Velocity PHTM2080H, Installation, Operating And Service Instructions

Page 1: ...t Works 8 5 Locating Boiler 10 6 Preparing Boiler 14 7 General Venting 17 8 Sidewall Direct Venting 24 9 Vertical Direct Venting 30 10 Heating System Piping 36 11 Gas Piping 43 12 Field Wiring 44 13 C...

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 operate...

Page 3: ...uction flue products and fuel contain alumina silica heavy metals carbon monoxide nitrogen oxides and or other toxic or harmful substances that can be hazardous to health and life and that are known t...

Page 4: ...seful life Be sure to protect walls carpets and valuables from water that could leak from boiler WARNING Asphyxiation Hazard Fire Hazard A qualified installer service agency or gas supplier should ann...

Page 5: ...inimum input increased to 10 MBH Model Number Depth in mm Width in mm Height in mm Space Heating Water NPT in Gas NPT Maximum Allowable Working Pressure psig kPa PHTM2080H 16 3 413 17 8 453 29 8 757 1...

Page 6: ...as Conversion Boiler is shipped from factory configured for natural gas and is field convertible to LP gas See Section 14 Start up and Checkout for instructions to convert to LP gas Altitude Only part...

Page 7: ...L ALTA GENERAL CONFIGURATION HEAT ONLY UNITS DES EJL CHK APVD SCALE 1 10 SIZE A SHEET 1 OF 1 DATE REVISION DRAWING NUMBER 09 03 2021 TS 103 62 A UNLESS OTHERWISE NOTED ALL DIMENSIONS IN INCHES TOLERAN...

Page 8: ...ge connection board Provides field connections for thermostats external limits remote firing devices 4 20mA or 0 10V header sensor outdoor sensor and LWCO 9 Control enclosure Houses boiler control and...

Page 9: ...9 110332 04 2 23 PHTM II Installation Operating Service Instructions 4 How It Works continued Figure 4 1 How It Works 1 2 4 3 12 17 13 15 8 7 9 11 14 10...

Page 10: ...n 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 flammabl...

Page 11: ...pening 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...

Page 12: ...taminants 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...

Page 13: ...n 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...

Page 14: ...e over requirements in these instructions Unpack Boiler Figure 6 1 What s In The Box CAUTION Boiler Damage Do not attempt to lift boiler using water or gas pipe connection as hand holds Do not drop bo...

Page 15: ...alled vent reducer 3 in to 2 in could cause unreliable operation at elevated carbon monoxide levels resulting in severe personal injury death or substantial property damage 3 Lubricate heat exchanger...

Page 16: ...ll bracket hole locations using dimensions shown in Figure 6 3 Ensure bracket is level 3 For wood studs drill 3 16 in 4 8 mm pilot holes A and B and attach bracket using provided 5 16 in x 2 in lag sc...

Page 17: ...ection 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 Terminat...

Page 18: ...e 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 insulatio...

Page 19: ...e 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...

Page 20: ...ebur 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 Fol...

Page 21: ...th 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 Wal...

Page 22: ...gths 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 Boi...

Page 23: ...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 Polypropylen...

Page 24: ...h 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...

Page 25: ...25 110332 04 2 23 PHTM II Installation Operating Service Instructions 8 Sidewall Direct Venting continued Figure 8 1 Vent Terminal Clearances Air Terminal not Shown for Clarity...

Page 26: ...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...

Page 27: ...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 building...

Page 28: ...NG 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...

Page 29: ...0 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 Gr...

Page 30: ...al 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 loca...

Page 31: ...al 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 Alter...

Page 32: ...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 M...

Page 33: ...rt 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 Ro...

Page 34: ...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 wit...

Page 35: ...ct 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...

Page 36: ...Clinical Toxicology of Commercial Products 5th edition 10 Heating System Piping 2 Pump required Boiler loop pump is supplied with this boiler and sized for near boiler piping equivalent length of 50 f...

Page 37: ...120HB 1 1 6 4 11 2 7 5 14 6 9 0 20 0 11 2 29 7 PHTM2150H 1 1 8 1 8 2 9 4 10 9 11 3 15 3 14 1 23 4 PHTM2180H 1 1 9 7 11 6 11 3 15 5 13 5 21 8 16 9 33 5 Notes 1 Required Flow GPM Output MBH x 1 000 500...

Page 38: ...LWCO 105591 01 Manual reset LWCO 108182 01 E Install LWCO in supply piping at point prescribed by the local jurisdiction generally at a point above boiler in common header piping F If probe type LWCO...

Page 39: ...A At least eight pipe diameters upstream of first tee B No further apart than 12 305mm or four pipe diameters whichever is smaller Safety Relief Valve System Zone Valves Heating System Circulator Opt...

Page 40: ...12 305mm or four pipe diameters whichever is smaller Full Port Isolation Valve Indirect Circulator Flow Check Valve Indirect Return Indirect Supply Indiect Domestic Water Heater IWH Safety Relief Valv...

Page 41: ...41 110332 04 2 23 PHTM II Installation Operating Service Instructions 10 Heating System Piping continued Figure 10 5 Near Boiler Piping Supplied with Boiler...

Page 42: ...NSI Z223 1 National Fuel Gas Code and or CAN CSA B149 1 Natural Gas and Propane Installation code Figure 11 1 shows typical gas piping and connection to boiler A Use thread compound compatible with li...

Page 43: ...ny field supplied controls NOTICE Boiler is equipped with a UL 353 listed high water temperature limit This limit provides boiler shutdown in event boiler water temperature exceeds setpoint of control...

Page 44: ...mum recommended current draw for auxiliary pump is 1 5A From left to right connections on terminal strip are Terminal Description Heat T Stat 24 VAC thermostat R 24V Hot Heat T Stat 24 VAC thermostat...

Page 45: ...ion from sun iv Avoid placing 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 ele...

Page 46: ...46 110332 04 2 23 PHTM II Installation Operating Service Instructions 12 Field Wiring continued Figure 12 5 TACO SR504 or Equivalent Zone Panel Wiring Connection Diagrams...

Page 47: ...it 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 cond...

Page 48: ...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 all...

Page 49: ...afe place away from controls before opening vent 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 and allow heat exchanger...

Page 50: ...d 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 Pressandholdfor five...

Page 51: ...nce This soft lockout can be reset by interrupting power to boiler 5 Once a flame has been established for first time subsequent calls for burner operation should result in a flame on first try 9 Chec...

Page 52: ...bove 50 firing rate Ensure door is sealed before taking combustion readings C For altitudes 0 to 2 000 ft 0 to 610 m CO should not exceed 200 ppm air free For altitudes above 2 000 ft 610 m CO should...

Page 53: ...e 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 autom...

Page 54: ...at Status Calibration Burner On Pump s On After burner is started a Calibration is initiated due to 1 Power Cycle 2 Periodic requirement Calibration after blower reaches calibration speed setting ioni...

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 Combi boilers only Visible...

Page 56: ...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...

Page 57: ...to B01 and hold reset button until B01 0 Figure 15 7 Adjusting Parameters Menu c c Diagnostic Menu Table 15 9 Diagnostic Menu Display Description C01 Active Detailed Fault Code see Table 18 6 C02 Dema...

Page 58: ...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 be...

Page 59: ...ion to LP Gas is required refer to manual Section 14 Startup and Checkout for complete instructions 0 Natural Gas 1 LP Gas 0 0 A07 A07 Altitude Selection visible only after password entered Boiler is...

Page 60: ...ing 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 100 0 100 F04 F04 Central Heat...

Page 61: ...ng this parameter 130 F 54 C 50 F to 180 F 10 C to 83 C 504 504 Central Heat 2 Min Boiler Water Temp Sets a low limit for Reset setpoint Set this parameter to lowest supply water temperature that will...

Page 62: ...oiler Pump Header Sensor Demand Pump runs when boiler is firing and when there is a DHW heat demand Selected when Header Sensor is selected as CH1 and CH2 modulation sensor and boiler is a stand alone...

Page 63: ...or Reset is Enabled boiler will automatically adjust heating zone setpoint temperature based on outdoor reset curve On Enable calculate temperature setpoint based on outdoor temperature using a reset...

Page 64: ...fter not being used for longer than 7 days This helps prevent pump rotor seizing 7 Pump Air Elimination Pump Purge Pump purge is entered when power is cycled or when there has been an over temperature...

Page 65: ...eeds 63 F 35 C a forced boiler recycle results Boiler will restart automatically once temperature difference has decreased and minimum off time has expired 3 Return Temperature Higher Than Supply Temp...

Page 66: ...f 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 res...

Page 67: ...ressure 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 functionality outlined...

Page 68: ...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 adequat...

Page 69: ...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 unobst...

Page 70: ...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 resultin...

Page 71: ...d during this inspection and for details on supporting pitching and terminating vent system 12 Inspect hydronic system A Look for leaks and repair if found If system contains antifreeze or other addit...

Page 72: ...StA 1 temperature is above setpoint Check temperature setpoint setting Faucet icon is on Servicing DHW demand Boiler is in Warm Weather Shutdown Status StA 14 Feature not available with local user di...

Page 73: ...rol fuel gas selection A06 0 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...

Page 74: ...re 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...

Page 75: ...Large differences may mean there is a problem with blower C05 3 way valve status 0 DHW 1 CH Combi boilers only C06 System Pump On Off Status Pump status indicate controller 120 VAC output status C07 B...

Page 76: ...cally 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...

Page 77: ...cessary Replace pump if necessary 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 m...

Page 78: ...ture difference between dual elements too high Measure resistance of each thermistor and compare refer to sensor temperature vs resistance Table 18 7 Replace sensor if necessary H11 E11 Flue Sensor Fa...

Page 79: ...election 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 Remo...

Page 80: ...ot available with local user display Check CH 20 mA Water Temperature is greater than CH 4 mA Water Temperature 18 6 Invalid Recirc Comfort Mode configuration Feature not available with local user dis...

Page 81: ...ntinued Detailed Fault Code found on b and c menus in brackets 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...

Page 82: ...ch 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 wirin...

Page 83: ...contact is closed when it should 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 senso...

Page 84: ...5 Warning Invalid Setpoint interpolation parameters H18 6 Hold Invalid Recirc Comfort Mode configuration E18 7 Lockout Selected boiler model default parameters not available H18 8 Hold Boiler pump ou...

Page 85: ...ault 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...

Page 86: ...00 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 18 8 Outdoor Air Temperature Sensor Temperature versus Resistance 10 kOhm...

Page 87: ...87 110332 04 2 23 PHTM II Installation Operating Service Instructions 19 Internal Wiring Diagrams Figure 19 1 Ladder Diagram...

Page 88: ...88 110332 04 2 23 PHTM II Installation Operating Service Instructions 19 Internal Wiring Diagrams continued Figure 19 2 Wiring Schematic Diagram...

Page 89: ...89 110332 04 2 23 PHTM II Installation Operating Service Instructions Figure 19 2 Wiring Schematic Diagram continued 19 Internal Wiring Diagrams continued...

Page 90: ...Burner Door Gasket 110880 01 6 7 Burner Door Assembly includes burner ignitor flame sensor gasket and hardware 111978 01 110575 01 111970 01 111560 01 8A 8B 8C Ignitor Flame Sensor includes sensor gas...

Page 91: ...10A 10B Water Pipe Gaskets 110577 01 11A 11B Water Pipes w gaskets 111561 01 111562 01 111561 01 12 Return Temp Sensor 106991 01 13 Supply Temp Sensor 106994 01 14 Boiler Pump Grundfos 26 99 Obtain l...

Page 92: ...6 01 111571 01 24A 24B 24C 24D 24E 24F 28 29 Gas Valve with gaskets o rings and hardware 111979 01 110587 01 111564 01 25A 25B Air Proving Switch tubing 5 16 in x 13 in long 107862 01 26 27 28 29 30 4...

Page 93: ...Part Number PHTM2080H PHTM2120H PHTM2120HB PHTM2150H PHTM2180H 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 01 111...

Page 94: ...Provide 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...

Page 95: ...m 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 Altitude Conversi...

Page 96: ...t Residential Hydronic Heating Installation and Design I B R Guide 2 If boiler is connected to heating coils located in air handling units where they may be exposed to refrigerated air boiler piping m...

Page 97: ...n 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 recom...

Page 98: ...t 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 requirement...

Page 99: ...ll 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 manufactur...

Page 100: ...ndant 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 fois...

Page 101: ...101 110332 04 2 23 PHTM II Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 102: ...102 110332 04 2 23 PHTM II Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 103: ...103 110332 04 2 23 PHTM II Installation Operating Service Instructions SERVICE RECORD SERVICE PERFORMED DATE...

Page 104: ...104 110332 04 2 23 PHTM II Installation Operating Service Instructions Velocity Boiler Works LLC P O Box 14818 3633 I Street Philadelphia PA 19134 www velocityboilerworks com...