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PEERLESS Combi 160, Installation, Operation & Maintenance Manual

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PEERLESS Combi 160 Installation, Operation & Maintenance Manual Download Page 7

7

1 - INSTALLATION - CODE REQUIREMENTS

1.1 - National 
installation 
legislation

- The installation must conform to the 
requirements of the authority having 
jurisdiction or, in the absence of such 
requirements, to the latest edition of 
the 

National Fuel Gas Code, ANSI 

Z223.1/NFPA 54

 and or  

CAN/CSA 

B149.1, Natural Gas and Propane 
Installation Code.

- Where required by the authority 
having jurisdiction, the installation 
must conform to the Standard for 

Controls and Safety Devices for 
Automatically Fired Boilers, ANSI/
ASME CSD-1

Summary of Contents for Combi 160

Page 1: ...Boiler Peerless Gas Installation Operation Maintenance Manual Combi 160 As an ENERGY STAR Partner PB Heat LLC has determined that this product meets the ENERGY STAR guidelines for energy efficiency...

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: ...nd wiring connections 20 6 INSTALLATION Electrical connections 21 6 1 Electrical connections overview 21 6 2 Connecting the power supply cable 22 6 3 Choosing the room thermostat 22 6 4 Thermostat wir...

Page 6: ...ch settings 49 12 12 Delays alarms and protective actions 49 12 13 Circulator pump and three way valve protection 49 12 14 Freeze protection 49 12 15 Display in energy saving mode 49 12 16 Users menu...

Page 7: ...ion or in the absence of such requirements to the latest edition of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Where required by the...

Page 8: ...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 9: ...sensor 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 10: ...Three way valve 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 Condensa...

Page 11: ...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 12: ...ils 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 13: ...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 14: ...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 15: ...o it is protectedfromrain wind sunandfrost NEVERplacethis boilerinalocationthatwouldsubjectittotemperaturesat or near freezing Failure to properly locate this boiler can result in premature failure vo...

Page 16: ...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 17: ...ensate neutralizer between pipe C of figure 10 and the waste disposal system be carried out with a pipe with an internal diameter equal to or greater than 1 2 in 13 mm be installed in such a way so as...

Page 18: ...3 and 5 of figure 7 and move switch No 5 see figure 18 from OFF position to ON position Now knob 32 of figure 1 is disabled 5 9 Low temperature heating systems CAUTION When the boiler is installed in...

Page 19: ...2 below to ensure that the gas supply piping is sized properly See section 14 for values of maximum gas supply pressure and minimum gas supply pressure and also section 11 7 Before installation a tho...

Page 20: ...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 21: ...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 22: ...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 23: ...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 24: ...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 14 and 15 10 insert the probe of the ta...

Page 25: ...B plastic spring to open the electrical box C Direction to open the electrical box D Switches for the functional setting of the boiler Figure 18 Control board and junction box board details 7 INSTALLA...

Page 26: ...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 27: ...the vent terminal s shall be located at least 5 ft 1 5 m above the air intake terminal s Avoid terminal locations likely to be affected by winds snowdrifts people and pets Item unique to CANADA vent s...

Page 28: ...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 29: ...or death Pipes or elbows connected directly to the boiler must be mechanically secure Follow these instructions make reference to figure 21 1 prepare the two collars G with springs E and F 2 insert t...

Page 30: ...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 22 Follo...

Page 31: ...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 32: ...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 33: ...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 34: ...r death In particular 1 slip fit the extension 1 and 2 see figure 27 together 2 drill a suitable hole 3 with a drill 4 see figure 27 in a position where the two pipes 1 and 2 are overlapped 3 insert a...

Page 35: ...o 1 In line 90 PP coaxial M F elbow 54349 No 6 In line 45 PP coaxial M F elbow 54341 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 36: ...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 37: ...e 29 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 38: ...ure 30 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 39: ...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 40: ...e 13 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 32 three turns counterclockwise 4 connect a manometer with graduations of a...

Page 41: ...manometer to it 9 the manometer connections must be made as shown in figure 34 to get the correct pressure reading 10 replace panel H of figure 40 and latch it closed If panel H is not properly in pla...

Page 42: ...t for the CO2 to stabilize to prevent overshooting the desired value 4 replace the gas valve cap item F in figure 32 5 seal screw F with red paint or nail polish to discourage tampering WARNING Compar...

Page 43: ...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 44: ...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 45: ...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 46: ...elected 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 contro...

Page 47: ...re 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 dwell...

Page 48: ...d by the heating knob item 7 of figure 37 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 49: ...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 50: ...of the parallel shift of the curve as shown in figures 38 and 39 when outdoor reset is active per section 12 9 Display of the calculated heating temperature when outdoor reset is active per section 12...

Page 51: ...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 37 Va...

Page 52: ...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 53: ...echnician Blocking error Contact a professionally qualified technician Blocking errors automatically reset if the condition causing the block disappears Auto purging procedure that last 3 minutes in p...

Page 54: ...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 55: ...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 56: ...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 57: ...ection 16 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 board have...

Page 58: ...ection SAFETY INSTRUCTION WARNING If maintenance is performed on the vent air intake system it must be properly reassembled and sealed Failure to properly maintain the vent air system can result in ex...

Page 59: ...from the combustion chamber detail H in figure 41 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 60: ...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 61: ...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 62: ...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 63: ...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 64: ...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 65: ...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 47 Water temperature sensor s curve Figure 48 Outdoor temperature sensor s cu...

Page 66: ...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 67: ...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 68: ...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 69: ...69 13 MAINTENANCE...

Page 70: ...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 1...

Page 71: ...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 72: ...1 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 F11...

Page 73: ...S VALVE 128 60701006 3 8 MALE CAP 129 62653003 DOMESTIC HEAT EXCHANGER ACQUAJET 130 54235 62110052 SENSOR NTC 10 KOHM KLIP WITH SCREW 131 60802008 NUT ZINC COATED 4MA 132 60702053 O RING 3037 EPDM 2 6...

Page 74: ...set 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 75: ...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 76: ...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 77: ...77 NOTES...

Page 78: ...78 NOTES...

Page 79: ...is the property 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 R0 5 10 1 5M Printed i...

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