Slant/Fin VGH-299-CH Installation And Service Manual Download

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E93.1601EN032.C VGH installation manual

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System Example 5

Low Voltage Connections

Name

Wire terminal

RT Room

thermostat

12-13

System

temperature sensor

3-4

OS outdoor

temperature

sensor 1-2

Tank thermostat or sensor

5-6

LLH

low loss header

T DHW

indirect

Tank

SNV

non-return valve (low resistance
type)

High Voltage Connections

DHW indirect tank circulator

2-3-PE

P1 boiler

circulator

4-PE-5

System heating circulator

6-PE-7

System Example 6

Low Voltage Connections

Name

Wire terminal

RT Room

thermostat

12-13

System

temperature sensor

3-4

OS outdoor

temperature

sensor 1-2

Tank thermostat or sensor

5-6

LLH

low loss header

T DHW

indirect

Tank

SNV

non-return valve
(low resistance type)

High Voltage Connections

P1 boiler

circulator

4-PE-5

P2 HWS

primary

circulator

2-3-PE

System heating circulator

6-PE-7

Figure 21-5

Figure 21-6

LLH

HEATING

ZONE

BOILER

SNV

LLH

HEATING

ZONE

BOILER

SNV

Summary of Contents for VGH-299-CH

Page 1: ...er Address Boiler Serial Number Phone Number Installation Date This manual must be left with owner and must be hung on or adjacent to the boiler for reference INSTALLATION AND SERVICE MANUAL Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance California Proposition 65 Warning This product contains chemicals known to the State ofCaliforn...

Page 2: ...PRESSURE RELIEF VALVE 22 NON RETURN VALVE 299 399 23 PRIMARY SECONDARY PIPING 23 CIRCULATOR FUNCTIONALITY 23 FROST PROTECTION 23 INSTALLING A STRAINER AND OR DIRT SEPARATOR 23 WATER QUALITY 24 USE OF GLYCOL 24 CHEMICAL WATER TREATMENT 25 UNDER FLOOR HEATING 26 FLUSH THE SYSTEM WITH FRESH WATER 26 PLASTIC PIPING IN THE HEATING SYSTEM 26 AUTOMATIC AIR PURGING OF THE HEAT EXCHANGER 26 AUTOMATIC FEED ...

Page 3: ...location 50 10 CASCADING 54 APPLIANCE 54 10 1 1 Calculation VGH 299 300 Valid for parts supplied by Duravent M G 54 10 1 2 Terminals equivalent feet 54 EXISTING COMMON VENTING GUIDELINES 55 11 ELECTRICAL INSTALLATION 56 GENERAL 56 CONNECTION MAINS SUPPLY 56 ELECTRICAL CONNECTIONS 56 EXPLANATION OF THE LOW VOLTAGE CONNECTIONS 57 EXPLANATION OF THE HIGH VOLTAGE CONNECTIONS 58 LADDER LOGIC DIAGRAM 59...

Page 4: ...om address selection through e2prom setting 94 15 2 3 Cascade Heating only Managing boiler 94 15 2 4 Cascade Domestic Hot Water Settings 95 15 2 5 Cascade DHW priority 95 15 2 6 Cascade Start stop sequence 95 15 2 7 Cascade Power balance mode 96 CASCADE BOILER ROTATION 96 15 3 1 Next depending to start selection 96 CASCADE ERROR HANDLING 97 15 4 1 Cascade Frost protection 97 15 4 2 Emergency mode ...

Page 5: ...Alert Symbol indicates a hazardous situation which will or can cause minor or moderate personal injury or property damage Caution Sign plus a lightning bolt indicates the risk of electric shock and the potential of hazards due to electric shock Notice Sign indicates special instructions on installation operation or maintenance that are important but not related to personal injury or property damag...

Page 6: ...E93 1601EN032 C VGH installation manual 6 1 SAFETY GUIDELINES ...

Page 7: ...onal injury exposure to hazardous materials or loss of life Installation and service must be performed by a qualified installer service agency or the gas supplier who must read and follow the supplied instructions before installing servicing or removing this boiler This boiler contains materials that have been identified as carcinogenic or possibly carcinogenic to humans Do not use this boiler if ...

Page 8: ...ck up power c Meet ANSI UL 2034 Standards and comply with NFPA 720 2005 Edition and d Have been approved and listed by a Nationally Recognized Testing Lab as recognized under 527 CMR 3 A product approved vent terminal must be used and if applicable a product approved air intake must be used Installation shall be performed in strict compliance with the manufacturer s instructions A copy of the inst...

Page 9: ...er Weather compensation control Outdoor reset Indirect tank control Connections for On Off thermostat or modulating thermostat 0 10 VDC remote flow temperature set point control 0 10 VDC remote boiler input control Outdoor temperature sensor External indirect tank circulator or diverter valve Boiler circulator PWM control for external boiler circulator System circulator External flow switch or ext...

Page 10: ...ch NPT 1 NPT 1 NPT 1 Flue connection Inch mm 4 100 4 100 6 150 GAS CONSUMPTION Values min max Natural gas ft3 h m3 h 54 8 274 1 6 7 8 74 3 368 2 1 10 4 91 1 465 2 6 13 2 Propane 1 ft3 h m3 h 23 6 118 0 7 3 3 32 0 159 0 9 4 5 39 2 200 1 1 5 7 Gas supply pressure nominal 2 Nat gas Inch W C mbar 7 0 17 4 Propane Inch W C mbar 11 0 27 4 NOTES 1 Using propane maximum fan speed needs to be reduced 2 Min...

Page 11: ... rate by 4 De rate by 8 De rate by 10 De rate 4 per 1000 ft In Canada No de rate De rate by 10 De rate by 10 De rate by 10 De rate 4 per 1000 ft In USA and Canada de rate by 4 extra for every 1000 ft above 4500 ft How to calculate De rating at intermediate elevations for US Elevation between 2000 and 3000 ft New value 2000 x 0 004 Example Elevation is 2600 ft De rating is 2600 2000 x0 004 2 4 3000...

Page 12: ...ers will be lower with longer venting and or altitudes greater than 2000 feet 610 m 2 Output means Heating Capacity for VGH 299 CH and Gross Output for VGH 399 CH and VGH 500 CH 3 The maximum input when operating on LP Gas is 397 MBH 4 Ratings have been confirmed by the Hydronics Section of AHRI 5 The ratings and efficiencies are based on standard test procedures and calculation methods as prescri...

Page 13: ...E93 1601EN032 C VGH installation manual 13 4 BOILER DIMENSIONS VGH 299 CH Connections VGH 299 CH A Supply NPT 1 B Return NPT 1 C Condensate Flexible hose Ø 1 06 26 9 mm D Gas NPT 1 Table 4 1 Figure 4 1 ...

Page 14: ...E93 1601EN032 C VGH installation manual 14 VGH 399 CH Table 4 2 Connections VGH 399 CH A Supply NPT 1 B Return NPT 1 C Condensate Flexible hose Ø 1 06 26 9 mm D Gas NPT 1 Figure 4 4 ...

Page 15: ...E93 1601EN032 C VGH installation manual 15 VGH 500 CH Connections VGH 500 CH A Supply NPT 1 B Return NPT 1 C Condensate Flexible hose Ø 1 06 26 9 mm D Gas NPT 1 Table 4 3 Figure 4 3 ...

Page 16: ...7124 000 French User Manual 81 7125 000 Gas pressure kit VGH 500 If protection from gas pressure faults is demanded this kit is available The kit consists of two gas pressure switches with connections to the gas valve and cabling to connect to the burner controller The gas pressure switches are factory set to the values for natural gas 81 7105 000 Unpacking The VGH boiler will be supplied with the...

Page 17: ...rce socket with ground Open connection to the sewer system for draining condensing water A wall or stand to properly support the weight of the boiler Depending on the current of the used circulator apply a circuit breaker up to a maximum of 15 A The installation of the Slant Fin gas appliance must conform to the requirements of this manual your local authority and the CAN CGA B149 Installation Cod...

Page 18: ...or at the highest point in the installation Do not install the boiler in a location where it will be exposed to temperatures 100 F or higher Do not install the boiler in a location where it will be exposed to high levels of humidity and moisture or where condensation might fall onto the boiler Make sure there is an open connection with the sewer to drain the condensate This connection must be lowe...

Page 19: ... holes ensure that the suspension bracket or frame is perpendicular and the boiler does not lean forward If necessary adjust the position with the leveling bolts at the lower rear side of the back panel see figure 6 2 When the leveling bolts aren t sufficient fill the gap behind the bolts to get the boiler in position The boiler position lies between the boiler hanging level and hanging slightly b...

Page 20: ...sized properly to prevent pressure drop greater than 1 wc as stated in the NFPA54 If you experience a pressure drop of greater than 1 w c regulator or gas line is undersized Slant Fin recommends a nominal value of 7 to 10 W C of gas pressure when using Natural gas and 11 to 13 W C when using LPG will be available at the boiler gas valve inlet at maximum boiler firing rate See technical specificati...

Page 21: ...and or pipes particularly those that are metal Ensure that the drain drainpipe and anything that will come in contact with the condensate can withstand the acidity or neutralize the condensate before disposal Damage caused by failure to install a neutralizer kit or to adequately treat condensate will not be the manufacturer s responsibility Figure 7 2 Figure 7 3 Open connection to the sewer WARNIN...

Page 22: ...has no internal pressure relief valve but a relief valve specially selected for this boiler is added to the boiler shipment and can be found in the box This must be installed close to the boiler in the flow pipe of the heating system and no shut off valve shall be placed between the relief valve and the boiler When having cascaded boilers each boiler must have its own pressure relief valve The pre...

Page 23: ...rops below the 41 F 5 C programmable the boiler is also ignited The circulator and or boiler will shut down as soon as the return temperature has reached the 59 F 15 C programmable The mentioned temperatures are related to the temperatures measured by the RETURN sensor of the boiler This frost protection function will not fire up the boiler in case of a general blocking of the boiler demand NOTICE...

Page 24: ...early basis when antifreeze is used in a system Replace the antifreeze every 5 years or sooner based on the instructions from the manufacturer or if the pH is out of the required range A micro bubble air elimination device is required to be installed in all heating systems An air scoop is not an acceptable substitute for a micro bubble air elimination device and may not be used in the installation...

Page 25: ...t with the corrosion inhibitors in preventative and curative treatment for gas fired central heating boilers If water treatment is required when filling the system or preforming maintenance an inhibitor must be used Follow the instructions provided by the inhibitor manufacturer when adding it to the system The following is a list of approved inhibitors Always check the water quality of the water a...

Page 26: ...t or 24 hours reset The display will show dAir indicating that the controller is performing the De Air sequence to purge the heat exchanger of air by sequencing the boiler circulator OFF and ON The installer technician can cancel the De Air sequence by pressing a specific key button combination from the display By default De Air sequence takes around 14 minutes 1st cycle The 3 ways valve moves to ...

Page 27: ...m of logging must take place to prevent continuously filling of the system with large amounts of oxygenated fresh water This can happen when a leak in the system is not detected and the total added water amount is not being logged Water pressure The installation must be designed and built to conform to all applicable regulations and standards including the right safety relief valves IMPORTANT Alwa...

Page 28: ...ensate trap circulator automatic air vent expansion vessel low loss header 7 21 2 EXAMPLE OF A MULTIPLE BOILER HEATING CIRCUIT WITH LOW LOSS HEADER Figure 7 9 Figure 7 10 P1 Boiler circulator P3 Heating circulator S3 Flow System temperature sensor HEATING ZONE BOILER P3 S3 P1 P1 NON RETURN VALVE low resistance type NOT SPRING LOADED P1 Boiler circulator P3 Heating circulator S3 Flow system tempera...

Page 29: ...2 BOILER RESISTANCE GRAPH VGH 399 CH Figure 8 1 Figure 8 2 0 5 10 15 20 25 30 0 5 10 15 20 25 30 presuure loss feet of head Flowrate gallons US minute Resistancegraph VGH 299 CH 35 F 25 F 20 F 0 5 10 15 20 25 30 35 0 5 10 15 20 25 30 35 40 presuure loss feet of head Flowrate gallons US minute Resistancegraph VGH 399 CH 35 F 25 F 20 F ...

Page 30: ... several modulating circulator modes implemented in the software By selecting a different modulating circulator mode the circulator behavior can be changed The following modulating circulator modes are available Modulating circulator mode Details 0 Disabled No circulator modulation the PWM duty cycle is always 0 1 Delta temperature modulation Calculated duty cycle to create a delta temperature bet...

Page 31: ...D Scaling Range parameter the PID calculation speed is scaled in a linear way Circulator maximum electrical power General The inrush current of a conventional circulator is approximately 2 x its nominal current The maximum switch current of the PCB is 4 A The total current of pcb and gas valve is approx 0 5 A All field supplied circulators and valves for the boiler loop DHW and the system that are...

Page 32: ...of 3 downwards in the direction of the boiler roughly equal to 1 4 inch per foot or 5 cm per meter When not installed accordingly it may result in condensate building up in the vent gas tube eventually causing component failure When using a wall terminal there is the possible risk of ice building up on surrounding parts structures because the condensate will freeze This risk must be taken into acc...

Page 33: ...rds Warning United States Canada 3 Flue piping and Fittings CPVC Schedule 40 ANSI ASTM F441 All venting material in Canada must be ULC S636 approved All Vent and Air Inlet materials installed on gas fired appliances in CAN US must meet the Standards listed in this Table Failure to comply could result in fire serious injury or death PVC Schedule 40 ANSI ASTM D1785 Stainless Steel SS UL 1738 Polypro...

Page 34: ...ind even if System 636 certified Check with the local safety inspector to verify compliance Canadian installations must comply with the current CSA B149 1 Installation Code and local building codes PVC exhaust venting When using PVC venting the first part of exhaust venting must be approved CPVC or PP This starter piece must have a minimum length in feet according to table 9 7 Design Supply Max Li...

Page 35: ... each pipe end to ensure even cement distribution when joining 4 Clean all pipe ends and fittings using a clean dry rag Moisture will retard curing and dirt or grease will prevent adhesion 5 Dry fit vent or air piping to ensure proper fi t up before assembling any joint The pipe must go a third to two thirds into the fitting to ensure proper sealing after cement is applied 6 Priming and Cementing ...

Page 36: ...PPS BG 810004367 4 concentric roof black 4PPS VKL 810009752 terra cotta 4PPS VK TCL 810009753 4 concentric wall white 4PPS HKL 810009742 VGH 500 5 Roof black 5PPS VTML 810009770 5 Single Pipe Side Wall Stainless 5PPS HSTL 810009763 6 Roof black 6PPS VTML 810009791 6 Single Pipe Side Wall Stainless 6PPS HSTL 810009784 6 Bird Screen Stainless 6PPS BG 810004276 Centrotherm Innoflue BOILER TERMINATION...

Page 37: ...imneys Secure Seal SS SSD SSID Heat Fab Saf T EZ Seal Use of FasNSeal Flex smooth inner wall vent is to be used in vertical or near vertical sections only taking precaution to ensure no sagging occurs of the vent system Connect to the FasNSeal rigid vent using specially designed adapters and sealing method see manufacturer s instructions Use only the materials vent systems and terminations listed ...

Page 38: ...ouses a double walled supply pipe or an insulated duct must be used to prevent the possible condensation on the outside of the pipe It is not possible to insulate the internal air pipes of the boiler and therefore condensation at the internal air canals must be prevented When the intake combustion air is terminated vertically through a roof an approved termination designed to prevent water from en...

Page 39: ...gh quality UL Listed silicone sealant such as those manufactured by Dow Corning or General Electric b Do not install seams of vent pipe on the bottom of horizontal runs c Secure all joints with a minimum of three 3 sheet metal screws or pop rivets Apply Aluminum Foil Duct Tape or silicone sealant to all screws or rivets installed in the vent pipe d Ensure that the air inlet pipes are properly supp...

Page 40: ...ovisions of the local building codes Indoor air kit Duravent Boiler Termination Color order stock VGH 299 VGH 399 4 Twin Pipe Side Wall black 4PPS HTPL 810009745 4 Single Pipe Side Wall Stainless 4PPS HSTSL 810009744 4 Bird Screen Stainless 4PPS BG 810004367 VGH 500 5 Roof black 5PPS VTML 810009770 5 Single Pipe Side Wall Stainless 5PPS HSTL 810009763 6 Single Pipe Side Wall Stainless 6PPS HSTL 81...

Page 41: ...tic manufacturing plants Furniture refinishing areas and establishments New building construction Remodeling areas Garages with workshops Proper vent installation and type of gas vent or vent connector For boilers for connection to gas vents or chimneys vent installations shall be in accordance with Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 or Venting Systems and Air S...

Page 42: ...or CSA B149 1 for Canadian installations Follow the instructions in this manual when removing a boiler from an existing vent system The boiler vent and air piping can be installed through the roof or through a wall Follow the procedures in this manual for the method chosen Refer to the information in this manual to determine acceptable vent and air piping length You may use any of the vent air pip...

Page 43: ...or more details Two pipe vertical See page 50 for more details Concentric wall two pipe to boiler Boilers VGH 299 and 399 only See page 45 for more details Concentric wall concentric to boiler Boilers VGH 299 and 399 only See page 45 for more details Figure 9 4 Figure 9 5 Figure 9 7 Figure 9 6 ...

Page 44: ...ion manual 44 Concentric vertical two pipe to boiler Boilers VGH 299 and 399 only See page 50 for more details Concentric vertical concentric to boiler Boiler VGH 299 and 399 only See page 50 for more details Figure 9 8 Figure 9 9 ...

Page 45: ...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 flue products impinge on building surfaces or plants d Avoid possibility of accidental contact of flue products with people or pets e Do not locate the terminations where wind eddies could affect performance or cause recirculation such ...

Page 46: ...nly 12 30 cm 299 36 91 cm 399 500 Non Direct vent 4 ft 1 2 m below or to side of opening 1 ft 30 cm above opening 3 ft 91 cm K Clearance to a mechanical air supply inlet 3 ft 91 cm above if within 10 ft 3 m horizontally 6 ft 1 83 m L Clearance above paved sidewalk or paved driveway located on public property Vent termination not allowed 7 ft 2 1 m M Clearance under veranda porch deck or balcony se...

Page 47: ...pipe sidewall termination of air intake and exhaust vent Alternate two pipe sidewall termination of air intake and exhaust vent Alternate two pipe sidewall termination of air intake and exhaust vent Figure 9 11 Figure 9 11 Figure 9 12 12 Min 16 Max ...

Page 48: ... obtain minimum clearance of 12 inches 305 mm between the inside edge of the exhaust vent and the inside edge of the air intake elbow as shown in Figure 9 14 for U S installations For Canadian installations provide clearances required by CSA B149 1 Installation Code 3 The air inlet of the boiler is part of a direct vent connection It is not classified as a forced air intake with regard to spacing ...

Page 49: ...n the concentric terminations or recirculation of combustion products may occur Water may also collect inside the larger combustion air pipe and flow to the burner enclosure Failure to follow this warning could result in product damage or improper operation personal injury or death Ensure termination location clearance dimensions are as shown in Figure 9 15 DO NOT use field supplied couplings to e...

Page 50: ...hich the exhaust vent penetrates the roof and at least 2 feet above any part of a building within 10 horizontal feet 4 The air intake piping must terminate in a down turned 180 direction utilizing two elbows see figure 9 17 5 The exhaust piping must terminate in a vertical coupling as shown in Figure 9 17 The top of the coupling must be at least 1 foot above the air intake When the vent terminatio...

Page 51: ...ight and all air intake pipes at the same height to avoid recirculation of flue products and the possibility of severe personal injury death or substantial property damage 2 Place roof penetrations to obtain minimum clearance of 12 inches 305 mm between outside edge of air intake an exhaust vent of another boiler for U S installations see Figure 9 18 For Canadian installations provide clearances r...

Page 52: ...ep the terminals at min 12 above grade or snow line Provide vent and air intake with bird screen Concentric Vertical Termination Do Not Install U Bend or elbow on concentric termination Figure 9 19 Figure 9 20 Figure 9 21 Minimum clearance above snow level 18 for Canada Maximum 24 above roof or snow level ...

Page 53: ...nticipated snow level 12 inches 305 mm in U S A or 18 inches 457 mm in Canada as shown in Figure 9 20 DO NOT use field supplied couplings to extend concentric terminations Airflow restriction will occur Multi venting vertical terminations When two 2 or more direct vent appliances are vented near each other each appliance must be individually vented see Figure 9 22 NEVER common vent or breach vent ...

Page 54: ...0 ft 30 m 4 36 ft 11 m 100 ft 30 m 100 ft 30 m 100 ft 30 m 5 100 ft 30 m 100 ft 30 m 100 ft 30 m 6 16 ft 5 m 100 ft 30 m 100 ft 30 m VGH 399 3 85 ft 26 m 100 ft 30 m 100 ft 30 m 100 ft 30 m 4 100 ft 30 m 100 ft 30 m 100 ft 30 m 5 16 ft 5 m 100 ft 30 m 100 ft 30 m 6 100 ft 30 m 100 ft 30 m Remark 1 Dn 150 200 means the diameter of the horizontal collector including the bend 150 mm and after the ben...

Page 55: ...yers and any appliance 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 fireplace dampers 4 Place in operation the appliance being inspected Follow the lighting instructions Adjust thermostat so appliance will operate continuously 5 Test for spillage at the d...

Page 56: ...here required that is skilled in working on electrical installations and according to all applicable standards It is not allowed to change the internal wiring fitted by the manufacturer A spare fuse is mounted on the casing of the burner controller Connection mains supply It is advised to use a flexible cable between the cabinet entry at the bottom and the connection terminal The earth wire has to...

Page 57: ... thermostat can be connected If these terminals are bridged the set programmed flow temperature of the boiler will be used OPTION 2 An modulating controller can be connected to these terminals The boiler software will detect and use this modulating signal automatically PARAMETER boiler parameter 124 see 11 9 programmable in and outputs 14 15 0 10 VDC CONTROL SIGNAL These terminals are used for an ...

Page 58: ...supply connection of the unit 8 Line voltage wire 9 Neutral wire PE Ground wire 10 11 ALARM RELAY A semiconductor alarm output This is a triac output with an active voltage of 120 VAC it can only handle resistive loads between 5 and 50 Watt E g an incandescent bulb of 10 50 Watt can be added to this This alarm will be activated 60 seconds after an error has occurred There are a few exceptions Alar...

Page 59: ...E93 1601EN032 C VGH installation manual 59 Ladder Logic Diagram Figure 11 3 ...

Page 60: ...E93 1601EN032 C VGH installation manual 60 Electrical schematics Figure 11 4 ...

Page 61: ...E93 1601EN032 C VGH installation manual 61 Figure 11 5 ...

Page 62: ...O O O O O O O O O Water Flow DHW O O O O O M O M M RT Switch O O M O O O O O O M Mandatory O Optional Disabled N A Not Available DHW mode 0 No Domestic Hot Water DHW mode 1 Storage with sensor DHW mode 2 Storage with thermostat DHW mode 3 Instantaneous water heating with plated heat exchanger flow switch and DHW out sensor N A DHW mode 4 Instantaneous water heating with plated heat exchanger and D...

Page 63: ...ade pump N A 1 Drain switch 6 Alarm relay 2 2 Gas pressure switch 7 Filling valve 2 122 Prog Input 7 0 Disabled 8 LPG tank 2 1 T_Flue_2 sensor N A 9 Ext Igniter 2 2 T_Flue_2 with blocked flue N A 10 Air damper 2 3 Cascade sensor 128 Prog Output 4 0 Disabled 4 Blocked Flue switch N A 1 Module pump 5 CH Sensor 2 CH pump 124 Prog Input RT 0 room thermstat off 3 DHW pump 1 room thermstat on 4 System p...

Page 64: ... RIGHT to confirm and use UP or DOWN to adjust value DOWN Directly select Actual setpoint of DHW setpoint in the Status overview push RIGHT to confirm and use UP or DOWN to adjust value ENTER Confirm a setting or enter a menu item 12 1 1 DISPLAY ICONS The following table gives a short description of the icons that can be visible on the main screen during operating Picture 12 1 Figure 12 1 Table 12...

Page 65: ...ONFIRM or RIGHT to confirm the mode and the Actual DHW setpoint becomes directly settable Use UP or DOWN to increase decrease the setpoint Press CONFIRM or RIGHT to confirm your alteration or press ESC or LEFT to cancel A setpoint is only visible on the display when no error or alert is active In case of an active error or alert the bottom right part of the display is used to display the error or ...

Page 66: ...owing password screen will then appear Changing protected safety parameters may only be conducted by experienced licensed boiler operators and mechanics Hazardous burner conditions can happen with improper operations that may result in PROPERTY LOSS PHYSICAL INJURY or DEATH Enter the password with the following steps 1 Use the UP DOWN button to adjust the first number 2 Press CONFIRM or RIGHT to c...

Page 67: ...Boiler history The boiler history found in the information menu displays several history counters that keep track of the boiler usage The history cannot be erased and will continue for the burner controller life cycle The following boiler history data is available Sub Menu item Description Successful Ignitions Number of successful ignitions Failed Ignitions Number of failed ignitions Flame Failure...

Page 68: ... stored maximum Lockout Error type Air Switch Not Closed Error description Wed 04 11 2018 14 50 Time stamp when the error occurred Service reminder The Service reminder will remind the owner user of the appliance to service the appliance at a specified Service_Interval factory set on 2000 burn hours When service is not done within this time a service reminder will be shown on the screen Service is...

Page 69: ... with a premix modulating burner and a pneumatic air gas system 12 6 1 CIRCULATOR START EXERCISE EVERY 24 HOURS To protect the circulator from getting stuck at a certain position it is forced to run for 10 seconds every 24 hours This is done only for the boiler loop circulator at the start up of the board 12 6 2 FROST PROTECTION The Frost protection function protects the boiler and boiler loop fro...

Page 70: ...eed Minimal fan speed Ignition speed Maximum flue gas temperature Ignition speed is the same as Pre Purge Speed and Post Purge speed The following appliances are available Appliance type 50 This is the standard mode used for Natural gas Appliance type 51 This is the standard mode used for Propane Appliance type 52 55 Not Used Ignition cycle During the ignition cycle multiple safety checks are acti...

Page 71: ...n be selected 12 8 1 ROOM THERMOSTAT ONLY CH MODE 0 DEFAULT SETTING For this mode the CH mode must be set to 0 and no outdoor sensor is needed If the room thermostat closes the boiler and system circulators are switched ON When the supply temperature drops CH_Hysterese_Down below the CH_Setpoint settable via the menu the boiler is switched ON The power for the boiler is PID regulated between T_Sup...

Page 72: ...ostat as described in 12 7 1 CH outdoor reset curve The outdoor reset curve can be changed by adjusting the design and mild weather reference temperatures The calculated CH setpoint is always limited between parameters Reset_Curve_Boiler_Minimum and Reset_Curve_Boiler_Maximum The outdoor temperature used for the CH_Setpoint calculation is measured once a minute and averaged with the previous measu...

Page 73: ...ode 2 Installer 1 Mode 0 5 Reset_Curve_Design_Boiler Sets high boiler CH setpoint when outdoor temp is equal to Reset_Curve_Outdoor_Design 2 Installer 176 ºF 80 ºC 32 176 ºF 0 80 ºC Reset_Curve_Outdoor_Design Sets the outdoor temp at which the boiler setpoint must be high as set by Reset_Curve_Design_Boiler 2 Installer 23 ºF 5 ºC 4 41 ºF 20 5 ºC Reset_Curve_Boiler_Mild_Weather Sets low boiler CH s...

Page 74: ...ller password and changing parameter 28 in the boiler parameters default value is setpoint 50 F Boiler Parameters 25 Warm Weather Shutdn 72 F 26 Boost Temp increment 0 F 27 Boost Time Delay 20 min 28 Night Setback Temp 7 F Adjustable constant Circulation Parameters Parameters Level Default Value Settable CH_Mode 2 Installer 0 Mode 0 5 Warm_Weather_Shutdown Set max outdoor temp Above this temperatu...

Page 75: ... to adverse condition and override control of the analog signal to prevent an upset condition This means for example that when signal is going up faster than the boiler can regulate that the boiler will slow down to prevent overshoot in temperature The CH_Setpoint_Min and CH_Setpoint_Max parameters can be adjusted to provide the desired temperature adjustment band A heat request will be generated ...

Page 76: ...ue will correspond to the minimum modulation rate and the maximum modulation analog input signal value will correspond to the maximum modulation rate All other safety and control functions associated with the boiler will react normally to adverse condition and override control of the analog signal to prevent an upset condition A heat request will be generated by an input of 1 5 volts or higher The...

Page 77: ... demand has priority over CH demand but the priority period is limited up to DHW_Max_Priority_Time The priority timer starts when both CH and DHW demand are present After the DHW_Max_Priority_Time is achieved the control will switch from DHW to CH operation CH has priority now for a maximum period of DHW_Max_Priority_Time Different DHW Priority types can be chosen DHW priority Description 0 Time D...

Page 78: ...pare DHW in the indirect tank 2 User 149 ºF 65 ºC 104 160 ºF 40 71 ºC DHW_Priority 2 0 Time 1 OFF 2 ON DHW_Max_Priority_Time Sets the maximum time for either DHW or CH priority 2 Installer 60 min DHW_Post_Circulator_Period 2 Installer 120 sec 10 900 12 9 4 INSTANTANEOUS WATER HEATING WITH PLATED HEAT EXCHANGER DHW MODE 3 In DHW mode 3 the water flow through a plated heat exchanger is checked with ...

Page 79: ...y temperature rises above Boiler_Setpoint plus DHW_Supp_Hysterese_Up the boiler is switched OFF When the Anti_Legionella_Sensor is above Anti_Legionella_Setpoint minus 5 4 F minus 3 C for Anti_Legionella_Burn_Time the controller goes into post circulation and ends the Anti Legionella demand When the controller has powered up the Anti_Legionella_Sensor temperature must reach a temperature of Anti_L...

Page 80: ... 32 0 95 35 72 22 F C Installer Set outdoor temperature above which CH demand is locked Bas Outd T 32 0 86 30 68 20 F C Installer Set the outdoor temperature at which CH setpoint is set to Bas Supply T Des Outd T 13 25 77 25 23 5 F C Installer Set the outdoor temperature at which CH setpoint is set to Des Supply T 2 Domestic Hot Water DHW min max Default unit Access level Description DHW Setpoint ...

Page 81: ...t Access level Description Successful Ignitions User Display the number of successful ignitions Failed Ignitions User Display the number of failed ignitions Flame Failures User Display the number of flame losses Operation Days days User Display the total time in operation CH Burner Hours hrs User Display the amount of burn hours for CH DHW Burner Hours hrs User Display the amount of burn hours for...

Page 82: ...cess level Description Time Notation 24h 24h 12h User Select 24h or 12h time notation Date Order User Select the date format Day of Month 2 1 or 2 dig User Select how the day of month is displayed Month User Select how the month is displayed Year 4 2 or 4 dig User Select how the year is displayed Date Separation Character User Select the date separation character Day of Week User Select how the da...

Page 83: ... Set the outdoor temperature at which CH setpoint is set to Bas Supply T 22 Design Supply Min Limit 39 4 180 82 68 20 F C Installer Set the outdoor reset curve minimum setpoint 23 Design Supply Max Limit 81 27 194 90 194 90 F C Installer Set the outdoor reset curve maximum setpoint 24 Warm Weather Shutdn 32 0 95 35 72 22 F C Installer Set outdoor temperature above which CH demand is blocked 25 Boo...

Page 84: ...Installer Set the modulating pump mode 136 Mod Pump Min Pwr 30 Installer Set the modulating pump minimum duty cycle 137 Appliance Type 50 55 50 Installer Set the appliance type 138 Dair active 0 1 yes Yes No Installer Enable disable the De Air function 139 Anti Legionella Day mon sun Sunday Installer Select the day for the anti legionella cycle 107 Anti Legionella Hour 0 23 0 hrs Installer Select ...

Page 85: ...er Set the maximum setpoint offset up 80 Start Mod Delay Fact 0 60 60 min Installer Set the setpoint modulation delay time 81 Next Module Start Rate 10 100 80 Installer Set the next module start rate 82 Next Module Stop Rate 10 100 25 Installer Set the next module stop rate 83 Module Rotation Interval 0 30 5 days Installer Set the rotation interval 84 First Module to Start 0 17 1 Installer Set the...

Page 86: ...as been exceeded 3 Factory 180 Sec 1 255 Sec 14 ERROR INFORMATION Errors can be divided in three groups Manual reset locking errors can only be reset by the reset button Blocking errors will disappear when error is gone Warnings will disappear when the warning is gone not stored in the BCU The boiler circulator will continue to run during most locking and blocking error codes This is to prevent th...

Page 87: ...ctioning Check wiring or replace Fan if not solved check fuse on BCU or replace BCU 7 FAN_ERROR_ TOO_FAST Fan runs too fast for more than 60 seconds electrical wiring not correctly connected or Fan is malfunctioning Check wiring or replace Fan if not solved check fuse on BCU or replace BCU 8 RAM_ERROR Internal software error wrongly programmed BCU or PB reset BCU or replace BCU and or display unit...

Page 88: ..._ TOO_LATE Flame still present 10 seconds after closing the gas valve wrong earthing of BCU and boiler Check earthing of BCU and boiler 21 FLAME_BEFOR E_IGNIT Flame is detected before ignition wrong earthing of BCU and boiler Check earthing of BCU and boiler 22 TOO_MANY_ FLAME_LOSS Three time flame lost during 1 demand bad gas supply or CO2 level is not correct or bad ignition rod check gas supply...

Page 89: ... heat exchanger if not so fill up the system 35 APS_NOT_CLO SED_IN_POST_ PURGE Air pressure switch not closing during post purge 1 no air transport to the burner after heat demand flue or air inlet is blocked or APS is jammed or air signal hose not connected to the air intake pipe or water in hose Check if there are any obstructions in the flue or air intake replace APS if jammed connect air hose ...

Page 90: ...s flow through the unit Check if the system resistance exceeds the spare capacity of the unit circulator 106 REFHI_TOO_HI GH Internal hardware error wrongly programmed BCU or PB reset BCU or replace BCU and or display unit 107 REFHI_TOO_LO W Internal hardware error wrongly programmed BCU or PB reset BCU or replace BCU and or display unit 108 REFLO_TOO_HI GH Internal hardware error wrongly programm...

Page 91: ...check connection to BCU or check resistance NTC sensor 127 SUPPLY_SHOR TED Supply sensor shorted malfunctioning supply sensor or short circuiting check connection to BCU or check resistance NTC sensor 129 DHW_SHORTE D DHW sensor shorted malfunctioning DHW sensor or short circuiting check connection to BCU or check resistance NTC sensor 130 FLUE_SHORTE D Flue sensor shorted malfunctioning Flue sens...

Page 92: ...Main supply voltage too high for more than 60 seconds peak in power supply to boiler check power supply Warnings Error no Error Description Cause Solving 200 CC_LOSS_COM MUNICATION Cascade System Managing cascade control lost communication with one of the depending connection between cascaded boilers is interrupted or wiring is broken Check wiring between boiler or distance between boilers is to b...

Page 93: ... In order for the system to work for cascade the communication busses must be parallel linked together The managing boiler uses the AL bus connection 20 21 for the cascade The depending boilers must be connected to the managing boiler on the 10 11 connection terminals It is important that the power on the 10 11 connection terminals on all dependent boilers is switched to the OFF position All boile...

Page 94: ...ler The outdoor temperature sensor connected to the managing boiler will be the outdoor sensor for the cascade operation The system sensor T_System connected to the managing boiler will be the control sensor for the cascade supply temperature The modulating thermostat connected to the managing boiler will be the CH heat demand input for the cascade system Based on the system temperature T_System a...

Page 95: ...st the managing boiler is going to burn for the DHW tank This the heating of the DHW tank is interrupted when there comes a central heating request and the managing boiler and cascade are burning for the central heating system 15 2 5 CASCADE DHW PRIORITY The boiler cascade system has multiple options for priority and parallel DHW and heating The following levels of priority are configurable and po...

Page 96: ...1 2 3 4 5 x Day 5 10 2 3 4 5 x 1 Day 10 15 3 4 5 x 1 2 Day 15 20 4 5 x 1 2 3 Day 20 25 5 x 1 2 3 4 With parameter First_Depending_To_Start the current depending that is first to start in the sequence is selected When the boilers are rotated the parameter First_Depending_To_Start is automatically updated to the next depending When boiler rotation is disabled the parameter First_Depending_To_Start i...

Page 97: ...mode the system setpoint is set to the temperature of the Emergency_Setpoint and all cascaded boilers start burning on this setpoint NOTE the default setting is 158 F 70 C Make sure the right temperature is set Specific Parameters Level Default Value Range Parameter Permit Emergency Mode Installer Yes Yes No Module Cascade parameter 72 Emergency Setpoint Installer 158 ºF 70 ºC 68 194 F 20 90 C Mod...

Page 98: ...ates the Max_Temp_Error 7 Low water cut off 1 error test Simulates the LWCO_1_ Error 8 Low water cut off 2 error test Simulates the LWCO_2_ Error Before running the system test modes first check if the heat can also be dissipated Note that during this mode the supply temperature can be raised above 203 ºF 95 ºC When this temperature is reached the boiler will switch OFF When the supply temperature...

Page 99: ...d inside the boiler This vent is always open and the venting outlet goes via a plastic tube through the bottom to the outside Shortly after putting the boiler into operation check the water pressure and add or remove some water to obtain the required pressure During the commissioning make sure that no water can enter the boiler and make contact with the electrical parts Third check the water flow ...

Page 100: ...d previous actions the boiler display will show the following graph This screen is active during power up and will remain active until communication with the main Control has been established After communication has been established one of the following Status overview screens appears The display describes The actual operation for heating or hot water The temperature setting Type of Gas p nom inch...

Page 101: ... The gas valve has been re placed Gas conversion to propane Prior to adjustments follow the procedure in 18 4 The venturi has been replaced Prior to adjustments follow the procedure in 18 3 The fan has been replaced The flue gas check valve has been replaced In any of the cases described always check the gas air ratio of the combustion figure CO2 at maximum and minimum input First set the boiler a...

Page 102: ... Location of the setting screws High Fire venturi adjustment screw use hex key 4 mm 5 32 Allen wrench Low Fire gas valve adjustment screw Torx T40 Picture 18 1 Picture 18 2 Picture 18 3 High Fire screw 2 Low Fire screw 1 Low Fire screw 1 High Fire screw 2 Gas pressure nipple 3 Gas pressure nipple 3 ...

Page 103: ...counterclockwise The system test automatically stops after 10 minutes after this the system continues with normal demand handling When the system test mode is changed during an active system test the 10 minute timer is restarted Procedure 2 adjust at Low Fire Carry out the next steps 1 Press UP DOWN multiple times to select Low Power Test State Low Power After about 10 seconds the boiler burns at ...

Page 104: ...ropane orifice between gas valve and venturi By using the correct orifice size see table the measured CO2 O2 percentage in the flue gas will already be close to the desired value Installing the orifice see also picture Required tools wrench 55 hex key 5 mm and hex key 4 mm 1 Close the external gas shutoff valve and disconnect the electrical power before opening the boiler 2 Use a wrench to open th...

Page 105: ...R 7 Press UP DOWN to change the parameter according to the table and press ENTER 8 To return to the status screen press ESCAPE or MENU 4 times or RESET once In case a CSD kit gas pressure switch kit is mounted on the gas valve adjust the right hand pressure switch to 9 0 inch w c Check during start up of the boiler no gas mixture is leaking on all parts that have been apart 5 Adjust the CO2 O2 per...

Page 106: ...k the level of the heat exchanger It must have a slight angle from the rear to ensure that the condensate drains from the heat exchanger YES NO Condensate trap from package installed according installation manual YES NO Inside diameter of drain piping mm inch Is there a definite air gap between the condensate trap and the connection to drain pipe YES NO Total drop in height from boiler to drain pi...

Page 107: ...itives Used chemical additions Mixing Ratio Picture 18 7 Gas supply Type of Gas from installation Is gas isolation valve installed under boiler according to installation manual YES NO Which diameter gas isolation valve is installed Gas piping inside diameter Gas piping material if possible specify mark type Gas piping flexible YES NO YES NO Gas piping inside structure e g smooth corrugated Measure...

Page 108: ... manufacturer The same procedure must be applied on the insulation and gaskets fitted on the burner door Refractory Ceramic Fibers RFC Personal Protective Equipment Required Read the following warnings and handling instructions carefully before commencing any service work in the combustion chamber The insulating material on the inside of the burner plate and the rear combustion chamber wall contai...

Page 109: ...develops Leave the area and move to a location with clean fresh air Seek immediate medical attention if breathing difficulties persist Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention Notes 1 Respirator recommendations based on OSHA and CCOHS requirements at the time this document was written Consult your local regulatory authority regarding current requireme...

Page 110: ...d before leaving the job site Gas supply safeties The gas pipes must be checked for gas tightness Also check if the mounting of these pipes is correct safe and not damaged Any built in safeties must be checked for a correct functioning Any gas pipe or fitting that have been opened or adjusted must be checked for leaks Remove complete burner unit The complete boiler unit consists of the fan venturi...

Page 111: ...efore the electrodes become hard and are difficult to bend While bending used electrodes they might break or burst Check the electrode after bending for any tear crack and signs of rust When they are damaged in any manner or rusty replace the electrode Also replace the electrode when there is a crack in the ceramic insulation of the electrode When the electrode is replaced also the gasket must be ...

Page 112: ... the wiring and remove the thermostat Tighten the burner door s thermostat with a torque of 2 Nm Reconnect the wiring Burner door gaskets If any part of a gasket has discolored changed texture or hardened then the rubber has cured and or has damages these gaskets must be replaced Notice only use the gaskets that are supplied by the boiler manufacturer Burner door gasket replacement Remove the old ...

Page 113: ... silicone glue Remove electrodes Remove the braids by sliding under the periphery a thin tool to loosen the braids and remove it Remove and clean the residues of the braids and silicone glue Put a thin string of glue silicone temperature resistant in the seal housing Loctite 5366 or Ottoseal S17 Engage the high temp braided rope and place it in contact of the glue and press the braids Reinstall el...

Page 114: ... click means the fitting is ok Replacement of burner door insulation Removal of the insulation remove electrode remove the defective insulation by sliding under the periphery of the insulation a thin tool to loosen the insulation and remove it remove and clean the residues of the insulation and silicone glue Install the new insulation put two dots of glue silicone temperature resistant Loctite 536...

Page 115: ... this the dirt and dust can be removed with a vacuum cleaner and by flushing the boiler combustion chamber with water Never expose the refractory insulation in the back of the combustion chamber to water or get it wet Don t forget afterwards to clean the condensate trap once again Gas air ratio With every service check and or maintenance of the boiler always check the gas air ratio by measuring th...

Page 116: ...tuds the burner door insulation and or gaskets can be damaged Ensure that the door is well positioned with respect to the threaded studs before pushing it onto the exchanger Keep the burner door firmly in place by pushing the gas air premix manifold with one hand at the middle at point A Hand tighten the flange nuts with the other hand as far as possible onto the threaded studs Now the burner door...

Page 117: ...ng Record gas pressure and note pressure drop upon start up Record CO2 at high and low fire Visual and Temperature Do visual inspection of all system components and verify programmed temperature settings Connections Check wire connections and make sure they are tight Combustion chamber Check burner tube and combustion chamber coils Clean with nylon brush and vacuum Avoid touching white ceramic fib...

Page 118: ...matics present several examples of heating installations All schematics are purely functional Safety components bypass control devices and so on must be added conform all applicable standards and regulations System Example 1 Low Voltage Connections Name Wire terminal RT Room thermostat 12 13 FS System temperature sensor 3 4 LLH Low loss header High Voltage Connections P1 boiler circulator 4 PE 5 P...

Page 119: ...ating circulator 6 PE 7 System Example 4 Low Voltage Connections Name Wire terminal RT Room thermostat 12 13 FS System temperature sensor 3 4 OS outdoor temperature sensor 1 2 ST Tank thermostat or sensor 5 6 LLH low loss header T DHW indirect Tank High Voltage Connections P1 boiler circulator 4 PE 5 P3 System heating circulator 6 PE 7 DV diverter valve 3 way valve 1 2 3 PE Figure 21 3 Figure 21 4...

Page 120: ...boiler circulator 4 PE 5 P3 System heating circulator 6 PE 7 System Example 6 Low Voltage Connections Name Wire terminal RT Room thermostat 12 13 FS System temperature sensor 3 4 OS outdoor temperature sensor 1 2 ST Tank thermostat or sensor 5 6 LLH low loss header T DHW indirect Tank SNV non return valve low resistance type High Voltage Connections P1 boiler circulator 4 PE 5 P2 HWS primary circu...

Page 121: ...ture sensor 1 2 FS System temperature sensor 3 4 SNV non return valve low resistance type LLH low loss header High Voltage Connections P1 boiler circulator 4 PE 5 P3 System heating circulator 6 PE 7 Figure 21 7 P1 P1 P1 P1 P3 LLH FS OS RT SNV SNV SNV SNV BOILER 1 managing HEATING ZONE BOILER 2 depending 1 BOILER 3 depending 2 BOILER 4 depending 3 ...

Page 122: ... Tank thermostat or sensor 5 6 T DHW indirect Tank SNV non return valve low resistance type LLH low loss header High Voltage Connections P1 boiler circulator 4 PE 5 P2 HWS primary circulator 2 3 PE P3 System heating circulator 6 PE 7 Figure 21 8 P1 P1 P1 P1 P3 LLH FS OS RT SNV SNV SNV SNV BOILER 1 managing HEATING ZONE BOILER 2 depending 1 BOILER 3 depending 2 BOILER 4 depending 3 T P2 SNV SNV ST ...

Page 123: ...E93 1601EN032 C VGH installation manual 123 22 SPARE PARTS Figure 22 1 ...

Page 124: ...E93 1601EN032 C VGH installation manual 124 Figure 22 2 ...

Page 125: ...nuts M5 self locking 4 pcs DIN985 elvz 81 7022 000 X X X 21 Air pressure switch DL 2 ET with S clip US 81 7023 000 X X X 22 Hose pressure switch 81 7024 000 X X X 23 Hose air vent 81 7025 000 X X X 24 PVC hose Ø 21 x Ø 15 81 7026 000 X X X 25 Gasket siphon bottom plate Ø30xØ21x3 81 7027 000 X X X 26 Condensate drain assembly l 800 81 7028 000 X X X 27 Electrode set Commercial Boiler 81 7029 000 X ...

Page 126: ...VGH 399 81 7074 000 X X NA 60 Gas pipe VGH 500 81 7075 000 NA NA X 61 Silicone seal 13x5 self adhesive L 838mm 81 7076 000 X X X 62 Front seal 15x5 short 81 7077 000 X X X 63 Special washer heat exchanger 81 7078 000 X X X 64 Anchoring bar VGH 299 81 7079 000 X NA NA 64 Anchoring bar VGH 399 81 7080 000 NA X NA 64 Anchoring bar VGH 500 81 7081 000 NA NA X 65 Bracket heat exchanger 81 7082 000 X X ...

Page 127: ...E93 1601EN032 C VGH installation manual 127 ...

Page 128: ... Slant Fin Corp 2019 0519 PUBLICATIONVGH 40 SLANT FIN CORPORATION Greenvale N Y 11548 Phone 516 484 2600 FAX 516 484 5921 Canada Slant Fin LTD LTEE Mississauga Ontario www slantfin com ...

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