Velocity PHANTOM II PHTM2200C, Installation, Operating And Service Instructions

Page 1: ...achusetts 97 D Code Required Text 99 110331 03 1 22 Combi Boiler Water Heater Condensing Direct Vent Gas Fired WARNING This boiler must only be installed serviced or repaired by a qualified heating installer or service technician Improper installation adjustment alteration service or maintenance can cause severe personal injury death or substantial property damage For assistance or additional info...

Page 2: ...h 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 operate any appliance DO NOT touch any electrical switch or use any phone in the building Immediately call the gas supplier from a remotely located phone Follow the gas supplier s instructions or if the su...

Page 3: ...harmful substances that can be hazardous to health and life and that are known to 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 pressure and that your clothing will protect you from a release of hot water or steam Do not rely solely on boiler tempera...

Page 4: ...4 PHTM II Combi Installation Operating Service Instructions 110331 03 1 22 SERVICE RECORD SERVICE PERFORMED DATE ...

Page 5: ... 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 instantly or death from scalds Under certain conditions this boiler can deliver domestic hot water DHW at temperatures in excess of the DHW set point on boiler control Children disabled and elderly a...

Page 6: ...piping and pickup requirements such as intermittent operation extensive piping systems etc 4 Min DHW flow rate required through boiler to initiate DHW demand Higher flow rate through fixture may be require due to mixing at tempering valve and or fixture itself Model Number Depth in mm Width in mm Height in mm Space Heating Water sweat in Domestic Water sweat in Gas NPT Relief Valve NPT Maximum All...

Page 7: ...A for boiler and internal pump current draw of any external pumps connected to boiler Controls Boiler flow switch and integrated manual reset high limit provided with boiler are both UL 353 listed LP Gas Conversion Boiler is shipped from factory configured for natural gas and is field convertible to LP gas See Section 15 Start up and Checkout for instructions to convert to LP gas Altitude Boiler i...

Page 8: ...Flue temperature sensor Used to monitor flue gas exiting boiler Boiler control will alarm reduce boiler firing rate and shut down boiler if flue gas temperature is too high 12 Boiler supply temperature sensor UL 353 Listed Dual element temperature sensor used to monitor boiler water exiting heat exchanger Boiler control uses supply temperature to initiate CH burner demand adjust firing rate to mai...

Page 9: ...9 110331 03 1 22 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 ...

Page 10: ...uitable 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 other flammable liquids from area around boiler 6 Check for and remove any potential combustion air contaminants from area around boiler and area around vent air termination See Table 5 2 WARNING Explos...

Page 11: ...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 1 4 in 6 4 mm 1 4 6mm 6 150mm 8 1 4 210mm 1 2 13mm 1 2 13mm Provide access to this area for inspection and cleanout of condensate trap Vent Air 1 2 13mm Closet Door 0 12 0 305mm 0 12 0 305mm Closet Door...

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 Sodium chloride used for water softening Refrigerant leaks Paint or varnish removers Hydrochloric acid muriatic acid Cements and glues Antistatic fabric softeners used in clothes dryers Chlorine type ble...

Page 13: ...ce 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 system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maxi mum speed Do not operate a summer exhaust fan Close fireplace dampers 4 Place in operation the appl...

Page 14: ...t boiler onto wall mounting bracket Ensure wall bracket is anchored to structure capable of supporting weight 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 What s in the Box Boiler Misc Parts Carton Wall Retaining Clip 2X Wall Hook DHW Connector 2X...

Page 15: ...nt 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 Installing Vent Connector Flue gas sample port facing front of boiler Vent Connector Attach with 4 screws Figure 6 3 Gas Valve Fuel Setting Preparing for Fuel Conversion If using LP gas LP conversion requi...

Page 16: ...mm 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 anchored to studs 2 Mark wall bracket hole locations using dimensions shown in Figure 6 4 Ensure bracket is level 3 For wood studs drill 3 16 in 4 8 mm pilot holes A and B and attach bracket using pr...

Page 17: ...ee 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 ...

Page 18: ...em Use only CPVC PVC or polypropylene venting systems listed in Tables 7 11 or 7 16 Thoroughly inspect finished vent and air piping to ensure 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 insulation is prohibited Follow all local codes for isolation of vent...

Page 19: ...C 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 D2665 Vent Fittings CPVC sched 80 ASTM F439 PVC sched 40 ASTM D2466 PVC sched 80 ASTM D2467 PVC DWV ASTM D2665 Primer Cement CPVC ASTM F493 PVC ASTM D2564 Table 7 11 Listed CPVC PVC Vent Materials 4 Wor...

Page 20: ...d air components before cementing any joints 12 Use field supplied primer and cement appropriate for materials being joined Follow primer and cement instructions to join pipe and fittings 13 Clean all pipe ends and fittings with appropriate primer before cement Apply primer to both pipe and fitting socket before applying cement 14 Boiler vent connector is gasketed Lubricate gasket with soapy water...

Page 21: ...Length 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 Wall Penetration Clearance Key Hanger allows linear movement Anchor restricts linear movement Can use either anchor or hanger Pipe Dia in X ft m Y in cm 2 20 6 1 41 104 30 9 1 50 127 40 12 2 58 147 5...

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 Boiler vent connector is gasketed Lubricate gasket with soapy water insert pipe until it bottoms out and tighten clamp See Figure 7 18 7 Assemble remainder of vent system in accordance with vent manu...

Page 23: ...NS03 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 Polypropylene Vent Fittings Vent Clamp PVC to polypropylene adapter required when using polypropylene air piping Joint connector required at all joints in venting system Air Vent Air PVC to polypropylene adap...

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 ft 900 mm above any forced air inlet located within 10 ft 3 1 m C Minimum 12 in 305 mm from inside corner 6 ft 1 8 m is generally recommended and requiredwhenwindowand orairinletiswithin 4 ft 1 2 m ...

Page 25: ...25 110331 03 1 22 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: ...al 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 runs of piping as required 7 Seal exterior openings thoroughly with exterior caulk Figure 8 5 CPVC PVC Fittings Terminal Assembly CPVC PVC or Polypropylene Fittings Terminal WARNING Asphyxiation Hazar...

Page 27: ...n Table 7 11 Figure 8 8 Low Profile Terminal Grade or Snow line From boiler vent connection Possible Orientations 12 305mm Min To boiler air connection Gra Sno Possible Orientations To boile air connec DuraVent Selkirk Remove gasket to install screen Elbow Screen Wall Thimble From boiler vent connection To boiler air connection Elbow Joint Connector Table 8 7 CPVC PVC Low Profile Terminal Kits Len...

Page 28: ...ARNING 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 could result in severe personal injury death or substantial property damage 2 Required vent pipe and fittings listed in Table 7 11 Table 8 9 CPVC PVC Concentric Terminal Kits Length Ipex Diversitech 2 i...

Page 29: ...in 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 Grade Snow line To boiler air connection C 12 305mm Min B Concentric Wye Fitting Inner Vent Pipe Rain Cap Outer Air Intake Pipe To install stainless steel screw and nut locate drill location dimple ...

Page 30: ...rminal 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 location Failure to comply could result in severe personal injury death or substantial property damage 1 Do not exceed maximum equivalent vent and air pipe length in Table 7 7 2 Vent must terminate at...

Page 31: ...rminal 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 Alternate Vertical Vent Sidewall Air Terminal Normal snow line on roof Elbow with screen Grade Snow Line 10 3 1m 24 610mm Min Air Intake Pipe PVC Coupling or Polypropylene end pipe with screen Fire Sto...

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 610mm Max Roof or snow line Figure 9 7 CPVC PVC Concentric Vertical Installation Wye Fitting Clamp or Strap field supplied Roof Line Rain Cap Outer Pipe Inner Pipe Storm collar and Roof Flashing or equiv...

Page 33: ...insert 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 Route smooth section of InnoFlue flex throughcapinbaseoftee Usewallplateand RTV silicone to seal this penetration Polypropylene Concentric Terminal WARNING Asphyxiation Hazard All polypropylene vent...

Page 34: ...ead 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 with RTV 3 Seal the Air Intake Pipe to the B Vent Cap with RTV Figure 9 13 Centrotherm Polypropylene B vent Air Chase System Fire Stop listed for use with B Vent PPs Flex B Vent Normal snow line on r...

Page 35: ...Direct 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 with flex length 2PF FLEX KIT chimney kit 2PF FLEX length Length 25 35 or 50 ft e g 2PPS FLEX25 for 25 ft length Note 2 in 60 mm components shown Replace 2 with 3 for 3 in 80 mm part numbers Figure 9 ...

Page 36: ...ogy 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 any shut off valves between 1 Safety relief valve and boiler 2 Safety relief valve and discharge Union may be installed in safety relief valve piping Pump required Boiler loop pump is factory instal...

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 Boiler and Pressure Vessel Code recognizes use of a listed flow switch in lieu of LWCO on water tube boilers D In event a local jurisdiction insists upon installation of LWCO with this boiler refer ...

Page 38: ...ain Valve Cold Water Fill Air Separator Expansion Tank Low Loss Header Fill Valve Backflow Preventer Safety Relief Valve Dirt Magnetic Filter highly recommended System Pump w Integral Flow Check Valve System Pump w Integral Flow Check Valve Manual Air Vent inside boiler Boiler Pump inside boiler Supplied with boiler Low Loss Header Boiler Supply Connection G 3 4 Boiler Return Connection G 3 4 T P ...

Page 39: ...pplicable codes 2 Flow limiter If DHW draw rate is in excess of rating in Table 3 1 temperature of hot water 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 shown in Table 3 1 at desired temperature rise 3 DHW pressure relief valve Limits pressure ...

Page 40: ...n DHW adapters and boiler Solder connections to DHW adapters before installing gaskets 11 Domestic Water Piping continued Figure 11 2 Standard DHW Piping NOTICE Water filter to prevent scale is strongly recommended on the potable cold water supply line to minimize sediment build up and loss of performance of the plate heat exchanger A Cold Water Supply Hot Water To Fixtures Expansion Tank Req d if...

Page 41: ... 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 close to boiler on cold water line Connect recirculation temperature sensor to Header Sensor terminals per Figure 13 3 Turn DHW comfort mode on See Section 16 Operation and Table 16 11 NOTICE Water filter to prevent scale is stron...

Page 42: ...54 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 liquefied petroleum gas B Asedimenttrapmustbeinstalledupstreamof gas controls C A manual shut off valve provided in parts carton must be installed within 6 ft 1 8 m of boiler D Support weight of gas...

Page 43: ...L 353 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 limit If necessary install an additional water temperature limit Honeywell L4006 Aquastat Wire as indicated in Figure 13 3 Locating Field Connection Terminal Strips Field connection terminal strip lo...

Page 44: ...nnections on terminal strip are Terminal Description Heat T Stat 24VAC thermostat R 24V Hot Heat T Stat 24VAC thermostat W Energized on Call for Heat Heat T Stat 24VAC thermostat C 24V Common Aux T Stat 24VAC thermostat R 24V Hot Aux T Stat 24VAC thermostat W Energized on Call for Heat External Limit Field supplied safety limit contacts 1 External Limit Field supplied safety limit contacts 2 0 10 ...

Page 45: ...ing sensor 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 avoided wire sensor using 2 conductor UL Type CM AWM Style 2092 shielded cable Connect one end of shielding on this cable to ground E Recirculation Header Temperature Sensor Whenoptionalsensoris...

Page 46: ... kit P N 101897 01 is available from manufacturer B Do not route or terminate condensate drain line piping through an area that is prone to freezing temperatures or that could be damaged by leaking condensate 3 4 PVC Connection Condensate Trap Vent Condensate Trap Cleanout C If point of condensate disposal is above trap it will be necessary to use a condensate pump to move condensate from boiler t...

Page 47: ...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 information Fill Water System WARNING Burn Hazard Never exceed maximum allowable working pressure on heat exchanger ASME plate 50 psig 345 kPa A 30 psig 207 kPa safety relief valve is included with this boiler ...

Page 48: ... 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 opening vent 4 Eliminate air in boiler by bleeding from heat exchanger manual air vent on top left side of heat exchanger Figure 15 1 A Use 1 4 in 6 mm ID tubing connected to hose barb and route tubing to a safe draining location B Turn vent counter clockwise a...

Page 49: ... visible Press button until A is visible and press enter Press or buttons until A06 is visible and press enter Press or buttons to change 0 to 1 Press menu 3 times to return to display mode 15 Start Up and Checkout continued Figure 15 4 Home screen at power up no call for heat Figure 15 5 Home screen with CH and DHW demands 7 Start boiler using lighting instructions in Figure 15 9 With boiler powe...

Page 50: ...ed 200 ppm air free in event of high CO see Section 19 Troubleshooting 17 Perform a check 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 18 Test any external limits or other controls in accordance with manufacturer s instructions 19 Refer to Section...

Page 51: ...endie ou une explosion entraînant 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 automatiquement le brûleur Ne tentez pas d allumer le brûleur manuellement B AVANT DE FAIRE FONCTIONNER reniflez tout autour de l appareil pour déceler une odeur de gaz Reniflez près du plancher car certains gaz sont plus lourds que l...

Page 52: ...tus 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 setting ionization setpoint is calibrated next blower drives to low fire and fuel valve output is calibrated runs for 1 minute Priority Central Heat Status Run Burner On Pump s On Three Way Valve CH ...

Page 53: ... Central 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 DHW Comfort Mode is active Visible after successful calibration Visible when CH setpoint reset is enabled Visible when adjust mode is active Icon will flash if manual mode is enabled Visible when manual rese...

Page 54: ...ader Temperature Fr Demanded Firing Rate rUn Run Time Hours CYC Boiler Cycles H Hold or Warning Condition E Manual Reset Lockout Not available with local user display The STA status display code contains below listed values Table 16 5 Managing of Status Numbers Display Description see Section 19 Troubleshooting for explanation 0 Self Check 1 Standby 2 Waiting For Air Pressure Switch To Close 3 Pre...

Page 55: ...kout Hold History Menu Figure 16 7 Adjusting 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 Domestic Hot Water 5 Sequencer Control 6 CH Frost Protection 7 DHW Frost Protection 8 Boiler On Off Switch 9 Warm Weather Shutdown C03 Fan Speed Demanded RPM x 10...

Page 56: ...hold 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 below and additional items in Quick Menu Accessing Password Protected Menus Password protected parameters are available by entering a password reset Figure 16 10 Menu Structure or IMPORTANT This boi...

Page 57: ... A05 Central 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 requires 2 steps changing this parameter to 1 LP Gas AND changing gas valve setting from position 1 to position 2 If conversion to LP Gas is required refer to manual Section 15 Startup and C...

Page 58: ...ighest modulation rate during a CH1 demand Heat T stat input If rated input of installed home radiation is less than maximum output of boiler change F03 setting to limit boiler output accordingly 136 combi 80 200 combi 75 136 combi 0 80 200 combi 0 75 F04 F04 Central Heat 2 Max Modulation Defines highest modulation rate during a CH2 demand Aux T stat input when selected If rated input of installed...

Page 59: ...supply water temperature that will provide enough heat for type radiation used to function properly Always consider type of radiation when adjusting this parameter 0 0 1 2 505 505 Auxiliary Thermostat Input Select May be used as Recirculation Enable Indirect Water Heater IWH DHW demand heating boilers only or CH Zone 2 Heat demand input 0 Recirculation Enable Recirculation enable input When Comfor...

Page 60: ... CH1 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 and DHW priority is active This function is selected when there is a direct piped IHW installed with a dedicated DHW pump 1 1 2 3 4 P03 P03 Auxiliary Pump Output Select Activates Auxiliary Pump ou...

Page 61: ...talled 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 temperature using a reset curve defined by Low Outdoor Temp High Outdoor Temp Min Boiler Temp and CH Setpoint and Boost Time parameters Off Disable do not calculate setpoint based on outdoor temperatu...

Page 62: ...onitors 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 sensor mounting or wiring is required Boost feature increases operating temperature setpoint by 10 F 5 6 C every 20 minutes CH demand is not satisfied This process will continue until heat demand is satisfied indoor air is at desir...

Page 63: ... 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 maximum speed and if temperature difference exceeds 63 F 35 C a forced boiler recycle results Boiler will restart automatically once temperature difference has decreased and minimum off time has expired ...

Page 64: ...demands when periodic calibration is required and boiler is cold 10 Ignition Failure Control monitors ignition using a burner mounted flame sensor In event of an ignition failure the control retries 2 times and then goes into soft lockout for one hour After a one hour soft lockout control will retry 2 additional times before control activates a manual reset Hard Lockout 16 Operation continued 11 C...

Page 65: ...et pressure Closed gas inlet pressure tapping Performed combustion test Screw cap in vent adapter No errors or holds present on display Tested additional field installed controls for functionality outlined by manufacturer i e LWCO high limit or other controls Set proper CH temperature setpoint Set proper DHW temperature setpoint Tested DHW operation to confirm tempering valve setting Verify system...

Page 66: ...ing 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 adequate ventilation Handle RCF carefully to minimize airborne dust Use hand tools whenever possible Dampen used RCF with light water spray prior to removal to prevent airborne dust Do not use compressed...

Page 67: ... following steps are not performed at the intervals specified 1 Inspect vent piping and air intake piping to verify it is free from leakage and deterioration Also verify vent and air intake terminals are unobstructed 2 Inspect condensate drain system to verify it is water tight and unobstructed 3 Inspect water and gas lines to verify they are free from leaks If above inspections reveal potential p...

Page 68: ...range shown in Figure 18 3 and Table 18 4 WARNING Asphyxiation Hazard Do not operate boiler without condensate trap ball and ball support in place Doing so could cause products of combustion and or carbon monoxide to enter building resulting in severe personal injury death or substantial property damage Figure 18 3 Ignitor flame sensor to burner gap 8 Inspect blower gas valve assembly A Look for d...

Page 69: ...o doors windows decks etc E Refer to Sections 7 thru 9 to re assemble any vent system components that are disassembled during this inspection and for details on supporting pitching and terminating vent system 12 Inspect hydronic system and DHW piping A Look for leaks and repair if found If system contains antifreeze or other additives test and or maintain them as directed by additive manufacturer ...

Page 70: ...onnecter C Initiate a call for heat and confirm that boiler shows an Active Fault H05 indicating flow switch is open WARNING Component Damage If burner comes on with no flow through boiler there is a problem with flow switch Turn boiler off immediately Failure to do so could result in severe heat exchanger damage 17 Assure that all safety and operating controls and components are operating properl...

Page 71: ...t icon is on Servicing DHW demand Boiler is in Warm Weather Shutdown Status StA 14 Feature not available with local user display No Central Heat Boiler Runs 3 way valve defective Check 3 way valve replace if necessary 3 way valve wiring defective Check wiring to 3 way valve Recirculation piping problem Recirculation sensor does not detect flow Check piping See Figure 11 3 Boiler Running But System...

Page 72: ...or flame sensor Refer to Section 18 Service and Maintenance for proper procedure to check ignitor flame sensor Check spark gap and ignitor flame sensor distance to burner Replace if necessary Relief Valve Opening System pressure exceeds relief valve setting Lower system pressure below rating of supplied safety relief valve Replace standard safety relief valve with higher rated valve up to the maxi...

Page 73: ...temperature 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 Gas temperature Raised minimum modulation due to loss of flame during run H24 8 Run Modulate Burner is on and is being allowed to freely modulate to match the heating load 9 Postpurge Blower run...

Page 74: ...to Fan Speed Demanded 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 Boiler Pump On Off Status C08 Auxiliary Pump On Off Status C09 Flame Signal Flame signal strength displayed in internal calibrated units C10 Safety Software Revision Safety software ...

Page 75: ...tically after the minimum off time Anti Short Cycle Time 1 1 Urgent calibration cooling delay Urgent calibration demand present waiting for supply temperature to decrease Boiler will start after supply temperature drops below 95 F 35 C Low supply temperature helps to ensure a successful calibration No action is necessary 1 2 Flow switch closed before boiler pump on Boiler start delayed waiting for...

Page 76: ...e is unpowered in DHW Powered in CH If stuck in between disassemble valve and clear any debris Confirm operator is driving fully to powered position Heating load at time of error below minimum firing rate of boiler Test individual zones and ensure proper zone sizes Header sensor not sensing temperature Boiler is multiple boiler slave or modulating based on header sensor Check header sensor install...

Page 77: ... sensor 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 Table 19 7 Replace sensor if necessary H11 E11 Flue Sensor Fault Shorted opened or miswired flue temperature sensor Check flue sensor wiring correct wiring if necessary Check flue sensor refer to s...

Page 78: ...lid altitude selection If fuel selection A06 on local display and power is cycled too fast select original fuel to clear alarm before reselecting desired fuel 17 8 BCC is missing has incompatible software revision or is damaged Remove and reconnect BCC and cycle power If problem persists replace control or BCC 19Troubleshooting continued Table 19 5 Active Fault Code and Corrective Actions continue...

Page 79: ...display Check CH 20 mA Water Temperature is greater than CH 4 mA Water Temperature 18 6 Invalid Comfort Mode configuration Feature not available with local user display Comfort mode selected and Header Recirculation Sensor selection is not set to Recirculation or Auxiliary thermostat input selection not set to Recirculation Enable 18 7 Factory defaults not turned on Ensure BCC is installed and sel...

Page 80: ...rackets e g 1 0 Code Name Possible Cause Corrective Action H22 E22 No Flame At Ignition No gas insufficient gas supply pressure Verify no air in gas line Check gas supply pressure Check gas valve inlet pressure during operation Ignition cable not plugged in Connect ignition harness check cable has continuity Fuel Gas Selection parameter A06 or gas valve setting is incorrect Check Fuel Gas Selectio...

Page 81: ...e each peer to peer boiler has a unique slave address between 1 and 8 30 1 Sequencer slave has lost communication with Sequencer Master master header sensor failure Check boiler to boiler connection wiring Check master is powered and configured Check header sensor wiring or configuration 30 2 Multiple sequencer masters detected Check each boiler Lead Lag Master Enable parameter L01 setup Only one ...

Page 82: ...uld be open H06 E06 H06 0 Hold Flue gas sensor detected temperatures in excess of 194 F 90 C or when used preferred stack flue limit minus 10 E06 1 Lockout Flue gas sensor detected temperatures in excess of 204 F 96 C or when used preferred stack flue limit H07 E07 H07 1 Hold Return temperature higher than supply temperature E07 0 Lockout Return temperature higher than supply temperature H08 H08 0...

Page 83: ...5 F H18 5 Warning Invalid Setpoint interpolation parameters H18 6 Hold Invalid comfort mode configuration E18 7 Lockout Selected boiler model default parameters not available H18 8 Hold Boiler pump output parameter set to Disabled or boiler pump output set to Boiler Pump CH Off for DHW and Auxiliary pump outlet is not set to DHW Boiler Piped IWH E19 E19 0 Lockout Air Fuel ratio outside acceptable ...

Page 84: ...on Fault Missing calibration Calibration not carried out although required calibration counter reached zero check why calibration management did not work H26 3 Warning Emergency stop The burner had to be stopped during calibration adaption either due to high outlet DHW temperature or a blocking lockout error H27 H27 0 Hold 120 VAC supply voltage less than 73 VAC H28 H28 0 Hold Control 24VAC wrong ...

Page 85: ...25 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 kOhm Outdoor Temperature Ohms of Resistance F C 20 28 9 106926 10 23 3 80485 0 17 8 61246 10 12 2 47092 20 6 7 36519 30 1 1 28558 40 4 4 22537 50 10 0 17926 60 15 6 14356 70 21 1 11578 76 24 4 10210...

Page 86: ...ew 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 Outdoor Sensor P2 24 VAC LWCO 1 2 3 4 5 6 7 9 8 10 1 2 3 4 GY Optional 24V LWCO Remove Jumper if used P2 P G P G PI Y G OR 10 9 8 7 6 1 2 3 4 5 YE GY YE GY BL Remove Jumper to connect External Limit Low Volta...

Page 87: ...such requirements follow The National Electric Code NFPA 70 and or CSA C22 1 Electrical Code Do not provide over current protection greater than 15 Amperes 3 Plugs P1 P2 are shown in line on PCB s for clarity 1 1 2 YE 1 BL CES10 Gas Valve 4 Y G 3 B G Remote Monitor Connector 1 3 1 3 Model Key Flue Temp Sensor Supply Sensor 2 1 4 3 3 1 2 1 2 1 2 1 4 3 Low voltage factory wiring size 20 AWG Type TEW...

Page 88: ... P2 1 P1 1 X1 6 X1 7 X2 3 X1 1 Chassis Ground X1 2 Ignitor Flame Rod Combustion Blower DC Conn Spark DC Tach PWM DC HT 1 X3 1 X3 2 X3 3 X3 4 V2 V2 V1 V1 X3 5 X3 6 X3 7 X3 8 Supply Sensor Return Sensor Flue Sensor DHW Sensor DHW Flow X5 1 X5 3 X5 2 X5 4 X5 5 X5 6 X5 7 X5 8 X5 9 X5 10 X5 11 X5 12 BCC X4 4 X4 10 P4 2 P4 1 Model Key C P2 3 W P2 6 R X6 2 X6 3 Aux T stat W P2 7 R X6 4 Recirculation Time...

Page 89: ...er Door Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 110575 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gasket and hardware 111423 01 8B Ignitor Flame Sensor Gasket 106527 01 9 M6 Serrated Flange Hex Nut Obtain locally 1 2A 2B 2C 2D 3A 3B 4 5 6 7 8B 8C 8A 9 All service parts may be obtained through your local Velocity Boiler Work...

Page 90: ...1 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 110581 01 19 3 Way Valve 110582 01 20 Air Vent 110583 01 21 Flow Restrictor 110584 01 22 DHW Flow Sensor 110585 01 41 Low Loss Header 110724 01 10G 44 DHW connector w gaskets 110878 01 12 14 13 19 20 21 22 DHW Blo...

Page 91: ... 01 25A 25B Air Proving Switch tubing 5 16 in x 12 in long 107862 01 26 47 27 28 29 30 Gas piping with gaskets o rings and hardware 110588 01 23B 23D 28 29 30 Gas pipe gaskets 110879 01 26 29 Gas adaptor 111422 01 23B 23A 23D 23E 23C 24A 24B 24C 25B 25A 24D 26 29 24E 24F 47 27 30 28 UNLESS OTHERWISE NOT ALL DIMENSIONS IN INC TOLERANCES X X 1 X XXX 005 X XX 03 ANGLE 1 PROPER U S Boiler Co LANCAS TH...

Page 92: ... Key No Description Part Number 136 Combi 200 Combi 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 45 46 Wall brackets 110882 01 Not shown Thumb screw 106033 01 31E 31D 31C 31A 31F 31G 31H 31B 33 32 42 45 46 ...

Page 93: ...oiler 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 20mm 250V Slow Blow 111420 01 Fuse 1 0A 5 x 20mm 250V Slow Blow Fuse 5 0A 5 x 20mm 250V Slow Blow 34 34 36 37 35 48 5A fuse 1A fuse 5A fuse 43 38 NOTICE When replacing control use boiler control service part Boiler control service part is compatible for all models Facto...

Page 94: ... Auto Reset LWCO 105591 01 Manual Reset LWCO 108182 01 Tempering Valve 70 145F ASSE 1017 108042 01 Fernox Alphi 11 108862 01 Hydronic System Corrosion and Lime scale Inhibitor 108863 01 Header Sensor 108703 01 Outdoor Temperature Sensor 108681 01 Service Kit 111419 01 Floor Stand 111576 01 Noise Attenuator N A 111588 01 Key No Description Part Number 136 Combi 200 Combi 39 Ignition Harness 110598 ...

Page 95: ...nsult 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 from combined heating cooling system 2 If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air boiler piping must be equipped with flow co...

Page 96: ...ition 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 recommended so routine additions of make up water can be detected and their cause corrected 3 Non metallic tubing even if system is tight oxygen can be introduced into system through some types of non ...

Page 97: ...pment 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 requirements of this subdivision can not be met at the time of completion of installation the owner shall have a period of thirty 30 days to comply with the above requirements provided however that during sa...

Page 98: ...e 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 manufacturer 1 The referenced special venting system instructions shall be included with the appliance or equipment installation instructions and 2 The special venting systems shall be Product Approved by t...

Page 99: ...ant 5 min ensuite déterminer si le coupe tirage déborde à l ouverture de décharge Utiliser la flamme d une allumette ou d une chandelle ou la fumée d une cigarette d un cigare ou d une pipe 6 Une fois qu il a été déterminé selon la méthode indiquée ci dessus que chaque appareil raccordé au système d évacuation est mis à l air libre de façon adéquate Remettre les portes et les fenêtres les ventilat...

Page 100: ...100 PHTM II Combi Installation Operating Service Instructions 110331 03 1 22 Velocity Boiler Works LLC P O Box 14818 3633 I Street Philadelphia PA 19134 ...