SSB255 SSB399 SSB512. 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. NOTICE: In Msschusetts, this pplince must be instlled by licensed plumber or gs fitter. 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

2 2 Contents 1 Key to symbols nd sfety instructions Key to symbols Sfety instructions Generl wrning Approved exmples of horizontl nd verticl venting instlltion Multiple boiler De-rting for ltitude instlltion Product description Introduction Scope of delivery Proper use Environmentl responsibility / disposl Dimensions nd Connections Min components Technicl dt Efficiency Curves Commissioning (for single boiler 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 2 limits Setting frost protection Regultions Complince with stndrds nd regultions Operting limits of the boiler Additionl regultions for instlltion in Msschusetts Troubleshooting Error codes re shown on the disply Lockout errors Blocking errors Errors not shown on disply Sensor Resistnce tble Instlltion Pckging nd product identifiction Instlltion room Wter Chemistry Guidelines Hydrulic connection Low wter cut off High limit sfety switch Pressure relief vlve (PRV) 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 systems Instlltion of the exhust nd ir intke system Vent nd combustion ir pipe length [For single boiler instlltions] 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 Applictions Multiple zone with indirect tnk (pump for ech zone) Settings Multiple zone with indirect tnk (vlve for ech zone) Settings Cscde connection Settings Commissioning log for the pplince Spre prts... 56

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. 1.2 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 equipment or vent dmper lekge of flue gses my endnger the lives of people. Crefully observe proper opertion of the vent dmper. Do not strt up the boiler unless the vent dmper is operting properly. Use only originl prts when replcing prts. When replcing the vent dmper, instll the new one in the specified position. 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 to life by poisoning by lekge of flue gses Mke sure tht the boiler is not equipped with thermlly controlled flue gs vent dmper fter the open drft hood. 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. Mintin minimum distnce of 15 inches from 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 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 Z223.1./NFPA 54. In Cnd, instlltion must be in ccordnce with the requirements of CAN/CSA B149.1, Nturl Gs nd Propne Instlltion Code. 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. In the Commonwelth of Msschusetts, this pplince must be instlled by licensed plumber or gs fitter. Vlves externl to the boiler must be fitted with T-hndles nd condenste piping must be instlled in ccordnce with the Stte Plumbing Code.

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 deg F (-15 C) nd 150 deg 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 instll the unit outdoors. Do not leve ny combustibles or continers of flmmble substnces in the room where the boiler is instlled. Keep pcking mteril out of rech of children s 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 uthorized personl. It s prohibited to dispose the product s domestic wste. The seprte disposl of household pplince voids possible negtive consequences for the environment nd humn helth deriving from inpproprite disposl nd llows to recover the mterils it is mde of in order to chieve significnt svings in energy nd resources. 2 Product description 2.1 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. 2.2 Scope of delivery Fig Scope of delivery Component Qty Pckging method [1] Gs condensing boiler 1 Pllet [2] 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 2 Crdbord box on pllet [6] Outdoor sensor 1 Crdbord box on pllet 1

5 Product description Proper use The Boilers re designed for lrge residentil, commercil nd light industril pplictions. The 512 is delivered in complince with CSD-1 Commercil Applictions. 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 or process wter heting het exchnger must to be instlled. 2.4 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.

6 6 Product description 2.5 Dimensions nd Connections F 15 7/32 (386mm) 16 19/32 (422mm) 18 (457mm) 60 3/16 (1529mm) 56 7/16 (1434mm) 47 1/32 (1195mm) 48 7/16 (1231mm) 49 27/32 (1266mm) 61 9/16 (1564mm) 58 7/8 (1496mm) G 5 7/16 (138mm) 16 17/32 (420mm) 21 21/32 (550mm) 23 31/32 (609mm) 10 1/16 (256mm) 2 3/32 (53mm) 21 5/8 (549mm) 5 1/2 (140mm) 19 19/32 (498mm) 17 21/32 (448mm) B D E C A 13 11/16 (348mm) Fig (dimension in inches [mm]) A B C System supply - 1 1/2 NPT System return - 1 1/2 NPT Gs inlet - 1 NPT D E Flue exhust - 3 (80mm) Intke ir - 3 (80mm)

7 Product description 7 F 15 7/32 (386mm) 16 19/32 (422mm) 18 (457mm) 60 3/16 (1529mm) 56 7/16 (1434mm) 47 1/32 (1195mm) 48 7/16 (1231mm) 49 27/32 (1266mm) 61 9/16 (1564mm) 58 7/8 (1496mm) G 5 7/16 (138mm) 16 17/32 (420mm) 21 21/32 (550mm) 23 31/32 (609mm) 21 5/8 (549mm) 10 1/16 (256mm) 2 3/32 (53mm) 5 1/2 (140mm) 19 19/32 (498mm) 17 21/32 (448mm) B D E C A 13 11/16 (348mm) Fig (dimension in inches [mm]) A B C System supply - 1 1/2 NPT System return - 1 1/2 NPT Gs inlet - 1 NPT D E Flue exhust - 4 (110mm) Intke ir - 4 (110mm)

8 8 Product description F 15 7/32 (386mm) 16 19/32 (422mm) 18 (457mm) 60 3/16 (1529mm) 56 7/16 (1434mm) 47 1/32 (1195mm) 48 7/16 (1231mm) 49 27/32 (1266mm) 61 9/16 (1564mm) 58 7/8 (1496mm) G 5 7/16 (138mm) 16 17/32 (420mm) 21 21/32 (550mm) 23 31/32 (609mm) 10 1/16 (256mm) 2 3/32 (53mm) 21 5/8 (549mm) 5 1/2 (140mm) 19 19/32 (498mm) 17 21/32 (448mm) B D E C A 13 11/16 (348mm) Fig (dimension in inches [mm]) A B C System supply - 2 NPT System return - 2 NPT Gs inlet - 1 NPT D E Flue exhust - 4 (110mm) Intke ir - 4 (110mm)

9 Product description Min components Fig (min components) [1] Min power switch [2] System return [3] Removble disply [4] Flue exhust [5] Intke ir [6] Gs inlet [7] System supply [8] Pressure Relief Vlve [9] Tridictor [10] Air pressure switch [11] Het exchnger supply pipe [12] Mx pressure switch [For 512 Only] [13] Min pressure switch [For 512 only]. Loction should be burner side of gs vlve. [14] Automtic ir vent [15] Low wter cut off probe [16] High limit temp. sfety switch [17] Sprk electrode [18] Het exchnger [19] Condenste mnifold [20] Air pressure switch connection [21] Low point drin vlve [22] Het exchnger return pipe [23] Return temperture probe [24] Wiring Control Pnel [25] Min shut off gs vlve [26] Fn [27] Gs pipe [28] Gs vlve [29] Flue gs probe

10 10 Product description 2.7 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) 255,900 (75) 399,000 (117) 512,000 (150) Min input rte BTU/hr (kw) 51,180 (15) 79,800 (23.4) 102,400 (30) Turndown Rte (%) 5:1 (20 %) 5:1 (20 %) 5:1 (20 %) Gs Connections (NPT) Ø Inch Mx. NG Pressure Inch W.C. (mbr) 10.5 (26.15) 10.5 (26.15) 10.5 (26.15) Min. NG Pressure Inch W.C. (mbr) 3.5 (8.72) 3.5 (8.72) 3.5 (8.72) Mx. LPG Pressure Inch W.C. (mbr) 13 (32.3) 13 (32.3) 13 (32.3) Min. LPG Pressure Inch W.C. (mbr) 8 (19.9) 8 (19.9) 8 (19.9) Wter Connections Ø Inch 1 ½ 1 ½ 2 Mx. Allowble Working Pressure (MAWP) PSI (br) 80 (5.5) 80 (5.5) 80 (5.5) Recommended wter mx power ( T 36 F / 20 C) GPM (m 3 /h) 14.2 (3.2) 22.2 (5.0) 28.4 (6.5) Mx wter mx power ( T 27 F / 15 C) GPM (m 3 /h) 18.9 (4.3) 29.5 (6.7) 37.9 (8.6) Min wter mx power ( T 54 F / 30 C) GPM (m 3 /h) 9.5 (2.2) 14.8 (3.4) 18.9 (4.3) Min wter min power ( T 27 F / 15 C) GPM (m 3 /h) 3.8 (0.9) 5.9 (1.3) 7.6 (1.7) Wter Pressure recommended wter flow Feet Hed (mbr) 3.8 (114) 8.3 (250) 21.7 (650) Wter Pressure mx wter flow Feet Hed (mbr) 6.4 (190) 13.8 (410) (1120) Wter Volume Gllon (liter) 4.0 (15.2) 4.5 (17.0) 6.0 (23.0) Vent/Air Intke Connections Ø Inch (Ø mm) 3 (80) 4 (100) 4 (100) Vent Mterils CPVC, PVC, PP, PP Flex, Stinless Steel AL29-4C IPEX type IIA & IIB CPVC, PVC, PP, PP Flex, Stinless Steel AL29-4C IPEX type IIA & IIB CPVC, PVC, PP, PP Flex, Stinless Steel AL29-4C IPEX type IIA & IIB Mx operting temperture F ( C) 194 (90) 194 (90) 194 (90) Mx HE llowble temperture F ( C) 210 (98.9) 210 (98.9) 210 (98.9) Ambient storge temperture dry F ( C) 5 to 150 (-15 to 65) 5 to 150 (-15 to 65) 5 to 150 (-15 to 65) Ambient functioning temperture F ( C) 32 to 120 (0 to 49) 32 to 120 (0 to 49) 32 to 120 (0 to 49) Ambient Reltive Humidity [RH] % RH Minimum 30%, Mximum 90% Minimum 30%, Mximum 90% Minimum 30%, Mximum 90% Surfce re het exchnger SQFT (m 2 ) 22.0 (2.0) 27.2 (2.5) 43.0 (4.0) Stndrd Listings & Approvls CSA, ASME, AHRI CSA, ASME, AHRI CSA, ASME, AHRI Electricl Req. 120VAC/1PH/60Hz 2 FLA** 2.5 FLA** 2.5 FLA** Noise rting db Weight (dry) lbs (kg) 198 (90) 220 (100) 242 (110) Min. clernce to combustibles *** Inch (mm) 2 (50.8) 2 (50.8) 2 (50.8) Dimension WxHxD Inch (mm) 23 31/32 x 61 9/16 x 21 21/32 (609x1564x550) 23 31/32 x 61 9/16 x 21 21/32 (609x1564x550) 23 31/32 x 61 9/16 x 21 21/32 (609x1564x550) AHRI certified rtings Unit Input MBH Heting Cpcity MBH n/ n/ Gross Output MBH n/ AFUE % 96 n/ n/ Combustion Efficiency % n/ Therml efficiency % n/ Net rting MBH CO2 % (*) With conversion. (**) FLA (Full Lod Amperge) - mximum current drwn by the boiler without pumps. (***) The 2 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.

11 Product description Efficiency Curves 100% 98% 96% 20% input 30% input 100% input Therml Efficiency 94% 92% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 6 Therml Efficiency Curves 255* * Therml Efficiency curve is for reference only s this is residentil boiler 100% 98% 96% 20% input 30% input 100% input Therml Efficiency 94% 92% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 7 Therml Efficiency Curves 399

12 12 Product description 100% 98% 96% 20% input 30% input 100% input Therml Efficiency 94% 92% 90% 88% 86% Return Wter Temperture ( 36 Degree Rise Fig. 8 Therml Efficiency Curves 512

13 Regultions 13 3 Regultions m Observe ll rules, regultions, stndrds nd guidelines mpplicble to the instlltion nd opertion of this pplince in your country. m In m the Commonwelth of Msschusetts, this pplince must be instlled by licensed plumber or gs fitter. Vlves 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 Z223.1./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 Z21.13/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 ). 3.2 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 [2150 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 720 nd be ANSI/UL 2034 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 248 CRM 5.08(2)() 1 through 4. (b) EXEMPTIONS: The following equipment is exempt from 248 CRM 5.08(2)() 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.

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. 20 (500mm) 40 (1000mm) 2 (50mm) 4.2 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! 20 (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 Connecting flue gs systems ). 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 120 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, resonting noises my occur. Isolte the boiler 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]) 2 (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.

15 Instlltion Wter Chemistry Guidelines NOTICE: If using nti-freeze: Follow the boiler mnufcturer s instructions on ntifreeze concentrtion. Frost protection nd inhibitor 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. 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 gskets. Using n utomtic wter fill system exposes the system to fresh oxygented wter. In commercil pplictions it is recommended to instll wter meter to mesure the introduction of fresh wter into the system. A minimum wter pressure is required for optimum performnce. Minimum wter pressure required: 7.25 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 welding flux residue. In ny of these instnces, the old system must be rinsed with cler wter mixed with highly concentrted rinse gent. For freeze protection use only propylene glycol, with scle inhibitors, with mximum volume [concentrtion] of 40% of glycol. NOTICE: DO NOT use PVC for exhust venting 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 2 SO 3 mg/l < 10 N 2 H 4 mg/l < 3 PO 4 mg/l < 15 Tb. 1 Wter specifiction 4.4 Hydrulic connection Hydrulic connection re shown in Fig. 2, 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 /2 NPT mle 1-1/2 NPT mle /2 NPT mle 1-1/2 NPT mle NPT mle 2 NPT mle 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.

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 sliding wiring center. 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 High limit sfety switch A high limit sfety switch is instlled in the boiler. To simulte high limit lockout t 208 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. LED Test Reset Fig. 10 Reset Fig Pressure relief vlve (PRV) 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 (2.07 br) psi (2.07 br) psi (5.17 br) A 75psi pressure relief vlve cn be purchsed seprtely nd field instlled. The pressure relief vlve (PRV) must be piped to suitble drin to prevent injury if the vlve releses. Use pipe of the sme dimeter of the outlet of the vlve

17 Instlltion Pump boilers must be fitted with circultor pump. The grph in the following figure shows the pressure drop through the boiler circuit depending on the flow rte. 255 p / Feet of Hed Flow rte / GPM Fig Pressure drop 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.

18 18 Instlltion 399 p / Feet of Hed Flow rte / GPM Fig Pressure drop 512 p / Feet of Hed Flow rte / GPM Fig Pressure drop

19 Instlltion Condenste removl The condenste wter produced by the boiler during its norml opertion is collected by two plstic pipes (A nd B) provided with the boiler nd connected with plstic collector inside the cse. A third tube (C) collects the condenste output from the collector [Arrow is the direction of flow of condenste]. strem. Never use copper pipes or of other mteril not intended for the specific purpose, becuse the ction of condenste will cuse rpid deteriortion. Check tht the condenste drin pipe is dequtely sloping towrds the dischrge point voiding high points, which cn inhibit the flow of condenste. Instll the condenste pipe in such wy so s to void the freezing of the liquid. NOTICE: Verify condenste disposl / neutrliztion is in ccordnce with locl, stte nd federl regultions. 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 nd furnces. The pump should hve n overflow switch to prevent property dmge from condenste lekge. 4.5 A B C Fig. 15 DANGER: The condenste pipe A nd B, shown in 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 dischrge dd wter from the vent (1) until you see wter come out of the condenste dischrge pipe (2). 1 Electricl connection Power supply cble connection To connect the boiler to the electricl supply, s required by locl, stte nd federl codes, provide nd instll service switch (15 mp is recommended). The power supply cble cn be inserted into the boiler using one of the six knock out holes (A) on the sides s shown in Fig. 17. WARNING: All the electricl wiring must be secured by pproprite strin reliefs. To secure the supply cble inside of the boiler use the cble clmp shown in position B shown in Fig. 18. H 2O A H 2O Fig B Fig. 16 The condenste wter shll be dischrged t tmospheric pressure, i.e. by dripping into siphon-shped continer connected to the home sewge system or suitble drin, nd shll be neutrlized prior to drining per locl codes. The boiler is equipped with three holes (in the right, left nd bck side) to crry the condenste out the condenste drin tube. Instll the condenste drin tube through the pproprite hole nd be sure to pitch wy from the boiler. Do not reduce the dimeter of the condenste drin pipe down Fig. 18

20 20 Instlltion The generl electricl connection is shown in the following digrm : CASCADE LINK MOD BUS Gs Switch Out Door DHW Tnk Room Sensor Thermostt L Pump DHW Pump CH Boiler Pump Supply Sensor N L 3 Wy N L N Alrm L N L (**) 120 V Min in 120 V Aux N N L Rely (*) Furnished nd Instlled by others Outdoor sensor DHW tnk sensor or qustt Room thermostt Rely (*) Furnished nd Instlled by others L N DHW tnk pump L N Rely (*) Furnished nd Instlled by others Supply sensor Boiler pump L N 120 V Line Ground 120 V Neutrl System pump Fig. 19 (*) NOTICE: The mximum mp lod for ech pump is 1 A when 2 or 3 pumps re connected. For this reson, if the power consumption of ech pump is higher thn 84 wtt, use rely s shown in figure. If just one pump is connected, the mximum mp lod of this single pump is 2 A. For this reson if the power consumption of the pump is higher thn 168 wtt, use rely s shown in figure Fig. 19. (**) 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. 20). 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 12 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 32 (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.

21 Instlltion Electricl wiring digrm 255 ONLY ONLY FLUE PRESSURE SWITCH PRESSURE SWITCH MAX 512 ONLY PRESSURE SWITCH MIN CASCADE LINK MOD BUS GAS SWITCH OUT DOOR LOW VOLTAGE IN / OUT DHW Tnk Sensor Room Thermostt Supply Sensor HIGH VOLTAGE OUT PUMP CH PUMP DHW MAIN PUMP ALLARM 120 V AUX L N L N 3 WAY L N L N L N L N L HIGH VOLTAGE 120 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 24 V blu brn GND w bl bl brn brn bl w w brn GND brn bl blu w brn bl w GND N L blu bl w 24V w AR1 bl 120V w w 209 w bl bl w CHASSIS GROUND (Vi Boiler / Piping) TEST Externl Test Switch (Normlly Closed, Opens to Test) 208 bl bl 214 AR1 HIGH VOLTAGE 24 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. 21 Wiring digrm

22 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. The minimum nd mximum pressure for nturl gs re 3.5 W.C. (8.72 mbr) nd 10.5 W.C. (26.15 mbr) respectively. The minimum nd mximum pressure for LP gs re 8 W.C. (19.9 mbr) nd 13 W.C. (32.3 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. LP conversion kit instlltion (255) 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 qulified instller or service technicin, ccording to the following procedure. Switching 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 3 screws A nd the swivel joint B indicted in Fig. 22 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 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 A C D E B 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 resp onsible 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. Fig. 22 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 2 prmeter s explined in chpter 5.7 Adjusting nd setting CO2 limits (see Tb. 17 Number of turns for gs vlve settings ) Affix the gs type lbel from the gs conversion kit to the pplince (Fig. 24). The gs-ir rtio must lwys be set on the bsis of CO 2 or O 2 reding tken t mximum nominl output nd minimum nominl output using n electronic flue gs nlyzer.

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 23 LP conversion kit instlltion ( ) 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 qulified instller or service technicin, 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 Switching 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 swivel joint A indicted in Fig. 23 to seprte the vlve from the connection pipe with the fn Seprting the two components, you cn see the hole where the gs psses with its gsket Plce the provided metl orifice B (Fig. 23) between the two gskets Tighten the swivel joint Switch the min power supply to ON (*) A Ctegory IV Ctégorie IV Model -512 Modèle -512 Model no Référence Converted to LPG (Propne) with conversion kit X XXX XXX XXX Convertie vers LPG (Propne) vec le kit de conversion X XXX XXX XXX CO2 (mx. rte/ min rte) 10,7/10,3 % CO2 ( 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 3,23 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 102,360 Btu/hr Consommtion clorifique min. 102,360 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 491,328 Btu/hr Puissnce utile nominl 144,0 kw 491,328 Btu/hr Minimun relief vlve cpcity 232,1 kg/hr 511,8 lbs/hr Cpcité minimle de l souppe de sécurité 232,1 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 Fig. 24 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. DANGER: (dy - month - yer) Ce ppreil été converti le gz pr (jour- mois- nnée) en X XXX XXX XXX (2015/04) The condenste dischrge must be filled with wter or combustion gses will enter the room with risk of n excessive level of crbon monoxide. For instruction see pr 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. 23 (*) Blncing tube shown removed for clrity. Boiler model N on orifice Tb. 2 B 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 2 prmeter s explined in chpter 5.7 Adjusting nd setting CO2 limits (see Tb. 17 Number of turns for gs vlve settings ) Affix the gs type lbel from the gs conversion kit to the pplince (Fig. 24). Mke sure tht the combustion ir is not contminted by: Permnent wve solutions; Chlorinted wxes/cleners; Chlorine-bsed swimming pool chemicls; Clcium chloride 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. To prevent contmintion do not connect the combustion it inlet nd exhust ner: Dry clening/lundry res nd estblishments; Swimming pools; Metl fbriction plnts; Beuty shops; Refrigertion repir shops; Photo processing plnts; Auto body shops; Plstic mnufcturing plnts; Furniture refinishing res nd estblishments;