Velocity PHTM2136CB Installation, Operating And Service Instructions Download

Page: 17 / 108

110331-07 - 8/23

PHTM II

Combi Installation, Operating & Service Instructions

General Venting

Figure 7-1: Sidewall

Termination with Fittings -

see Section 8 for details

Figure 7-2: Sidewall Low
Profile Termination - see

Section 8 for details

Figure 7-3: Sidewall

Concentric Termination -

see Section 8 for details

Direct Vent Sidewall Termination Options

Direct Vent Vertical Termination Options

Figure 7-4: Vertical

Termination with Fittings -

see Section 9 for details

Figure 7-6: Vertical Termination

with Abandoned B-vent or

Chimney Chase - see Section 9

for details

Figure 7-5: Vertical

Concentric Termination - see

Section 9 for details

Summary of Contents for PHTM2136CB

Page 1: ...assachusetts 103 D Code Required Text 105 110331 07 8 23 Combi Boiler Water Heater Condensing Direct Vent Gas Fired WARNING This boiler must only be installed serviced or repaired by a qualified heati...

Page 2: ...or serious injury DANGER Explosion Hazard DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance If you smell gas vapors DO NOT try to operat...

Page 3: ...o the State of California to cause cancer birth defects and other reproductive harm Do not disconnect pipe fittings on boiler or in heating system without first verifying system is cool and free of pr...

Page 4: ...exposure Do not block air flow into or around boiler Insufficient air may cause the boiler to produce carbon monoxide or start a fire BURN HOT Water temperature over 125 F 52 C can cause severe burns...

Page 5: ...at max vent length and altitude 3 Net AHRI Water Ratings shown are based on a piping and pickup allowance of 1 15 The manufacturer should be consulted before selecting a boiler for installations havi...

Page 6: ...0 ft 3 079 m See Section 15 Start up and Checkout for altitude conversion instructions For part no containing S i e PHTM2200CNG1SUA0 boiler is listed for 0 to 2 000 ft 610 m Do not install above 2 000...

Page 7: ...tions 3 Specifications continued Safety Relief Valve Vent Connector Air Intake Front View 120 VAC Knockouts Low Voltage Knockouts Domestic Cold Water Inlet Boiler Return Condensate Trap Cleanout Conde...

Page 8: ...s exiting boiler Boiler control will alarm reduce boiler firing rate and shut down boiler if flue temperature is too high 12 Boiler supply temperature sensor UL 353 Listed Dual element temperature sen...

Page 9: ...9 110331 07 8 23 PHTM II Combi Installation Operating Service Instructions 4 How It Works continued Figure 4 1 How It Works 1 2 4 15 7 8 3 18 12 9 17 13 20 21 22 19 16 11 14 10 23...

Page 10: ...itable drain location Manufacturer will not be held responsible for water damage resulting from this appliance or any of its components 5 Check for and remove any combustible materials gasoline or oth...

Page 11: ...r opening within 12 in 305 mm of floor Minimum free area 100 in 2 650 cm2 for each opening This free area takes into account blocking effect of grills and louvers If using screens minimum screen size...

Page 12: ...Contaminants to avoid Spray cans containing chloro fluorocarbons CFC s Permanent wave solutions Chlorinated waxes cleaners Chlorine based swimming pool chemicals Calcium chloride used for thawing Sodi...

Page 13: ...e in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting sys...

Page 14: ...of boiler and attached piping when filled with water Areas subject to earthquakes may have special requirements that take precedence over requirements in these instructions Unpack Boiler Figure 6 1 Wh...

Page 15: ...vent gasket with soapy water 4 Insert vent connector through jacket into heat exchanger with flue gas sample port facing forward See Figure 6 2 5 Tighten 4 screws Install Vent Connector Figure 6 2 Ins...

Page 16: ...m centers or a masonry wall For other stud spacing mount bracket to 3 4 in 19 mm plywood or horizontal 2 x 4 anchored to studs CAUTION Heavy Object Do not mount boiler to a hollow wall Boiler must be...

Page 17: ...e Section 8 for details Figure 7 3 Sidewall Concentric Termination see Section 8 for details Direct Vent Sidewall Termination Options Direct Vent Vertical Termination Options Figure 7 4 Vertical Termi...

Page 18: ...nsure air tightness and compliance with provided instructions and code requirements Do not mix components from different venting systems Covering non metallic vent pipe and fittings with thermal insul...

Page 19: ...PVC The following or equivalent may be used to join CPVC to PVC A Primer IPS P 70 B Cement IPS 790 Material Standard Vent Pipe CPVC sched 40 or 80 ASTM F441 PVC sched 40 or 80 ASTM D1785 PVC DWV ASTM...

Page 20: ...d debur inside and outside of pipe ends after cutting 11 Dry fit all vent and air components before cementing any joints 12 Use field supplied primer and cement appropriate for materials being joined...

Page 21: ...ength of straight run between anchors X Loop horizontal only top view Y 5 6 150mm Min 6 150mm Min 2Y 5 7 General Venting continued Figure 7 15 CPVC PVC Venting Expansion Loops Figure 7 14 PVC Venting...

Page 22: ...lengths of elbows and fittings 5 Only cut polypropylene vent pipe as permitted by vent manufacturer and in accordance with their instructions Ensure cut end is square and deburred prior to assembly 6...

Page 23: ...S03 PF LB or 4PF LB Increaser 2 in 60 mm to 3 in 80 mm 2PPS X3L ISIA0203 2PF 2I3 PF LB locking band PVC to PP Adapter 2 in 60 mm 2PPS ADL ISAGL0202 adapter IAFC02 clamp N A Table 7 17 Listed Polypropy...

Page 24: ...such as stones or balls or subject to buildup of leaves or dirt 4 Maintain clearances to vent terminal per Figure 8 1 A Minimum 12 in 305 mm from any door window or other gravity air inlet B Minimum 3...

Page 25: ...25 110331 07 8 23 PHTM II Combi Installation Operating Service Instructions 8 Sidewall Direct Venting continued Figure 8 1 Vent Terminal Clearances Air Terminal not Shown for Clarity...

Page 26: ...l B If venting with polypropylene i Use UV resistant or UV stabilized components for all exterior pipe and fittings ii Remove gasket from terminal fitting to install screen 6 Brace exterior vertical r...

Page 27: ...een Elbow Screen Wall Thimble From boiler vent connection To boiler air connection Elbow Joint Connector 1 Low profile terminals listed in Table 8 7 may be used to terminate air and vent outside build...

Page 28: ...RNING Asphyxiation Hazard If vent system is too short to accommodate required 30 in 760 mm of CPVC pipe and CPVC elbow between boiler and PVC venting use listed CPVC terminal kit Failure to comply cou...

Page 29: ...n 80 mm 3PPS HKC ICWT352 terminal ICCT3503 two pipe adapter 3PF HCT terminal 3PF CTA two pipe adapter Polypropylene Concentric Sidewall Terminal DuraVent shown From boiler vent connection 12 305mm Min...

Page 30: ...minal arrangement with vertical vent and sidewall air intake is permitted See Figure 9 5 9Vertical Direct Venting WARNING Asphyxiation Hazard Follow these instructions when determining vent terminal l...

Page 31: ...minal Fittings DuraVent PolyPro Centrotherm InnoFlue Selkirk PolyFlue UV resistant single wall pipe 2PPS BG screen UV stabilized end pipe IASPP02 screen UV resistant pipe 2PF HVST screen Figure 9 5 Al...

Page 32: ...and Figure 9 7 for assembly Figure 9 6 CPVC PVC Concentric Terminal 9Vertical Direct Venting continued From boiler vent connection To boiler air connection 12 305mm Min USA 18 460mm Min Canada 24 610m...

Page 33: ...nsert PVC adapter and install electrical conduit locknut to secure Seal all joints with RTV silicone B DuraVent InstallPolyProlowerB ventadapter in base of tee C Centrotherm Install cap in base of tee...

Page 34: ...ad adapter See Text Flex Male Adapter 10 3 1m 24 610mm Min 12 305mm Min Boiler Notes 1 All B Vent joints must be sealed with RTV 2 Seal the Flex Male Adapter to the inside of the lower B Vent Adapter...

Page 35: ...irect Venting continued Table 9 15 Polypropylene Masonry Chimney Chase Components DuraVent PolyPro Centrotherm InnoFlue Selkirk PolyFlue 2PPS FKC chimney kit 2PPS FLEX flex length IFCK02 chimney kit w...

Page 36: ...gy of Commercial Products 5th edition 10 Heating System Piping 2 WARNING Burn Hazard Safety relief valve discharge piping must be piped near floor to eliminate potential of severe burns Do not pipe in...

Page 37: ...inadequate flow is provided by UL353 listed flow switch built into boiler B Thisisawatertubeboilerandthisflowswitch is therefore only effective way to provide such protection C Section HG614 c of ASME...

Page 38: ...or other means CAUTION Component Damage Excessive heat from soldering could damage gaskets at connection between low loss header and boiler Solder connections to low loss header before installing gask...

Page 39: ...may be too low for comfortable use Internal 6 GPM 23 L min flow limiter is factory installed but an additional flow limiter may be required Select one having a flow rating approximately equal to that...

Page 40: ...ER Scald Hazard Under certain conditions this boiler can deliver domestic hot water DHW at temperatures in excess of DHW setpoint in boiler control A field supplied ASSE 1017 or ASSE 1070 listed tempe...

Page 41: ...Connect recirculation pump to Aux Pump terminals per Figure 13 2 Connect jumper time of day clock or momentary push button to Aux T Stat terminals per Figure 13 3 Secure recirculation temp sensor clos...

Page 42: ...4 ANSI Z223 1 National Fuel Gas Code and or CAN CSA B149 1 Natural Gas and Propane Installation code Figure 12 1 shows typical gas piping and connection to boiler A Use thread compound compatible with...

Page 43: ...53 listed high water temperature limit This limit provides boiler shutdown in event boiler water temperature exceeds set point of control Certain local codes require an additional water temperature li...

Page 44: ...erminal strip are Terminal Description Heat T Stat 24 VAC thermostat R 24V Hot Heat T Stat 24 VAC thermostat W Energized on Call for Heat Heat T Stat 24 VAC thermostat C 24V Common Aux T Stat 24 VAC t...

Page 45: ...near potential sources of electrical noise such as transformers power lines and fluorescent lighting v Wire sensor to boiler using minimum 22 AWG wire vi Where electrical noise sources cannot be avoid...

Page 46: ...46 PHTM II Combi Installation Operating Service Instructions 110331 07 8 23 13 Field Wiring continued Figure 13 5 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagram...

Page 47: ...g kit P N 101897 01 is available from manufacturer 3 4 PVC Connection Condensate Trap Vent Condensate Trap Cleanout B Do not route or terminate condensate drain line piping through an area that is pro...

Page 48: ...sed oils lubricants These could attack seals in both boiler and system which could result in property damage Freeze Protection If freeze protection is required see Appendix B for additional informatio...

Page 49: ...ins open to atmosphere See Figure 4 1 for location A Flame Rod Detail A Scale 2 1 Manual Air Vent Confirm 1 4 ID tubing is connected to hose barb Route tubing to a safe place away from controls before...

Page 50: ...o 1 Press and hold menu for 3 seconds Press or buttons until PAS is visible and press enter Press enter button while PA1 is visible Press or buttons until password 86 is reachedandpress enter Pressand...

Page 51: ...tions in Figure 15 10 With boiler powered up and with no call for heat display should look like Figure 15 5 Once a call for heat is present it will look like Figure 15 6 Final Check Before Starting Bo...

Page 52: ...of ignition safety shut off device With burner firing carefully unplug black ignitor flame sensor wire at burner door using a pair of insulated pliers Figure 15 1 Burner should shut off immediately 1...

Page 53: ...tice risque de d clencher un incendie ou une explosion entra nant des dommages des blessures ou la mort A Cet appareil ne comporte pas de veilleuse Il est muni d un dispositif d allumage qui allume au...

Page 54: ...s Calibration Burner On Pump s On Three Way Valve CH After burner is started a Calibration is initiated due to 1 Power Cycle 2 Periodic requirement Calibration after blower reaches calibration speed s...

Page 55: ...al Heat demand is present Visible when DHW demand is present Icon will flash if DHW setpoint is being adjusted Visible when burner is firing Icon adjacent to active priority Visible when Recirculation...

Page 56: ...nded Firing Rate rUn Run Time Hours CYC Boiler Cycles H Hold or Warning Condition E Manual Reset Lockout Feature available with PAT Connect Bluetooth Adaptor and App The STA status display code contai...

Page 57: ...g Parameters Menu c c Diagnostic Menu Table 16 9 Diagnostic Menu Display Description C01 Active Detailed Fault Code see Table 19 6 C02 Demand Source 1 Standby 2 Central Heat 1 3 Central Heat 2 4 Domes...

Page 58: ...old for 5 seconds enables adjustment by increments of 10 Press enter to accept value password only Pressing menu to exit Navigating Menus Entering password in Adjust Mode allows access to shaded menus...

Page 59: ...Heat 2 Setpoint Desired water temperature of CH2 0 0 1 A06 A06 Fuel Gas Selection visible only after password entered Boiler is shipped from factory configured for natural gas Conversion to LP Gas re...

Page 60: ...an maximum output of boiler change F03 setting to limit boiler output accordingly 136 combi 80 136 combi B 88 200 combi 75 136 combi 0 80 136 combi B 0 88 200 combi 0 75 F04 F04 Central Heat 2 Max Mod...

Page 61: ...ly water temperature that will provide enough heat for type radiation used to function properly Always consider type of radiation when adjusting this parameter 2 0 1 2 505 505 Auxiliary Thermostat Inp...

Page 62: ...and CH2 modulation sensor and boiler is a stand alone boiler 3 Boiler Pump CH Only Off for DHW Pump runs during CH1 CH2 and CH frost protection demand and will be forced off if there is a DHW demand a...

Page 63: ...alled and Lead Lag Outdoor Reset is Enabled boiler will automatically adjust heating zone set point temperature based on outdoor reset curve On Enable calculate temperature setpoint based on outdoor t...

Page 64: ...ess Reset Control system monitors recent firing rate and burner cycle data to infer current building heat loss Target supply water temperature is then adjusted to match this heat load No outdoor senso...

Page 65: ...to any demands 2 High Differential Temperature Limit Control monitors temperature difference between return and supply sensors If this difference exceeds 58 F 32 C control begins to reduce blower maxi...

Page 66: ...ld Supply temp 95 F 35 C Boiler can continue to run after demand is removed in order to complete calibration se quence 10 Ignition Failure Control monitors ignition using a burner mounted flame sensor...

Page 67: ...osed gas inlet pressure tapping Performed combustion test Screw cap in vent adapter No errors or holds present on display clear recent error codes Tested additional field installed controls for functi...

Page 68: ...ng clothing that is sufficiently tight around potential entry points for RCF dust 3 Gloves 4 Eye protection such as goggles safety glasses with side shields or full facepiece Take steps to assure adeq...

Page 69: ...over plates enclosures and guards must be in place when boiler is left in operation NOTICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the interval...

Page 70: ...2 Ignitor Flame Sensor Spark Gap 16 4mm 19 5mm Gap 7 Inspect ignitor flame sensor A Clean off any deposits found with steel wool Do not use sand paper or Emory cloth for this cleaning B Inspect ceram...

Page 71: ...pect vent system A All gaskets and joints between boiler heat exchanger and terminal are leak tight B All supports are intact and vent system is properly pitched C All pipe is in good condition Look f...

Page 72: ...be used to help remove deposits 14 Inspect safety relief valve WARNING Explosion Hazard Safety relief valves require periodic maintenance Refer to relief valve manufacturer s instructions for frequenc...

Page 73: ...n Remote thermostat is satisfied Check remote thermostat setting Loose thermostat wiring Check thermostat wiring correct if necessary Blown T0 5A Fuse supplies power to thermostats Check T0 5 A Fuse r...

Page 74: ...e heat exchanger performance and back flush if necessary Replace if back flushing does not improve performance Recirculation Comfort Mode is used and Recirculation Pump is not On Recirculation pump is...

Page 75: ...for Natural Gas 1 for LP C Control altitude selection A07 for 0 0 to 2 000 ft 0 to 610 m 1 2 001 to 6 000 ft 611 to 1 828 m 2 6 001 to 8 000 ft 1 829 to 2 438 m 3 8 001 to 10 100 ft 2 438 to 3 079 m D...

Page 76: ...ure overshoot if heating load is too small 7 Rate Limit Firing rate is being limited due to an abnormal condition such as High supply water temperature High differential water temperature High flue te...

Page 77: ...nded Large differences may mean there is a problem with blower C05 3 way Valve Status 0 DHW 1 CH 3 way valve and pump status indicate controller 120 VAC output status C06 System Pump On Off Status C07...

Page 78: ...tat demand present boiler has cycled off too quickly due to temperature and restart is delayed Boiler will restart automatically after the minimum off time Anti Short Cycle Time default 3 min 01 1 Urg...

Page 79: ...with appropriate demand Heating zone too small for installed boiler Test individual zones and ensure proper zone sizes Header sensor not sensing temperature Modulation sensor set to header sensor or m...

Page 80: ...nsor if necessary H10 DHW Sensor Fault Shorted opened or miswired DHW temperature sensor Check DHW sensor wiring correct wiring if necessary Check DHW sensor refer to sensor temperature vs resistance...

Page 81: ...ve pressure Replace APS if necessary Defective blower Check blower wiring connections 120 VAC and control connectors correct wiring if necessary Replace blower if necessary H17 E17 Invalid Safety Para...

Page 82: ...ory defaults not turned on Ensure BCC is installed and select A10 factory Default On Table 16 11 18 8 Pump mismatch P02 Boiler Pump Output Selection parameter set to Pump Not Used or P02 Boiler Pump O...

Page 83: ...place gas valve If problem persists replace control 21 3 Gas valve wiring problem H22 E22 No Flame After Ignition Ignition cable not plugged in Connect ignition cable Break in ignition cable Check ign...

Page 84: ...d clean if necessary Fuel Gas Selection parameter A06 Altitude Selection parameter A07 or gas valve setting is incorrect Check Fuel Gas Selection parameter A06 and gas valve setting Figure 15 3 Both s...

Page 85: ...Pump feedback fault Check wiring to Variable Speed Pump Defective pump electronics or control replace pump or control if necessary H32 Zone Panel Fault 32 0 to 32 3 Zone Panel Communication Lost Check...

Page 86: ...f 194 F 90 C or when used Pre ferred Stack Flue Limit parameter minus 10 E06 1 Lockout Flue sensor detected temperatures in excess of 204 F 96 C or when used Pre ferred Stack Flue Limit parameter H07...

Page 87: ...energy management CH setpoint 0Vdc 4mA and 10Vdc 20mA settings H18 6 Hold Invalid recirculation vs header selection parameter setting E18 7 Lockout Selected boiler model default parameters not availa...

Page 88: ...core error H26 E26 H26 0 Hold Calibration fault stable conditions to perform gas valve offset adaptation not reached H26 1 Hold Calibration fault stable conditions to perform calibration not reached...

Page 89: ...H32 H32 0 Warning Zone Panel 1 Communication Lost H32 1 Warning Zone Panel 2 Communication Lost H32 2 Warning Zone Panel 3 Communication Lost H32 3 Warning Zone Panel 4 Communication Lost H32 4 Warni...

Page 90: ...5 10000 86 30 8056 104 40 5324 122 50 3599 140 60 2483 158 70 1748 176 80 1252 194 90 912 212 100 674 230 110 506 248 120 384 Table 19 8 Outdoor Air Temperature Sensor Temperature versus Resistance 10...

Page 91: ...91 110331 07 8 23 PHTM II Combi Installation Operating Service Instructions 20 Internal Wiring Diagrams Figure 20 1 Ladder Diagram...

Page 92: ...Screw bottom panel 3 1 2 RD BK BK YE WH WH GND Screw bottom panel L N L N L N L N 120V Line Boiler Pump System Pump Aux Pump R Heat T stat W C R W Aux T stat Ext Limit 0 10V 4 20mA Header Sensor Outd...

Page 93: ...93 110331 07 8 23 PHTM II Combi Installation Operating Service Instructions 20 Internal Wiring Diagrams continued Figure 20 2 Wiring Schematic Diagram...

Page 94: ...rner Door Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 110575 01 111970 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gasket and hard...

Page 95: ...r 110579 01 13 Supply Temp Sensor 106994 01 14 Pump 110580 01 15 T P Gauge 108215 01 16 Boiler Flow Switch O ring 105892 01 17 30 psig 207 kPa Safety Relief Valve 108680 01 18 Plate Heat Exchanger 110...

Page 96: ...0586 01 111571 01 24A 24B 24C 24D 24E 24F 28 29 Gas Valve with gaskets o rings and hardware 110587 01 111564 01 25A 25B Air Proving Switch tubing 5 16 in x 12 in long 107862 01 26 27 28 29 30 47 Gas p...

Page 97: ...Description Part Number PHTM2136C PHTM2136CB PHTM2200C 31A 31B 31C 31D 31E 31F 31G 31H Condensate Trap 110589 01 32 Front Door 110596 01 33 Vent connector 107160 01 42 Side panel 110725 01 111565 01...

Page 98: ...e boiler serial number 37 Model Key 38 120 VAC Connection Board 110726 01 43 Low Voltage Connection Board 110594 01 48 Fuse 0 5A 5 x 20 mm 250V Slow Blow 111420 01 Fuse 1 0A 5 x 20 mm 250V Slow Blow F...

Page 99: ...bi Installation Operating Service Instructions 21 Service Parts continued Key No Description Part Number PHTM2136C PHTM2136CB PHTM2200C 39 Ignition Harness 110598 01 40A Main Control Harness 110599 01...

Page 100: ...l 1100M with H5 cable 108182 01 CSD 1 Kit 108183 01 Tempering Valve 70 145F ASSE 1017 3 4 in sweat 108042 01 Fernox Alphi 11 antifreeze with inhibitor 5 gal 108862 01 Hydronic System Corrosion and Lim...

Page 101: ...sult Residential Hydronic Heating Installation and Design I B R Guide Water Chiller Shut off Valves Expansion Tank Circulator Shut off Valves Supply main to combined heating cooling system Return main...

Page 102: ...tion if it is not safety relief valvemayopenfrequently resultinginregular additions of make up water D If an automatic fill valve is installed installation of a water meter in fill line is strongly re...

Page 103: ...ment is installed in a crawl space or an attic the hard wired carbon monoxide detector with alarm and battery back up may be installed on the next adjacent floor level b In the event that the requirem...

Page 104: ...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 satisfied by the manufac...

Page 105: ...pendant 5 min ensuite d terminer si le coupe tirage d borde l ouverture de d charge Utiliser la flamme d une allumette ou d une chandelle ou la fum e d une cigarette d un cigare ou d une pipe 6 Une f...

Page 106: ...106 PHTM II Combi Installation Operating Service Instructions 110331 07 8 23 SERVICE RECORD SERVICE PERFORMED DATE...

Page 107: ...107 110331 07 8 23 PHTM II Combi Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 108: ...108 PHTM II Combi Installation Operating Service Instructions 110331 07 8 23 Velocity Boiler Works LLC P O Box 14818 3633 I Street Philadelphia PA 19134...

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