5
Table of Contents
Part 1 - General Safety Information
6
A. Operation and Installation Warnings
6
B. Improper Combustion
7
C. Gas
7
D. When Servicing the Boiler
7
E. Boiler System
7
F. CH and DHW Loop Water Chemistry Requirements
8
G. Freeze Protection
8
H. Water Temperature Adjustment and Scalding
9
I. High Elevation Installations
9
Part 2 - Before You Start
10
A. What’s in the Box
10
B. Optional Equipment
11
Part 3 - Prepare the Boiler for Installation
12
A. Locating the Boiler
12
B. Leveling
13
C. Clearances for Service Access
13
D. Wall Mounting Considerations
14
E. Wall Mounting Instructions
14
1. Mounting to a Concrete Wall
14
2. Mounting to a Wood Studded Wall
14
F. Residential Garage and Closet Installations
14
G. Exhaust Vent and Intake Pipe
15
1. Direct Vent of Exhaust and Intake
15
2. Power Venting, Indoor Combustion Air in Confined or Unconfined Space
15
H. Carbon Monoxide Detectors
15
I. Prevent Combustion Air Contamination
16
J. Removing a Boiler from a Common Vent System
16
K. Technical Specifications
17
Part 4 - Water Piping
21
A. General Plumbing Information
21
B. Backflow Preventer
21
C. Expansion Tank
21
D. Piping the Boiler
21
E. Internal Circulation Pump
23
F. CH and DHW Pressure Relief Valves
24
G. Air Elimination Device
25
H. Low Water Cut-Off (Field Supplied)
25
I. Applications*
25
J. Floor Drying Function
33
Part 5 - Venting
34
A. General
34
B. Approved Materials for Exhaust Vent and Intake Pipe
35
C. Additional Requirements for Installation in Canada
35
D. Exhaust Vent and Intake Pipe Location
36
E. Exhaust Vent and Intake Pipe Sizing
37
F. Tightening Boiler Collar to Exhaust Vent and Intake Pipe
37
G. Exhaust Vent and Intake Pipe Installation
37
H. Applications
40
1. Direct Vent Installation of Exhaust and Intake
40
2. Venting Through an Existing System
46
3. Power Venting, Indoor Combustion Air in Confined or Unconfined Space
47
Part 6 - Installing the Condensate Drain
48
Part 7 - Connecting Electrical Service
49
A. Wiring
49
1. Connecting Power (120V) for DHW and CH Circulators
49
2. Low Voltage Wiring Connections
49
3. Room Thermostat Wiring Connections
50
4. Outdoor Sensor Connections
50
5. Aquastat (Default) and Tank Sensor (Optional) Connections (non-Combi
Models)
50
B. Internal Wiring Details
51
Part 8 - Gas Connections
55
A. Gas Pipe Sizing Tables
55
1. Gas Pipe Sizing
55
2. Natural Gas Pipe Sizing
55
3. LP (Liquid Propane) Gas Pipe Sizing
55
B. Gas Connection Requirements
55
C. Additional Precaution for Excess Flow Valve (EFV)
56
D. Checking Gas Pressure at the Boiler for Proper Operation
56
Part 9 - Controls
57
A. Control and Display Overview
57
B. Ignition Procedure
58
C. Central Heating (CH) Temperature Adjustment
58
D. Domestic Hot Water (DHW) Temperature Adjustment
58
E. User Menu
59
F. INFO Menu
60
G . Date and Time (If ITIME is set to OFF)
60
H. Automatic CH Temperature Control (AUTO)
61
I. Type of Temperature Control
62
J. Slope of Outdoor Reset Curve
62
K. Parallel Shift of Reset Curve
63
L. Auto Boost
63
M. Room Temperature Day /Night
64
N. Time Programs – Heating Schedule
64
O. Automatic Summer / Winter Changeover
64
P. Technical Menu - Access and Navigation
65
Q. Technical Menu - Menu Structure
66
R. Complete Menu Parameters
67
Part 10 - Start-Up Preparation
75
A. Check / Control Water Chemistry
75
B. Check for Gas Leaks
75
C. Freeze Protection (When Used)
75
D. System Water Fill, Purge, and Test
76
E. Purge Air from DHW System
76
F. Check Thermostat Circuit(s)
76
G. Condensate Removal
76
Part 11 - Start-Up
78
A. First Ignition
78
B. Combustion Checking Procedure
78
C. Checking Combustion Parameters
80
D. Converting the Appliance from Natural Gas to Propane Operation
80
Part 12 - Installation Checklist
81
Part 13 - Troubleshooting
83
A. Boiler Protection Devices
83
1. Blocking Error
83
2. Lockout Error
83
3. Malfunction Warning
83
B. Boiler Error Codes
84
Part 14 - Maintenance
88
A. Procedures
88
B. Maintenance That May be Performed by the User
88
C. Maintenance Only to be Performed by a Qualified Service
Technician
89
D. Replacing Components
92
E. After Maintenance is Complete
95
Part 15 - Maintenance Report
95
A. Shutdown Procedure
97
B. Failure to Operate
97
C. Important
97
Part 16 - Shutdown
97
Maintenance Notes
98
Customer Installation Record Form
99
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