PB Heat Peerless Combi 160 User Manual Download Page 94 | Manualshive

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94

13.15 - Functional wiring
diagram

13 - MAINTENANCE

WARNING!!! Label all wires prior to disconnection
when servicing controls. Wiring errors can cause
improper and dangerous operation! Verify proper
operation after servicing Failure to comply with
this warning can cause extensive property damage,
severe personal injury or death!

LEGEND:

ALA - Alarm output
CM - Power control board
CR - Remote command (optional)
EA - Ignition electrode
ER - Flame detection electrode
EV3V - External three way valve (optional)
F1 - Fuse 2Amps
FPS - Flue pressure switch
GS - Spark generator
IG - Main electrical switch
J1 - Six poles connector
J2 - Four poles connector
J3 - Twelve poles connector
J4 - Four poles connector
J5 - Sixteen poles connector
J10 - Ten poles connector
J18 - Height poles connector
U1 - Supply temperature sensor
U2 - Domestic hot water temperature sensor
U3 - Domestic cold water temperature

sensor

U3 TANK - Storage tank temperature sensor

(optional)

U4 - Outside temperature sensor (optional)
U6 - Heating Safety high limit temperature

sensor

U7 - Flue gas temperature sensor
U8 - Return temperature sensor
PO1 - Heating pump
PR - Heating pressure switch
SDC - Electrical connection board
RT1 - Room thermostat connection
RT2 - Room thermostat connection on

remote control “CR” (optional)

VE - Fan
VG1 - Gas valve
V3V - Three way valve

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Summary of Contents for Peerless Combi 160

Page 1: ...ating installer service technician Read all instructions including this manual before installing Perform steps in the order given Failure to comply could result in severe personal injury death or subs...

Page 2: ...t autre appareil QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ Ne pas tenter d allumer l appareil Ne touchez aucun interrupteur ne pas vous servir des t l phones se trouvant dans le b timent Appelez imm d...

Page 3: ...3 SAFETY INSTRUCTIONS...

Page 4: ...or death Any optional extras or kit fitted subsequently must be original Cosmogas parts SAFETY INSTRUCTIONS WARNING These instructions must be read prior to installation If the information in these i...

Page 5: ...the defect and associated hazard in writing When servicing the boiler to avoid severe burns allow the boiler to cool before performing maintenance When calling or writing about the boiler Please have...

Page 6: ...ef valve 23 5 9 Supply and return piping 23 5 9 1 Converting a combi boiler into a heating only boiler 24 5 10 Low temperature heating systems 24 5 11 Use of glycol and other chemicals 24 5 12 Domesti...

Page 7: ...2 Vertical termination Two pipes 50 8 12 1 Determine location 50 8 12 2 Prepare roof penetrations 50 8 12 3 Termination and fittings 50 8 12 4 Multiple vent air terminations 51 8 13 Vertical terminati...

Page 8: ...0 3 Outdoor reset setting parameters 74 12 10 4 Outdoor reset zone adjustments 74 12 10 5 Outdoor reset activation 74 12 10 6 Outdoor reset with room compensation 74 12 11 Boiler switch settings 76 12...

Page 9: ...output 92 13 12 4 Checking the flame current 92 13 13 Water and flue temperature sensor 93 13 14 Outdoor temperature sensor optional 93 13 15 Functional wiring diagram 94 13 16 Multiwire wiring diagra...

Page 10: ...feet above finished grade in the area of the venting including but not limited to decks and porches the following requirements shall be satisfied 1 INSTALLATION OF CARBON MONOXIDE DETECTORS At the tim...

Page 11: ...nting system components and 2 A complete parts list for the venting system design or venting system d MANUFACTURER REQUIREMENTS GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED When the manufacturer of a Pro...

Page 12: ...to individuals animals or property CAUTION General caution Failure to observe this warning may compromise the smooth running of the appliance or cause serious damage to individuals animals or property...

Page 13: ...ensor 8 Heating pressure switch low water cut off 9 Heating supply connection 10 DHW connection 11 Gas inlet connection 12 Cold water connection 13 Heating return connection 14 Power Control Board 15...

Page 14: ...lve 36 U3 domestic cold water temp sensor 37 Cable clamp Figure 1 Main components 3 MAIN COMPONENTS 38 ASME Safety relief valve 39 U8 return temperature sensor 40 By pass pipe 41 Condensation discharg...

Page 15: ...valve 17 safety relief valve 21 condensate discharge pipe 22 heating supply pipe 23 domestic hot water outlet 24 gas inlet 25 cold water inlet 26 heating return pipe 45 U7 flue gas temperature sensor...

Page 16: ...ails the setting changes that should be made to best match the boiler s operation to the needs of each application The PC160 can be connected to an indirect storage tank for the production of domestic...

Page 17: ...ample on how it can work This graph is an example where is represented an installation where the supply and return temperatures are 139 F and 115 F respectively and the outside temperature is 23 F The...

Page 18: ...s shown in graph form in figure 4 4 5 Characteristic curve of the domestic side The PC160 boiler offers resistance to the passage of domestic water see graph flow pressure of figure 5 The installer or...

Page 19: ...inches 0 mm Sides 2 inches 51 mm Floor 2 inches 51 mm Concentric vent 0 inches 0 mm Split vent first 12 from the boiler 1 inch 25 mm Split vent after 12 from the boiler 0 inches 0 mm Figure 6 Recomme...

Page 20: ...ucted to bear its weight or the boiler and building may be damaged NOTE The boiler must never be installed on carpeting CAUTION This boiler is not designed for direct outdoor installation If installed...

Page 21: ...t of the boiler or the boiler and building may be damaged 3 mark the screw holes for the wall bracket A 4 remove the cardboard template 5 install the wall bracket A using the screws E provided 6 hang...

Page 22: ...to determine the flow characteristics of the selected product used 4 Boiler isolation valves Field supplied Full port ball valves are required Failure to use full port ball valves could result in res...

Page 23: ...move sediment flux filings and other foreign matter An approved inhibitor should be added to the heating system water to prevent limestone and magnetite deposits from forming and to protect the boiler...

Page 24: ...re of the gas supplied correspond with those required for the boiler as stated on the rating plate Never use a gas different than that stated on the boiler rating plate Failure to comply with this war...

Page 25: ...by closing its individual manual shutoff valve during any pressure testing at test pressures equal to or less than 1 2 psi 3 5 kPa Install 100 lockup gas pressure regulator in supply line if inlet pr...

Page 26: ...boiler 6 on the boiler s display you ll see followed by a number 7 using the push buttons and set the input to 61 to convert the boiler from LP GAS to NATURAL GAS or 62 to convert the boiler from NATU...

Page 27: ...URAL GAS Maximum inlet gas pressure 13 In W C Minimum inlet gas pressure 3 In W C Manifold pressure see rating plate Input rating see rating plate This water heater was converted on day month year ___...

Page 28: ...ediment trap 5 ground joint union 8 Relief valve drain 9 Condensate drain 10 Domestic mixing valve 12 Flow restrictor 13 Fill valve 14 Heating supply 15 Domestic Hot Water 16 Cold water 17 Heating ret...

Page 29: ...h the National Electrical Code ANSI NFPA 70 and or the Canadian Electrical Code Part I CSA C22 1 Electrical Code This is an essential safety requirement which must be checked Check that the electrical...

Page 30: ...ny type of room thermostat which has an electrical contact with the following specifications open end call for heat closed call for heat clean dry contact not powered electrical capacity of 24Vac 1A 6...

Page 31: ...emperature sensor NOTICE the maximum outdoor temperature sensor cable length permitted is 65 ft 20 m For longer lengths up to 300 ft 100 m a shielded cable with the shield connected to the ground must...

Page 32: ...ect the plug from the diverter valve 9 use a 18 AWG two wire cable to connect the indirect storage tank temperature sensor to terminals TS item M as per figures 17 and 18 10 insert the probe of the ta...

Page 33: ...the capacity of the indirect water heater reaches temperature In some cases this will result in house cooling because the central heating function was stopped by the DHW priority mode Once the indirec...

Page 34: ...ized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Cod...

Page 35: ...ld This is a simply water vapor a purely natural phenomenon and not a reason for concern The minimum clearance measurement between two vent end terminations of this kind of boilers shall be not less t...

Page 36: ...ct venting Figure 23 Vertical two pipes Direct venting Figure 24 Side wall air intake vertical vent Direct venting Figure 25 Vertical concentric Direct venting Figure 26 Side wall concentric Direct ve...

Page 37: ...rgents and cleaning solvents found in household laundry rooms Adhesives used to fasten building products and other similar products Do not pipe combustion air near sources of products that may contami...

Page 38: ...ene COSMOGAS 61302003 Concentric boiler adapter Polypropylene COSMOGAS 62617224 Concentric roof terminal Polypropylene COSMOGAS 62617304 Concentric wall terminal Polypropylene COSMOGAS 62617232 Single...

Page 39: ...ly System a Seal all joints and seams of the air inlet pipe using either Aluminum Foil Duct Tape meeting UL Standard 723 or 181A P or a high quality UL Listed silicone sealant b Do not install seams o...

Page 40: ...the lengths given in Section 8 3 2 Cut pipe to the required lengths and deburr the inside and outside of the pipe ends 3 Bevel outside of each pipe end to ensure even cement distribution when joining...

Page 41: ...ould result in excessive levels of carbon monoxide or a fire which can result in severe personal injury or death 2 Insert one side of clamp D onto the air intake of boiler adapter A side C 3 Insert ad...

Page 42: ...I 3 ft USA clearance to service regulator vent outlet I 6 ft CANADA clearance to service regulator vent outlet J 9 USA clearance to non mechanical air supply inlet to building or the combustion air i...

Page 43: ...s and with the National Fuel Gas Code ANSI Z223 1 for U S installations or CSA B149 1 for Canadian installations For installation in Canada vent pipe system must be certified to ULC S636 see Table 4 N...

Page 44: ...terminate in an elbow pointed outward as shown in Figure 46 or 49 WARNING Do not exceed the maximum lengths of the outside vent piping shown in Figures 46 or 49 Excessive length exposed to the outside...

Page 45: ...h of piping for vent or air must not exceed the limits given in the Section 8 3 2 You must consider the surroundings when terminating the vent and air a Position the vent termination where vapors will...

Page 46: ...6 feet from adjacent walls No closer than 12 inches below roof overhang At least 7 feet above any public walkway At least 3 feet above any forced air intake within 10 feet No closer than 12 inches bel...

Page 47: ...ine as shown in Figures 31 and 32 2 Maintain the required dimensions of the finished termination piping as shown in Figures 31 and 32 3 Do not extend exposed vent pipe outside of the building more tha...

Page 48: ...rmination where vapors will not damage nearby shrubs plants or air conditioning equipment or be objectionable b The flue products will form a noticeable plume as they condense in cold air Avoid areas...

Page 49: ...oncentric vent termination connections 8 11 3 Multiventing sidewall terminations When two or more direct vent appliances are vented near each other each appliance must be individually vented and vent...

Page 50: ...at least 1 foot above the air intake 5 Locate terminations so they are not likely to be damaged by foreign objects such as stones or balls or subject to buildup of leaves or sediment 8 12 2 Prepare r...

Page 51: ...ons see Figure 38 For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet is part of a direct vent connection It is not classified as a forced air intake...

Page 52: ...ucts will form a noticeable plume as they condense in cold air Avoid areas where the plume could obstruct window views c Prevailing winds could cause freezing of condensate and water ice buildup where...

Page 53: ...NEVER common vent or breach vent this appliance to avoid possibility of severe personal injury death or substantial property damage When two or more direct vent appliances are vented near each other...

Page 54: ...maintenance See Section 8 4 for a list of corrosive contaminants and sources Two example scenarios of a concentric venting arrangement are shown for illustrative purposes in Figures 42 and 43 8 13 5...

Page 55: ...ion and clearance requirements of section 8 12 The maximum allowable equivalent vent and air intake lengths for this venting arrangement are to be determined from Section 8 3 Use only approved venting...

Page 56: ...2 insert the collars L in hole M 3 insert pipe N inside fitting A 4 tight the two collars O in a manner to mechanically secure pipe N to fitting A DO NOT FORCE Horizontal vent sections must always be...

Page 57: ...ting can result in excessive levels of carbon monoxide or a fire which can result in severe personal injury or death Mechanically secure each joint with the supplied clamps as shown in figure 47 Follo...

Page 58: ...F extension 54387 60 ft PP flexible extension 54388 Spacer for PP flexible extension 54345 No 3 90 PP M F in line elbow 54346 45 PP M F in line elbow 54347 No 4 Secure clamp for PP extensions 54352 No...

Page 59: ...ed below Terminal Type Heatfab Saf T Vent Part Number Pro Tech FasNSeal Part Number Z FLex Part Number Elbow Termination w Screen 9314TERM n a 2SVSTEX0390 Tee Termination w Screen 9330TEE FSTT3 2SVSTT...

Page 60: ...ation examples of the Split system see section 9 2 for the reference of the numbers 2 the second example shows the vent system run through a vertical wall Condensation is collected inside the boiler i...

Page 61: ...r death In particular 1 slip fit the extension 1 and 2 see figure 52 together 2 drill a suitable hole 3 with a drill 4 see figure 52 in a position where the two pipes 1 and 2 are overlapped 3 insert a...

Page 62: ...o 1 In line 90 PP coaxial M F elbow 54304 No 6 In line 45 PP coaxial M F elbow 54302 No 7 3ft 1m PP coaxial extension 54348 No 3 PP coaxial roof end piece 54342 No 5 PP Coaxial wall end piece 54340 No...

Page 63: ...ow Terminal Type Heatfab Saf T Vent Part Number Pro Tech FasNSeal Part Number Z FLex Part Number Elbow Termination w Screen 9314TERM n a 2SVSTEX0390 Tee Termination w Screen 9390TEE FSTT3 2SVSTTF 3 Mi...

Page 64: ...e 54 between the vent terminal and the wall and also between the vent terminal and the ground level snow line Maintain 3ft distance also between the vent terminals of two or multiple boilers see figur...

Page 65: ...ure 55 WARNING If boiler stays off for more than 3 months repeat the above operation to again fill the condensate trap 11 1 3 Filling the heating system WARNING Never use non approved additives or tox...

Page 66: ...jury or loss of life 11 3 Confirming the boiler s gas type The type of gas and the gas supply pressure that the boiler is set up for is listed on the rating label The boiler can operate using one of t...

Page 67: ...e 16 item 3 2 follow the steps in section 13 2 to remove the front cover 3 turn the screw in pressure port D shown in figure 57 three turns counterclockwise 4 connect a manometer with graduations of a...

Page 68: ...manometer to it 9 the manometer connections must be made as shown in figure 59 to get the correct pressure reading 10 replace panel H of figure 65 and latch it closed If panel H is not properly in pla...

Page 69: ...t for the CO2 to stabilize to prevent overshooting the desired value 4 replace the gas valve cap item F in figure 57 5 seal screw F with red paint or nail polish to discourage tampering WARNING Compar...

Page 70: ...flow should generally be regulated according to the values given in section 14 under the heading instantaneous d h w production rise 75 F 42 C Factory set heat input To adjust see section 11 10 Figure...

Page 71: ...ime the pressure drops restore the correct value This operation may have to be repeated several times during the first month of operations to remove any gas bubbles present 12 2 Overview The boiler is...

Page 72: ...the following on display 1 if a domestic water request is active if a heating request is active if there is no domestic water or heating request active 12 5 Summer mode To disable the heating functio...

Page 73: ...e selected CH 00 Wall stat control follow section 12 8 CH 01 Outdoor reset control follow section 12 10 an outdoor temperature sensor is required CH 02 Outdoor reset control with room compensation con...

Page 74: ...ure systems 122 F 50 C for high temperature systems 12 10 4 Outdoor reset zone adjustments The default values previously suggested are for boilers using an outdoor temperature sensor installed in dwel...

Page 75: ...d by the heating knob item 7 of figure 62 OA Slope of the line Ob Minimum heating temperature Oc Maximum heating temperature br Set point of the angle fulcrum of the line b parallel shift of the line...

Page 76: ...off access the Installers Menu in section 12 17 and set the parameter at a value other than zero Keep in mind that each value will correspond to a delay in minutes until the display goes into Energy...

Page 77: ...of the parallel shift of the curve as shown in figures 63 and 64 when outdoor reset is active per section 12 9 Display of the calculated heating temperature when outdoor reset is active per section 12...

Page 78: ...not saved using the button will be lost The next table lists each Installers menu parameter what it affects and its adjustment range PARAMETER DESCRIPTION INFORMATION ON DISPLAY ITEM 2 OF Figure 62 Va...

Page 79: ...to 2 F Can be changed between 104 and 122 F Default value is 104 F Never set domestic setpoint see section 12 7 at a value lower than this parameter Can be changed between 1 and 99 Default value is 15...

Page 80: ...qualified technician Blocking error Contact a professionally qualified technician Blocking errors automatically reset if the condition causing the block disappears Auto purging procedure that last 3 m...

Page 81: ...3 4 If position is correct check for 120Vac at the supply of the spark generator c if the combustion air pressure is incorrect inspect the vent system and eliminate any obstructions d if the voltage t...

Page 82: ...check that there are no water leaks in the heating system Check a that no obstructions are in the flue discharge air intake line b check the flue pressure switch setting point setting is 4 5 in W C c...

Page 83: ...nd carry current Check that the electrical resistance of the sensor corresponds with the graph in section 13 13 check that the electrical connection cables between the sensor and the power control boa...

Page 84: ...ontrol board have continuity and carry current Check if the boiler is properly grounded Push ON switches 7 an set again the correct tY value see section 16 If the sensor resistance does not correspond...

Page 85: ...e by a trained technician in accordance with all applicable local and national codes Improper servicing or adjustment could damage the boiler Failure to comply with this warning can result in a fire o...

Page 86: ...follow the steps below while refering to figure 65 1 remove screws A 2 raise latch C 3 remove the front cover 4 press the two plastic springs item L down 5 lower the electrical box 6 lift latch G 7 p...

Page 87: ...from the combustion chamber detail H in figure 66 10 using the same vacuum cleaner clean the surfaces of the burner and around the electrodes WARNING Before proceeding to the next step verify that the...

Page 88: ...be between 0 08 in 2 mm and 0 10 in 2 5 mm the distance of the ignition electrodes to the burner surface must be between 0 20 in 5 0 mm and 0 22 in 5 5 mm the distance of the flame detection electrode...

Page 89: ...terial B to prevent water from entering the electrical system 4 grip spring clamp G with a pair of pliers and slide it downwards 5 pull the condensation trap hose H off the trap 6 remove the fan burne...

Page 90: ...iler 8 open the heating system isolation valves and heating system fill valve 9 follow the steps in section 11 1 3 to bleed the air from the heating system NOTE If display shows L05 reverse polarity p...

Page 91: ...on 13 10 to isolate and drain the water from the boiler 2 follow the steps in section 13 2 to gain access the internal components 3 disconnect fittings A 4 remove screws C 5 rotate D flange in the sen...

Page 92: ...o carry out specific checks covered in the manual it is possible to override the control logic of the boiler See the next 13 12 1 Auto purging To reset the auto purging procedure press the and keys to...

Page 93: ...U2 U3 U6 U7 and U8 The location of each sensor can be found in figure 1 and sections 13 15 and 13 16 13 MAINTENANCE Figure 72 Water temperature sensor s curve Figure 73 Outdoor temperature sensor s cu...

Page 94: ...rk generator IG Main electrical switch J1 Six poles connector J2 Four poles connector J3 Twelve poles connector J4 Four poles connector J5 Sixteen poles connector J10 Ten poles connector J18 Height po...

Page 95: ...de l entretien des commandes tiquetez tous les fils avant de les d brancher Des erreurs de c blage peuvent entra ner un fonctionnement inad quat et dangereux S assurer que l appareil fonctionne ad qua...

Page 96: ...eating Safety high limit temperature sensor U7 Flue gases temperature sensor U8 Return temperature sensor PO1 Heating pump PR Heating pressure switch SDC Electrical connection board RT1 Room thermosta...

Page 97: ...97 13 MAINTENANCE...

Page 98: ...8 Maximum pressure of domestic hot water circuit PSI 150 Minimum pressure of domestic hot water circuit PSI 1 Capacity of expansion tank gal 2 64 Supply voltage 120Vac 60Hz Absorbed electric power W...

Page 99: ...7 60406074 BRACKET SIPHON L84 H130 P32 18 60702055 O RING 134 EPDM 3 53 X 25 8 19 60801043 SCREW SELFTAPPING 3 9 X 9 5 CROSS HEAD Stock Code Part No Description 20 62630136 SIPHON 21 60801100 SCREW SE...

Page 100: ...51 O RING 3825 SIL 2 62 X 209 22 72 61404109 COVER MANIFOLD AIR ALUMINUM 73 60801080 SCREW SELFTAPPING 4 X 10 TC S TT UNI 8112 74 60801111 SELFTAPPING BOLT 6 3 X 38 75 60701013 GASKET FRIZITE D15 5 F1...

Page 101: ...ALVE 128 60701006 3 8 MALE CAP 129 54339 62653003 DOMESTIC HEAT EXCHANGER ACQUAJET 130 54325 62110052 SENSOR NTC 10 KOHM KLIP WITH SCREW 131 60802008 NUT ZINC COATED 4MA 132 60702053 O RING 3037 EPDM...

Page 102: ...eset CH settings to 01 or 02 see section 12 16 Installer s menu see section 12 17 Overrides menu see section 13 12 Boiler in stand by Domestic hot water Central heating temp setting D H W temp setting...

Page 103: ...om therm state Fan speed rpm 100 Setting output for heating Heating service mode Reaction to outdoor temp Angle fulcrum Heat temp reduction by open RT State of the knobs Energy saver display Disabled...

Page 104: ...w for more explication Domestic functionalities selection Must be always at 00 Master or slave selection in a batterie configuration Must be always at 00 Rotating selection in a batterie configuration...

Page 105: ...105 NOTES...

Page 106: ...106 NOTES...

Page 107: ...operty of the owner and must be affixed near the boiler for future reference TO THE OWNER This boiler should be inspected annually by a Qualified Service Agency PC8000 R2 1 14 1M Printed in U S A WEB...

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