-B Hydronic functional schematic Figure 4-2 - 160-C Hydronic functional schematic 12 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.
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.
5 - INSTALLATION - Location 5.1 - Choosing the installation location 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!!! 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.
5 - INSTALLATION - Location When locating the boiler the following - Ceiling: factors must be considered: - Front: the location of vent/air intake -- Rear: Sides: terminals; - Floor: connection to the gas supply; - Concentric vent: - Split vent (two connection to the water supply; boiler: connection to the heating system; connection to the domestic hot water system; connection to the electrical supply; disposal of the condensation produced by the boiler; connection to the room thermostat
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!!! 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.
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.
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.
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.
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.
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.
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).
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.
7 - INSTALLATION - Water connections 7.5 - Condensate disposal WARNING!!! The condensate trap must be connected to the boiler per the following instructions or combustion gases will enter the room. This can result in excessive levels of carbon monoxide which can cause severe personal injury or death! This boiler produces water as a byproduct of combustion.
8 - INSTALLATION - Electrical connections 8.1 - Electrical connections: overview 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!!! Label all wires prior to disconnection when servicing controls.
8 - INSTALLATION - Electrical connections Outdoor sensor (optional) 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.
8 - INSTALLATION - Electrical connections NOTICE! the maximum room thermostat 2. use a two conductor cable with a minimum cross section of # 18 AWG cable length permitted is 32 ft (10 m). than 1 hp or 1 amps, you must between the boiler and the outdoor For longer lengths, up to 300ft (100 m) a isolate with a relay. temperature sensor. shielded cable, with the shield connected to the ground, must be used. 6.
9 - INSTALLATION - Connecting to an indirect water heater 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.
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.
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 main burner operation. Use the flame of a match or candle, or WARNING!!! smoke from a cigarette, cigar or DO NOT pipe.
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 (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.
10 - INSTALLATION - Vent and combustion air Figure 10-2 Vertical two pipes Figure 10-3 Side wall air intake, vertical vent (Direct (Direct Venting). 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). 32 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 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.
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
10 - INSTALLATION - Vent and combustion air 10.6 - Air inlet pipe materials: 10.6.1 - Sealing of Type “B” double-wall vent material or galvanized vent pipe 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 vent The air pipe manufacturer’s recommended material or galvanized vent pipe inlet pipe(s) must be sealed.
10 - INSTALLATION - Vent and combustion air 10.7 - PVC/CPVC vent piping materials 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!!! This appliance requires a special venting system. The field provided vent fittings must be connected to the boiler following Section 10.
10 - INSTALLATION - Vent and combustion air 2. insert the clamp “D” into convertor Tight the clamps with a tork of 1.5 - 2 the adapter “E”. To do this tighten “A” in the “C” side. lbf ft (2-3 Nm). the half clamp on the pipe and half 3. insert the adapter “E” into connection 5. insert the clamp “F” into convertor clamp to the adapter “E”. Tight the “C” of the convertor “A”; “E”. clamps with a tork of 1.5 - 2 lbf ft 4. use the precedent clamp “D” to 6. insert the air inlet PVC/CPVC pipe, (2-3 Nm).
10 - INSTALLATION - Vent and combustion air 10.8 - Stainless steel vent piping materials WARNING!!! Use only the materials, vent systems, and terminations listed in Tables 10-1 and 10-2. DO NOT mix vent systems of different types or manufacturers, unless listed in this manual. Failure to comply could result in severe personal injury, death, or substantial property damage. WARNING!!! This appliance requires a special venting system.
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.
10 - INSTALLATION - Vent and combustion air 10.9 - Polypropylene vent piping materials 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!!! This appliance requires a special venting 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”.
10 - INSTALLATION - Vent and combustion air 10.9.
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.
10 - INSTALLATION - Vent and combustion air 10.9.
10 - INSTALLATION - Vent and combustion air 10.10 - Single pipe vent (not sealed combustion) WARNING!!! When utilizing the single pipe method, provisions for combustion and ventilation air must be in accordance with Air for Combustion and Ventilation, of the latest edition of the National Fuel Gas Code, ANSI Z223.1, in Canada, the latest edition of CGA Standard B149 Installation Code for Gas Burning Appliances and Equipment, or applicable provisions of the local building codes.
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.
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: a.
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!!! Do not exceed the maximum lengths of the outside vent piping shown in Figures 10-17 and 1018.
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.
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.
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.
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 air must not exceed the limits given in the Section 10-4. WARNING!!! Follow 2.
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.
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.
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!!! 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.
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.
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.
11 - INSTALLATION - Gas supply 11.1 - Gas supply piping WARNING!!! Check that the type and the pressure of the gas supplied correspond with those required for the boiler as stated on the rating plate. Never use a gas different than that stated on the boiler rating plate. Failure to comply with this warning can result in a fire or explosion causing extensive property damage, severe personal injury or death! INSTAL MANUAL SHUT-OFF VALVE 5 FT (1.
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.
11 - INSTALLATION - Gas supply 11.6 - Convert the boiler from Natural Gas to Propane gas or viceversa stamping on the orifice matches the gas type (See Table 11-3).
11 - INSTALLATION - Gas supply 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.
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.
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.
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.
12 - START-UP 12.7 - Gas supply pressure checking WARNING!!! DO NOT adjust or attempt to measure gas valve outlet pressure. The gas valve is factory-set for the correct outlet pressure. This setting is suitable for natural gas and propane, requiring no field adjustment. Attempting to alter or measure the gas valve outlet pressure could result in damage to the valve, causing potential severe personal injury, death, or substantial property damage. Check the gas supply pressure by following the steps below: 1.
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.
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).
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.
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.
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.
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 and the 13-1, shows a flashing temperature being selected. The range within which the domestic hot water can be set is 104°F (40°C) to 140°F (60°C) or from 104°F (40°C) to 158°F (70°C) when an indirect storage tank is used.
13 - 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).
13 - USE 13.10.6 – Outdoor reset with room compensation While in the “Installers’ Menu” (section 13.17) set the parameter to 02. The system will function exactly as described in the previous “Outdoor reset adjustment” sections except that now the boiler pump will stay on permanently. The opening of the room thermostat contacts will translate into a parallel downward movement of the curve in Figures 13-2 and 13-3.
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.
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 parameter at a value and set the other than zero. Keep in mind that each value will correspond to a delay in minutes until the display goes into Energy Saving mode. PARAMETER 13.
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.
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.
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.
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.
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.
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.
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 - 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. 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.
14 - MAINTENANCE 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.
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.
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.
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!!! Before proceeding to the next step, verify that the electrical supply to the boiler, and any other electrical supply near the boiler, is off.
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.
14 - MAINTENANCE 14.6 - Condensate trap cleaning 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.
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.
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.
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.
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 - MAINTENANCE 14.15 - Functional wiring diagram WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death! WARNING!!! ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher.
14 - MAINTENANCE 95
14 - MAINTENANCE 14.16 - Multiwire wiring diagram WARNING!!! Label all wires prior to disconnection when servicing controls. Wiring errors can cause improper and dangerous operation! Verify proper operation after servicing Failure to comply with this warning can cause extensive property damage, severe personal injury or death! WARNING!!! ATTENTION!!! Au moment de l’entretien des commandes, étiquetez tous les fils avant de les débrancher.
14 - MAINTENANCE 97
15 - TECHNICAL DATA MODEL VSL-160-B; VSL-160-C; Country of destination Type of boiler Category of discharge chimney CSA certificate N° Maximum Heat input Minimum heat input Efficiency at maximum heat input (160°F/140°F) Maximum Heat output (160°F/140°F) Efficiency at minimum heat input (122°F/86°F) Minimum heat output (122°F/86°F) Certified AFUE rate Gas flow rate Natural gas LP Gas Gas supply pressure Natural gas LP Gas Minimum gas supply pressure Natural gas LP Gas Maximum gas supply pressure Natural gas LP
16 - SPARE PARTS 99
16 - SPARE PARTS 100
16 - SPARE PARTS 101
16 - SPARE PARTS Bottom side of the 160-B model Spare parts list 1 - 81 9010 000 - CABLE UL IGNITOR CONN 90° L155 2 - 81 9011 000 - NUT ZINC COATED 6MA 3 - 81 9012 000 - SILICONE PIPE D 4X8 4 - 81 9013 000 - TEE FOR DRY WATER CONDENSATION 5 - 81 9014 000 - SPARK GENERATOR NO CABLE UL 6 - 81 9015 000 - SENSOR NTC 10 KOHM A KLIP DIAM.22 7 - 81 9016 000 - COPPER PIPE D22 M/F 3/4”G-1”G 8 - 81 9017 000 - 3/4” RING NUT 9 - 81 9018 000 - O-RING NBR 2,62 X 20,63 10 - 81 9019 000 - PRIMARY HEAT EXCHANGER C.R.
16 - SPARE PARTS 38 - 81 9047 000 - 3/8G MALE to 1/8NPT FEMALE BUSHING 39 - 81 9048 000 - GASKET EPDM D38 F20 SP6 40 - 81 9049 000 - 45xx WALL MOUNTING BRACKET 41 - 81 9050 000 - SCREW SELFTAPPING 5X50 WOOD 42 - 81 9051 000 - EXP TANK LT. 8 561X203X80 RETT. 43 - 81 9052 000 - GLASS WINDOW WITH GASKET 44 - 81 9053 000 - 3/8” G GASKET 45 - 81 9054 000 - FAIRLEAD 6 POLES SILICONE 46 - 81 9055 000 - EXP TANK PIPE 47 - 81 9056 000 - PLASTIC CAP TPP 8.
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.
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/100 105 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.
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.
62403559 R00 May 03, 2012 NOTE 107
