RBI Infinite Energy2 IW1000 Installation And Operation Instructions Manual Download Page 148

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148

18 - SPARE PARTS

750 and 1000

CODE

DESCRIPTION

MOD

63505006

10 O-RING KIT EPDM 1,78 X 12,42

62630211

LP-NAT CONV KIT 500-750-1000 RBI

62630209

CONV KIT 199-1000 NG-LP RBI

63505007

10 O-RING KIT 2,62 X 17,86

63504009

HIGH POWER SILENCER GROUP - REPLACEMENT

63504010

COSMOMIX GAS MIXER - REPLACEMENT

63505071

SHAPED GASKET DIAM. 71,2 H. 9,2 - REPLACEMENT

60406142

AIR MIXER DIAPHRAGM 7 D.10-1 D.17

62649086

CONDENSING HE 70KW 15T ASME H

62649089

CONDENSING HE 70KW 15T ASME HLW

60434036

EXCHANGERS BRACKET

60406137

SHAPED BRACKET 67X54X36

63505019

10 NUT KIT ZINC COATED 6MA

63503006

FAN COLLECTOR BASE - REPLACEMENT

63505021

10 SCREW KIT 6X16 8.8 WITH WASHER

63501054

BAYONETTE SENSOR NTC 10K 2P MOLEX - REPLACEMENT

63501055

BAYONETTE FUSE 102°C 2P MOLEX - REPLACEMENT

63505081

10 OR RING 3137 EPDM 2,62 X 34,60 - REPLACEMENT

63505082

CONDENSATION DISCHARGE PIPE D.46.7 - REPLACEMENT

100

63505022

10 SCREW KIT 4X8 ZINC TC-CR DIN4042

101

62632008

GRP IGNITION ELECTRODE

102

63505028

10 GASKET KIT 56X21 SP.2

103

62632087

SPARE PART KIT INSULATION HE

104

63505072

GASKET S.WOLL PLUS D.100 SP.2 - REPLACEMENT

105

62629045

FIBER BURNER D.70 H200

106

63505073

5 GASKET KIT Ø71 - 80.5 MM SP.2 - REPLACEMENT

107

63503003

AXIAL BURNER GROUP 58-70KW - REPLACEMENT

108

63501010

FAN CABLE UL 885 - REPLACEMENT

109

63505011

10 BOLT KIT 5X12 CROSS HEAD

110

63501056

BOILER FAN 135 KW 115V - REPLACEMENT

111

63501044

OUTDOOR SENSOR - REPLACEMENT

112

63501038

SENSOR 10K D6X45 L=2500 T - REPLACEMENT

113

62630211

LP-NAT CONV KIT 500-750-1000 RBI

114

62630209

CONV KIT 199-1000 NG-LP RBI

116

62403822

IW - RBI 199-1000 INSTALLER INSTRUCTIONS

117

63505048

NEUTRALISING LIMESTONE 10 KG - REPLACEMENT

118

63505074

SIL. GASKET D.200 F.188 H.7,2 - REPLACEMENT

119

63502015

1P1/4 F BRASS PLUG - REPLACEMENT

120

63501057

RELAY 115V 16A EXCHANGE - REPLACEMENT

121

63501058

10 FUSE KIT 3A DELAYED GLASS KIT – REPLACEMENT

122

63501059

10 FUSE KIT 10 A DELAYED GLASS - REPLACEMENT

123

63503004

3/8G MALE TO 1/8NPT FEMALE BUSHING - REPLACEMENT

124

63505075

CONICAL PLUG TAB D.29.2-32,7 - REPLACEMENT

125

62617375

6” H252 COMPLETE INOX CONNECTION

126

63505077

POLY PROP EXHAUST GASKET 170X170 - REPLACEMENT

Summary of Contents for Infinite Energy2 IW1000

Page 1: ...burner resulting in possible severe personal injury death or substantial property damage The boiler can only be operated with a dust free air supply Follow the instruction manual procedures to duct ai...

Page 2: ...any phone in your building Immediately call your gas supplier from a neighbor s phone Follow the gas supplier s instructions If you cannot reach your gas supplier call the fire department Installation...

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

Page 4: ...assur s par un installateur ou un service d entretien qualifi ou par le fournisseur de gaz AVERTISSMENT Assurez vous de bien suivre les instructions donn es dans cette notice pour r duire au minimum l...

Page 5: ...5 SAFETY INSTRUCTIONS...

Page 6: ...ersonal injury or death WARNING Qualified installer qualified installer is an individual with specific technical training in space heating systems domestic hot water systems fuel gas systems and elect...

Page 7: ...m me partiellement Faites inspecter l appareil par un tecnicien qualifi et remplacez toute partie du syst me de contr le et toute commande qui ont t plong s dans l eau WARNING Ensure the appliance and...

Page 8: ...7 INSTALLATION Water connections 42 7 1 Water connections 42 7 2 Local pump and water flow limits 42 7 3 Quality of the water 42 7 4 Near appliance piping components 44 7 5 Temperature and pressure Re...

Page 9: ...termine location 75 11 12 2 Prepare roof penetrations 75 11 12 3 Termination and fittings 75 11 12 4 Multiple vent air terminations 76 11 13 Vertical termination Concentric vent 77 11 13 1 Description...

Page 10: ...d air lines in good condition and sealed tight 103 16 1 4 Check system water pressure system piping expansion tank 103 16 1 5 Check control settings 103 16 1 6 Check ignition and flame sense electrode...

Page 11: ...117 16 12 199 model wiring diagram 118 16 13 399 to 1000 models wiring diagram 120 17 TECHNICAL DATA 124 18 SPARE PARTS 126 19 READ OUT FLOW CHART 150 20 FACTORY MENU 151 21 SEQUENCE OF OPERATION 154...

Page 12: ...f the National Electric Code ANSI NFPA 70 and or Canadian Electrical Code Part 1 CSA C22 1 Where required by the authority having jurisdiction the installation must conform to the Standard for Control...

Page 13: ...uct Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases but identifies special venting systems the following requirements shall be satisfi...

Page 14: ...observe this indication may compromise the smooth running of the appliance or cause serious damage to individuals animals or property NOTICE Indicates special instructions on installation operation or...

Page 15: ...1001 6 Burner unit supply connection 7 Burner unit supply pipe 8 Gasket 9 Unit heat exchanger 18 8 11 17 9 7 15 16 6 14 10 5 12 13 1 3 4 2 020009 01 004 10 Burner unit return connection 11 Support ar...

Page 16: ...al insulation 23 Sight glass 24 Raccord fan burner 25 Modulating Fan 26 Return temperature sensor par 1007 27 Left ignition electrode 28 Right ignition electrode 29 Motorized valve body optional 30 Ga...

Page 17: ...Condensate discharge hose 6 Gas inlet pipe 7 Supply pipe 9 Air inlet connection 10 Electrical cable passages 11 Air filter 12 Flue exhaust connection 13 885IF board Optional 14 Electrical terminals Ju...

Page 18: ...re sensor Blue color connector 1006 29 High limit flue gas temperature fuse Red color connector 30 Flue gas exhaust manifold 31 Water Return connection 32 Flue blocked pressure switch pipe connection...

Page 19: ...Flue gas manifold cap 35 Automatic air vent 36 Water Supply connection 37 Water Return connection 38 Draining valves 39 Header temperature sensor 1102 40 Fan cover 41 ASME P T safety relief valve 42...

Page 20: ...ir inlet connection 10 Electrical cable passages 11 Air filter 5 10 12 7 7 4 1 8 24 9 6 25 2 3 11 14 20 18 40 13 40 15 17 16 21 19 5 10 12 7 7 4 1 8 24 9 6 25 2 3 11 14 20 18 40 13 40 15 17 16 21 19 0...

Page 21: ...ctor 1006 29 High limit flue gas temperature fuse Red color connector 30 Flue gas exhaust manifold 31 Water Return pipe 31 28 28 22 29 31 33 34 30 44 44 32 23 24 29 020010 01 003 32 Flue blocked press...

Page 22: ...ly connection 37 Water Return connection 38 Draining valves 39 Header temperature sensor 1102 41 ASME P T safety relief valve 42 Pressure and temperature gauge 43 Supply and return headers 44 Primary...

Page 23: ...0 Electrical cable passages 11 Air filter 12 Flue exhaust connection 13 885IF board 14 Electrical terminals 15 Control panel cover 16 Display 17 Control keys 18 Power control boards the highest power...

Page 24: ...color connector 1006 29 High limit flue gas temperature fuse Red color connector 30 Flue gas exhaust manifold 31 Water Return connection 32 Flue blocked pressure switch pipe connection 33 Condensate...

Page 25: ...nection 37 Water return connection 38 Drain valves 39 Header temperature sensor 1102 41 ASME P T relief valve 42 Pressure and temperature gauge 43 Supply and return headers 44 Primary heat exchanger t...

Page 26: ...rature fuse 12 Premix burner 13 Ignition electrodes 14 Ignitor 15 Return temperature sensor 16 Modulating PWM fan 17 Back flue preventer 20 Gas valve 22 Detection electrode 24 CRV Stainless steel heat...

Page 27: ...odes 14 Ignitor 15 Return temperature sensor 16 Modulating PWM fan 17 Back flue preventer 20 Gas valve 22 Detection electrode 23 Supply and return manifolds 24 CRV Stainless steel heat exchanger 25 Wa...

Page 28: ...odes 14 Ignitor 15 Return temperature sensor 16 Modulating PWM fan 17 Back flue preventer 20 Gas valve 22 Detection electrode 23 Supply and return headers 24 CRV Stainless steel heat exchanger 25 Wate...

Page 29: ...odes 14 Ignitor 15 Return temperature sensor 16 Modulating PWM fan 17 Back flue preventer 20 Gas valve 22 Detection electrode 23 Supply and return headers 24 CRV Stainless steel heat exchanger 25 Wate...

Page 30: ...with a one pipe vent system and getting combustion air from room The quality of the system water is very important Poor water quality can damage the appliance due to scale formation and corrosion Sect...

Page 31: ...llect Appliances so fueled shall not be installed in an abovegrade under floor space or basement unless such location is provided with an approved means for removal of unburned gas Failure to comply w...

Page 32: ...ings to the equipment room see Fig 5 1 a Combustion air opening with a minimum free area of one square inch per 4000 Btu hr input 5 5 cm2 per kW This opening must be located within 12 30 cm of the bot...

Page 33: ...tdoors the opening must be sized based on a minimum free area of one square inch per 3000 Btu hr 7 cm2 per kW This opening must be located within 12 30cm of the top of the enclosure see Fig 5 3 Figure...

Page 34: ...Opening in2 Bottom Opening in2 Top Opening in2 Bottom Opening in2 199 50 323 cm2 50 323 cm2 67 433 cm2 100 646 cm2 100 646 cm2 399 100 646 cm2 100 646 cm2 134 865 cm2 200 1201 cm2 200 1201 cm2 500 125...

Page 35: ...products Do not pipe combustion air near sources of products that may contaminate the air combustion like Dry cleaning laundry areas and establishments Swimming pools Metal fabrication plants Beauty...

Page 36: ...e materials 5 6 Vent and combustion air piping This appliance requires a special vent system designed for pressurized venting The appliance is to be used for either direct vent installation or for ins...

Page 37: ...roper installation and servicing for models 199 399 and 500 G Center of gravity Figure 5 7 Recommended minimum clearance distances for proper installation and servicing for models 750 and 1000 G1 Cent...

Page 38: ...ansported CAUTION The unpacked appliance may be damaged when not protected against contamination Only transport the appliance using the right transportation equipment such as a hand truck with a faste...

Page 39: ...e weight of the unit in Section 17 and lift the unit from the wood pallet and move it to the installation location 6 Install the leveling feet and plumb the unit accordingly see Figure 6 5 WARNING The...

Page 40: ...40 6 INSTALLATION Mounting the appliance Figure 6 6 Dimensions for models 199 399 and 500 Figure 6 7 Dimensions for models 750 and 1000...

Page 41: ...CONNECTION 3 AIR INTAKE CONNECTION 4 FLUE EXHAUST CONNECTION 5 GAS CONNECTION 6 CONDENSATE HOSE 199 2 2 3 3 1 1 1 4 399 2 2 4 4 1 1 1 4 500 2 2 4 4 1 1 1 4 750 2 1 2 2 1 2 6 6 1 1 4 1 1 4 1000 2 1 2...

Page 42: ...rdness of your water and cross with your appliance model CAUTION If the water flow is lower than required by Figure 7 1 scale will form into the heat exchanger dramatically reducing the life expectati...

Page 43: ...RE F Minimum Maximum water flow in function of the water hardness and water maximum temperature Model 199 Model 399 and 500 Model 750 Model 1000 210 12 8 140 12 19 gpm 24 38 gpm 36 57 gpm 48 76 gpm 24...

Page 44: ...ASME specifications Storage tanks may require additional valves depending on local codes 8 Appliance isolation valves Field supplied Install isolation valves as shown on Figure 7 5 or 7 6 Full port b...

Page 45: ...nections WARNING Failure to properly pipe the relief valve discharge can result in scalding of individuals and animals WARNING Never block the outlet of the safety relief valve or an explosion causing...

Page 46: ...ep the water temperature setpoint at least at 140 F 60 C This temperature will prevent the proliferation of the legionella bacteria WARNING Your domestic hot water system must be protected against leg...

Page 47: ...2 Check valve 13 Recycling pump If needed 14 Balancing valve mandatory if appliance is equipped with motorized valve item 17 Fig 3 1 CAUTION This is a concept drawing only It is up to the system desig...

Page 48: ...erformance 9 Secondary return pump 10 Timer 12 Hot water outlets 13 Cold water inlet 7 INSTALLATION Water connections CAUTION Size secondary return system pipes and pump item 9 in order to have a mini...

Page 49: ...ducts CAUTION The condensate discharge line must be of materials approved by the authority having jurisdiction In the absence of other authority PVC and CPVC pipe must comply with ASTM D1785 or D2845...

Page 50: ...3 through 3 11 Item 3 A Condensate drain pipe B Floor drain or drain pan Below this point there must be a trap capable of preventing the return of sewer gas C A D B E C A D B E 020010 01 029 A Pipe co...

Page 51: ...se only type 105 C wire or equivalent Installation must comply with 1 National Electrical Code and any other national state provincial or local codes or regulations 2 In Canada CSA C22 1 Canadian Elec...

Page 52: ...sing following the instructions given in Section 16 2 and open the junction box cover 2 Install the power supply wires B and C to terminals 101 and 102 connect the ground wire to the ground terminal 3...

Page 53: ...20 if the inpult voltage move between 2V and 10V the supply temperature will change proportionally between the Minimum setpoint parameter 3018 see Section 20 and the Maximum setpoint parameter 3017 s...

Page 54: ...re 9 3 9 INSTALLATION Electrical connections Figure 9 3 Electrical customer connection for appliance connected to a storage tank 4 The storage tank temperature sensor must be connected to terminals 8...

Page 55: ...gure 9 4 a field supplied pump relay must be installed if the pump current draw is greater than 3 amps 3 A secondary return pump must be connected to terminals 105 and 106 See Figure 9 4 4 A timer to...

Page 56: ...plied on demand Operative instructions on how to connect the appliances in cascade are supplied together the 885HC command For water gas flue exhaust and air intake connections ask for conceptual draw...

Page 57: ...etermined using the appropriate Annex G of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or CAN CSA B149 1 Natural Gas and Propane Installation Code Au moment du retrait d une chaudi re existante...

Page 58: ...death Be sure to locate the appliance such that the vent and air piping can be routed through the building and properly terminated The vent air piping lengths routing and termination method must all c...

Page 59: ...ure 11 4 Vertical concentric Direct venting Figure 11 5 Side wall concentric Direct venting Figure 11 2 Vertical two pipes Direct Venting Figure 11 6 Side wall or vertical in a roof one pipe venting c...

Page 60: ...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 Figure 11 7 11...

Page 61: ...opylene Centrotherm Innoflue System 750 1000 ISELL0687UV 3 80mm Appliance adapter Polypropylene Cosmogas 199 62617361 4 110 mm Appliance adapter Polypropylene Cosmogas 399 500 62617359 6 160mm Applian...

Page 62: ...ppliance connection and the air inlet cap connection Proper sealing of the air inlet pipe ensures that combustion air will be free of contaminants and supplied in proper volume When a sidewall or vert...

Page 63: ...nce to vent or air termination Do not exceed the lengths given in Section 11 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...

Page 64: ...pare the connection between adapter P and pipe N like described on Section 11 6 1 2 Insert the air inlet PVC CPVC pipe for 3 into the adapter P 3 Tighten the clamp F to mechanically secure the adapter...

Page 65: ...connection P to ensure proper fit up before assembling the adapter to the appliance The adapter R should go completely into the appliance connection to ensure proper sealing after sealant is applied a...

Page 66: ...wet insert the adapter R into the appliance connection B NOTICE If voids are present sufficient MOMENTIVE RTV 106 was not applied and joint could be defective d Tight the clamp to mechanically secure...

Page 67: ...n monoxide or a fire which can result in severe personal injury or death WARNING Improper installation of Polypropylene systems may result in injury or death WARNING Use only water based lubricants on...

Page 68: ...s E 2 Insert vent pipe G into adapter B following instruction of polypropylene pipe manufacturer WARNING Do not cover with thermal insulation polypropylene exhaust pipe nor install into an enclosure c...

Page 69: ...ents paints glues etc in the vicinity of the appliance Do not store and use these chemicals in the appliance room Avoid excessive dust formation and build up Failure to comply could result in fire sev...

Page 70: ...CATEGORY IV Vent and combustion air 11 10 Sidewall termination Two pipes 11 10 1 Vent air termination WARNING A gas vent extending through an exterior wall shall not terminate adjacent to a wall or b...

Page 71: ...public walkway At least 3 feet above any forced air intake within 10 feet No closer than 12 inches below or horizontally from any door or window or any other gravity air inlet b Air inlet must termin...

Page 72: ...1 16 Condensate could freeze and block vent pipe 11 10 5 Multiple vent air terminations 1 When terminating multiple appliances terminate each vent air connection as shown in Figure 11 18 WARNING All v...

Page 73: ...g winds could cause freezing of condensate and water ice buildup where flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or an...

Page 74: ...n to avoid recirculation of flue gas WARNING Do not connect any other appliance to the vent pipe or multiple appliances to a common vent pipe Failure to comply could result in severe personal injury d...

Page 75: ...ove the air intake The air inlet pipe and vent pipe can be located in any desired position on the roof but must always be no further than 2 feet apart and with the vent termination at least 1 foot abo...

Page 76: ...ns 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 with regard to spacing from adjacent appl...

Page 77: ...pliance one 1 heat cycle to ensure combustion air and vent pipes are properly connected to the concentric vent termination connections 11 13 3 Vertical termination installation 1 Determine the best lo...

Page 78: ...h or substantial property damage When two or more direct vent appliances are vented near each other two vent terminations may be installed as shown in Figure 11 27 It is important that vent terminatio...

Page 79: ...URAVENT 810005545 810005375 810005385 FSBS8 FSELB9008 FSVL 3608 750 1000 6 to 8 Stainless steel DURAVENT 810005231 810005385 FSBS8 FSELB9008 FSVL 3608 Figure 12 1 Adapter and increaser A B C A B C 020...

Page 80: ...ertical direct vent installation with rooftop combustion air inlet The vertical direct vent system is installed with a Category II flue and a separate combustion air pipe to the outdoors The flue outl...

Page 81: ...esigned to ensure that flue products will be properly exhausted from the building at all times WARNING Failure to use the correct vent increaser or a properly sized vent system may result in excessive...

Page 82: ...The appliance must be isolated from the gas supply piping system by closing a manual shutoff valve during any pressure testing of the gas supply piping system at test pressures equal to or less than...

Page 83: ...W C maximum pressure 2 Pressure required at gas valve inlet pressure port Maximum 13 W C with no flow lockup or with appliance off Minimum 3 W C with gas flowing verify during high fire WARNING Ensur...

Page 84: ...3 If the gas pressure is out of range contact the gas utility gas supplier qualified installer or service agency to determine the necessary steps to provide proper gas pressure to the appliance 4 Tur...

Page 85: ...nts The conversion kit supplied with the appliance is composed of the following elements which are necessary for the gas change a label rating stating the new gas setting an instruction sheet an orifi...

Page 86: ...WC 7 6 mbar and the maximum gas supply pressure must not be higher than 13 WC 33 mbar 16 Verifying the CO2 rate and its eventual adjustment following Section 13 8 The appliance during its normal oper...

Page 87: ...omposed of the following elements which are necessary for the gas change a label rating stating the new gas setting an instruction sheet an orifice per each burner present on the unit Installing in or...

Page 88: ...N The water s pH must fall within the following limit 7 5 pH 9 5 and if the system contains aluminium parts it must be 7 5 pH 8 5 This pH value must be measured after steady condition and after air pu...

Page 89: ...ns blinking can arrive at 15 20 minutes 6 Open the manual gas shutoff valve see Figure 13 1 7 Verify your gas meter Gas flow must be zero WARNING If gas flow occurs close the manual gas shutoff valve...

Page 90: ...the gas supply pressure between 12 WC and 13 WC 7 Turn the power switch to on and generate a heat demand by pressing button to its maximum setting Also ensure that the room thermostat is calling for h...

Page 91: ...fire range given in Figure 13 7 making sure to use the range for the gas type in use The CO2 reading must be inside the specified range If not STOP the appliance and call the Factory service departmen...

Page 92: ...l running mode On models 399 to 1000 set parameter 2200 to OFF to return the appliance to its normal running mode 6 If the capacity input is higher than the expected value repeat the procedure as per...

Page 93: ...t of measure of the water system pressure L Burner unit indicators Light when burner is burning blinking when burner is in lockout or in blocking error Burner 1 master Burner 2 Burner 3 Burner 4 M Wat...

Page 94: ...y mode press and hold for at least 5 seconds RESET key The appliance will automatically attempt another start up CAUTION If the appliance frequently shuts down contact a qualified technician to restor...

Page 95: ...ours of operation of the indirect water heater N A Hr x 10 1059 Burner 1 Interval between Lockouts May be 1 MIN 2 HRS 3 DAY 4 WK 1060 Burner 1 Interval between Blocking errors May be 1 MIN 2 HRS 3 DAY...

Page 96: ...For appliances models 399 up to 1000 parameters addressed to Burner 1 are applicable for that burner only If you want to see the same parameters for the other burners you have to connect the display t...

Page 97: ...ULTIBURNER calculated setpoint Max offset up F 1 to 36 9 2108 MULTIBURNER calculated setpoint Max offset down F 1 to 36 9 2109 MULTIBURNER next burner start rate 1 to 100 70 2110 MULTIBURNER next burn...

Page 98: ...mperature fuse WARNING If the high limit temperature fuse melt before any replacement it is mandatory to contact the appliance manufacturer to prevent any permanent damages to the heat exchanger Failu...

Page 99: ...of carbon monoxide which can result in severe personal injury or death Loc 26 Internal software error Replace the power control board Loc 27 Flame present with closed gas valve Replace the gas valve...

Page 100: ...ustion efficiency is lower than 88 try to clean the flue gas side and the water side of the heat exchanger c If flue temperature sensor do not match Section 16 10 it must be replaced Err 61 Return tem...

Page 101: ...rner master failure Reset via 3013 parameter Err 116 Multiple burner communication failure This error will stops all modules a Bus communication interrupted b Burner is not working a Check for the bus...

Page 102: ...er pressure system piping expansion tank Follow Section 16 1 4 Check control settings Follow Section 16 1 5 Check ignition and flame sense electrodes Follow Section 16 1 6 Check wiring and connections...

Page 103: ...cal damage water stains any signs of rust other corrosions or separation of the vent and air intake piping 2 Check outside terminations Screens and louvers should be free of any debris and must be cle...

Page 104: ...om contaminated areas 1 Combustible flammable materials Do not store combustible materials gasoline or any other flammable vapors or liquids near the appliance Remove immediately if found 2 Air contam...

Page 105: ...ing the low water cutoff manufacturer s instructions 16 1 20 Reset button low water cutoff Testing the low water cut off shuts the unit off Press the RESET button on the low water cutoff to turn the u...

Page 106: ...generator A Figure 16 3 4 Disconnect the two wires D Figure 16 4 from the ignition electrodes and the wire E Figure 16 4 from the flame detection electrode 5 Rotate the air inlet silencer B Figure 16...

Page 107: ...an approved leak detection method Failure to comply with this warning can cause fire extensive property damage severe personal injury or death 18 Reassemble the components by proceeding in reverse or...

Page 108: ...0009 01 032 CAUTION If gasket is damaged DO NOT reuse the heat exchanger door must be replaced NOTICE Gasket is intended for sealing combustion If damaged DO NOT reuse the heat exchanger door must be...

Page 109: ...ations items C and E are showned already disassembled from heat exchanger 16 MAINTENANCE R H N C A E Q B F S L G M D 020022 01 009 A Fixing screw B Washer C Thermal Insulation D Stainless steel tube E...

Page 110: ...appliance the distances listed above shall be verified very carefully also using a hand caliper 16 MAINTENANCE 16 5 Clean the air filter For the appliance to work properly the air filter must be clean...

Page 111: ...eakage from the top it is suggested to bend box 2 to 5 in the direction of discharge pipes to empty some condensate water Leaking condensate water may cause severe property damage 3 Open cover C Figur...

Page 112: ...ct plug B plug coming from display from plug A plug coming from Burner 1 Master 4 Connect plug B to the plug C D or E follow which burner you want to question considering that plug C is for Burner 2 p...

Page 113: ...from the appliance 6 Following step 3 to 5 above to remove the board located in the lower side of the unit 7 Install this last control board in the site where there where the Burner 1 Master control b...

Page 114: ...114 Figure 16 14 Complete situation of addresses and switches S4 Appliance models 1000 Appliance models 750 Appliance models 399 500 Appliance models 199 16 MAINTENANCE...

Page 115: ...e entire heating system will have to be drained 6 Check that the heating system fill valve is closed 7 Connect a hose to the drain valves item 38 of Figures 3 5 3 8 and 3 11 and place the other end of...

Page 116: ...temperature sensor The appliance has a number of sensors that measure temperature The electrical resistance between the sensor wires must correspond with the values shown in Figure 16 15 Figure 16 15...

Page 117: ...er of a turn item A 6 pull out item B 7 remove o rings C and D from their sites and replace them NOTICE Use only original parts Failure to comply with this notice could cause water leakage and consequ...

Page 118: ...abel 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 c...

Page 119: ...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 120: ...G 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 ca...

Page 121: ...ment 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 a...

Page 122: ...122 16 MAINTENANCE...

Page 123: ...Gas valve 22 Detection electrode 28 Blocked flue pressure switch 29 Condensate blocked drain switch 32 Main electrical switch 34 Display 35 IF 885 board Optional on 199 version Fuse F1 5x20 3A 47 Wate...

Page 124: ...l gas ppm 150 CO Carbon monoxide with LP gas ppm 250 NOx 0 O2 with natural gas ppm 30 CO2 Carbon dioxide for Natural gas at high fire 8 4 to 8 7 CO2 Carbon dioxide for Natural gas at low fire 8 4 to 8...

Page 125: ...20 120 150 150 150 150 250 250 250 250 30 30 30 30 8 4 to 8 7 8 8 to 9 1 8 8 to 9 1 8 8 to 9 1 8 4 to 8 7 8 8 to 9 1 8 8 to 9 1 8 8 to 9 1 9 5 to 10 9 5 to 10 9 5 to 10 9 5 to 10 10 5 to 11 5 10 5 to...

Page 126: ...126 18 SPARE PARTS Spare parts...

Page 127: ...27 18 SPARE PARTS WARNING Only use the appliance in combinations and with the spare parts listed in this manual Failure to do so can cause severe personal injury or death Spare parts for models 199 19...

Page 128: ...ON 020010 03 012 17 45 43 44 123 117 28 24 22 122 6 29 35 113 39 36 40 4 26 114 114 114 115 11 11 38 25 25 16 33 119 118 34 18 31 23 30 15 116 19 3 10 9 121 121 21 5 27 46 42 37 41 20 1 1 2 135 136 13...

Page 129: ...129 020010 03 011 132 133 49 131 47 129 129 130 130 128 126 57 57 57 57 57 57 125 127 134 29 55 58 124 120 52 52 145 144 146 146 158 18 SPARE PARTS 199...

Page 130: ...0 89 88 83 83 112 108 105 110 87 106 79 103 101 99 107 95 102 81 94 94 96 96 80 80 86 85 100 93 82 92 91 66 74 78 67 75 64 84 104 76 98 97 70 69 77 63 62 62 111 68 68 68 68 65 61 109 109 71 72 59 60 7...

Page 131: ...63501043 PRESSURE SWITCH ON 3 2 INWC REPLACEMENT C 25 63505058 GASKET EPDM D 125 REPLACEMENT C 26 63504006 D 125 H 703 COLLECTOR 1 EXCHANGER C 27 63504007 SYNTHETIC PLATE FILTER REPLACEMENT C 28 6350...

Page 132: ...SP1 5 C 76 63505069 PIREX GLASS D15 5 SP5 REPLACEMENT C 77 60404253 FLANGE L21 2 H34 SP1 C 78 63501053 MASTER GAS CABLE UL 885 REPLACEMENT C 79 63503001 FLANGE GAS 32X32 3 4P REPLACEMENT C 80 6350507...

Page 133: ...170X170 REPLACEMENT C 122 60338042 GAS COLLECTOR 1P NPT 4 HOLE FLANGE C 123 62626008 GAS VALVE PIPE C 124 62621151 COPPER TUBE D28 F F 1 1 4 H 550 C 125 63505041 10 SPRING KIT FOR 3 4 RING NUT C 126...

Page 134: ...SPARE PARTS WARNING Only use the appliance in combinations and with the spare parts listed in this manual Failure to do so can cause severe personal injury or death Spare parts for models 399 500 399...

Page 135: ...STALLER S INSTRUCTION 020010 03 010 13 34 32 33 127 35 2 21 125 23 27 28 7 6 36 19 4 8 8 1 1 17 17 16 16 120 15 121 121 121 122 26 14 14 11 40 126 12 38 20 37 10 124 42 3 128 128 18 41 41 5 9 9 9 22 3...

Page 136: ...to 500 020010 03 002 62 52 49 49 48 53 53 55 55 118 54 54 61 61 47 123 123 117 36 59 59 60 60 58 58 57 57 56 56 44 44 44 44 44 44 44 44 44 44 44 44 43 43 43 43 45 45 46 46 147 147 146 146 149 151 148...

Page 137: ...88 88 113 110 115 92 111 84 108 106 104 112 100 107 86 99 99 101 101 85 85 91 90 105 98 87 97 96 71 79 83 72 80 69 89 109 81 103 102 75 74 82 68 67 67 116 73 73 73 73 70 66 114 114 76 63 77 64 65 78 1...

Page 138: ...RD CLAMP REPLACEMENT CD 18 63501040 SINGLE BLUE BOARD CLAMP REPLACEMENT CD 19 63501041 BLACK 2 POLES SWITCH REPLACEMENT CD 20 63501042 CONNECTION BOARD 160X100 REPLACEMENT CD 21 63501043 PRESSURE SWIT...

Page 139: ...F F 1 1 4 1 1 4 RIT E 62 63505079 10 SCREW 6X12MM TC CR REPLACEMENT CD 63 63502023 P SENS 0 10B RAST 2 5 G1 4P WRAS CD 64 63502021 PLUG BRASS 1 4P M WITH O RING REPLACEMENT CD 65 63505003 10 SCREW KI...

Page 140: ...63505081 10 OR RING 3137 EPDM 2 62 X 34 60 REPLACEMENT CD 105 63505082 CONDENSATION DISCHARGE PIPE D 46 7 REPLACEMENT CD 106 63505022 10 SCREW KIT 4X8 ZINC TC CR DIN4042 CD 107 62632008 GRP IGNITION...

Page 141: ...2 UL 885 REPLACEMENT CD 147 63501009 GAS CABLE UL 885 REPLACEMENT CD 148 63501011 SENSOR CABLE MASTER 2 UL 885 REPLACEMENT CD 149 63501006 SENSOR CABLE SLAVE UL 885 REPLACEMENT CD 150 63501005 CONNEC...

Page 142: ...RE PARTS 750 to 1000 WARNING Only use the appliance in the combinations and with the spare parts listed in this manual Failure to do so can cause severe personal injury or death Spare parts for models...

Page 143: ...LLER S INSTRUCTIONS 7 15 30 124 23 11 56 13 12 125 19 2 27 4 18 21 16 16 16 16 17 17 17 17 31 112 6 26 28 34 111 35 8 8 8 8 122 14 14 14 121 121 121 117 10 33 32 9 9 9 9 1 1 24 113 20 116 114 25 25 25...

Page 144: ...0 50 1 1 49 49 49 49 43 43 53 53 53 53 55 55 55 55 46 52 52 52 52 45 123 123 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 38 54 54 54 54 37 37 37 37 37 37 37 37 40 40 40 40 39 39...

Page 145: ...76 61 61 107 118 104 86 82 82 78 105 79 79 74 102 100 98 106 83 94 80 101 59 95 95 84 93 93 85 99 92 81 109 91 65 90 77 73 66 89 63 103 75 97 96 69 68 110 67 67 67 67 62 64 70 60 57 71 58 108 108 72 1...

Page 146: ...NT CD 19 63501041 BLACK 2 POLES SWITCH REPLACEMENT CD 20 63501042 CONNECTION BOARD 160X100 REPLACEMENT CD 21 63501043 PRESSURE SWITCH ON 3 2 INWC REPLACEMENT CD 22 63504007 SYNTHETIC PLATE FILTER REPL...

Page 147: ...RING REPLACEMENT CD 59 63505003 10 SCREW KIT 4X10 GALVANIZED CD 60 63502011 BRASS CONNECTION 1 1 4 SUPPLY REPLACEMENT CD 61 62616111 KIT FOR 6 OR AND 3 WASHERS CD 62 63502012 BRASS CONNECTION 1 1 4 RE...

Page 148: ...ION ELECTRODE CD 102 63505028 10 GASKET KIT 56X21 SP 2 CD 103 62632087 SPARE PART KIT INSULATION HE CD 104 63505072 GASKET S WOLL PLUS D 100 SP 2 REPLACEMENT CD 105 62629045 FIBER BURNER D 70 H200 CD...

Page 149: ...L 885 REPLACEMENT CD 148 63501011 SENSOR CABLE MASTER 2 UL 885 REPLACEMENT CD 149 63501006 SENSOR CABLE SLAVE UL 885 REPLACEMENT CD 150 63501005 CONNECTION CABLE VALV UL 885 REPLACEMENT CD 151 6350100...

Page 150: ...T button and button for the time in seconds displayed Push button Push button Parameters shown during normal operations See Section 15 12 User s menu parameters see Section 15 10 Gain access to users...

Page 151: ...iance s micro processor makes this menu of parameters available to the qualified technician for the setting of the appliance To enter this menu operate as follow 1 Turn the main electrical supply Off...

Page 152: ...ab dISA 3008 Flue gas detector SEnS Sensor StCH Switch SEnS SEnS SEnS SEnS 3009 Outdoor thermistor type 10 10kohms 12 12kohms 10 10 10 10 3010 Other thermistor type 10 10kohms 12 12kohms 10 10 10 10 3...

Page 153: ...Number of slave burners 0 to 3 3 0 399 1 500 1 750 2 1000 3 3 3085 Modbus address 0 to 126 1 1 1 1 3086 Number of Stopbits 1 or 2 1 1 1 1 3100 Material selection ABS CPVC PVC SST PP PVC PVC PVC PVC 3...

Page 154: ...154 21 SEQUENCE OF OPERATION...

Page 155: ...ual Yes No Static Dynamic Gas Inlet Pressure W C VENTING Vent and combustion air Combustion air from room Direct vent Are all requirements in terms of ventilation of the equipment room be met Yes No M...

Page 156: ...urnished written instructions or has been altered or modified in any way These include but not limited to Excessive water hardness causing a lime build up in the heat exchanger tubes is not a fault of...

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