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100275091_2000533998_Rev C

F I R E T U B E C O M B I

™

Noble Combi Boiler

Installation & Service Manual

Models: 110 - 199

This manual must only be used
by a qualified heating installer
/ service technician. Read all
instructions, in this manual before
installing. Perform steps in the
order given. Failure to comply
could result in severe personal
injury, death, or substantial
property damage.

WARNING

Save this manual for future reference.

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Summary of Contents for NKC 110

Page 1: ...99 This manual must only be used by a qualified heating installer service technician Read all instructions in this manual before installing Perform steps in the order given Failure to comply could res...

Page 2: ...ion Air Piping 15 Sizing 16 Max Allowable Vent Piping Lengths 16 Materials 16 Optional Room Air 17 PVC CPVC 18 Polypropylene 19 Stainless Steel Vent 20 4 SIDEWALL DIRECT VENTING Vent Air Termination S...

Page 3: ...e to sediment Freeze protection fluids NEVER use automotive antifreeze Use only inhibited propylene glycol solutions which are specifically formulated for hydronic systems Ethylene glycol is toxic and...

Page 4: ...oiler water inlet is the boiler water connection for water entering the boiler from the system 15 DHW water inlet The DHW water inlet is the DHW water connection for water entering the boiler from the...

Page 5: ...36 00 28 FRONT LEFT RIGHT BACK 21 15 14 22 12 13 16 19 DIR 2000528036 00 Side_Rear View The Noble Combi Boiler How it works continued 5 Bottom View Front Inside View 32 4 3 6 33 31 7 30 DIR 2000528036...

Page 6: ...rate 4 45 for each 1 000 feet above 5 000 feet The operation given in this manual remains the same as the standard boilers A high altitude label as shown in FIG A is also affixed to the unit De rate v...

Page 7: ...from the boiler area WARNING This appliance is certified as an indoor appliance Do not install the appliance outdoors or locate where the appliance will be exposed to freezing temperatures or to tempe...

Page 8: ...closet structure due to elevated temperatures Failure to follow this warning could result in fire personal injury or death Note Service clearances are recommendations only Note Service clearances are...

Page 9: ...ace of a dwelling shall be installed so that all burners and burner ignition devices are located not less than 18 inches 46 cm above the floor The appliance shall be located or protected so that it is...

Page 10: ...e system should be tested to the procedure listed in parts c through f of the Removal of an Existing Boiler Section on page 11 With polypropylene and stainless steel vent seal and connect all pipe and...

Page 11: ...ce not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close firepla...

Page 12: ...installed a Disconnect the wiring from the fan and remove the bolts securing the fan to the heat exchanger top plate b Remove the fan and gasket and install the air shutter provided in the kit Note O...

Page 13: ...ll 1 Mount the wall bracket using the two 2 wedge anchor bolts provided with the bracket FIG 2 4 To mount the wedge anchor bolts drill a 1 4 diameter hole 1 1 8 deep and insert anchor Hang the bracket...

Page 14: ...or more details Direct venting options Sidewall Vent DIR 2000534588 00 DIR 2000534587 00 Figure 3 3 Two Pipe Vertical Termination See page 28 for more details Figure 3 5 Vertical Vent Sidewall Air Fig...

Page 15: ...ted per guidelines listed in the National Mechanical Code Section 305 Table 305 4 or as local codes dictate 2 Vent Connector FIG s 3 6 thru 3 10 Used to provide a passageway for conveying combustion g...

Page 16: ...or property damage NOTICE The use of double wall vent or insulated material for the combustion air inlet pipe is recommended in cold climates to prevent the condensation of airborne moisture in the i...

Page 17: ...air Please refer to instructions provided with the room air kit There will be a noticeable increase in the noise level during normal operation from the inlet air opening Using the room air kit makes...

Page 18: ...into the fitting if possible twist the pipe a 1 4 turn as you insert it NOTE If voids are present sufficient cement was not applied and joint could be defective g Wipe excess cement from the joint rem...

Page 19: ...t comply with applicable national state and local codes For Canadian installation polypropylene vent must be listed as a ULC S636 approved system Installation of a polypropylene vent system should adh...

Page 20: ...ble national state and local codes Stainless steel vent systems must be listed as a UL 1738 approved system for the United States and a ULC S636 approved system for Canada NOTICE Installation of a sta...

Page 21: ...irculation such as inside building corners near adjacent buildings or surfaces window wells stairwells alcoves courtyards or other recessed areas TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE...

Page 22: ...leaves or sediment Vent air termination sidewall ALTERNATE VENTING ARRANGEMENT IF SPACE PERMITS BIRD SCREEN 12 MIN 12 MIN 15 MAX COUPLING TO BOILER INTAKE AIR CONNECTION FROM BOILER VENT PIPE CONNECTI...

Page 23: ...ze the air pipe hole as close as desired to the air pipe outside diameter 2 Vent pipe penetration a Cut a hole for the vent pipe For either combustible or noncombustible construction size the vent pip...

Page 24: ...3 Cut one 1 hole 5 inch diameter for 100140480 installations or 4 inch diameter for 100140485 installations into the structure to install the termination kit 4 Partially assemble the concentric vent...

Page 25: ...product damage or improper operation personal injury or death Figure 4 9 Rain Cap to Vent Pipe Alternate Assembly 5 Install the Y concentric fitting and pipe assembly through the structure s hole Do...

Page 26: ...made as shown to avoid recirculation of flue gases VENT COMBUSTION AIR 12 MINIMUM Figure 4 11 Concentric Vent and Combustion Air Termination Figure 4 10 Concentric Vent Sidewall Attachment DO NOT use...

Page 27: ...f piping for vent or air must not exceed the limits given in the General Venting Section on page 16 of this manual 2 Prepare the vent termination and the air termination elbow FIG 5 1A by inserting bi...

Page 28: ...boots sized for the vent pipe and air pipe Multiple vent air terminations 1 When terminating multiple boilers terminate each vent air connection as described in this manual FIG 5 2 Terminate all vent...

Page 29: ...field disassembly is desired for cleaning see FIG 4 9 page 25 When using the alternate screw assembly method drill a clearance hole in the rain cap and a pilot hole in the vent pipe for the screw size...

Page 30: ...vent appliances are vented near each other each appliance must be individually vented see FIG 5 7 NEVER common vent or breach vent this appliance When two 2 or more direct vent appliances are vented...

Page 31: ...ith the National Fuel Gas Code The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from the General Venting Section If an existing unused ven...

Page 32: ...ing vent as a chase Follow all existing termination and clearance requirements and allowable pipe lengths Use only approved venting materials listed in the General Venting Section of this manual 32 Fo...

Page 33: ...ow along with illustrations on the following pages FIG s 6 3 through 6 6 which will guide you through the installation of the Noble Combi Boiler reference FIG s 6 1A and 6 1B 1 Connect the system retu...

Page 34: ...essure relief valve is sized to ASME specifications Install the 3 4 NPT fitting on the top right side of the boiler images in this manual show relief valve installed 8 Boiler purge valve Field supplie...

Page 35: ...1 Pipe 34 7 F 10 6 4 0 53 40 F 9 2 9 6 162 45 F 8 2 13 1 277 Assumed Equivalent Lengths 1 Pipe Fitting Component Eq Ft 90 Elbow 2 5 45 Elbow 1 0 Tee straight run 0 5 Tee side port 4 5 Ball Valve 4 3...

Page 36: ...SYSTEM NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART SYSTEM CIRCULATOR TO SYSTEM SYSTEM SUPPLY SENSOR OPTIONAL DRAIN MAY SUBSTITUTE LOW LOSS HEADER Y STRAINER RECOMMENDED DIR 2000529680 00 CHECK VALVE P...

Page 37: ...KFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK ZONE 1 ZONE 2 ZONE 3 ZONE 4 BALL VALVE TYPICAL UNION TYPICAL DRAIN DRAIN POINT TYPICAL MA...

Page 38: ...ANK BALL VALVE TYPICAL DRAIN POINT TYPICAL MAKE UP WATER ZONE CIRCULATORS TYPICAL FLOW CHECK VALVE TYPICAL NOT TO EXCEED 4 PIPE DIA OR MAX OF 12 APART UNION TYPICAL BOILER 1 SYSTEM SUPPLY SENSOR OPTIO...

Page 39: ...nt and detailing required by local codes NOTICE BOILER BACKFLOW PREVENTER PRESSURE REDUCING VALVE PRESSURE GAUGE TEMPERATURE PRESSURE GAUGE AIR SEPARATOR EXPANSION TANK BALL VALVE TYPICAL UNION TYPICA...

Page 40: ...lied from utility or well water in compliance with EPA secondary maximum contaminant levels 40 CFR Part 143 3 as shown in Table 6C Potable Water Potable Water Levels Contaminant Level Aluminum 0 05 to...

Page 41: ...TER SUPPLY TEMPERATURE PRESSURE GUAGE UNION TYPICAL HOT WATER SUPPLY FLOW CHECK EXPANSION TANK DIR 2000534676 00 H C M PRESSURE RELIEF VALVE REQUIRED FIELD SUPPLIED ASSE 1070 ANTI SCALD MIXING VALVE R...

Page 42: ...G To prevent scalding from DHW recirculation temperature creep a suitable method to stop recirculation flow once water in the loop has reached the desired temperature must be used Failure to stop wate...

Page 43: ...Service Manual WARNING To prevent scalding from DHW recirculation temperature creep a suitable method to stop recirculation flow once water in the loop has reached the desired temperature must be used...

Page 44: ...supply piping 4 Before placing the boiler in operation check the boiler and its gas connection for leaks a Close manual main shutoff valve during any pressure testing at more than 14 inches w c b Dis...

Page 45: ...pply pressure requirements 1 Pressure required at the gas valve inlet pressure port Maximum 14 inches w c with no flow lockup or with boiler on Minimum 4 inches w c with gas flowing verify during boil...

Page 46: ...upply pressures are specified in this section of the manual 10 If gas supply pressure is within normal range and no adjustments are needed proceed on to Step 11 11 If the gas pressure is out of range...

Page 47: ...mportant that the gas line is properly purged by the gas supplier or utility company Failure to properly purge the lines or improper line sizing will result in ignition failure The problem is especial...

Page 48: ...0 of this manual and the boiler wiring diagram DIR 2000529643 00 LOW VOLTAGE WIRING HOLES LOW VOLTAGE CONNECTION BOARD Figure 8 3 Routing Field Wiring 48 Do not run low voltage wires next to high volt...

Page 49: ...ler before allowing it to fire The flow switch must be installed at the boiler outlet 2 Connect the normally open contacts on the flow switch to these terminals FIG 8 4 System supply sensor 1 By insta...

Page 50: ...ENSOR FLOW SWITCH FIELD SUPPLIED AUXILIARY LIMIT FIELD SUPPLIED LOW WATER CUT OFF OPTIONAL ROOM THERMOSTAT FIELD SUPPLIED DIR 2000534741 00 COM NO Figure 8 4 Low Voltage Field Wiring Connections Insta...

Page 51: ...nd CPVC pipe must comply with ASTM D1785 or D2845 Cement and primer must comply with ASME D2564 or F493 For Canada use CSA or ULC certified PVC or CPVC pipe fittings and cement 6 A condensate removal...

Page 52: ...ly filling your boiler with the appropriate water chemistry for closed loop boilers Good fill water quality will help extend the life of the appliance by reducing the effects of lime scale buildup and...

Page 53: ...er valve and purge valve and remove the hose Open all isolation valves Watch that system pressure rises to correct cold fill pressure h After the system has operated for a while eliminate any residual...

Page 54: ...time and check the voltmeter reading across the incoming wires 3 There should NEVER be a voltage reading 4 If a voltage does occur under any condition check and correct the external wiring This is a...

Page 55: ...alled on the outlet of the domestic hot water piping Check gas piping 1 Check around the boiler for gas odor following the procedure on page 44 of this manual connecting gas supply piping If you disco...

Page 56: ...10 Start up Figure 10 2 Operating Instructions 56 Move switch to the OFF position Installation Service Manual F I R E T U B E C O M B I...

Page 57: ...th Space Heating and DHW demands Indicates the burner is firing and a flame signal is detected Indicates that the DHW pump contacts are being powered Boiler Only Indicates that the system pump contact...

Page 58: ...highest space heating water set point that can be used for the specific space heating system This parameter is the upper limit of what the user can adjust the SH SETPT COLD DAY parameter to This param...

Page 59: ...flue plug from the vent pipe adapter Note Combustion measurements will be made at this point DIR 2000534695 00 REMOVE THE FLUE PLUG FROM THE VENT PIPE ADAPTER Figure 10 7 Flue Plug Removal Service mo...

Page 60: ...be based on the outlet or the system supply sensor optional The control will automatically switch to the system supply sensor once it is connected Verify space heat circulator operation The Space Heat...

Page 61: ...setting greater than the desired domestic hot water temperature Range 60 F MAX DHW SETPT Default 120 F TEMPERATURE UNITS This parameter can be used to select temperature units to be displayed on the...

Page 62: ...TIME DATE Sub menu FAULT LOG SETPOINTS Sub menu Set Points Menu duplicate SH SETPT COLD DAY DHW SETPT TEMPERATURE UNITS CASCADE Sub menu CASCADE ADDRESS CASCADE TYPE only available if address is 0 Bo...

Page 63: ...perature sensor This sensor is used to control modulation of the boiler during a DHW call for heat When this sensor is missing limited operation in DHW Mode is possible by controlling the boiler outle...

Page 64: ...re at which the Space Heating demand is blocked DHW demands will still be active Space heating operation will resume once the outdoor temperature falls below 10 F less than the Outdoor Air Shutdown se...

Page 65: ...If the flue temperature exceeds 215 F the control will reduce the maximum fan speed If the flue temperature exceeds 240 F the control will shut the unit down The unit will restart automatically once...

Page 66: ...circulate water in both Space Heating and DHW Modes Space heat temperature regulation Operating temperature target The boiler control module senses water temperature and regulates boiler firing rate t...

Page 67: ...ntrol starts the pre purge cycle by initiating the blower 4 The control starts the trial for ignition by firing the spark electrode and opening the gas valve 5 If flame is not detected after the spark...

Page 68: ...divert the boiler s outlet water from the heating system to the brazed plate heat exchanger The control will then modulate to maintain the DHW outlet temperature at the DHW set point 8 Once all calls...

Page 69: ...at least 10 microamps at high fire Clean the heat exchanger if flue temperature is more than 54 F above return water temperature If combustion or performance indicate need Clean heat exchanger Remove...

Page 70: ...condensate trap 1 Remove the clean out cap on the bottom of the trap Let the condensate and any debris drain out 2 Replace the clean out cap and resume operation Eliminate all system or boiler leaks C...

Page 71: ...t down the boiler until a new relief valve has been installed 2 After following the warning directions in this manual if the relief valve weeps or will not seat properly replace the relief valve Ensur...

Page 72: ...Research on Cancer IARC has concluded Crystalline silica inhaled in the form of quartz or cristobalite from occupational sources is carcinogenic to humans Group 1 Normal operating temperatures in thi...

Page 73: ...al and reinstall the condensate trap 12 Maintenance continued Installation Service Manual CAUTION Damaged gaskets and seals in the system can result in substantial property damage Ensure that damaged...

Page 74: ...Delta T T is maintained Installation Service Manual 5 When the unit stabilizes begin to slowly shut off the isolation valve on the outlet piping of the boiler see FIG 12 5 This will begin to restrict...

Page 75: ...boiler on Minimum 4 inches w c natural 8 inches w c LP with gas flowing verify during boiler startup Check control module fuses ALWAYS check control module fuses before replacing control module or any...

Page 76: ...D Flue Sensor Resistance vs Temperature Temperature Resistance Temperature Resistance 50 18 780 158 1 990 68 12 263 176 1 458 86 8 194 194 1 084 104 5 592 212 817 122 3 893 140 2 760 Temperature Resis...

Page 77: ...r assembly as necessary Low water flow through the heat exchanger Refer to Section 6A Hydronic Piping for minimum flow rates Verify that the boiler and system pump are running on a call for heat Air i...

Page 78: ...al reset once condition has been corrected Press the RESET button on the SMART SYSTEM display to reset Either the optional flow switch or the low water cutoff LWCO is not making Check boiler pump oper...

Page 79: ...of the device Check resistance of water sensors and compare to Table 13 2A on page 76 of this manual Replace sensor if necessary Check operation of diverter valve motor Replace if necessary AIR PRESSU...

Page 80: ...f 24 vac is present at the main control board check the wiring between the main control board and the gas valve Replace the wiring if necessary Do not disconnect the wiring from the gas valve and atte...

Page 81: ...heat If voltage is not present check wiring back to the main control board Replace the main control board if necessary If 120 vac is present on a call for heat and the boiler pump is not operating rep...

Page 82: ...ly after the previous call for heat has ended The control board will release the call for heat after 60 seconds The control board will release the call for heat if the outlet temperature drops 10 F DE...

Page 83: ...d wiring Repair or replace as needed LOCKOUT INLET SENSOR FAULT The inlet sensor has been disconnected Check the sensors and their associated wiring Repair or replace the sensor or wiring if damaged M...

Page 84: ...s connections between the Low Voltage Connection Board CN4 and the combi diverter valve motor Check that diverter valve motor is operating Verify that the voltage between wire CN4 2 Black and ground i...

Page 85: ...nnection Board or wire harness Space Heating System Heat Emitters Get Hot During a DHW Draw and the Combi Boiler does not Provide Hot Enough Domestic Hot Water Diverter valve not operating correctly V...

Page 86: ...eath or substantial property damage WARNING Gas valve adjustment procedure 4 Once the combustion analysis is complete test the safety shutoff device by turning the manual shutoff switch to the OFF pos...

Page 87: ...ipment wire as supplied with the appliance must be replaced it must be replaced with wire having same wire gauge AWG and rated for a minimum of 105 C Exceptions Replacement high voltage spark lead and...

Page 88: ...LOW VOLTAGE 120 VAC BOX DEPICTS DUAL SENSOR SINGLE HOUSING X1 7 1 2 3 4 5 G R RW R T W BK Y BL BLOWER T HIGH LIMIT SENSOR S1b OPERATING SENSOR S1a INLET SENSOR S2 FLUE SENSOR S3a FLUE SENSOR S3b INTE...

Page 89: ...89 Installation Service Manual Notes F I R E T U B E C O M B I...

Page 90: ...90 Installation Service Manual Notes F I R E T U B E C O M B I...

Page 91: ...91 Installation Service Manual Notes F I R E T U B E C O M B I...

Page 92: ...vision B PCP 3000005203 CN 500005353 reflects the addition of the DHW flow switch filter cleaning section and the Noble logo Revision C PCP 3000005203 CN 500005353 reflects updates made to the mixing...

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