SSB85 SSB120 SSB160. Gas Condensing Stainless Steel Boiler BUDERUS SSB BOILER. Installation and Service Instructions for Contractors

Transcription

1 WARNING: Improper instlltion, set-up, modifiction, opertion or mintennce of the heting system cn cuse personl injury nd property dmge. Follow these instructions precisely. If you require ssistnce or further informtion, contct licensed contrctor / gs fitter. WARNING: The operting instructions re prt of the technicl documents tht must be hnded over to the owner or opertor of the heting system. Explin to the owner or opertor how to use the heting system using the operting instructions. Mke sure tht they re fmilir with ll required informtion for the sfe nd proper opertion of the heting system. These instructions re vilble in English nd French. Plese keep these instructions for future reference. Gs Condensing Stinless Steel Boiler BUDERUS BOILER Instlltion nd Service Instructions for Contrctors (018/03) US

2 Contents 1 Key to symbols nd sfety instructions Key to symbols Sfety instructions Generl wrning...3 Product description Introduction Scope of delivery Proper use Environmentl responsibility / disposl Dimensions nd Connections Min components Technicl dt Efficiency Curves Regultions Complince with stndrds nd regultions Operting limits of the boiler Additionl regultions for instlltion in Msschusetts Instlltion Pckging nd product identifiction Instlltion room Wter Chemistry Guidelines Hydrulic connection Low wter cut off High limit sfety switch Pressure relief vlve (PRV) ASME pproved Expnsion tnk Pump Condenste removl Electricl connection Power supply cble connection Access to the electricl terminl strip Room thermostt connection Outside temperture sensor Electricl wiring digrm Gs supply piping Connection of gs supply piping Gs type conversion Venting nd ir piping system Generl venting nd combustion ir piping system Connecting flue gs ccessories Instlltion of the exhust nd ir intke system Vent nd combustion ir pipe length [For single boiler instlltions] Approved exmples of horizontl nd verticl venting instlltion Multiple boiler Commissioning (for single ppliction) Switching the pplince ON/OFF Setting dte nd time Setting CH nd DHW setpoint Boiler informtion Prmeters list Outdoor reset Adjusting nd setting CO limits Setting frost protection Troubleshooting Error codes re shown on the disply Lockout errors Blocking errors Errors not shown on disply Sensor Resistnce tble Mintennce Generl Mintennce / inspection schedule for end user Mintennce / inspection schedule for licensed contrctor / gs fitter Gs leking inspection Check exhust nd combustion ir pipe system Inspection of ignition electrode Checking for wiring nd connections Burner gsket inspection Instlltion schemes Multiple zone with indirect tnk (pump for ech zone) Settings Multiple zone with indirect tnk (vlve for ech zone) Settings Cscde Settings Commissioning log for the pplince Spre prts (018/03) US

3 Key to symbols nd sfety instructions 3 1 Key to symbols nd sfety instructions 1.1 Key to symbols Wrnings Wrnings in this document re identified by wrning tringle printed ginst grey bckground. Keywords t the strt of wrning indicte the type nd seriousness of the ensuing risk if mesures to prevent the risk re not tken. The following keywords re defined nd cn be used in this document: DANGER indictes hzrdous sitution which, if not voided, will result in deth or serious injury. WARNING indictes hzrdous sitution which, if not voided, could result in deth or serious injury. CAUTION indictes hzrdous sitution which, if not voided, could result in minor to moderte injury. NOTICE is used to ddress prctices not relted to personl injury. Importnt informtion m This symbol indictes importnt informtion where there is mno risk to people or property. 1. Sfety instructions Observe these instructions for your sfety. The burner nd control must be correctly instlled nd djusted to ensure sfe nd economicl opertion of the gs boiler. Red this instlltion nd mintennce mnul crefully nd note the detils on the boiler nmeplte before plcing the boiler in opertion. Risk of ftl injury from explosion of flmmble gses If you smell gs there is dnger of explosion. Never work on gs lines unless you re licensed contrctor / gs fitter. Mke sure tht licensed contrctor / gs fitter instlls the boiler, connects gs nd vent, plces the boiler in opertion, connects the electricl power, nd mintins nd repirs the boiler. No open flme! No smoking! Do not use lighters. Prevent sprk formtion. Do not operte electricl switches, including telephones, plugs or door bells. Close min gs vlve. Open doors nd windows. Wrn other occupnts of the building, but do not use door bells. Cll gs compny from outside the building. If gs cn be herd escping, leve the building immeditely, prevent other people from entering, notify police nd fire deprtments from outside the building Risk to life from electricl shock. Disconnect the power supply to the boiler heting system before conducting ny work on it, e.g. turn off the heting system emergency switch outside the boiler room. It is not sufficient just to turn off the control. Do not crry out electricl work unless you re qulified for this type of work. Before servicing disconnect electricl power nd lock out to prevent ccidentl reconnection. Observe nd follow the locl, stte nd federl instlltion regultions. Risk of ftl injury from flue gs poisoning Insufficient ventiltion or combustion ir vilbility my cuse dngerous flue gs leks or formtion. Mke sure tht inlets nd outlets re not reduced in size or closed. If fults re not corrected immeditely, the boiler must not be operted until ll fults hve been corrected. Inform the system opertor nd/or owner of the fult nd the dnger in writing. When working on the flue gs venting lekge of flue gses my endnger the lives of people. Use only originl prts when replcing vent system prts. Risk to life by poisoning by spillge of flue gses If the blocked vent switch trips frequently the fult must be corrected nd proper opertion of the blocked vent switch test must be conducted. Risk of ftl injury from neglecting your own sfety in cse of emergency, such s with fire Never put yourself t risk. Your own sfety must lwys tke priority. Fire dnger due to flmmble mterils or liquids Mke sure tht there re no flmmble mterils or liquids in the immedite vicinity of the boiler. Instlltion nd mintennce Observe ll current stndrds nd guidelines pplicble to the instlltion nd opertion of the boiler heting system s pplicble in your stte or locl jurisdiction. Clen nd service the boiler system once yer. Check tht the complete heting system opertes correctly. Immeditely correct ll fults to prevent system dmge. Only use originl Bosch spre prts. Losses cused by the use of prts not supplied by Bosch re excluded from the Bosch wrrnty. 1.3 Generl wrning The instlltion of the unit must comply with ll locl, stte nd federl pplicble codes nd regultion or, in bsence of locl codes in conformity with ANSI Z3.1 / NFPA 54 for gs-fired boilers nd ANSI/ NFPA 58 for LP gs-fired boilers. The equipment shll be instlled in ccordnce with the current Instlltion Code for Gs Burning Applinces nd Equipment, CSA B149.1 Cnd. Authorities hving jurisdiction nd locl inspection gencies must be informed before instlltion strts. Where required by locl, stte nd federl regultions, the system must comply with the Americn Society of Mechnicl Engineers Sfety Code for Controls nd Sfety Devices for Automticlly Fired Boilers (ASME CSD-1). The hot wter distribution system must comply with ll pplicble codes nd regultions. When replcing n existing boiler, it is importnt to check the condition of the entire hot wter distribution system to ensure sfe opertion. Vlves externl to the boiler must be fitted with T-hndles nd condenste piping must be instlled in ccordnce with the Stte Plumbing Code (018/03) US

4 4 Product description NOTICE: This boiler must be instlled by licensed contrctor/ gs fitter. Filure to do so shll void the product wrrnty. The boiler is intended only for the use for which it ws specificlly designed nd built. Bosch is hereby excluded from ny libility for dmges cused to persons, nimls or property resulting from instlltion errors, improper djustment, mintennce or use. In order to ensure sfety nd correct opertion, the instlltion shll lwys tke plce in full complince with the pplicble Codes nd following with the instructions provided by the mnufcturer, nd must lwys be crried out by licensed contrctor / gs fitter only. The equipment must be instlled in pproprite plce nd in combintion with pproprite systems s specified by code. The unit my be exposed to tempertures between 5 F (-15 C) nd 150 F (65 C) in its originl pckging. Do not expose the unit to wether without the protection of the originl pckging until the boiler hs been properly instlled. Until then there is no frost protection for the boiler. After removing the pckging check the integrity nd completeness of delivery nd in cse of non-complince, contct your deler. If there is wter loss, disconnect the boiler from the min power supply, close the wter supply nd immeditely cll technicl ssistnce or instller/locl contrctor. Periodiclly check tht the condenste drin is free from obstruction. Periodiclly check the system pressure. System pressure should be checked when the system is in stndby mode nd no cll for het is present. Mintennce is mndtory nd shll be crried out t lest once yer. This mnul shll be red crefully, in order to instll nd operte the boiler ppropritely, nd sfely. Boiler instlltions, settings nd service should only be performed by experienced licensed contrctor / gs fitter. End Users should only mke djustments with the ssistnce of licensed contrctor / gs fitter. Any mintennce opertion or service before disconnecting the boiler from the min power supply is forbidden. Do not remove or modify sfety equipment. Do not pull or twist the electricl wires, from the boiler, even if the device is disconnected from the min power supply. Do not obstruct or reduce the ventiltion openings. Do not put the unit outdoors. Do not leve ny combustibles or continers of flmmble substnces in the room where the boiler is instlled. Do not dump the pcking mteril. Keep out of rech of children the pcking mteril becuse it cn be potentilly dngerous. It must be disposed of s required by lw. The opening of metl csing of the device nd removing of the cover re prohibited to the end user. Any service on the boiler must be crried out by qulified technicin. Dispose of equipment in ccordnce with locl codes, nd in environmentlly responsible mnner. Product description.1 Introduction The gs-fired condensing boilers re designed to be used in centrl heting systems. Any other use is prohibited. This boiler cn be connected to n indirect storge tnk for the production of domestic hot wter. There re severl options for venting including single pipe, two pipe nd concentric. See section 4.7 Venting nd ir piping system for detils. The qulity of the system wter is very importnt. Poor wter qulity cn dmge heting systems nd boilers due to scle formtion nd corrosion (see wter qulity section). The boilers cn lso function directly with ny hydronic emitter. When instlling the boiler nd system connections, the instller must consider the totl hed loss nd flow rtes in order to dequtely size piping nd circultor pumps. The boiler cn be connected to room thermostt. An outdoor ir temperture sensor must lso be connected to the boiler for n outdoor reset supply temperture control for incresed fuel efficiency nd comfort.. Scope of delivery Fig Scope of delivery Component Qty Pckging method [1] Gs condensing boiler 1 Pllet [] Set of documents for pplince 1 Plstic pckge [3] Sfety relief vlve 1 Crdbord box on pllet [4] LP conversion kit 1 Plstic pckge [5] Universl Sensor for LLH or DHW Crdbord box on pllet [6] Outdoor sensor 1 Crdbord box on pllet (018/03) US

5 Product description 5.3 Proper use The Boilers re designed for residentil, nd light commercil pplictions. The pplince my only be instlled in closed loop hot wter centrl heting systems. Any other purpose is considered improper use. Any resulting dmge is excluded from the mnufcturer s wrrnty. In some heting pplictions like pool, sp snow melt or process wter heting het exchnger must to be instlled..4 Environmentl responsibility / disposl Environmentl responsibility is one of the fundmentl compny policies of the Bosch Group. We regrd qulity of performnce, economy nd environmentl responsibility s equl objectives. Environmentl protection lws nd regultions re strictly dhered to. To protect the environment, we use the best possible technology nd mterils tking into ccount economic points of view. Pckging All pckging mterils used re environmentlly-friendly nd recyclble (018/03) US

6 6 Product description.5 Dimensions nd Connections F 10 1/ (67mm) 11 1/ (9mm) 1 1/ (317mm) 38 7/8 (988mm) G 11 3/16 (83mm) 15 9/3 (388mm) 7 3/16 (18mm) 30 3/16 (766mm) 31 1/8 (791mm) 3 1/8 (816mm) 13 1/ (343mm) 13 1/8 (333mm) 35 7/8 (91mm) 5 3/8 (137mm) 1 15/16 (50mm) 0 (506mm) 18 1/16 (458mm) 14 1/4 (361mm) 9 1/ (41mm) B C D E A Tolernces on ll dimensions shown is +/- 1/4 (6.35mm) Fig. 85 (dimension in inches [mm]) A B C D System supply - Ø 1 NPT System return - Ø 1 NPT Gs inlet - Ø 3/4 NPT Flue exhust - Ø (60mm) E Intke ir - Ø (60mm) F Electricl connection knock outs G Condenste drin outlet - Ø 3/ (018/03) US

7 Product description 7 F 10 9/16 (68mm) 11 5/8 (93mm) 1 5/8 (318mm) 43 7/8 (111mm) 9 7/8 (5mm) 37 15/16 (964mm) 38 15/16 (989mm) 39 7/8 (1014mm) 47 1/ (186mm) G 11 3/16 (83mm) 15 3/8 (388mm) 0 (508mm) 9 1/ (41mm) 5 3/8 (137mm) 1 15/16 (58mm) 18 1/16 (458mm) 14 1/4 (361mm) 13 1/ (343mm) 13 1/8 (333mm) B C D E A Tolernces on ll dimensions shown is +/- 1/4 (6.35mm) Fig (dimension in inches [mm]) A B C D System supply - Ø 1 NPT System return - Ø 1 NPT Gs inlet - Ø 3/4 NPT Flue exhust - Ø (60 mm) E Intke ir - Ø (60 mm) F Electricl connection knock outs G Condenste drin outlet - Ø 3/ (018/03) US

8 8 Product description F 10 9/16 (68mm) 11 5/8 (93mm) 1 5/8 (318mm) 43 7/8 (111mm) 9 7/8 (5mm) 37 15/16 (964mm) 38 15/16 (989mm) 39 7/8 (1014mm) 47 1/ (186mm) G 11 3/16 (83mm) 15 3/8 (388mm) 0 (508mm) 9 1/ (41mm) 5 3/8 (137mm) 1 15/16 (58mm) 18 1/16 (458mm) 14 1/4 (361mm) 13 1/ (343mm) 13 1/8 (333mm) B C D E A Tolernces on ll dimensions shown is +/- 1/4 (6.35mm) Fig (dimension in inches [mm]) A B C D System supply - Ø 1 NPT System return - Ø 1 NPT Gs inlet - Ø 3/4 NPT Flue exhust - Ø (60 mm) E Intke ir - Ø (60 mm) F Electricl connection knock outs G Condenste drin outlet - Ø 3/ (018/03) US

9 Product description 9.6 Min components Fig (min components) [1] Min power switch [] System return [3] Gs inlet [4] Flue exhust [5] Intke ir [6] System supply [7] Pressure Relief Vlve [8] Tridictor [9] Low wter cut off probe [10] Het exchnger supply pipe [11] Fn [1] Gs vlve [13] Automtic ir vent [14] Supply temperture probe [15] High limit temp. sfety switch [16] Het exchnger [17] Condenste trp [18] Low point drin vlve [19] Circultion pump [0] Return temperture probe [1] Wiring Control Pnel [] Sprk electrode [3] Gs pipe [4] Removble disply [5] Pressure differentil switch [6] Condenste dischrge pipe (018/03) US

10 10 Product description.7 Technicl dt Unit Boiler Ctegory ASME Sect.IV ASME Sect.IV ASME Sect.IV Type of Gs Nturl Gs, Propne * Nturl Gs, Propne * Nturl Gs, Propne * Mx input rte BTU/hr (kw) 85,300 (5) 119,40 (35) 160,364 (47) Min input rte BTU/hr (kw) 17,060 (5) 3,884 (7) 3,073 (9.4) Turndown Rte (%) 5:1 (0 %) 5:1 (0 %) 5:1 (0 %) Gs Connections (NPT) Ø Inch 3/4 3/4 3/4 Mx. NG Pressure Inch W.C. (mbr) 10.5 (6.15) 10.5 (6.15) 10.5 (6.15) Min. NG Pressure Inch W.C. (mbr) 3.5 (8.7) 3.5 (8.7) 3.5 (8.7) Mx. LPG Pressure Inch W.C. (mbr) 13 (3.3) 13 (3.3) 13 (3.3) Min. LPG Pressure Inch W.C. (mbr) 8 (19.9) 8 (19.9) 8 (19.9) Wter Connections Ø Inch Mx. Allowble Working Pressure (MAWP) PSI (br) 80 (5.5) 80 (5.5) 80 (5.5) Recommended wter mx power ( T 36 F / 0 C) GPM (m 3 /h) 4.7 (1.1) 6.6 (1.5) 8.5 (1.9) Mx wter mx power ( T 7 F / 15 C) GPM (m 3 /h) 6.3 (1.4) 8.8 (.0) 11.4 (.6) Min wter mx power ( T 54 F / 30 C) GPM (m 3 /h) 3. (0.7) 4.4 (1.0) 5.7 (1.3) Min wter min power ( T 7 F / 15 C) GPM (m 3 /h) 1.3 (0.3) 1.8 (0.4).3 (0.5) Wter Pressure recommended wter flow Feet Hed (mbr).34 (70) 5.35 (160) (310) Wter Pressure mx wter flow Feet Hed (mbr) 3.81 (114) 9.0 (75) (550) Wter Volume Gllon (liter) 0.79 (3) 1 (3.8) 1.1 (4.6) Vent/Air Intke Connections Ø Inch (Ø mm) (60) (60) (60) Vent Mterils CPVC, PVC, PP, PP Flex, Stinless Steel AL9-4C IPEX type IIA & IIB CPVC, PVC, PP, PP Flex, Stinless Steel AL9-4C IPEX type IIA & IIB CPVC, PVC, PP, PP Flex, Stinless Steel AL9-4C IPEX type IIA & IIB Mx operting temperture F ( C) 194 (90) 194 (90) 194 (90) Mx HE llowble temperture F ( C) 10 (98.9) 10 (98.9) 10 (98.9) Ambient storge temperture F ( C) 5 to 158 (-15 to 70) 5 to 158 (-15 to 70) 5 to 158 (-15 to 70) Ambient functioning temperture F ( C) 3 to 10 (0 to 49) 3 to 10 (0 to 49) 3 to 10 (0 to 49) Surfce het exchnger SQFT (m ) 8.61 (0.8) (1.0) 1.91 (1.) Stndrd Listings & Approvls CSA, ASME, AHRI CSA, ASME, AHRI CSA, ASME, AHRI Electricl Req. 10VAC/1PH/60Hz 1.5 FLA**.0 FLA** 3.4 FLA** Noise rting db Weight (dry) lbs (kg) 110 (50) 13 (60) 154 (70) Clernce to combustibles *** Inch (mm) (50.8) (50.8) (50.8) Dimension WxHxD Inch (mm) 0 x 39 5/8 x 15 3/8 (508x1006x388) 0 x 47 1/ x 15 3/8 (508x106x388) 0 x 47 1/ x 15 3/8 (508x106x388) AHRI certified rtings Unit Input MBH Heting Cpcity MBH AFUE % Net rting MBH CO (For Annul Vlidtion progrm only) % (*) With conversion. (**) FLA (Full Lod Amperge) - mximum current drwn by the boiler. (***) The minimum clernce is required for ll sides of the boiler. The boiler my be instlled on combustible (wood) floors excluding crpets. See Fig. 9 for minimum clernce recommendtion for servicebility (018/03) US

11 Product description 11.8 Efficiency Curves 100% 98% 96% 0% input 30% input 100% input Therml Efficiency 94% 9% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 6 Therml Efficiency Curves 85* * Therml Efficiency curve is for reference only s this is residentil boiler 100% 98% 96% 0% input 30% input 100% input Therml Efficiency 94% 9% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 7 Therml Efficiency Curves 10* * Therml Efficiency curve is for reference only s this is residentil boiler (018/03) US

12 1 Product description 100% 98% 96% 0% input 30% input 100% input Therml Efficiency 94% 9% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 8 Therml Efficiency Curves 160* * Therml Efficiency curve is for reference only s this is residentil boiler (018/03) US

13 Regultions 13 3 Regultions m Observe ll rules, regultions, stndrds nd guidelines mpplicble to the instlltion nd opertion of this pplince. m Vlves m externl to the boiler must be fitted with T-hndles nd condenste piping must be instlled in ccordnce with the Stte Plumbing Code. 3.1 Complince with stndrds nd regultions The instlltion must conform to the requirements of the uthority hving jurisdiction or, in the bsence of such requirements, to the ltest edition of the Ntionl Fuel Gs Code, ANSI Z3.1./NFPA 54. In Cnd, instlltion must be in ccordnce with the requirements of CAN/CSA B149.1, Nturl Gs nd Propne Instlltion Code. This condensing gs boiler complies in its design nd mode of opertion with the Americn Ntionl Stndrd ANSI Z1.13/CSA4.9, ltest edition for Gs Fired Low Pressure Stem nd Hot Wter Boilers. Other confirmed pprovls nd certifictions re indicted by lbels on the boiler. Where required by the uthority hving jurisdiction, the instlltion must conform to the Stndrd for Controls nd Sfety Devices for Automticlly Fired Boilers, ANSI/ASME CSD-1. Instll CO detectors per locl regultions. Boiler requires yerly mintennce (see section 7 Mintennce ). 3. Operting limits of the boiler The het exchnger hs been designed nd certified in ccordnce with the ASME Boiler nd Pressure Vessel Code, Section IV. The hot wter distribution system must comply with ll pplicble codes nd regultions. When replcing n existing boiler, it is importnt to check the condition of the entire hot wter distribution system to ensure sfe opertion. Common prctice clls for inspecting n existing system in its entirety nd bringing it up to code. All pipework should be properly clened nd flushed. 3.3 Additionl regultions for instlltion in Msschusetts () For ll side wll horizontlly vented gs fueled equipment instlled in every dwelling, building or structure used in whole or in prt for residentil purposes, including those owned or operted by the Commonwelth nd where the side wll exhust vent termintion is less thn seven (7) feet [150 mm] bove finished grde in the re of the venting, including but not limited to decks nd porches, the following requirements shll be stisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of instlltion of the side wll horizontl vented gs fueled equipment, the instlling plumber or gsfitter shll observe tht hrd wired crbon monoxide detector with n lrm nd bttery bckup is instlled on the floor level where the gs equipment is to be instlled. In ddition, the instlling plumber or gsfitter shll observe tht bttery operted or hrd wired crbon monoxide detector with n lrm is instlled on ech dditionl level of the dwelling, building or structure served by the side wll horizontl vented gs fueled equipment. It shll be the responsibility of the property owner to secure the services of qulified licensed professionls for the instlltion of hrd wired crbon monoxide detectors. -- In the event tht the side wll horizontlly vented gs fueled equipment is instlled in crwl spce or n ttic, the hrd wired crbon monoxide detector with lrm nd bttery bck-up my be instlled on the next djcent floor level. - - In the event tht the requirements of this subdivision cn not be met t the time of completion of instlltion, the owner shll hve period of thirty (30) dys to comply with the bove requirements; provided, however, tht during sid thirty (30) dy period, bttery operted crbon monoxide detector with n lrm shll be instlled. APPROVED CARBON MONOXIDE DETECTORS. Ech crbon monoxide detector s required in ccordnce with the bove provisions shll comply with NPA 70 nd be ANSI/UL 034 listed nd IAS certified. SIGNAGE. A metl or plstic identifiction plte shll be permnently mounted to the exterior of the building t minimum height of eight (8) feet bove grde directly in line with the exhust vent terminl for the horizontlly vented gs fueled heting pplince or equipment. The sign shll red, in print size no less thn one-hlf (.) inch in size, GAS VENT DIRECTLY BELOW. KEEP CLEAR OF ALL OBSTRUCTIONS. INSPECTION. The stte or locl gs inspector of the side wll horizontlly vented gs fueled equipment shll not pprove the instlltion unless, upon inspections, the inspector observes crbon monoxide detectors nd signge instlled in ccordnce with the provisions of 48 CRM 5.08()() 1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 48 CRM 5.08()() 1 through 4: The equipment listed in Chpter 10 entitled Equipment Not Required To Be Vented in the most current edition of NFPA 54 s dopted by the bord; nd Product Approved side wll horizontlly vented gs fueled equipment instlled in room or structure seprte from the dwelling, building or structure used in whole or in prt for residentil purposes. (c) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM REQUIRED. When the mnufcturer of Product Approved side wll horizontlly mounted gs equipment provides venting system design or venting system components with the equipment, the instructions provided by the mnufcturer for the instlltion of the equipment nd venting shll include: Detiled instructions for the instlltion of the venting system or the venting system components; nd A complete prts list for the venting system design or venting system. (d) MANUFACTURERS REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the mnufcturer of Product Approved side wll horizontlly vented gs fueled equipment does not provide the prts for the venting of flue gses, but identifies specil venting systems, the following requirements shll be stisfied by the mnufcturer: The referenced specil venting systems shll be included with the pplince or equipment instlltion instructions; nd The specil venting systems shll be Product Approved by the Bord, nd the instructions for tht system shll include prts list nd detiled instlltion instructions. (e) A copy of ll instructions for ll Product Approved side wll horizontlly vented gs fueled equipment, ll venting instructions, ll prts lists for venting instructions, nd/or venting design instructions shll remin with the pplince or equipment t the completion of the instlltion (018/03) US

14 14 Instlltion 4 Instlltion The recommended clernce for ese of instlltion nd service re illustrted in the following picture: 4.1 Pckging nd product identifiction The is delivered strpped to pllet, pcked nd protected in crdbord crton. WARNING: m In NOTICE: The pckging shows the chrcteristics of the product: model, power, fuel type nd version. In cse of devition from the order, contct your locl deler. After removing the pckging check the condition nd completeness of delivery. Keep the pcking mteril out of rech of children s it my be dngerous. Dispose of pckging in n environmentlly responsible mnner. m order to ensure proper product identifiction do not remove or tmper with ny product identifiction tgs or lbels. 0 (500mm) 40 (1000mm) (50mm) 4. Instlltion room The boiler must be instlled in rooms tht comply with ll locl, stte nd federl codes nd lws. Before commissioning the boiler verify exhust flue nd termintions re properly seled nd secured. Adequte combustion ir nd ventiltion is required for sfe nd proper instlltion of the boiler, regrdless whether the combustion ir is tken from the outside (Direct Vent, seled combustion) or inside (room ir for combustion). WARNING: Insufficient ventiltion of the boiler room cn led to high ir tempertures nd led to risk of personl injury or deth from flue gs poisoning! 0 (500mm) Mke sure tht intke nd exhust openings re sufficiently sized nd no reduction or closure of openings tkes plce. If these re not provided, do not operte the boiler (see section 4.7. Connecting flue gs ccessories ). The heting units cnnot be instlled outdoors. NEVER plce this pplince in loction tht would subject it to tempertures t or ner freezing or temperture tht exceed 10 F (49 C) while in opertion. Filure to properly locte this unit cn result in premture filure. This pplince must be instlled in loction so tht ny wter leking from the unit or piping connections or relief vlve openings will not cuse dmge to the re surrounding the unit or ny lower floors in the structure. When such loctions cnnot be voided, it is recommended tht suitble drin pn, dequtely drined, be instlled under the boiler. The pn must not restrict combustion ir flow. When instlled in room with thin flooring. Isolte the from direct contct with the floor to minimize noise trnsmission. Do not llow excessive dust to collect on the pplince. WARNING: If the informtion in these instructions is not followed exctly, fire or explosion my result cusing property dmge, personl injury or deth. Do not store or use gsoline or other flmmble vpors nd liquids in the proximity of this or ny other pplince. Instlltion nd service must be performed by qulified instller, service gency or the gs supplier. Plese consider the spce needed for ccessibility to sfety nd control devices nd for performing mintennce opertions. Fig. 9 4 (100mm) 4 (100mm) Recommended minimum clernces for instlltion nd servicing (dimension in inches [mm]) (50.8 mm) clernce from combustibles is permitted, but respect the clernce in Fig. 9 for servicebility. The boiler cn be instlled on combustible (wood) floor excluding crpets. NOTICE: This device is equipped with freeze protection function. For further informtion see section 5.8 Setting frost protection (018/03) US

15 Instlltion Wter Chemistry Guidelines NOTICE: If using nti-freeze: For freeze protection use only propylene glycol, with scle inhibitors, with mximum of 40% glycol. Frost protection level hs to be checked nnully during the regulr scheduled mintennce of the condensing boiler. NOTICE: System dmge! It is the instller s responsibility to ensure tht the heting system is comptible with the boiler type nd size instlled. ph-vlue of the heting wter to be kept between 6.5 nd 9. IMPORTANT: To void ny presence of oxygen in the system, it is dvised to prevent s little s possible ir during instlltion. Usul spots where ir is most likely to seep in re: gskets, pumps, ir vents nd O-rings. Using n utomtic wter fill system exposes the system to fresh oxygented wter. A minimum wter pressure is required for optimum performnce. Minimum wter pressure required: 7.5 psi (0.5 br). Before nd during ssembly, the system must be kept free of impurities, construction dust, snd, copper dust, grese, crbon deposits, etc., s well s soldering flux residue. In ny of these instnces, the old system must be rinsed with cler wter mixed with highly concentrted rinse gent. NOTICE: DO NOT use PVC for vent piping when using nti-freeze in the primry circuit of the boiler. Use CPVC, PP or stinless steel only!. Wter hrdness must fll within the following limits: 50 ppm of CCO 3 < (lkli strength) < 150 ppm of CCO 3. Use only untreted wter to fill the system. Do not use TSP (tri-sodium phosphte). Do not use fill wter treted with slt bedding type exchngers (ion exchnger). Never introduce non-pproved boiler tretment or similr dditives. Only use fill wter with hrdness below 7 grins. Filling with chlorinted wter is cceptble if chlorine levels re below 100 ppm. Consult locl wter tretment specilist for recommendtions if ny of the bove is outside the stted rnges. When using oxygen permeble PEX, the system must be seprted from the boiler by het exchnger. A correctly sized nd working expnsion vessel must be instlled. Do not exceed the mximum permissible flow rte through the boiler. Excessive flow cn cuse erosion dmge to the het exchnger. Eliminte System Leks: Continuous ddition of mke-up wter will constntly dd oxygen to the system nd led to corrosion. All system leks must be repired. In the following tble re listed the chemicl wter specifictions. Prmeters Units Vlue Generl feture - Colorless, no sediment Dissolved Oxygen mg/l < 0,05 Totl iron (Fe) mg/l < 0,3 Totl copper (Cu) mg/l < 0,1 N SO 3 mg/l < 10 N H 4 mg/l < 3 PO 4 mg/l < 15 Tb. 1 Wter specifiction 4.4 Hydrulic connection Hydrulic connection re shown in Fig., Fig. 3 nd Fig. 4. In the following tble re listed the pipe dimension for ech model: Model Ø Wter supply Ø Wter return connection connection NOTICE: Before connecting the boiler to the heting system, flush the heting system to remove sediment, flux, dirt, nd other foreign mtter. The het exchnger my be dmged by sediment or corrosion. Do not use clening fluids tht re not comptible with the boiler mterils, including cids (e.g. hydrochloric cid nd similr ones) t ny concentrtion Introducing fresh wter to the system increses the oxygen presence nd cn cuse corrosion of metllic components. Immeditely repir ny drips or leks in the system to void constnt introduction of ir into the system. Do not use the wter contined in the boiler for domestic use or s drinking wter or within swimming pools. Excessive fluctution in pressure chnges in the system cn cuse ftigue nd stress on the het exchnger. This is detrimentl to the integrity of the boiler nd system components, it is mndtory to mintin constnt operting pressure (018/03) US

16 16 Instlltion Low wter cut off A low wter cut off (LWCO) is instlled in the boiler, the mnul reset button is locted on the front of the internl control box. To check the functionlity of LWCO press the test button (the top button shown in Fig. 10). The LED on the block will light nd in the screen will pper the error MN: Low Wter Cutoff Error. At this point press the reset button (the bottom button). The LED will turn off. Restrt the boiler by pressing reset button on the removble disply Pressure relief vlve (PRV) ASME pproved The boiler is supplied with pressure relief vlve (PRV). The relief pressure for ech vlve for ech model of the boiler is shown in the following tble: Boiler model Relief Pressure psi (.07 br) psi (.07 br) psi (.07 br) The pressure relief vlve (PRV) must be piped to suitble drin to prevent injury if the vlve opens due to n overpressure sitution. Use pipe of the sme dimeter of the outlet of the vlve Fig. 10 LED LWCO test LWCO reset 4.4. High limit sfety switch A high limit sfety switch is instlled in the boiler. Refer to Fig. 11. To simulte high limit lockout t 08 F press the MENU nd OK buttons simultneously for 10 seconds. The control will disply MN: Mx. Thermostt Lock Error. At this point press the reset button on the removble disply to restrt the boiler Expnsion tnk An expnsion tnk must be instlled in the hydrulic system. The expnsion tnk must be properly sized for the boiler nd the system volume, temperture nd pressure. WARNING: An undersized expnsion tnk will cuse lekge of wter from the pressure relief vlve nd introduce fresh wter into the system. Excessive ddition of mkeup wter cn cuse corrosion of metllic components nd compromise the functionlity of the boiler. Refer to instructions provided by the mnufcturer of the expnsion tnk for detils on its instlltion nd sizing. Reset Fig (018/03) US

17 Instlltion Pump 85/10/160 boilers re fitted with circultor pump. The grph in the following figure shows the hed rnge of the pump depending on the flow rte compred to the relevnt pressure drop. 85 UPS15-58 HD pressure drop Hed vilble for the system t speed speed speed3 0 speed Flow rte / GPM Fig Pump curve m It m is importnt to ensure the pump hs the correct flow rte for the system to void low wter circultion sitution. In event of n indequte flow rte, the sfety devices of the boiler will utomticlly stop the burner (018/03) US

18 18 Instlltion 10 UPS5-78 HD Hed vilble for the system t speed3 10 pressure drop speed speed3 speed Flow rte / GPM Fig Pump curve 160 UPS5-78 HD Hed vilble for the system t speed3 160 pressure drop speed speed3 speed Flow rte / GPM Fig Pump curve (018/03) US

19 Instlltion Condenste removl The condenste wter produced by the boiler during its norml opertion is collected by condenste trp (A) provided with the boiler nd connected to the het exchnger. Tube (B) is the condenste outlet. specific purpose, becuse the cidic ction of condenste will cuse rpid deteriortion. Pitch the condenste drin pipe towrds the dischrge point voiding high points, which cn inhibit the flow. Do not run the condenste pipe through unconditioned res where it my freeze. NOTICE: Verify condenste disposl / neutrliztion is in ccordnce with federl stte nd locl regultions. A B Fig. 15 DANGER: The condenste trp A shown on Fig. 15, must be filled with wter or combustion gses will enter the room with risk of n excessive level of crbon monoxide. To fill the condenste trp dd wter to the vent (1) until you fill the condenste trp (3) with wter. 1 A condenste removl pump is required if the boiler is below the drin. When instlling condenste pump, select one pproved for use with condensing boilers. The pump should hve n overflow switch to prevent property dmge from condenste lekge. 4.5 Electricl connection Power supply cble connection To connect the boiler to the electricl supply, s required by locl, stte nd federl codes. The power supply cble cn be inserted into the boiler using one of the three knock out holes (A) on ech side s shown in Fig. 17. WARNING: All the electricl wiring must be secured by pproprite strin reliefs per electricl code requirements. To secure the supply cble inside of the boiler use the cble clmp shown in position B shown in Fig. 18. HO A Fig Fig. 16 The condenste is dischrged t tmospheric pressure, i.e. by dripping to the home sewge dringe system or into drin or drin pn. The boiler is equipped with three holes (in the right, left nd bck side) to crry the condenste out the dischrge pipe. Instll the condenste drin tube through the pproprite hole nd be sure to pitch wy from the boiler. Do not reduce the condenste drin pipe down strem. Plese dispose of condenste in complince per Federl, stte nd locl code requirements. Never use copper pipes or of other mteril not intended for the B Fig (018/03) US

20 0 Instlltion The generl electricl connection is shown in the following digrm : CASCADE LINK MOD BUS Gs Switch Out Door DHW Tnk Sensor Room Thermostt Supply Sensor L Boiler Pump N L Pump CH 3 Wy N Pump DHW L N L Alrm N L 10 V Aux N L 10 V Min in N (**) Outdoor sensor DHW tnk sensor or qustt L N DHW tnk pump Room thermostt Supply sensor L N Boiler pump Rely (*) Furnished nd Instlled by others L N 10 V Line System pump Ground 10 V Neutrl Fig. 19 (*) NOTICE: The mximum mp lod for ech pump (in ddition to the boiler pump) is Amps when 1 pump is connected. For this reson, if the power consumption of ech pump is higher thn 84 wtt, use rely s shown in figure. (**) NOTICE: line voltge Access to the electricl terminl strip To hve ccess to the internl terminl strip of the boiler follow the steps below (see Fig. 0). Rotte the lock t the top on the front pnel nd remove the front pnel s shown. Slide out the electricl box nd remove the two screw from the front. Remove the box cover to hve ccess to the terminl strip. Fig Room thermostt connection Connect the thermostt to terminls 11 nd 1 s shown in Fig Outside temperture sensor If outside temperture control is to be used, the outside probe needs to be connected to terminls 7 nd 8 s shown in Fig. 19. The outside probe shll be instlled on n outer wll, North or North/Est, wy from windows, door, nd ventiltion grids. Never instll the probe in position exposed to the sun. The mximum length is 300 (100 meter), if the cble length exceeds 3 (10 meters) shielded cble is required nd shll be connected to chssis ground. NOTICE: All Sensors nd low voltge wiring shll not be routed in direct contct or ner high voltge power (018/03) US

21 Instlltion Electricl wiring digrm FLUE PRESSURE SWITCH CASCADE LINK Jumper fctory instlled MOD BUS GAS SWITCH OUT DOOR LOW VOLTAGE IN / OUT DHW Tnk Sensor Room Thermostt Supply Sensor bl w HIGH VOLTAGE OUT PUMP CH PUMP DHW MAIN PUMP ALLARM 10 V AUX L N L N 3 WAY L N L N L N L N L HIGH VOLTAGE 10 V MAIN IN L N 118 brn blu brn blu brn blu brn blu brn blu brn blu brn blu bl w brn w bl w bl w bl w bl w blu o bl brn g blu bl blu brn bl w GND blu brn brn blu 4 V blu brn GND w bl bl brn brn bl w w brn GND blu w bl L brn bl brn w GND N blu bl w 4V w AR1 bl 10V w w 09 w bl bl w CHASSIS GROUND (Vi Boiler / Piping) TEST Externl Test Switch (Normlly Closed, Opens to Test) 08 bl bl 14 AR1 HIGH VOLTAGE 4 VAC HOT Mnul Reset Switch (Normlly Closed, Opens to Reset) RESET P GND PROBE AC COMMON Alternte Chssis Ground Connection brn= CABLE BROWN blu= CABLE BLUE bl= CABLE BLACK w= CABLE WHITE o= CABLE ORANGE g= CABLE GRAY L= LINE N= NEUTRAL grn/yel = Ground Fig. 1 Wiring digrm (018/03) US

22 Instlltion 4.6 Gs supply piping Verify tht the type nd the pressure of the gs supplied correspond with those required for the boiler. When field converting the boiler from Nturl to LP gs be sure to dhere the new gs lbel on the boiler [see section converting from Nturl Gs to LP for detils]. The minimum nd mximum pressure for nturl gs re 3.5 W.C. (8.7 mbr) nd 10.5 W.C. (6.15 mbr) respectively. The minimum nd mximum pressure for LP gs re 8 W.C. (19.9 mbr) nd 13 W.C. (3.3 mbr) respectively Connection of gs supply piping Connect the gs supply to the unit s follows: Instll ground joint union for servicing s required. Instll mnul shutoff vlve in the gs supply piping Instll sediment trp/ drip leg Purge ll ir from the gs supply piping. Before plcing the pplince in opertion, check the pplince nd its gs connection. Check the pplince nd its gs connection with lek test before plcing in opertion. WARNING: Gs piping must be supported with proper hngers nd not from the boiler itself or its devices nd ccessories. DANGER: WARNING: Never use n open flme to test for gs leks. Alwys use n pproved lek detection method. Filure to properly pply pipe seling compound cn result in severe personl injury, deth, or substntil property dmge. The Commonwelth of Msschusettes prohibits the use of copper tubing for the gs line Gs type conversion DANGER: Personl injury nd property dmge. This conversion shll only be performed by trined nd certified instller in ccordnce with the mnufcturer s instructions nd ll pplicble codes nd requirements of the uthority hving jurisdiction. If the informtion in these instructions is not followed exctly, or the instlltion, djustment, modifiction, opertion or mintennce is crried out by n unqulified person, fire, explosion or genertion of lrge mounts of crbon monoxide my result cusing property dmge, personl injury or loss of life. Before crrying out electricl work: Disconnect the pplince from the power supply t the emergency shutoff switch or by disengging the heting system circuit breker. Tke pproprite mesures to prevent ccidentl reconnection. The instller is responsible for the proper conversion of this pplince. The conversion is not complete until the opertion of the converted pplince is checked s specified in these instructions. The gs-ir rtio must lwys be set on the bsis of CO or O reding tken t mximum nominl output nd minimum nominl output using n electronic flue gs nlyzer. LP ORIFICE INSTALLATION (85 10) Nturl Gs to LP conversion The heting unit is fctory preset for operting with nturl gs. This set-up cn be chnged using the conversion kits supplied by the mnufcturer with ech boiler. NOTICE: This chnge my only be performed by n Licensed contrctor ccording to the following procedure. Converting from NATURAL GAS to LP Close the gs cock Disconnect the electric power supply from the boiler WARNING: to void electricl shock, it is mndtory to disconnect the boiler from the power supply using service disconnect externl switch. Remove the front pnel Unscrew the screws A nd the swivel joint B indicted in Fig. to seprte the vlve from the fn Seprting the two components, you cn see the hole where the gs psses with its gsket Remove the gsket D nd insert inside the provided metl orifice C Boiler model Orifice Dimeter (mm) Tb. Reinstll gsket D with LP metl orifice C. Check the condition of the gsket E. Replce if necessry Tighten the screws A Tighten the swivel joint B Switch the min power supply to ON Fig. D C A NOTICE: Mke sure there is no demnd or cll for het. Use the control pnel to enter in the prmeter list nd chnge the prmeter N 98 (Gs Type) from NG to LPG Reopen the gs shut-off cock Adjust the CO prmeter s explined in chpter 5.7 Adjusting nd setting CO limits Affix the gs type lbel from the gs conversion kit to the pplince (Fig. 4). E B (018/03) US

23 F (nme nd ddress of orgniztion mking this conversion), which ccepts the responsbility tht this conversion hs been properly mde. (nome ed dtrsse de l orgnisme effectunt cette conversion), qui ccepte l responsbilité de l bonne execution de cette conversion. Instlltion 3 LP ORIFICE INSTALLATION (160) Nturl Gs to LP conversion The heting unit is fctory preset for operting with nturl gs. This set-up cn be chnged using the conversion kits supplied by the mnufcturer. NOTICE: This chnge my only be performed by n uthorized Servicing Center, ccording to the following procedure. DIRECT VENT BOILER FOR EITHER DIRECT VENT INSTALLATION OR FOR INSTALLATION USING INDOOR COMBUSTION AIR CHAUDIÈRE À ÉVENT DIRECT PUT INSTALLATION AVEC ÈVACUATION DIRECTE OU AVEC AIR COMBURANT Ctegory Model Model no. IV Ctégorie Modèle Référence IV Converting from NATURAL GAS to LP Close the gs cock Disconnect the electric power supply from the boiler WARNING: to void electricl shock, it is mndtory to disconnect the boiler from the power supply using bipolr externl switch.. Remove the front pnel Unscrew the 3 screws A nd the swivel joint B indicted in Fig. 3 to seprte the vlve from the fn Seprting the two components, you cn see the hole where the gs psses with its gsket Insert the provided metl orifice C into the gsket D without removing the gsket itself Boiler model Orifice Dimeter (mm) Tb. 3 Check the condition of the gsket E. Replce if necessry Tighten the swivel joint B Tighten the 3 screws A Switch the min power supply to ON Fig. 4 Converted to LPG (Propne) with conversion kit X XXX XXX XXX Convertie vers LPG (Propne) vec le kit de conversion X XXX XXX XXX CO (mx. rte/ min rte) 10,7/10,3 % CO ( mx / min) 10,7/10,3 % Min. inlet gs pressure 1,99 kp 8,0 in.w. C. Min. pression d limenttion en gz 8,0 in.w. C. Mx. inlet gs pressure 3,3 kp 13,0 in.w. C. Mx. pression d limenttion en gz 13,0 in.w. C. Minfold pressure cfctory set - not djustble Pression à l conduite de gz cfctory set - not djustble Min. input rte 30,0 kw 10,360 Btu/hr Consommtion clorifique min. 10,360 Btu/hr Mx. input rte 150,0kW 511,800 Btu/hr Consommtion clorifique mx. 150,0kW 511,800 Btu/hr Output rte 144,0 kw 491,38 Btu/hr Puissnce utile nominl 144,0 kw 491,38 Btu/hr Minimun relief vlve cpcity 3,1 kg/hr 511,8 lbs/hr Cpcité minimle de l souppe de sécurité 3,1 kg/hr 511,8 lbs/hr Altitude m ft Altitude m ft (Refer to instlltion instruction for higher ltitudes) (Se référ à l notice d instlltion en cs d ltitude plis élevée) This boiler ws converted on to gs. By Affixing the gs type lbel 4.7 Venting nd ir piping system WARNING: Do not connect this gs pplince with ny other pplince unless pproved by mnufcturer. Filure to comply with this WARNING could result in the ccumultion of crbon monoxide gs which cn cuse severe personl injury or deth. WARNING: DANGER: Do not connect models 85, 10 nd 160 to shred/common or cscde vent system. Ech boiler must hve seprte, dedicted vent system. (dy - month - yer) Ce ppreil été converti le gz pr (jour- mois- nnée) en X XXX XXX XXX (015/04) The condenste trp must be filled with wter or combustion gses will enter the room with risk of n excessive level of crbon monoxide. For instruction see section E B NOTICE: DO NOT use PVC for vent piping when using nti-freeze in the primry circuit of the boiler. Use CPVC, PP or stinless steel only!. Fig. 3 D C A IMPORTANT: Mke sure there is no het demnd from the thermostt inputs. Reopen the gs shut-off cock Use the control pnel to enter in the prmeter list nd chnge the prmeter N 98 (Gs Type) from NG to LPG Adjust the CO prmeter s explined in chpter 5.7 Adjusting nd setting CO limits Affix the gs type lbel from the gs conversion kit to the pplince (Fig. 4). Mke sure tht the combustion ir is not contminted by: Permnent wve solutions; Chlorinted wxes/cleners; Chlorine-bsed swimming pool chemicls; Clcium chloride used for thwing Sodium chloride used for wter softening; Refrigernt leks; Pint or vrnish removers; Hydrochloric cid/muritic cid; Cements nd glues; Antisttic fbric softeners used in clothes dryers; Chlorine-type bleches, detergents, nd clening solvents found in household lundry rooms; Adhesives used to fsten building products nd other similr products. In ny cse to prevent contmintion do not connect the suction nd dischrge ner: Dry clening/lundry res nd estblishments; Swimming pools; Metl fbriction plnts; Beuty shops; Refrigertion repir shops; (018/03) US

24 4 Instlltion Photo processing plnts; Auto body shops; Plstic mnufcturing plnts; Furniture refinishing res nd estblishments; Remodeling res; Grges with workshops Generl venting nd combustion ir piping system The boilers require n pproved vent system-designed for pressurized venting Vent connectors serving pplinces vented by nturl drft shll not be connected to ny portion of mechnicl drft systems operting under positive pressure. Ensure tht the flue pipes nd sels re not dmged. Use only seling compounds (primer nd glue) pproved for use with the vent mteril. Never instll brometric or thermlly controlled vent dmper with this boiler. Do not route the flue system piping through or inside nother duct tht is used for exhusting ir or other flue gses. The condenste trp must be primed t ll times. Filure to do so my llow combustion gses to escpe into boiler room. The unit is to be used for either direct vent instlltion or for instlltion using room ir for combustion. When room ir is used, it is necessry to provide n dequte opening for the fresh ir intke. You must use ny of the vent/ir piping methods shown in this mnul. Be sure to locte the unit such tht the vent nd combustion ir piping cn be routed through the building nd properly terminted. The vent instlltion must be in ccordnce with Venting of Applinces, of the ltest edition of the Ntionl Fuel Gs Code, ANSI Z3.1/ NFPA 54 or section, Venting Systems nd Air Supply for Applinces, of the CAN/ CSA , Nturl Gs nd Propne Instlltion code or pplicble provisions of the locl, stte nd federl building codes. All vent pipes must be instlled ccording to the vent mnufcturer s instructions. The exhust vent nd the combustion ir inlet lines must be supported to prevent sgging per the vent mnufcturer s instructions. Do not mix components from different systems. The vent system could fil, cusing lekge of flue products into the living spce. Use only pproved mterils. Use of cellulr core PVC nd CPVC for venting system is not llowed. WARNING: Improper venting due to filure to comply with the wrnings bove cn result in excessive levels of crbon monoxide! The exhust pipe must be pitched minimum of 1/4 inch per foot bck to the boiler (to llow dringe of condenste). The vent system shll be instlled so s to prevent the ccumultion of condenste. Consult locl nd stte codes pertining to specil building code nd fire deprtment requirements. Adhere to ntionl code requirements. The boiler must be vented in ccordnce with the Venting of Equipment section of the ltest edition of ANSI Z 3.1 / NFPA 54 Nturl Fuel Gs Code nd/or the Venting systems nd ir supply for pplinces section of the ltest version of CAN/CGA B149.1 Nturl Gs nd Propne Instlltion Code in Cnd nd in ccordnce with ll pplicble locl building codes. Observe the listed mximum lengths of vent system, which re boiler model dependent To void moisture nd frost build-up nd to mintin clernces to openings on djcent structures, 45 nd 90 elbows or tees my be ttched to the end of the vent termintion pipe to direct exhust plumes wy from the djcent structure. The totl llowble vent length, mximum number of elbows nd distnce to ir intke restrictions must be dhered to. Due to the high efficiency of the unit it my dischrge wht looks like white smoke especilly when the outside ir temperture is cold. This is due to the presence of wter vpor, normlly present in the flue. The following figure shows the cceptble piping instlltion for venting nd combustion ir. Two pipes side wll (Direct venting) Two pipes verticl (Direct venting) Air intke side wll, vent verticl (Direct venting) Air intke verticl, vent side wll (Direct venting) Fig. 5 Concentring verticl pipe (Direct venting) Concentring side wll pipe (Direct venting) One pipe venting side wll (or verticl) (Not direct venting) (018/03) US

25 Instlltion Connecting flue gs ccessories Approved vent systems re: Twin pipe, concentric pipe nd 1 pipe using room ir PVC / CPVC / Stinless Steel Approved mterils PVC, CPVC, Stinless Steel, PP nd PP-Flex (M&G Durvent PolyPro nd Centrotherm InnoFlue) Seled combustion or room ir intke Termintions cn be either horizontl or verticl, see detils following The dimeters of the flue outlet nd combustion ir intke inlet re designed to fit stndrd PP, PVC, CPVC nd stinless steel pipes. The following tble gives the dimeter of the flue dpter on the boiler. Boiler Dimeters - 60mm - 60mm - 60mm Tb. 4 Insert the exhust pipe nd the ir intke pipe s shown in the following figure: A C B Fig. 7 D Instlltion of the exhust nd ir intke system NOTICE: Do not extend exposed vent pipe outside the building beyond Do not extend exposed vent pipe outside the building beyond recommended distnce of 39 or 1 meter. Condenste could freeze nd block vent pipe Vent should terminte t lest 3 feet (915 mm) wy from djcent wlls, inside corners nd 5 feet (155 mm) below roof overhng ( [X], [X4], see Fig. 8) Fig. 6 Insert the flue exhust pipe A completely into the dpter nd tighten the clmp B present in the flue exhust dpter. Insert the ir intke pipe C completely into the dpter nd tighten the clmp D present in the ir intke dpter. The correct flow direction into two pipes is shown in Fig (018/03) US

26 6 Instlltion 3 3 X 1 X 4 X 1 X 3 X 5 X 3 X 3 X 3 Y B X X 1 3 Y A 1 Y A Fig. 8 Direct vent (seled combustion) [1] Forced ir inlet [] Grvity ir inlet [3] Exhust terminl X1 1 foot (305 mm) X 3 feet (915 mm) see Note ) X3 1 foot (305 mm) USA 3 feet (915 mm) Cnd X4 See Note 1) X5 7 feet (135 mm) (see Note ) YA At lest 1 foot (305 mm) bove grde or snow line YB Exhust terminl must be t lest: 3 feet (915 mm) bove forced ir inlet within 10 feet (3050 mm) horizontlly USA 6 feet (915 mm) bove forced ir inlet - Cnd Fn ssisted pplince (Room ir for combustion) [1] Forced ir inlet [] Grvity ir inlet [3] Exhust terminl X1 1 foot (305 mm) X See Note 1) X3 1 foot (305 mm) USA 3 feet (915 mm) Cnd X4 See Note 1) X5 7 feet (135 mm) see Note ) YA At lest 1 foot (305 mm) bove grde or snow line YB Exhust terminl must be t lest: 3 feet (915 mm) bove forced ir inlet within 10 feet (3050 mm) horizontlly USA 6 feet (915 mm) bove forced ir inlet - Cnd It is not recommended to terminte vent bove ny door or window, condenste cn freeze cusing ice formtions. Do not use chimney s rcewy if nother boiler or fireplce is vented into or through chimney. All PVC/CPVC vent pipes must be glued, except for the flue gs dpter pipe connection. NOTICE: DO NOT use PVC for vent piping when using nti-freeze in the primry circuit of the boiler. Use CPVC, PP or stinless steel only!. Vent termintions must keep the following minimum clernces from electric meters, gs meters, regultors nd relief equipment: 4 feet (10 mm) [Cnd 6 feet (1830 mm)] horizontlly nd in no cse bove nd below, unless horizontl distnce of 4 feet (10 mm) [Cnd 6 feet (1830 mm)] is mintined. NOTES: 1) For Clernces not specified in ANSI Z3.1 / NFPA 54 or CSA B149.1 Clernce in ccordnce with locl instlltion codes nd the requirements of the gs supplier including the Authority hving jurisdiction. ) A vent shll not terminte directly bove sidewlk or pved drivewy tht is locted between single fmily dwellings nd serves both dwellings (018/03) US

27 Instlltion 7 Mteril Item Stndrd [USA] PVC schedule 40, 80 1 Flue gs or combustion ir PVC-DWV CPVC schedule 40, 80 PP [pproved vendor(s)/ mteril - M&G Durvent PolyPro nd Centrotherm Innoflue SW] PP-Flex [pproved vendor(s)/prt number - M&G Durvent PPS- FLEX (5, 50) or 3PPS-FLEX (5, 50] Stinless Steel AL9-4C PVC CPVC Tb. 5 Flue gs or combustion ir Flue gs or combustion ir Flue gs or combustion ir Flue gs or combustion ir Flue gs or combustion ir ANSI/ASTM D1785 ANSI/ASTM D665 ANSI/ASTM F441 ANSI Ct IV Approved Polypropylene ANSI Ct IV Approved Polypropylene UL1738 Stndrd [Cnd] BH Gs venting systems, ULC S636, Clss IIA - PVC, Clss IIB - CPVC, Clss IIC - Polypropylene 85 (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) Pipe dimeter per boiler 10 (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) 160 (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) (60mm) 3 (80mm) 4 (100mm) Pipe cement/ primer ANSI/ASTM D564 X X X Pipe cement/ primer ANSI/ASTM F493 X X X Approved Flue gs or combustion ir mterils nd fittings per boiler 1 Components of the certified vent systems must not be interchnged with other vent systems or unlisted pipe fittings. Plstic components, nd specified primers nd glues of the certified vent system must be from single system mnufcturer nd not intermixed with other system mnufcturer s vent system prts. For instlltions in Cnd, field supplied plstic vent piping must comply with CAN/CGA B149.1 (ltest edition) nd be certified to the Stndrd for Type BH Gs Venting systems. ULC S636. The supplied vent connector nd seprte vilble vent termintions re certified s prt of the boiler. Stndrd stright pipes, 90 -elbows or Tees re pproved s roof or wll termintions in ll the pproved mterils. Furthermore the following termintions re pproved. For detils plese refer to the supplier s informtion. Roof Terminl Mteril Supplier Prt Number Ø (100 mm) Ø 3 (15 mm) Ø 4 (100mm) Concentric kits Ø / Ø 4 (Ø 60/100 mm) Concentric Ø 3 / Ø 5 (Ø 80/15 mm) Concentric Ø 4 /6 (100/150 mm) Concentric Ø (Ø 50 mm) Chimney Cp Ø 3 (Ø 80 mm) Chimney Cp Tb. 6 Roof terminls PVC or CPVC PP PP PP PP Flex PP Flex IPEX System 636 Type II & IIb M&G Durvent PolyPro or Centrotherm InnoFlue M&G Durvent PolyPro or Centrotherm InnoFlue M&G Durvent PolyPro or Centrotherm InnoFlue M&G Durvent PolyPro or Centrotherm InnoFlue M&G Durvent PolyPro or Centrotherm InnoFlue (PVC) (PVC), (CPVC) (PVC), (CPVC) PPS-VKL (-TCL) (M&G Durvent) or ICRT439 (Centrotherm) 3PPS-VKL (-TCL) (M&G Durvent) or ICRT3539 (Centrotherm) 4PPS-VKL (-TCL) (M&G Durvent) or (ICRT4679)Centrotherm PPS-FCTL(M&G Durvent) or ISCP0 (Centrotherm) 3PPS-FTCL(M&G Durvent) or ISCP03 (Centrotherm) (018/03) US

28 8 Instlltion Wll Terminl Mteril Supplier Prt Number 3" (80 mm) prllel stinless steel Fields Ø (60 mm) Ø 3 (80 mm) Concentric kits Ø (60 mm) Ø 3 (15mm) Wll termintion kit Ø (60 mm) Ø 3 (80 mm) Low profile termintion kit Ø 3 (Ø 80 mm) twin pipe termintion Ø 4 (Ø 100 mm) twin pipe termintion Ø 3 (Ø 80 mm) twin pipe termintion Ø 4 (Ø 100 mm) twin pipe termintion (60mm) single pipe horizontl termintion Ø 3 (Ø 80 mm) single pipe horizontl termintion / 4 (80/15 mm) concentric termintion 3 / 5 (80/15 mm) concentric termintion Tb. 7 Wll terminls PVC or CPVC IPEX System 636 PVC IPEX System 636 PVC IPEX System (PVC) (PVC), (CPVC) PVC/prllel stinless steel ANSI/ASTM D1785 or Field Controls PVC/prllel stinless steel ANSI/ASTM D1785 or Field Controls PP M&G Durvent PolyPro or Centrotherm InnoFlue 3PPS-HTPL (M&G Durvent) Or ISLPT0303 (Centrotherm) PP M&G Durvent PolyPro 3PPS-HTPL (M&G Durvent) PP PP M&G Durvent PolyPro M&G Durvent PolyPro or Centrotherm InnoFlue PPS-HSTL 3PPS-HSTL (M&G Durvent) PPS-HSTL (M&G Durvent) or ICWT35 or ICWS3513 (Centrotherm) 3PPS-HKL (M&G Durvent) or ICWT35 or ICWS3513 (Centrotherm) Vent nd combustion ir pipe length [For single boiler instlltions] The mximum length for vent nd combustion ir pipes cn be found in the following tble. Plese note the length is for ech vent / combustion ir pipe nd not combined Ø (60 mm) 50 ft (15 m) 50 ft (15 m) 50 ft (15 m) Ø3 (80 mm) 60 ft (18 m) 60 ft (18 m) 60 ft (18 m) Ø4 (110 mm) 80 ft (4 m) 80 ft (4 m) 80 ft (4 m) Tb. 8 Mximum length for ir nd combustion pipe In the following tbles re listed the equivlent length for PVC/CPVC pipes nd PP pipes: Ø (60 mm) Ø3 (80 mm) Ø4 (100 mm) 1 ft vent pipe 1 ft 1 ft 1 ft 45 elbows.5 ft 3 ft 4 ft 90 elbows 5 ft 6 ft 7 ft Tb. 9 Equivlent length for PVC nd CPVC pipes Ø (60 mm) Ø 3 (80 mm) Ø 4 (110 mm) Ø 5 (130 mm) Ø 6 (150 mm) Ø 8 (00 mm) 1 ft vent pipe 1 ft 1 ft 1 ft 1 ft 1 ft 1 ft 1 ft flex pipe ft ft ft ft N/A N/A 45 elbows 3 ft 3 ft 5 ft 6 ft 6 ft 13 ft 90 elbows 5 ft 7 ft 1 ft 14 ft 14 ft 19 ft Tee 9 ft 1 ft 19 ft 1 ft ft 9 ft Tb. 10 Equivlent length for PP pipes For the equivlent vent length of Stinless Steel AL9-4C venting mteril nd the roof nd wll terminls plese refer to the instlltion mnul of the vent system supplier. To clculte the llowed length of vent nd combustion ir system follow this exmple: When using 85 with Ø (Ø 60 mm) PP system with 3 x 45 -elbows nd 90 -elbow s termintion, then the totl venting length my not exceed 50 ft. ( 15 m) elbow = 3 x 3 ft. (0.9 m) = 9 ft. (.7 m) elbow terminl = 5 ft. (1.5 m). Totl friction loss equivlent =14 ft. (4. m) Totl venting length for this exmple is: 85 = 50 ft. (15 m) 14 ft. (4.m) = 36 ft. (11 m) ech for the intke nd exhust piping. When the totl flue system equivlent length is verified it is necessry to set the pr N 99 Flue length rnge ccording to the totl length of the instlled flue system s defined in the following tble: Vlue for pr 99 System with Mx. eq. length of 3 System with Mx. eq. length of 4 System with Mx. eq. length of 1 0 to 5 ft 0 to 30 ft 0 to 40 ft 6 to 50 ft 31 to 60 ft 41 to 80 ft 3 51 to 75 ft 61 to 90 ft 81 to 10 ft 4 76 to 100 ft 91 to 10 ft 11 to 160 ft Tb. 11 Vlue for the pr N 99 depending on the sum of equivlent length of vent nd combustion ir pipe (018/03) US

29 Instlltion 9 Defining the correct vlue to ssign to pr N 99 follow this exmple: When using 85 with (60 mm) PP venting mteril the mximum equivlent length is 50 feet for both vent nd combustion ir piping. Consider the equivlent length of vent pipe is 36 ft. nd the combustion ir pipe is ft. First step is to verify tht both the vent nd combustion ir pipe is less thn 50 ft: 36<50 : verified < 50 : verified The sum of equivlent length of vent nd combustion ir pipe is: 36+=58 ft. See Tb. 9 for defining prmeter 99. Column - System with Mx eq. length of 50 ft + 50 ft. The exmple provided totl equivlent length of 58 ft. which flls in between ft found on row 3. So pr N 99 = 3. 1 X Approved exmples of horizontl nd verticl venting instlltion m Plce pipe supports every 5 feet (1,55 mm) of horizontl mnd verticl run, beginning with support ner boiler. The condenste must be disposed of in ccordnce with pplicble rules. Periodic clening of the vent terminl nd ir-intke screens is mndtory. Avoid locting vent terminls ner equipment or building fetures which cn be subject to degrdtion from exhust gses. If multiple boilers re instlled in row, llow t lest 1 foot (305 mm) clernce between the vent termintion of one nd the combustion ir intke of the other. In the following figures the ir intke pipe is indicted with the number 1 (one) nd the vent pipe with the number (two) Fig. 30 Horizontl venting system (room ir only); X 4 (10 mm) X Y 1 1 Fig. 31 Verticl venting system (room ir only); X > 1 (305 mm); Y 1 bove mximum snow level or t lest 4 whichever is greter Fig. 9 Horizontl venting system (room ir only) (018/03) US

30 Y X X Y X Y 30 Instlltion X Y Fig. 3 Horizontl venting system (seled combustion); X 4 (10 mm); Y 1 (305 mm) Fig. 34 Verticl venting system (seled combustion); X > 1 ; Y 1 bove mximum snow level or t lest 4 whichever is greter 1 1 Fig. 33 Verticl venting system (seled combustion); Y 1 bove mximum snow level or t lest 4 whichever is greter Fig. 35 Horizontl venting system (seled combustion) (018/03) US

31 Y X Instlltion Fig. 38 Horizontl concentric system (seled combustion) Fig. 36 Horizontl venting system (seled combustion) ; 3 is wll termintion 1 X 1 Fig. 37 Horizontl venting system (seled combustion); X 4 (10 mm) Fig. 39 Verticl venting system (seled combustion) ; ); X > 1 (305 mm); Y 1 bove mximum snow level or t lest 4 whichever is greter (018/03) US

32 3 Instlltion 1 H>. inch w.c. Fig. 40 Verticl venting system (seled combustion) Fig. 4 Recommended dditionl condenste drin for high vent stck Flexible vent nd combustion ir pipe 1 H>. inch w.c. Fig. 41 Verticl venting system (seled combustion) Fig. 43 Recommended dditionl condenste drin for long horizontl vent piping (018/03) US

33 Instlltion 33 Air intke Vent Air intke Vent X Y Y Multiple boiler WARNING: Do not connect models 85, 10 nd 160 to shred/common or cscde vent system. Ech boiler must hve seprte, dedicted vent system. When instlling multiple ir nd vent termintions, be sure tht: The clernce between the vent nd ir termintion re in ccordnce with the figures shown in this chpter All vent pipes nd ir inlet must terminte t the sme height X Y X Y Fig. 47 Multiple ir nd vent verticl termintion; X 1 ; Y 1 Vent Air intke Vent Air intke Fig. 44 Concentric vent nd combustion ir verticl termintion; X 1 ; Y 1 (18 for Cnd nd/or per CAN/CSA B149.1) bove highest snow level. Mximum 4 bove roof X Combustion ir intke X Y Vent Fig. 48 Multiple ir nd vent verticl termintion; X 1 ; Y 1 Vent terminls Y Vent terminls Fig. 45 Concentric vent nd combustion ir horizontl termintion; X 1 min or mx; Y 4 ; Note: the level of the termintion must be the sme t 1 min from grde or snow line Z Air intke Vent Air intke Vent X Air intke Fig. 49 Multiple ir nd vent verticl termintion ; X 1 ; Y 5 ; Z = 1 to 16 Fig. 46 Multiple ir nd vent verticl termintion; X 1 ; Y (018/03) US

34 34 Commissioning (for single ppliction) 5 Commissioning (for single ppliction) 5. Setting dte nd time Press the menu button nd select Settings using the UP/DOWN button. 1 8 Menu Domestic Hot Wter Informtion Settings System Test Fig Press the OK button nd select Generl Settings using the UP/DOWN button. Settings Generl Settings Boiler Settings Fig. 50 No. Description 1 ON/OFF power switch Reset button 3 Menu button 4 ESC button 5 PC service connection 6 OK button 7 UP/DOWN/LEFT/RIGHT button 8 Disply 5.1 Switching the pplince ON/OFF Switch the pplince ON using the ON/OFF switch. The disply will pper s follow: 70.0 F Fig DHW Setpoint 10.0 F 04:9 pm In the left of the disply is shown the externl temperture 1 (if connected to n outdoor sensor). In the right of the disply is shown the set setpoint vlue. In the top right side is displyed the time 3. To switch off the pplince use the ON/OFF switch. 3 Fig. 53 Press the OK button nd select Dte & Time using the UP/DOWN button. Generl Settings Lnguge Unit type Dte & Time Other settings Fig. 54 Press the OK button. The disply will pper s follow: Dte & Time Dte: Sun 10/5/015 Time: 03:0 pm Time Zone Settings Disply Settings Fig. 55 Press the OK button to highlight the vlues. The vlues cn be chnged using the UP/ DOWN keys. When the vlue entered is correct then press OK to insert the next vlue (018/03) US

35 Commissioning (for single ppliction) 35 Entering in Time Zone Settings menu it is possible to set the time zone prmeter s shown in the following figure: Time Zone Settings Time Zone Correction UTC Dylight Svings Time Disbled Fig. 56 To modify the visuliztion of the dte nd time vlue, entering in the Disply Settings menu it is possible to chnge the following fetures: Disply Settings Time Nottion Dte Order Dy Of Month Month 4h DMY Digits Digits m CH m setpoint cnnot be chnged when outdoor reset function is enbled. See section 5.5 Prmeters list for detiled instructions regrding outdoor reset. The DWH setpoint cn only be chnged, when the DHW function is enbled. See section 5.5 Prmeters list. It is possible to chnge the CH nd the DHW setpoint directly from the first disply pge; logiclly the chnge of the two setpoint must to be enbled: when the text in the lower left side is CH Setpoint press the RIGHT button. The vlue shown in the lower right side will be highlighted; using the UP/DOWN keys it is possible to chnge the vlue. Once ssigned the vlue desired press the RIGHT button. The new vlue will be stored. To chnge the DHW setpoint press the UP/DOWN keys. The string in the lower left side will chnge in DHW Setpoint. Now it is possible to chnge the DHW setpoint in the sme wy in which we described the other opertion F 04:9 pm Fig. 57 DHW Setpoint 10.0 F Disply Settings Yer 4Digits Dte Seprtion Chrcter - Dy Of Week Short Text Seconds No Fig Setting CH nd DHW setpoint To chnge the CH nd DHW setpoint in the Centrl Heting nd Domestic Hot Wter menu, press menu select [see Fig. 59 below] use UP/DOWN rrows to choose prmeter nd select by pressing the OK button. Once selected use the right rrow key to highlight the vlue, nd use the UP/DOWN rrow to chnge selected vlue. Press OK to confirm/sve new vlue. Menu Centrl Heting Domestic Hot Wter Informtion Settings Fig. 59 Fig Boiler informtion To show in the screen the most importnt system informtion press menu button nd select Informtion using the UP/DOWN keys. Menu Centrl Heting Domestic Hot Wter Informtion Settings Fig. 6 Press OK nd the screen below will pper: Informtion Softwre Versions Boiler Sttus Fig. 63 Menu Centrl Heting Domestic Hot Wter Informtion Settings Fig (018/03) US

36 36 Commissioning (for single ppliction) Selecting Boiler Sttus nd pressing OK for the following vlues: Flow Temperture Return Temperture DHW Temperture [Sensor must be connected to show vlue. If not, the defult vlue will pper] Outside Temperture Flue Temperture [Sensor must be connected to show vlue. If not, the defult vlue will pper] System Temperture [Sensor must be connected to show vlue. If not, the defult vlue will pper] Fn Speed Ioniztion Stte Error The disply shows four lines t time: Boiler Sttus Flow Temperture F Return Temperture F DHW Temperture F Outside Temperture 50.0 F Fig. 64 Using the UP/Down button it is possible to scroll list. 5.5 Prmeters list To hve ccess to the prmeter list press menu button nd select Settings using the UP/DOWN button: Menu Domestic Hot Wter Informtion Settings System Test Fig. 65 Press the OK button nd select Boiler Settings using the UP/DOWN button. Settings Generl Settings Boiler Settings Press the OK button. At this point is request pssword [Pssword is required for boiler settings only]: Fig. 67 Enter one digit t time using the UP/DOWN button to increse/decrese the vlue. When the vlue is correct then press OK. In the system there is pssword for the three levels: Level 1: (no pssword needed i.e. pssword N 0000) USER Level : (pssword 0300 ) INSTALLER 5.6 Outdoor reset To set the outdoor reset curve enter in Centrl Heting (CH) menu nd press OK. The disply will pper s follow: Fig. 68 Pssword 0 * * * Outdoor reset 194 Des. Supply T. 180 F Bs. Supply T. 104 F 3 5 WW Shutdown 70 F 95 Bs. Outd. T. 70 F T_Outside [ F] Des. Outd. T. 5 F Setp. [ F] Des. Supply T nd Des. Outd T will be highlighted to chnge either vlue press OK : Use up/down rrows to chnge the Des. Supply T. Use the left/right rrows to chnge the Des Outd. T Press ok to sve chnges 3 Use the left/right rrows to select the other vlues Repet steps 1 thru 3 to mke dditionl chnges Once set the prmeters press Esc to exit the menu. Fig (018/03) US

37 Commissioning (for single ppliction) 37 Below is list of prmeters: Number Description Unit Defult Min Mx Step 3 CH Setpoint C / F 176 F 68 F 194 F 0.9 F 19 Design Supply Temp C / F 176 F 68 F 194 F 1.8 F 1 Bseline Supply Temp C / F 104 F 68 F 194 F 1.8 F 48 DHW/Tnk Setpoint C / F 10. F 104 F 140 F 0.9 F 64 Prehet Mode - Comfort Eco Comfort - 7 Permit emergency mode - Yes No Yes - Tb. 1 Level 1 prmeters Number Description Unit Defult Min Mx Step 1 Centrl Heting (CH) Mode Pump Mode System Pump Overrun Seconds Boiler Pump Overrun Seconds CH Hysteresis C / F 5.4 F 0 36 F 0.9 F 9 Anti Cycle Period Seconds Anti Cycle Temp Diff C / F 1.6 F 0 F 36 F 0.9 F 11 Rmp Dely Step Mod. On / Off Disbled 14 Mx Power CH % Min Power CH/DHW % Design Outdoor Temp C / F 4.8 F -13 F 77 F 1.8 F Bseline Outdoor Temp C / F 69.8 F 35.6 F 86 F 1.8 F 3 Design Supply Min Limit C / F 68 F 39. F F 1.8 F 4 Design Supply Mx Limit C / F 194 F 80.6 F 194 F 1.8 F 5 Wrm Wether Shutdn C / F 69.8 F 35.6 F 95 F 1.8 F 6 Boost Temp Increment C / F 0 F 0 F 54 F 0.9 F 7 Boost Time Dely Minutes Night Setbck Temp. C / F 18 F 0 F 90 F 0.9 F 9 Wether Setpoint C / F 68 F 3 F 1 F 0.9 F 35 DHW Mode DHW Tnk Hyst. Down C / F 7. F 0 F 36 F 0.9 F 37 DHW Tnk Hyt. Up C / F 0 F 0 F 36 F 1.8 F 38 DHW Tnk Supply Extr C / F 54 F 0 F 54 F 0.9 F 4 DHW Priority DHW Mx Priority Time Minutes DHW Pump Overrun Seconds Boiler Address Emergency Setpoint C / F 113 F 68 F 149 F 0.9 F 75 Dely Per Strt Next Dep. Seconds Dely Per Stop Next Dep. Seconds Hyst Down Strt Boiler C / F 9 F 0 F 36 F 0.9 F 78 Hyst Up Stop Boiler C / F 3.6 F 0 F 36 F 0.9 F 79 Mx Setp Offset Down C / F 7. F 0 F 36 F 0.9 F 80 Mx Setp Offset Up C / F 18 F 0 F 36 F 0.9 F 81 Strt Mod Dely Fct Minutes Next Boiler Strt Rte % Next Boiler Stop Rte % Boiler Rottion Intervl Dys DHW Boiler Assign Tb. 13 Level prmeters (018/03) US

38 38 Commissioning (for single ppliction) Number Description Unit Defult Min Mx Step 89 Frost Protection Off / On Disbled Disbled Enbled - 90 Frost Protection Setpoint C / F 50 F 33.8 F 68 F 0.9 F 91 DHW Mx Limit C / F 140 F 104 F 158 F 0.9 F 9 Fn Speed Mximum RPM * * * Fn Speed Minimum RPM * * * Fn Speed Ignition RPM * * * Applince Model ** - * Gs Type - NG NG LPG 99 Flue length rnge Tb. 13 Level prmeters (*) Depend on pplince type (**) The vlue for this prmeter is: 4 for for 10 6 for (018/03) US

39 Commissioning (for single ppliction) Adjusting nd setting CO limits NOTICE: Plese verify prmeter 99 is to be set first. Insert combustion nlyzer probe into the test port A s shown in Fig. 69. CO + A CO + B A Fig. 70 Gs vlve screw regultion for 85 nd 10 Fig. 69 Press Menu key. Select System Test : Menu Domestic Hot Wter Informtion Settings System Test In System test menu select High Power using Up/Down keys nd press OK : ù CO + B CO + A (*) System Test Test Stte Fn Speed Ionistion High Power 0 rpm 0.0 μa The Test Sttus switches to on nd in the disply will pper the fn speed. Wit or 3 minutes to to rech stedy stte conditions nd record the CO vlue. To djust the CO vlue t the mximum power turn the screw A shown in Fig. 70 (for 85 nd 10) nd in Fig. 71 (for 160), llen type wrench is necessry for this djustment. Fig. 71 Gs vlve screw regultion for 160 Verify tht the vlue of CO is stble nd is within the rnge indicted in the following tble (be creful to mke smll chnges nd confirm tht the vlue is stble before mking dditionl djustment). Select Low Power using UP/Down button nd press OK : System Test Test Stte Fn Speed Ionistion Low Power 0 rpm 0.0 μa (018/03) US

40 40 Troubleshooting The fn will run t the minimum speed. To djust the CO vlue t the minimum power turn the screw B shown in Fig. 70 nd in Fig. 71. Verify tht the vlue of CO is stble nd is within the rnge indicted in the following tble (be creful to mke smll chnges nd confirm tht the vlue is stble before mking dditionl djustment). Select OFF using UP/Down button nd press OK : System Test Test Stte Fn Speed Ionistion Off 0 rpm 0.0 μa The Test Stte switches to OFF nd the boiler return to the stnd by mode. Gs Type Mx. power CO% Min. power CO% Nturl gs LP gs Tb. 14 CO vlue for gs vlve clibrtion A combustion nlyzer must be used to set mximum nd minimum CO s listed in tble Tb Setting frost protection The boiler is equipped with system frost protection function, see section 5.5 Prmeters list for list of ll prmeters nd settings. The fctory defult setting Frost Protection (prmeter # 89) is DISABLED. To enble frost protection simply djust prmeter # 89 to ENABLE. When the frost protection is enbled, Prmeter #90 (Frost Protection Setpoint) hs to be set. Prmeter #90 hs defult setting of 50 F nd cn be djusted from F. When the supply temperture flls below the vlue set by the prmeter #90, the boiler pump strts. If the supply temperture continues to fll nd reches 9 F (5 C) below the vlue set by the prmeter #90 the burner will switch on t minimum power. When the supply temperture increses to temperture of 9 F (5 C) greter thn the vlue of the prmeter # 90 the burner will switch off. Then fter the post circultion time hs elpsed the pump will stop (prmeter #5 djustble from seconds. Defult is 300 seconds). 6 Troubleshooting WARNING: Close the gs cock prior to working on the gs trin or boiler. WARNING: WARNING: DANGER: WARNING: Check for gs leks fter crrying out work on the gs trin. Check for leks fter crrying out work on the venting system. Alwys disconnect the pplince from the min power before performing ny work. Disconnect the emergency shutoff switch or disengge the heting system circuit breker. Tke mesures to prevent ccidentl reconnection. Hot wter cn scld. Drin the pplince before working on components tht re filled with wter. 6.1 Error codes re shown on the disply If the symbol 70.0 F Fig. 7 ppers on the screen s follow: 04:9 pm n error hs occurred in the system tht is displyed on the screen. The bottom row in the disply will show the description of the error occurred. For exmple, prmeter #90 is set t 50 F (10 C), when the Supply temperture is lower thn 50 F (10 C) the pump strts. If the supply temperture is lower thn 41 F (5 C) the burner strts t the minimum power. The burner switches off when temperture of 59 F (15 C) is chieved. NOTICE: This sequence protects the boiler only from freezing. Be sure dequte mesures re in plce to protect the system (018/03) US

41 Troubleshooting Lockout errors If n error is Lockout error, it is necessry to press RESET button (fter eliminting the reson for the filure) to restrt the boiler. In the following tble the Lockout errors re listed: Error Int. nr. Description Checks Solutions "Ignit Error" 1 "Gv Rely Error" "Gv Rely Not Open" 3 "Gv Rely Not Close" 4 Three unsuccessful ignition ttempts in row Filure detected in the GV (gs vlve) Rely Filure detected in the GV (gs vlve) Rely Filure detected in the GV (gs vlve) Rely - Check gs supply pressure; b- Check ignition sprk c- Correct mount of gs; d-check for10vac t the gs vlve; - Check the integrity of the wire connections between gs vlve nd control bord. - Check the integrity of the wire connections between gs vlve nd control bord. - Check the integrity of the wire connections between gs vlve nd control bord. - If the gs supply pressure is incorrect, it must be djusted to the correct pressure; b- If sprk is not present check for correct ignition electrode position; c- If the combustion ir pressure is incorrect, inspect the vent system nd eliminte ny obstructions; d- If the voltge to the gs vlve is not 10Vc the power control bord must be replced. - If wires re dmged, replce them b- If wires re ok, replce the gs vlve or the power control bord. - If wires re dmged, replce them; b- If wires re ok, replce the gs vlve or the power control bord. - If wires re dmged, replce them; b- If wires re ok, replce the gs vlve or the power control bord. "Sfety Rely Error" 5 Filure detected in the Sfety Rely Replce the power control bord "Sfety Rely Open" 6 Filure detected in the Sfety Rely Replce the power control bord "Sfety Rely Closed" 7 Filure detected in the Sfety Rely Replce the power control bord "Blocking Too Long Error" 11 Control hd blocking error for more thn 0 hours in row "Fn Error" 1 Fn MF devition for more thn 60 sec Press RESET button to disply the Blocking error description - Check for 10 Vc power connection of the fn. b- Check PWM connection of the fn. Remove the cuse of the Blocking error - If no 10 VAC voltge is present, replce the power control bord. b- If no PWM signl is present, replce power control bord. c- Replce the fn "Rm Error" 13 Internl softwre error Replce the power control bord "Wrong Eprom Signture" 14 Contents of Eprom is not up-to-dte Replce the power control bord "X Rm Error" 15 Internl softwre error Replce the power control bord "EProm Error" 16 No communiction with Eprom Replce the power control bord "EProm Error C" 17 Wrong sfety prmeters in Eprom Replce the power control bord "EProm Error Cl Tble" 18 Wrong clibtrtion tble prmeters Replce the power control bord "Stte Error" 19 Internl softwre error Replce the power control bord "Rom Error" 0 Internl softwre error Replce the power control bord "Rom Error C" 1 Internl softwre error Replce the power control bord "Air Sw Not Open" Air pressure switch not working "15Ms Xrl Error" 3 Internl softwre error Replce the power control bord "Air Sw Not Closed" 4 Air pressure switch not working Mx. Thermostt Lock Error 5 The externl overhet protection is ctivted - Check the pump to verify the flow circultion b- Check if the vlves on hydrulic circuit re open c- Check the high limit switch d- To reset - see Fig. 10, section Chnge the pump or restrt it b- Open the vlves on hydrulic circuit c- Chnge the high limit switch "Stck Error" 6 Internl error Replce the power control bord "Flme Out Too Lte Error" 7 Flme still present 10 sec. fter closing the gs vlve Replce the gs vlve "Flme Error 1" 8 Flme is detected before ignition Replce the gs vlve "0Ms Xrl Error" 9 Internl softwre error Replce the power control bord "41Ms Error" 30 Internl softwre error Replce the power control bord Tb. 15 Lockout codes (018/03) US

42 4 Troubleshooting Error Int. nr. Description Checks Solutions - Check the integrity of Three times flme lost during one the wire connections of the demnd sprk nd the erth on het exchnger "Too Mny Flme Filures" 31 - If wires re dmged, replce them "Flow Switch Not Closed Error" 3 Flow switch not working / No flow "Flow Switch Not Open Error" 33 Flow switch not working / No flow "Flg Byte Integrity Error" 34 Internl softwre error Replce the power control bord "Ad Hi Cpl Error" 35 Internl softwre error Replce the power control bord "Ad Lo Cpl Error" 36 Internl softwre error Replce the power control bord "Register Error" 37 Internl softwre error Replce the power control bord Tb. 15 Lockout codes 6.1. Blocking errors If it is Blocking error the boiler will go bck to norml opertion, with no need to press the RESET button, once the reson for the filure hs been eliminted. In the following tble the Blocking errors re listed: Error Int. nr. Description Checks Solutions "WD Error Rm" 45 Internl softwre error Replce the power control bord "WD Error Rom" 46 Internl softwre error Replce the power control bord "WD Error Stck" 47 Internl softwre error Replce the power control bord "WD Error Register" 48 Internl softwre error Replce the power control bord "WD Error Xrl" 49 Internl softwre error Replce the power control bord "Refhi Too Lo Error" 50 Internl softwre error Replce the power control bord "Refhi Too Hi Error" 51 Internl softwre error Replce the power control bord "Reflo Too Lo Error" 5 Internl softwre error Replce the power control bord "Reflo Too Hi Error" 53 Internl softwre error Replce the power control bord "Flme Error " 54 Flme is detected in stte in which no Replce the power control bord flme is llowed to be seen "Wter Level Detect" 55 Low wter level detected "Wter Level Mes" 56 Low wter level mesurement error "Low Wter Cutoff Error" 57 Low wter sensor error Check the LWCO "Low Wter Pressure Error" 58 Low wter pressure error "Low Wter Pressure Sensor" 59 Low wter pressure "Flue Gs Error" 60 Flue gs pressure error "Return Temp Error" 61 Return temperture is higher thn sty burning temperture "Blocked Drin Error" 6 Block drin switch is ctive "Wd Freq Error" 64 Incorrect Frequency signl or no communiction with the WD "Phse Error" 65 Hot neutrl reversed "Net Freq Error" 66 Net freq. error detected in the min - Check the flue gs pressure switches b- Check the gs pressure - Check the return temperture sensor b- Verify the pump for flow circultion Verify the supplied 10 V c current Check the supply 10 V c connection Check the frequency of the supply 10 V c connection If the LWCO is in lrm, try to reset it. - If the flue gs pressure switches don t work, replce them b- If the gs supply pressure is incorrect, it must be djusted to the correct pressure - Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. b- Chnge the pump or restrt it - If the supplied 10 V c current hs frequency of 60HZ +/- %, replce the power control bord b- If the frequency is out of rnge, consult electricin Reverse the supply voltge polrity - If the supplied 10 V c current hs frequency of 60HZ +/- %, replce the power control bord b- If the frequency is out of rnge, consult electricin "Fulty Erth Error" 67 Fulty erth connection Check the erth connection to the pplince Restore the erth connection "WD Communiction Error" 68 Wtchdog communiction error Replce the power control bord Tb. 16 Blocking errors (018/03) US

43 Troubleshooting 43 Tb. 16 Error Int. nr. Description Checks Solutions Overhet Error 70 Supply temp exceed the limit "T Supply Open" 7 Supply sensor open "T Return Open" 73 Return sensor open "T Dhw Out Open" 76 DHW sensor open "T Supply Shorted" 80 Supply sensor shorted "T Return Shorted" 81 Return sensor shorted "T Dhw Out Shorted" 84 DHW sensor shorted "T Flue Shorted" 86 Flue sensor shorted - Check the pump to verify the flow circultion b- Check if the vlves on hydrulic circuit re open c- Check the supply temperture sensor - Check the integrity of the wire connections b- Check the supply temperture sensor - Check the integrity of the wire connections b- Check the return temperture sensor - Check the integrity of the wire connections b- Check the DHW temperture sensor - Check the integrity of the wire connections b- Check the supply temperture sensor - Check the integrity of the wire connections b- Check the return temperture sensor - Check the integrity of the wire connections b- Check the DHW temperture sensor - Check the integrity of the wire connections b- Check the flue temperture sensor - Chnge the pump or restrt it b- Open the vlves on hydrulic circuit c- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. - If the wiring is dmged, replce it b- Verify tht the temperture sensor hs the correct resistnce vlues. If vlues re incorrect sensor must be replced. Too mny reset button "Reset Button Error" 87 Reset button error pushes in 60 sec period "Applince Selection" 93 Applince selection error Replce the power control bord "Gs Pressure Error" 107 Gs pressure too low or too high "Flue Press Error" 108 Flue gs pressure error Blocking errors - Check for ny obstruction in the exhust system b- Check the condenste dischrge - Remove ny obstructions from the exhust system b- Remove ny obstruction from condenste dischrge nd verify if the condenste cn flow freely (018/03) US

44 44 Troubleshooting 6. Errors not shown on disply Symptoms Combustion noise too loud; rumbling noises Flow noises Heting-up tkes too long Flue gs redings incorrect; CO levels too high Hrd ignition, poor ignition Tb. 17 Possible solutions Check gs type. Check inlet gs pressure; djust s needed. Check flue gs system; clen or repir s needed. Check gs/ir rtio in the combustion ir nd flue gs; replce gs vlve s needed. Set pump speed correctly to mtch mximum output. Set pump mode. Purge system. Set pump speed correctly to mtch mximum output. Set pump mode. Check gs type. Check inlet gs pressure; djust s needed. Check flue gs system; clen or repir s needed. Check gs/ir rtio in flue gs; replce gs vlve s needed. Check gs type. Check inlet gs pressure; djust s needed. Check power supply. Check electrodes for visul dmge; replce s needed. Check flue gs system; clen or repir s needed. Check gs/ir rtio; replce gs vlve s needed. Check gs vlve; replce s needed. Check burner; replce if required. 6.3 Sensor Resistnce tble Temperture F ( C) Testing tolernce ±10% Resistnce [Ω] 3 (0) (5) (10) (15) (0) (5) (30) (35) (40) (45) (50) (55) (60) (65) (70) (75) (80) (85) (90) (95) (100) (105) (110) (115) (10) (15) 59 Tb. 18 Resistnce tble for: Supply temperture sensor, Return sensor, Flue sensor, DHW tnk temperture sensor, LLH sensor, Outdoor temperture sensor (018/03) US

45 Mintennce 45 7 Mintennce 7.1 Generl CAUTION: m A WARNING: NOTICE: The instller must inform the user bout the contents of this section. The user must mke the necessry rrngements with qulified service gency for the cre nd periodic mintennce of the boiler. m Lck of cre nd mintennce of this boiler nd equipment my cuse n unsfe condition. qulified nd dequtely trined technicin must perform the inspection s specified in these instructions nd in the Service Mnul (provided seprtely) before ech heting seson nd t regulr intervls. Servicing, inspection nd djustment must be done by trined technicin in ccordnce with ll pplicble locl nd ntionl codes. Improper servicing or djustment could dmge the boiler nd result in equipment dmge or dngerous condition! 7. Mintennce / inspection schedule for end user Time intervl Mintennce Annully Verify the clenliness of the re round the boiler Annully Check the pressure of the hydrulic system Annully Check vent piping nd verify if leks re present Annully Check ir piping nd verify if leks re present Annully Check relief vlve Monthly (follow locl, stte, federl or locl uthority hving Verify the condenste dischrge system jurisdiction guidelines) Every two months Test low wter cut off Every two months Verify the reset button of low wter cut off Every six months Check ll piping (gs nd wter) for leks End of heting seson Shut off the boiler Tb. 19 User mintennce / inspection schedule 7.3 Mintennce / inspection schedule for licensed contrctor / gs fitter Time intervl Mintennce Annully * Combustion test Annully * Verify condition of flue nd ir system (including Venturi nd fn) Annully * Check ignition electrode Annully * Clening the combustion chmber (including the burner tube) Annully * Clen condenste dischrge Annully * Sfety block check, modultion rnge check, gs vlve closing fter burner stop Annully * Check control prmeters Annully * Check for gs piping lek Annully * Check wiring nd connection (*) Annully or every 000 hours. Which occurs first. Tb. 0 Licensed contrctor / gs fitter mintennce / inspection schedule Time intervl Mintennce Annully * Verify strtup Annully * Verify the flme Annully * Check relief vlve Annully * Inspect the burner gsket (*) Annully or every 000 hours. Which occurs first. Tb. 0 Licensed contrctor / gs fitter mintennce / inspection schedule Gs leking inspection Verify ll gs piping to ensure tht there re no leks. DANGER: To verify the gs leks use sop solution or gs lek detector. Do not use methods tht cn cuse explosions! 7.3. Check exhust nd combustion ir pipe system Cler vent systems of ny obstructions, corrosion, physicl dmge, wter stins, rust. Verify the connection between the single components. Verify the outside termintions re cler. Clen the screens nd the louvers if there is ny debris Inspection of ignition electrode Verify tht the electrode is clen of deposits nd use dollr bill or other mteril to remove deposits s required. Fig mm Inspection of ignition electrode No. Description 1 Burner tube Ignition electrode 8-10 mm Checking for wiring nd connections Check tht ll wiring is securely fstened nd in good condition without ny crcking or ltertion of isoltion or presence of corrosion in metllic connection Burner gsket inspection You must mintin the boiler s outlined in this mnul nd hve the boiler strted up nd serviced t lest nnully by qulified service technicin to ensure boiler/system relibility. This includes combustion test nd the clening of the combustion chmber. When disssembling the het exchnger it is crucil to inspect the Burner Gsket (green: prt number ) for dmge. It is must to replce the burner gsket when servicing nd required if there is ny signs of wer, deformity or discolortion of the gsket nd in ny cse not lter thn every two yers (018/03) US

46 46 Instlltion schemes 8 Instlltion schemes The following shows possible system digrms. NOTICE: Appliction drwings in this mnul re conceptul only nd do not purport to ddress ll design, instlltion, code, or sfety considertions. The digrms in this mnul re for reference only for code officils, designers nd licensed instllers. It is expected tht instllers hve dequte knowledge of ntionl nd locl codes, s well s ccepted industry prctices, nd re trined on equipment, procedures, nd pplictions involved. Drwings re not to scle. Refer to the boiler, control nd module instlltion mnuls for dditionl detiled informtion. 8.1 Multiple zone with indirect tnk (pump for ech zone) The following system digrms re showing primry/secondry piping. As lterntive pproprite sized low loss heder cn lso be used. When using primry/secondry piping plese follow the following guidelines: Fig. 75 D Primry Loop Secondry Supply Minimum 8 X D Mximum 4 X D Not to exceed 1 Secondry Return D Minimum 4 X D Purge Drin Outdoor ir sensor DHW Sensor or Aqustt Zone rely X X 1 5 (optionl) Heting zone Auto-Fill Air Elimintor T T T T T T Flow Check Condenste drin Room Thermostt Expnsion Tnk Relief vlve nd pressure guge 3 Bck-flow preventer Shut-off vlve Supply sensor Domestic Hot Wter 4 Circultor... Fig (018/03) US

47 Instlltion schemes 47 Wiring digrm for multiple zone with indirect tnk (pump for ech zone): CASCADE LINK MOD BUS Gs Switch Outdoor ir sensor DHW Tnk Sensor Room Thermostt Supply Sensor Boiler Pump Pump CH Pump DHW 10 V Min in GND GND GND L N GND GND GND L N L N 3 Wy L N L N L N Alrm 10 V Aux Outdoor sensor (5) DHW tnk sensor or Aqustt (4) Zone rely switch (1) L GND N Rely (*) Furnished nd Instlled by others DHW tnk pump (3) Boiler pump () L N 10 V Line Ground 10 V Neutrl Fig. 76 (*) NOTICE: The mximum mp lod for ech pump (in ddition to the boiler pump) is 1 A when 1 or pumps re connected. For this reson, if the power consumption of ech pump is higher thn 84 wtt, use rely s shown in figure. Connect the following low voltge connection: Terminl Number. Device 11-1 Zone rely end switch 9-10 DHW tnk sensor or Tnk Thermostt (Aqustt) 7-8 Outdoor ir sensor (optionl) Connect the following high voltge pin: Terminl Number. Device DHW tnk pump Settings Set the prmeters s indicted in the following tble (for the prmeter list see section 5.5 Prmeters list ): No. Description Vlue Comment 1 0 Outdoor ir sensor not present Centrl Heting Mode Outdoor ir sensor present. Reset 1 curve ctivted Mod Pump Mode Enbled CH pump nd DHW pump 0 No indirect snitry wter instlled 1 Indirect snitry wter with sensor 35 DHW mode Indirect snitry wter with tnk thermostt If CH mode is set to 1 nd n outdoor ir sensor is present, set the reset curve prmeter s follows (to set these vlues see lso section 5.6 Outdoor reset ): No. Description Vlue ( F) 19 Design Supply Temp Design Outdoor Temp 5 1 Bseline Supply Temp 104 Bseline Outdoor Temp 70 3 Design Supply Min Limit 40 4 Design Supply Mx Limit Wrm Wether Shutdn (018/03) US

48 48 Instlltion schemes 8. Multiple zone with indirect tnk (vlve for ech zone) Purge Drin Outdoor ir sensor Pressure By-pss Heting zone Zone rely X X 1 5 (provided with boiler instlled by others) Auto-Fill Air Elimintor Flow Check Condenste drin Room Thermostt Expnsion Tnk Relief vlve nd pressure guge Bck-flow preventer 3 Isoltion vlve Temperture sensor 4 Domestic Hot Wter... Zone Vlve Fig (018/03) US

49 Instlltion schemes 49 Wiring digrm for multiple zone with indirect tnk (vlve for ech zone): CASCADE LINK MOD BUS Gs Switch Outdoor ir sensor DHW Tnk Sensor Room Thermostt Supply Sensor Boiler Pump Pump CH Pump DHW 10 V Min in GND GND GND L N GND GND GND L N L N 3 Wy L N L N L N Alrm 10 V Aux Outdoor sensor (5) DHW tnk sensor or Aqustt (4) Zone rely switch (1) L GND N Rely (*) Furnished nd Instlled by others DHW tnk pump (3) Boiler pump () L N 10 V Line Ground 10 V Neutrl Fig. 78 (*) NOTICE: The mximum mp lod for ech pump (in ddition to the boiler pump) is 1 A when 1 or pumps re connected. For this reson, if the power consumption of ech pump is higher thn 84 wtt, use rely s shown in figure. Connect the following low voltge connection: Terminl Number. Device 11-1 Zone rely end switch 9-10 DHW tnk sensor or Tnk Thermostt (Aqustt) 7-8 Outdoor ir sensor (optionl) Connect the following high voltge pin: Terminl Number. Device DHW tnk pump 8..1 Settings Set the prmeters s indicted in the following tble (for the prmeter list see section 5.5 Prmeters list ): No. Description Vlue Comment 1 0 Outdoor ir sensor not present Centrl Heting Mode Outdoor ir sensor present. Reset 1 curve ctivte Mod Pump Mode Enbled CH pump nd DHW pump 0 No indirect snitry wter instlled 1 Indirect snitry wter with sensor 35 DHW mode Indirect snitry wter with tnk thermostt If CH mode is set to 1 nd n outdoor ir sensor is present, set the reset curve prmeter s follows (to set these vlues see lso section 5.6 Outdoor reset ): No. Description Vlue ( F) 19 Design Supply Temp Design Outdoor Temp 5 1 Bseline Supply Temp 104 Bseline Outdoor Temp 70 3 Design Supply Min Limit 40 4 Design Supply Mx Limit Wrm Wether Shutdn (018/03) US

50 50 Instlltion schemes 8.3 Cscde The boilers cn be connected together to form cscde with mximum of 16 boilers. In this cse, one boiler will be the mnger of the other boilers connected. This boiler is nmed Primry. The other one(s) re nmed Secondry. To hve cscde it is necessry to connect together the boilers using the Cscde link (pin 1-) in prllel s shown in the following figure: Boiler 1 CASCADE LINK MOD BUS Gs Switch Out Door DHW Tnk Sensor Room Thermostt Supply Sensor Ech cscde boiler hs to be identified by n ddress (prmeter N 73 Boiler Address )different from the others. To define these ddress follow the steps below: Switch on the Primry boiler nd set the prmeter N 73 ( Boiler Address ) to 1 Switch off the Primry boiler Switch on the second boiler nd set the prmeter N 73 to. Switch off the second boiler Continue with steps 3 nd 4 for ech boiler (ech Secondry boiler hs to be different number from to 16 nd the Primry must be number 1) Switch on ll boilers strting with the Primry boiler Boiler... Boiler 16 CASCADE LINK 1 3 CASCADE LINK 1 3 Fig. 79 To define the Primry boiler of the cscde set to ON the S4 switch. This switch hs to be set OFF in ll the Secondry boilers (see the following figure). ON S4 OFF Fig. 80 CAUTION: Chnge the position of the S4 switch only when the boiler is off (018/03) US