VELOCITY PHTM2120H PHTM-II Water Boiler Instruction Manual
- June 12, 2024
- Velocity
Table of Contents
VELOCITY PHTM2120H PHTM-II Water Boiler
Product Information
The Phantom II Boiler is a high-efficiency heating system designed for residential use. It is capable of providing reliable and efficient heating for homes. This boiler must only be installed, serviced, or repaired by a qualified installer, service agency, or gas supplier to ensure proper functionality and safety.
It is important to read and understand all the instructions provided in this manual before installing or operating the boiler. Failure to do so may result in personal injury, death, or property damage.
The Phantom II Boiler has been approved by the Massachusetts Board of Plumbers and Gas Fitters and complies with the regulations set forth by the Commonwealth of Massachusetts. It is recommended to consult a licensed plumber or gas fitter for the installation of this product in Massachusetts.
Product Usage Instructions
- Installer Read Before Proceeding – This section provides important information for the installer regarding safety precautions, installation procedures, and contact information for support.
- Homeowner Read Before Proceeding – This section is intended for homeowners and contains essential information about the boiler, its operation, and maintenance requirements. It is recommended to retain these instructions for future reference.
- Specifications – This section provides detailed specifications of the Phantom II Boiler, including its model number, serial number, and other technical details.
- How It Works – This section explains the functioning of the boiler and its components.
- Locating Boiler – This section provides guidance on selecting an appropriate location for installing the boiler.
- Preparing Boiler – This section outlines the necessary steps to prepare the boiler for installation.
- General Venting – This section explains the venting requirements for the boiler.
- Sidewall Direct Venting – This section provides instructions for sidewall direct venting installation.
- Vertical Direct Venting – This section provides instructions for vertical direct venting installation.
- Heating System Piping – This section covers the piping requirements for the heating system connected to the boiler.
- Gas Piping – This section provides guidelines for gas piping installation.
- Field Wiring – This section explains the electrical wiring requirements for the boiler.
- Condensate Disposal – This section provides instructions for disposing of condensate from the boiler.
- Start-up and Checkout – This section explains the steps to start up and check the functionality of the boiler.
- Operation – This section provides information on operating the boiler and adjusting its settings.
- Before Leaving Jobsite – This section outlines the necessary precautions to take before leaving the installation site.
- Service and Maintenance – This section provides guidance on servicing and maintaining the boiler to ensure optimal performance.
- Troubleshooting – This section offers troubleshooting tips for identifying and resolving common issues with the boiler.
- Internal Wiring Diagrams – This section includes wiring diagrams for reference during servicing or maintenance.
- Service Parts – This section provides a list of service parts and their corresponding part numbers.
- Appendix A. Combination Refrigeration/Heating System – This appendix covers additional information regarding combination refrigeration/heating systems.
- Appendix B. Water Quality and Boiler Additives – This appendix provides information on water quality requirements and recommended boiler additives.
- Appendix C. Special Requirements In Massachusetts – This appendix outlines special requirements for installing the boiler in Massachusetts.
- Appendix D. Code Required Text – This appendix includes code required text for compliance purposes.
For any further assistance, information, or support, it is recommended to consult a qualified installer, service agency, or the gas supplier.
Installation, Operating and Service Instructions for
Models: · PHTM2120H · PHTM2150H · PHTM2180H
II
· Water Boiler · Condensing · Direct Vent Models · Gas Fired
TO THE INSTALLER:
Affix these instructions adjacent to boiler. Provide model number and serial
number when seeking information and support.
TO THE HOMEOWNER:
Retain these instructions for future reference. Contact heating installer or
technician for all issues and support.
Version en Español disponible en el web del fabricante.
www.velocityboilerworks.com
! WARNING
This boiler must only be installed, serviced, or repaired by a qualified
installer, service agency or gas supplier. Improper installation, adjustment,
alteration, service or maintenance can cause severe personal injury, death, or
substantial property damage. For assistance or additional information, consult
a qualified installer, service agency, or the gas supplier. Read these
instruction carefully before installing.
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
The Massachusetts Board of Plumbers and Gas Fitters has listed the Phantom II
Boiler. See the Massachusetts Board of Plumbers and Gas Fitters website for
the latest Approval Code or ask your local Sales Representative. The
Commonwealth of Massachusetts requires this product to be installed by a
licensed Plumber or Gas fitter.
The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life.
! DANGER
Indicates a hazardous situation that, if not avoided, will result in death or
serious injury.
! CAUTION
Indicates a hazardous situation that, if not avoided, could result in minor or
moderate injury.
! WARNING
Indicates a hazardous situation that, if not avoided, could result in death or
serious injury.
NOTICE: Indicates special instructions on installation, operation, or service which are important but not related to personal injury hazards.
! 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 supplier is unavailable, contact the fire department.
! WARNING
This boiler must only be serviced and repaired by qualified installer, service
agency or gas supplier.
· If any controls are replaced, they must be replaced with identical models. ·
Read, understand and follow all the instructions and warnings contained in all
the sections of this
manual. · If any electrical wires are disconnected during service, clearly
label the wires and assure that the wires
are reconnected properly. · Never jump out or bypass any safety or operating
control or component of this boiler. · Assure that all safety and operating
controls and components are operating properly before placing
the boiler back in service. · Annually inspect boiler. · Annually inspect all
vent gaskets and replace any exhibiting damage or deterioration.
2
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
1 Installer or Qualified Service Agency Read Before Proceeding
! WARNING
Asphyxiation Hazard, Burn Hazard, Electrical Shock Hazard.
· Carefully read all instructions in literature packet and posted on boiler
before attempting installation, startup, or service of this boiler. Perform
steps in order given. Failure to follow all instructions in proper order could
result in severe personal injury, death or substantial property damage.
· Use proper personal protective equipment when installing, servicing, or
working near this boiler. Materials of construction, 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 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
temperature and pressure gage when making this judgement.
· Install all guards, cover plates, and enclosures before leaving boiler in
operation.
· Disconnect electrical supply before installing or performing maintenance.
· Always use a combustion analyzer to verify proper operation. See Section 14
Start-up and Checkout for procedure and guidelines for checking carbon
monoxide (CO) levels. Failure to use a combustion analyzer could cause
operation of boiler with elevated (CO) levels, resulting in severe personal
injury, death or substantial property damage.
· Do not install at altitudes above 2,000 ft. (610 m).
NOTICE: Size boiler properly relative to design heat load or, if using DHW
priority, the peak hot water load, whichever is larger. A grossly oversized
boiler will cycle excessively leading to premature failure of boiler and its
components. Warranty does not cover damage from excessive cycling.
· For heating systems employing convection radiation (baseboard or radiators),
use an industry accepted sizing method such as the I=B=R Guide RHH published
by the Air Conditioning, Heating and Refrigeration Institute (AHRI).
· For new radiant heating systems, refer to radiant tubing manufacturer’s
boiler sizing guidelines.
· For system including indirect water heater, ensure boiler has output called
for per indirect water heater manufacturer’s instructions.
1. Phantom II boiler is a Direct Vent space heating boiler.
2. A hot water boiler installed above radiation level or as required by the
authority having jurisdiction must be provided with a low water cutoff (LWCO)
device. This boiler is equipped with a UL353 listed flow switch which provides
low water protection on this boiler. Where authority having jurisdiction
requires a separate LWCO, the following kits are available:
· Auto reset LWCO: 105591-01
· Manual reset LWCO: 108182-01
Factory installed flow switch in this boiler meets requirements of 248 CMR
5.00 Massachusetts Amendments to NFPA 54 Section 5.10(6) 10.3.5 Safety
Control.
3. Inspect shipment carefully for signs of damage. See Figure 6-1 for
location of parts shipped loose with boiler. Any claim for damage or shortage
in shipment must be filed immediately against carrier by consignee. No claims
for variances or shortages will be allowed by boiler manufacturer, unless
presented within 60 days after receipt of equipment.
NOTICE: When replacing control, use boiler control service part listed in
Section 20 Service Parts. Boiler control service part is compatible for all
models. Factory installed control is only compatible with purchased boiler.
110332-01 – 1/22
3
PHTM II Installation, Operating & Service Instructions
2 User/Homeowner Read Before Proceeding
! WARNING
Asphyxiation Hazard. Fire Hazard. · A qualified installer, service agency or
gas supplier should annually inspect boiler including annually inspecting all
vent gaskets and replacing any exhibiting damage or deterioration.
· If you are not qualified to install or service boilers, do not install or
service this one.
· Carbon monoxide is an odorless, deadly gas that may be introduced into your
home by any malfunctioning fuel burning product or vent system failure. It is
strongly recommended that CO alarms be installed near bedrooms and on all
levels of building to warn you and your family of potential CO exposure.
· Do not block air flow into or around boiler. Insufficient air may cause the
boiler to produce carbon monoxide or start a fire.
3 Specifications
Table 3-1: Ratings
NOTICE: Protect your home in freezing weather. A power outage, safety lockout,
or component failure will prevent your boiler from lighting. In winter your
pipes may freeze and cause extensive property damage. Do not leave heating
system unattended during cold weather unless alarms or other safeguards are in
place to prevent such property damage.
! CAUTION
Burn Hazard. Keep children and pets away from hot surfaces of the boiler
including boiler piping, vent piping, and vent terminals.
NOTICE: Boiler may leak water at the end of its useful life. Be sure to
protect walls, carpets, and valuables from water that could leak from boiler.
Model Number
Input1 (MBH) Min Max
DOE Heating Capacity (MBH)
AHRI Net Rating2 (MBH)
AFUE
PHTM2120H 13.6 120
112
97
95
PHTM2150H 20 150
141
123
95
PHTM2180H 20 180
169
147
95
1 Input for elevations up to 2,000 ft. (610 m) with min vent length. See Table
3-3 for derate at max vent length. 2 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 having unusual piping
and pickup requirements, such aBs intermittent operation, extensive piping
systems, etc.
Table 3-2: Dimensions and Connections
Model Number
Depth
Width
in. (mm) in. (mm)
Height in. (mm)
Space Heating Water sweat, in.
PHTM2120H 16.3 (413) 17.8 (453) 29.8 (757)
1
PHTM2150H 20.4 (518) 17.8 (453) 29.8 (757)
1
PHTM2180H 20.4 (518) 17.8 (453) 29.8 (757)
1
Maximum
Gas NPT
Allowable Working Pressure
psig (kPa)
1/2 50 (345)
1/2 50 (345)
1/2 50 (345)
4
110332-01 – 1/22
3 Specifications (continued)
PHTM II Installation, Operating & Service Instructions
Table 3-3: Air Intake and Vent Lengths
Model Number Intake/Vent Size in. (mm)
PHTM2120H
PHTM2150H PHTM2180H
Standard w/ increaser
Standard w/ increaser
2 (60) 3 (80) 2 (60) 3 (80)
Min Length ft. (m)
2.5 (0.76)
2.5 (0.76)
2.5 (0.76)
2
2.5 (0.76)
Max Length ft. (m)
70 (21.3) 135 (41.1) 70 (21.3) 135 (41.1)
Table 3-4: Inlet Gas Pressure Range
REV.
Min in. wc (kPa) A
Natural Gas
2.5 (0.62)
LP Gas
8.0 (1.99)
EN
DATE
103-M14a3-x14i5n9.9wc (k9/P3a/2)021
14.0 (3.48)
Approx. Derate at Max. Length (%)
7 1 9
1
5
REVISIONS
DESCRIPTION
PRODUCTION RELEASE
DWN CH EJL
Table 3-5: Weights and Volume
Model Number
Shipping Weight lb.
(kg)
Empty Boiler Weight lb. (kg)
Vent
Shipping Shipping Shipping
Crate D in. Crate W in. Crate H in.
(mm)
(mm)
(mm)
Water Content gal (L)
Air Intake
Heat Exchanger Surace Area
ft2 (m2)
PHTM2120H 112 (51) B 76 (35) 41.4 (1050) 20.0 (508) 18.3 (465) 0.75 (2.8) 11.99 (1.11)
PHTM2150H 132 (60) 103 (47) 41.4 (1050) 20.0 (508) 22.3 (567) 1.0 (3.8) 17.98 (1.67)
PHTM2180H 132 (60) 103 (47) 41.4 (1050) 20.0 (508) 22.3 (567) 1.0 (3.8) 17.98 (1.67)
2
1
Electrical Requirements: 120 VAC, 60 Hz, 1-ph. 1.8A for boiler and pump + current draw of any external pumps
connected to boiler.
REVISIONS
REV. ControlsEN: Boiler flowDAsTwEitch and inteDgErSaCtReIPdTIOmNanual resetDhWigNh limCiHtKprovAiPdVeDd with boiler are both UL-353 listed.
A LP G10a3-s14C3-1o4n59v9ersio9n/3:/B20o21iler is shiPpRpOeDdUCfTrIOomN RfEaLEcAtSoEry configEuJLred 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: Boiler is listed for 0 to 2,000 ft. (610 m). Do not install above 2,000 ft. (610 m).
Vent
Air Intake
Front View
B
Low Voltage Knockouts
120 VAC Knockouts
Boiler Supply
Gas
Condensate Trap Cleanout
Boiler Return
A
Condensate Drain
Bottom View
LKon1wo1c0Vko3olu3tat2sg-e01 – 1/22
Boiler Supply
Front View
UNLESS OTHERWISE NOTED: THIRD ANGLE MATERIAL:
ALL DIMTOENLSEIROANNSFCINiEgSI:NuCreHE3S.-6:PRBOoJEiCleTIrONConITnEMecNtUiMonBEsR:
X.X ±.1 X.XXX ±.005 X.XX ±.03 ANGLE ±1°
FIRST USE: ALTA
PROPERTY OF
TITLE:
U.S. Boile1r2C0 VoACmpany, Inc. LAKNnoCcAkSoTuEtRs, PA
GENERAL CONFIGURATION
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION
Gas AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER
COMPANY, INC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN
PERMISSION OF U.S. BOILER COMPANY, INC. IS STRICTLY PROHIBITED.
HEAT ONLY UNITS
DES: EJL
SCAL
CHK: —
SIZE: A
APVD: –DATE:
09/03/20521
SHEET REVIS
DRAWING NUMBER:
TS-103-62
4 How It Works
PHTM II
1. Heat exchanger Water flows through heat exchanger’s stainless steel tubes.
Heat is transferred to water as flue products are cooled below point of
condensation for maximum heat transfer and efficiency. An enclosure contains
and directs flue products to vent piping.
2. Blower Pulls air and gas through venturi. Air and gas mixture is then
pushed into burner where it burns inside combustion chamber.
3. Gas valve Precisely controls gas flow rate in response to electronic
signal from control.
4. Venturi Creates suction at gas valve outlet and mixes air and gas before
they flow into blower.
5. Burner (not shown) Constructed of stainless steel, burner uses pre-mixed
air and gas to meet modulation requirements.
6. Boiler control (not shown) Monitors internal and external sensors and
controls blower, gas valve, and pumps to meet heating and DHW demand. Control
is a “gas adaptive system” that regulates air and gas flow mixture by
measuring flame ionization and adjusting gas valve to achieve a target air-
fuel ratio. This eliminates need to make throttle screw or offset adjustments.
System is self-calibrating and continuously maintains air-fuel ratio at
desired value.
7. 120 VAC connection board Provides field connections for line voltage
boiler pump and two additional pumps (system pump and aux. pump).
8. Low voltage connection board Provides field connections for thermostats,
external limits, remote firing devices (4-20mA or 0-10V), header sensor,
outdoor sensor and LWCO.
Installation, Operating & Service Instructions
9. Control enclosure Houses boiler control and provides access to installed
fuses and spare fuses.
10. Local user display Allows review of boiler status and parameter
adjustment. In event of fault condition, LCD display turns red and fault
condition is displayed.
11. 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
maintain CH setpoint temperature and shut down the boiler if supply
temperature is too high.
13. Boiler return temperature sensor Used to monitor boiler water entering
heat exchanger.
14. Ignitor/flame sensor A single ignitor/flame sensor is used to both
provide ignition energy and monitor flame.
15. Air pressure switch Proves air flow (closes) prior to boiler ignition.
Switch is proven open prior to starting blower.
16. Boiler Pump, field installed (not shown) External boiler pump provides
flow through heat exchanger.
17. Boiler flow switch (UL 353 Listed) Proves water is present in boiler and
flow rate is adequate prior to starting boiler.
18. Condensate trap (not shown) Allows combustion chamber and vent condensate
to drain from boiler while retaining flue products in boiler.
6
110332-01 – 1/22
4 How It Works (continued)
PHTM II Installation, Operating & Service Instructions
15
13 17
11 1
14
2 4
9
12
10
3 87
Figure 4-1: How it works
110332-01 – 1/22
7
5 Locating Boiler
PHTM II
Code Requirements
! WARNING
Asphyxiation Hazard. Adequate combustion and ventilation air must be provided
to assure proper combustion and to prevent damage to boiler components.
Provide ventilation openings into boiler room as described in “Air for
Ventilation” in this manual. Combustion air must be brought to boiler from
outdoors using an intake piping system meeting requirements in Section 7.
1. Installations must conform to the requirements of the authority having
jurisdiction or, in the absence of such requirements, to the National Fuel Gas
Code, ANSI Z223.1/NFPA 54, or Natural Fuel Gas and Propane Installation Code,
CAN/CSA B149.1.
2. All wiring must comply with National Electrical Code ANSI/NFPA 70 (in the
USA) or the Canadian Electrical Code CSA C22.1 (in Canada) and any local
regulations.
3. Where required by authority having jurisdiction, installation must conform
to Standard for Controls and Safety Devices for Automatically Fired Boilers,
ANSI/ASME CSD1.
Location Considerations
1. If replacing an existing boiler, check for and correct common system
problems including:
A. System leaks, which can result in premature heat exchanger failure from
oxygen corrosion or hardness deposits
B. Inadequate freeze protection resulting in system freezing and leaking
C. Dirt or debris left in existing piping if it has not been properly flushed
or cleaned
D. Incorrectly sized expansion tank
2. Boiler is listed for indoor installation only. Do not install where boiler
will be exposed to freezing temperatures or ambient air temperatures in excess
of 104°F (40°C). Do not install in an attic.
3. Protect gas ignition system components from water (dripping, spraying,
rain, etc.) during appliance operation and service (circulator replacement,
condensate trap cleaning, control replacement etc.).
8
Installation, Operating & Service Instructions
4. Locate boiler to avoid water damage in case there is a leak. If boiler
must be located in an area sensitive to water damage, install drain pan
underneath boiler and pipe to a suitable 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
Explosion Hazard. Do not store or use gasoline or other flammable vapors or
liquids in the vicinity of this or any other appliance. Do not install
vent/air termination where gasoline or other flammable vapors or liquids are
stored. Avoid locating vent/air termination near chemical products containing
chlorine, chlorine based salts, chloro/fluorocarbons, paint removers, cleaning
solvents, and detergents. Boiler could ignite vapors from flammable liquids
resulting in explosion or fire.
Wall Mounting
1. Wall must be plumb and comprised of cement, brick, block, or wooden studs
on 16 in. (406 mm) centers.
2. If flooding is possible, elevate boiler to prevent water reaching boiler.
3. Ensure boiler location minimizes risk of water damage from valves, pumps,
etc.
Clearances
1. Provide clearances between boiler jacket and combustible material in
accordance with authority having jurisdiction. Minimum clearances to
combustible material shown in Figure 5-1.
2. Provide practical service clearances. 24 in. (610 mm) service clearance
are recommended from left side, right side and front. If providing less than
24 in. (610 mm) front clearances are recommended, ensure access through a
door. Minimum 6 in. (150 mm) clearance required to remove side panels.
3. Boiler must not be installed on carpeting.
NOTICE: If recommended service clearances are not provided, it may be
necessary to remove boiler for service.
110332-01 – 1/22
5 Locating Boiler (continued)
PHTM II Installation, Operating & Service Instructions
Ventilation Air
1. Combustion air must be obtained directly from outdoors, however
ventilation openings may still be required to prevent overheating of boiler
components if boiler is installed in small space such as a closet.
2. If a 24″ clearance from boiler sides, front, and bottom can be maintained
with all doors to the boiler room closed, no ventilation openings are
required.
3. If 24″ clearances described in (2) cannot be maintained, provide two openings into room, one near floor and other near ceiling. Top of upper opening to be within 12 in. (305 mm) of ceiling and bottom of lower 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).
Closet Door
1 2
”
(13mm)*
Vent
Air
1 4
”
(6mm)
This boiler is listed for closet installation with the following clearances
from the boiler jacket to combustible construction:
Top: 814″ (210mm), Sides: 12″ (13mm), Front: 12″ (13mm), Bottom: 6″ (150mm)
Clearances also apply to non-combustible walls, doors, ceilings and floors.
Clearances from piping to combustible construction: Non-Concentric Vent
(exhaust):14″ (6mm) Concentric Vent or Air Intake Piping: 0″ Hot Water Piping:
14″ (6mm)
*Recommended Service Clearances: Sides, Front and Bottom: 24″ (610mm)
8
1 4
”
(210mm)
0-12″ (0-305mm)
Ventilation Opening (if required)
1 2
”
(13mm)*
1 2
”
(13mm)*
Closet Door
6″ (150mm)*
Ventilation Opening (if required)
0-12″ (0-305mm)
Provide access to this area for inspection and cleanout of condensate trap
Figure 5-1 : Minimum Clearances to Combustible Construction
110332-01 – 1/22
9
5 Locating Boiler (continued)
PHTM II Installation, Operating & Service Instructions
4. If boiler is installed in room with other appliances, provide adequate air
for combustion and/or ventilation in accordance with other appliance
manufacturer’s instructions and applicable code. If other appliance(s) require
two openings at least 100 in.2 (650 cm2) each, no additional openings are
required for this boiler.
Combustion Air and Venting
! WARNING
Asphyxiation Hazard. Boiler requires a special venting system designed for
positive pressure. Supplied vent connector connects to CPVC, polypropylene,
and stainless steel venting listed in Section 7, General Venting. Failure to
vent boiler in accordance with these instructions could cause products of
combustion to enter the building resulting in severe personal injury, death or
substantial property damage.
! DANGER
Component Malfunction. Outdoor combustion air must be piped directly to boiler
air connection. Ensure combustion air does not contain contaminants and is not
drawn from an area likely to have contaminants per Table 5-2. For example,
never pipe combustion air from areas near swimming pools or laundry room
exhaust vents. Contaminated combustion air will damage boiler resulting in
severe personal injury, death or substantial property damage.
1. Use only vent and air piping and termination methods listed in Section 7,
General Venting. Vent and air piping must terminate either horizontally
through a sidewall or vertically through a roof or chase. Locate boiler so
vent and air intake piping can be routed through building and properly
terminated.
2. Ensure installation does not exceed maximum air and vent pipe lengths and
terminations are located in acceptable location per these instructions and all
applicable local codes.
Table 5-2: Corrosive Combustion Air Contaminants and Sources
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 bleaches, detergents, and cleaning solvents found
in household laundry rooms. Adhesives used to fasten building products and
other similar products Excessive dust and dirt
Areas likely to have contaminants: Dry cleaning/laundry areas and
establishments Swimming pools Metal fabrication plants Beauty shops
Refrigeration repair shops Photo processing plants Auto body shops Plastic
manufacturing plants Furniture refinishing areas and establishments New
building construction Remodeling areas Garages with workshops
10
110332-01 – 1/22
5 Locating Boiler (continued)
PHTM II Installation, Operating & Service Instructions
Connecting New Boiler to Existing Vent System
! WARNING
Asphyxiation Hazard. If any of below conditions cannot be met, existing vent
system must be updated or replaced. Failure to follow these instructions could
cause products of combustion and/ or carbon monoxide to enter living space,
resulting in severe personal injury, death or substantial property damage.
1. If using existing vent system to vent new boiler, check the following: A.
Material and manufacturer are listed in Section 7 General Venting. B. Proper
size and length per Table 7-7. C. Appropriate supports to prevent sagging and
vertical movement. D. Minimum slope per Section 7 guidelines. E. Terminations
and their location comply with Section 7 General Venting, Section 8 Sidewall
Direct Venting, or Section 9 Vertical Direct Venting. F. Seals and connections
per Section 7 General Venting and /or vent system manufacturer’s instructions.
System must be tested per procedure Removing Existing Boiler in this section.
G. Vent pipe and components should be replaced if there is any question to
their integrity.
Removing Existing Boiler
! DANGER
Asphyxiation Hazard. Do not vent this boiler into a common vent with any other
appliance. Connecting this boiler to a common vent will cause products of
combustion and/or carbon monoxide to enter living space as well as appliance
malfunction, resulting in severe personal injury, death or substantial
property damage.
When an existing boiler is removed from a common venting system, the common
venting system is likely to be too large for proper venting of the appliances
remaining connected to it.
At the time of removal of an existing boiler, the following steps shall be
followed with each appliance remaining connected to the common venting system
placed in operation, while the other appliances remaining connected to the
common venting system are not in operation:
110332-01 – 1/22
1. Seal any unused openings in the common venting system.
2. Visually inspect the venting system for proper size and horizontal pitch
and determine there is no blockage or restriction, leakage, corrosion, and
other deficiencies which could cause an unsafe condition.
3. Insofar as is practical, close all building doors and windows and all
doors between the space 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 maximum speed. Do not operate a summer exhaust fan. Close
fireplace dampers.
4. Place in operation the appliance being inspected. Follow the Lighting (or
Operating) Instructions. Adjust thermostat so appliance will operate
continuously.
5. Test for spillage at the draft hood relief opening after 5 minutes of main
burner operation. Use the flame of a match or candle, or smoke from a
cigarette, cigar or pipe.
6. After it has been determined that each appliance remaining connected to
the common venting system properly vents when tested as outlined above, return
doors, windows, exhaust fans, fireplace dampers and any other gas-burning
appliance to their previous condition of use.
7. Any improper operation of the common venting system should be corrected so
the installation conforms with the National Fuel Gas Code, ANSI Z223.1/NFPA
54. When resizing any portion of the common venting system, the common venting
system should be resized to approach the minimum size as determined using the
appropriate tables in Chapter 13 of the National Fuel Gas Code, ANSI
Z223.1/NFPA 54.
Residential Garage Installation
1. If installing in residential garage or adjacent space open to garage that
is not part of living space:
A. Burner and burner ignition devices must be a minimum of 18 in. (46 cm)
above floor.
B. Boiler must be located and/or protected to prevent damage from moving
vehicle.
2. Follow local codes for locating a residential boiler in a garage or
National Fuel Gas Code, ANSI Z223.1/NFPA 54. in absence of such codes.
11
6 Preparing Boiler
PHTM II Installation, Operating & Service Instructions
Unpack Boiler
Remove boiler and parts carton from outer shipping carton.
! CAUTION
Boiler Damage. Do not attempt to lift boiler using water or gas pipe
connection4as hand holds.
! CAUTION
Boiler Damage. Do not drop boiler. Damage to boiler can result.
! CAUTION
Heavy Object. Boiler weighs up to 130 lb (59 kg). Two people are required to
lift boiler onto wall mounting bracket. Ensure wall bracket is anchored to
structure capable of supporting weight of b3 oiler and attached piping when
filled with 2 water. Areas subject to earthquakes may have special
requirements that take precedence over
REV.
requirements in these instructions. A
EN 103-143
Misc. Parts Carton B
Boiler
Screw (4X)
Vent Connector
Wall Hook
Lag Screw (4X) Washer (4X)
Gas Valve Inlet Adapter
Gasket (3/4″ Fiber)
Circulator
Circulator Flange (2X)
Safety Relief Valve
Temp./Pressure Gauge
Drain Valve
Wall Retaining Clip (2X)
Gas Shutoff Valve
A
4
12
Figure 6-1: What’s in the Box
3
UNLESS OTHERWISE NOTED: ALL DIMENSIONS IN INCHES.
TOLERANCES:
THIRD ANGLE PROJECTION
MA ITEM
X.X ±.1 X.XXX ±.005
X.XX ±.03 ANGLE ±1°
FIRS
A
PROPERTY OF
TITLE
U.S. Boiler Company, Inc.
LANCASTER, PA
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER COMPANY, INC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN PERMISSION OF U.S. BOILER COMPANY, INC. IS STRICTLY PROHIBITED.
2
110332-01 – 1/22
6 Preparing Boiler (continued)
PHTM II Installation, Operating & Service Instructions
Install Vent Connector
1. Remove vent connector and screws from parts carton.
2. Check vent reducer on top of heat exchanger to ensure it is installed
properly.
! WARNING
Asphyxiation Hazard. A boiler operating with an improperly installed vent
reducer (3″ to 2″) could cause unreliable operation at elevated carbon
monoxide levels resulting in severe personal injury, death, or substantial
property damage.
Vent Connector
Flue gas sample port facing front of boiler
Attach with (4) screws
3. Lubricate heat exchanger 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.
Figure 6-2: Installing Vent Connector
110332-01 – 1/22
13
6 Preparing Boiler (continued)
PHTM II Installation, Operating & Service Instructions
Mount Boiler
3. For wood studs, drill 3/16 in. (4.8 mm) pilot holes
“A” and “B” and attach bracket using provided
1. Wall bracket is designed to mount on studs
5/16 in. x 2 in. lag screws and washers. For wood
with 16 in. (406 mm) centers or a masonry
studs with drywall or paneling greater than 1/2
wall. For other stud spacing, mount bracket
in. (12 mm) thick, metal studs, or masonry wall,
to 3/4 in. (19 mm) plywood or horizontal 2 x 4
use anchors suitable for boiler weight and
anchored to studs.
appropriate for wall material.
4. Hang boiler on wall bracket. See Figure 6-4.
! CAUTION
5. Attach bottom retaining clips to boiler and mark
Heavy object.
Do not mount boiler to a hollow wall. Boiler must
4
be anchored to studs.
3
hole locations. Drill 3/16 in. (4.8 mm) pilot holes
“C” and “D” and attach to wall using provided 5/16
in. x 2 in. lag screws or other anchors appropriate
for wall material.
2
2. Mark wall bracket hole locations using dimensions
6. Verify boiler is level and plumb.
shown in Figure 6-3. Ensure bracket is level.
REV.
EN
DATE
16″ (406mm) 14″ (356mm) 9″ (229mm)
1″ (25mm)
A .4″ (10mm)
Vent CL Air CL
Wall Bracket
B
(2X) Retaining Clip
Boiler
Boiler Supply & Return CL Gas CL Condensate Drain CL
Boiler Outline
30″ (762mm)
1″ (25mm)
C
D
5″ (127mm) 11″ (279mm) 14″ (356mm)
Figure 6-3: Wall Layout and Mounting Holes
14
2 X 4 Wood Stud
See detail
(4X) 5/16″ X 2″ Lag Screw
(4X) 5/16″ Flat Washer
Drywall or other sheathing
Rear of Boiler
Support Rail
Retaining Clip
Installed Retaining Clip Detail
Figure 6-4: Mounting Boiler on Wall
UNLESS OTHERWISE NOTED: THIRD ANGLE MATERIAL:
ALL DIMENSIONS IN INCHES. PROJECTION
TOLERANCES:
ITEM NUMBER:
X.X ±.1 X.XXX ±.005 X.XX ±.03 ANGLE ±1°
110332-01 – 1FI/R2ASTL2TUASE:
PROPERTY OF
TITLE:
U.S. Boiler Company, Inc.
LANCASTER, PA
BOILER MOU
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION
CONNECTI
7 General Venting
PHTM II Installation, Operating & Service Instructions
Direct Vent Sidewall Termination Options
Figure 7-1: Sidewall Termination with Fittings see Section 8 for details
Figure 7-2: Sidewall Low Profile Termination – see
Section 8 for details
Direct Vent Vertical Termination Options
Figure 7-3: Sidewall Concentric Termination see Section 8 for details
Figure 7-4: Vertical Termination with Fittings see Section 9 for details
110332-01 – 1/22
Figure 7-5: Vertical Concentric Termination – see
Section 9 for details
Figure 7-6: Vertical Termination with Abandoned B-vent or
Chimney Chase – see Section 9 for details
15
7 General Venting (continued)
PHTM II
Vent and Air Sizing
! WARNING
Asphyxiation Hazard. · Failure to vent this boiler in accordance with these
instructions could cause products of combustion and/or carbon monoxide to
enter living space, resulting in severe personal injury, death or substantial
property damage.
· Vent installations shall be in accordance with provisions of the National
Fuel Gas Code, ANSI Z223.1/NFPA 54, or “Natural Gas and Propane Installation
Code, CAN/CSA B149.1, or applicable requirements of the local building codes.
· This boiler requires a special venting system. 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 pipe when passing through
floors or walls.
· Do not use a barometric damper, draft hood, or vent damper with this boiler.
· Do not connect any other appliance to vent pipe or multiple boilers to a
common vent pipe.
· Follow instructions in Section 5, Locating Boiler, when removing a boiler
from an existing vent system.
· Failure to comply with any of the above requirements could result in severe
personal injury, death or substantial property damage.
Table 7-7: Vent and Air Sizing
Installation, Operating & Service Instructions
1. Min and max lengths are calculated separately for air and vent. For
example, max length 135 ft. (41.1 m) means up to 135 ft. (41.1 m) air piping
and up to 135 ft. (41.1 m) vent piping.
2. If using 2 in. x 3 in. increaser, use max 12 in. (305 mm) of 2 in. pipe
before increaser. For equivalent length, count only 3 in. (80 mm) pipe
starting from increaser.
3. Maximum length of flexible polypropylene venting is reduced due to higher
pressure drop. See Table 7-10.
4. If using B-vent air chase, 1 ft. (0.30 m) B-vent equals 1 equivalent ft. (
0.30 m).
Table 7-8: CPVC/PVC Fitting Equivalent Lengths
Fitting
Equivalent Length ft. (m)
2 in.
3 in.
90° Short Elbow
6.0 (1.8) 10 (3.0)
90° Sanitary Elbow 2.6 (0.8) 4.0 (1.2)
45° Elbow
1.5 (0.5)
2 (0.6)
Table 7-9: Rigid PolyPro Fitting Equivalent Lengths
DuraVent PolyPro
Centrotherm Selkirk
InnoFlue
PolyFlue
2 in. (60 mm) 45° elbow
3 ft. (0.91 m)
3 ft. (0.91 m)
3.3 ft. (1.0 m)
2 in. (60 mm) 90° or 87° 5 ft. (1.5 m) elbow
5 ft. (1.5 m)
4.8 ft. (1.5 m)
3 in. (80 mm) 45° elbow
3 ft (0.91 m)
3 ft. (0.91 m)
3.6 ft. (1.1 m)
3 in. (80 mm) 90° or 87° 7 ft. (2.1 m) elbow
7 ft. (2.1 m)
7.2 ft. (2.2 m)
Table 7-10: Flexible Polypropylene Equivalent Length for 1 ft. (0.30 m) Measured Length
DuraVent PolyPro Flex
Centrotherm InnoFlue Flex
Selkirk Polyflue Flex
2 in.
2 ft.
(60 mm) (0.61 m)
2.5 ft. (0.76 m)
2.5 ft. (0.76 m)
3 in.
2 ft.
(80 mm) (0.61 m)
2.3 ft. (0.70 m)
2.36 ft. (0.70 m)
Model Number
Vent/Air Size in. (mm)
PHTM2120H
PHTM2150H PHTM2180H
2 (60) 3 (80) 2 (60) 3 (80)
Min Equivalent Length ft.
(m)
2.5 (0.76)
2.5 (0.76)
2.5 (0.76)
2.5 (0.76)
Max Equivalent Length ft.
(m)
70 (21.3)
135 (41.1)
70 (21.3)
135 (41.1)
Approx. Derate at Max Length
(%)
7
1
9
5
16
110332-01 – 1/22
7 General Venting (continued)
PHTM II Installation, Operating & Service Instructions
5. Example equivalent length calculation for 2 in. vent:
A. 1 ft. CPVC straight pipe =1 eq ft. B. 90° CPVC short elbow = 6 eq ft. C.
1.5 ft. CPVC straight pipe=1.5 eq ft. D. Coupling = 0 eq ft. E. 10 ft. PVC
straight pipe = 10 eq ft. F. 90° PVC sanitary elbow = 2.6 eq ft. G. 15 ft. PVC
straight pipe = 15 eq ft. H. PVC coupling (terminal) = 0 eq ft. I. Total vent
length = 36.1 eq ft.
(acceptable length per Table 7-7)
6. Listed Air Piping Materials
A. PVC/CPVC B. Polypropylene C. B-vent double wall vent (with joints and
seams sealed with RTV silicone)
7. Listed Vent Materials
A. CPVC/PVC – See Table 7-11 B. Polypropylene – See Table 7-16
CPVC/PVC Venting
! WARNING
Asphyxiation Hazard. · Use only vent materials, primer, and cement listed in
Table 7-11 to make vent connections.
· Use of cellular core PVC (ASTM F891), cellular core CPVC, or Radal®
(polyphenolsulfone) in venting systems is prohibited.
· PVC vent systems must include at least 30 in. (760 mm) of CPVC pipe and one
CPVC elbow between boiler and PVC vent piping.
· CPVC is required within any interior space where air cannot circulate
freely, including a vertical or horizontal chase, inside a stud wall, in a
closet, and through wall penetrations.
· Maintain clearances to vent piping per Figure 5-1.
· Failure to comply with venting instructions could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage.
110332-01 – 1/22
NOTICE: PVC may not be used to penetrate combustible or non-combustible walls
unless all of the following conditions are met. If any of these conditions
cannot be met, use CPVC for wall penetration. See Figure 7-14.
· Wall penetration is at least 66 in. (1.7 m) from boiler measuring along vent
pipe.
· Wall is less than or equal to 12 in. (305 mm) thick.
· Air space shown in Figure 7-14 is maintained around outside diameter of
vent.
1. Slope CPVC/PVC vent pipe not less than 1/4 in. per foot (21 mm per m) upwards from boiler to vent terminal for condensate drainage.
2. Support CPVC/PVC pipe at intervals not exceeding 4 ft. (1.2 m).
3. Be sure to use appropriate primer and cement
when joining CPVC to PVC. The following or
equivalent may be used to join CPVC to PVC:
A.
Primer: IPS P-70
B.
Cement: IPS 790
Table 7-11: Listed CPVC/PVC Vent Materials
Vent Pipe
Vent Fittings
Primer/ Cement
Material CPVC, sched. 40 or 80 PVC, sched. 40 or 80 PVC, DWV CPVC, sched. 80 PVC, sched. 40 PVC, sched.80 PVC, DWV CPVC PVC
Standard ASTM F441 ASTM D1785 ASTM D2665 ASTM F439 ASTM D2466 ASTM D2467 ASTM D2665 ASTM F493 ASTM D2564
NOTICE: In Canada, CPVC and PVC vent pipe, fittings, and cement/primer must be
ULC-S636 listed.
4. Work from boiler towards vent or air termination. Do not exceed maximum
equivalent lengths shown in Table 7-7. See Table 7-8 for equivalent lengths of
elbows and fittings.
5. Starting from the boiler, first 30 in. (760 mm) of vent pipe and first
elbow must be CPVC. 30 in. (760 mm) CPVC pipe may be cut at any location and
CPVC elbow installed between two resulting CPVC pipes before transitioning to
PVC. PVC coupling may be used to join CPVC to PVC vent piping. See Figure
7-12.
17
PHTM II Installation, Operating & Service Instructions
7 General Venting (continued)
6. CPVC/PVC vent starter kits are available. Kits include 30 in. (760 mm)
CPVC pipe, 90° short CPVC elbow, PVC coupling (vent terminal), 90° short PVC
elbow (air terminal), and 2 terminal screens. Components in these kits are not
ULC-S636 listed and are therefore not usable in Canada.
PVC coupling may be used to join CPVC to PVC vent pipe.
At least 30in. (760mm) of CPVC pipe and one CPVC elbow required between boiler
and PVC vent piping.
To vent termination
From air termination
A.
2 in. kit: 107039-01
B.
3 in. kit: 107039-02
7. Allow for 3/8 in. (9.5 mm) of thermal
expansion per 10 ft. (3.0 m) of CPVC/PVC pipe. If
Clamp
a straight run of pipe exceeds 20 ft. (6.0 m) and
is restrained at both ends, an offset or expansion
loop is required per Figure 7-15. If a straight
horizontal run of pipe exceeds 20 ft. (6.0 m) and
is restrained at one end with an elbow at the other,
ensure hanger or guide is not less than Y in from
elbow per Figure 7-15. Thermal expansion fittings
not permitted.
8. All air piping may be PVC.
9. Vent and air can be up-sized to 3 in. for longer runs. If up sizing to 3
in. vent material, maximum length of 2 in. pipe is 12 in. (305 mm) before
transitioning with 2 x 3 CPVC increaser for vent piping and similar PVC
fittings for air. Increaser must be installed in vertical section of pipe. See
Figure 7-13.
Figure 7-12: Near Boiler CPVC/PVC Venting
At least 30in. (760mm) of CPVC pipe and one CPVC elbow required between boiler and PVC vent piping.
PVC coupling may be used to join CPVC to PVC vent piping.
To vent termination
From air termination
10. Cut pipe squarely and 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. Follow primer and cement instructions to join pipe and fittings.
3in. X 2in. CPVC Increaser
Max. 12in. (305mm) 2in. CPVC pipe
3in. X 2in. PVC Increaser
Max. 12in. (305mm) 2in. PVC pipe
13. Clean all pipe ends and fittings with
appropriate primer before cement. Apply
primer to both pipe and fitting socket before
Clamp
applying cement.
14. Boiler vent connector is gasketed. Lubricate gasket with soapy water, insert pipe until it bottoms out, and tighten clamp.
15. Boiler air connector in PVC socket fitting. Drill 7/32 in. (5.5 mm) hole
in air connector. Drill 1/8 in. (3.2 mm) hole in air pipe to align with hole
in connector. Insert pipe into air connector and use #10 x 1 in. sheet metal
screw to secure. Seal joint between air connector and pipe with RTV silicone.
16. To the extent possible, slope horizontal air piping towards outdoors.
Figure 7-13: Near Boiler CPVC/PVC Venting with Increaser
Note: Length of 2 in. pipe is counted toward 30 in. CPVC requirement.
18
110332-01 – 1/22
7 General Venting (continued)
PHTM II Installation, Operating & Service Instructions
Maximum Wall Thickness (“T”)
2″*
6″
12″
(50mm) (150mm) (305mm)
Minimum air space around pipe (“C”)
0″*
1″
1-3/4″
(0mm) (25mm) (45mm)
*Wall must be of non-combustible construction
PVC Vent Pipe
“C”
One end of opening may be closed
Boiler
66″ Min (168cm)
“T” Wall
Figure 7-14: PVC Venting Wall Penetration Clearance
Loop (horizontal only)
(top view)
2Y/5
6″ (150mm) Min
Y/5 Length of straight run between anchors (“X”)
6″ (150mm) Min
Pipe Dia., in. 2
3
X, ft. (m) 20 (6.1) 30 (9.1) 40 (12.2) 50 (15.2) 60 (18.3) 20 (6.1) 30 (9.1) 40 (12.2) 50 (15.2) 60 (18.3)
Y, in. (cm) 41 (104) 50 (127) 58 (147) 65 (165) 71 (180) 50 (127) 61 (155) 70 (178) 79 (201) 86 (218)
Key Anchor (restricts linear movement)
Hanger (allows linear movement)
110332-01 – 1/22
Can use either anchor or hanger
Figure 7-15: CPVC/PVC Venting Expansion Loops 19
7 General Venting (continued)
PHTM II Installation, Operating & Service Instructions
Polypropylene Venting
! WARNING
Asphyxiation Hazard. · Use only vent materials listed in Table 7-16 to make
vent connections. Consult vent manufacturer’s instructions for required
support and special connections.
· Follow vent manufacturer’s instructions supplied with vent system.
· Do not mix vent systems of different types or manufacturers.
· Maintain clearances to vent piping per Figure 5-1.
· Failure to comply with venting instructions could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
! WARNING
Asphyxiation Hazard. All polypropylene vent systems rely on gaskets for
sealing. Ensure gaskets are installed in each female end of vent pipe or
fitting. Failure to make proper joint connections could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
NOTICE: Polypropylene vent connections must be secured by vent manufacturer’s
joint connector.
1. Slope polypropylene vent pipe not less than 5/8 in. per ft. (52 mm per m)
upwards from boiler to vent terminal for condensate drainage.
2. Support polypropylene venting per vent manufacturer’s instructions.
3. Examine all components for possible shipping damage prior to installation.
4. Work from boiler towards vent or air termination. Do not exceed maximum
equivalent lengths shown in Table 7-7. See Table 7-9 for equivalent 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.
Table 7-16: Listed Polypropylene Vent Materials (ULC-S636 Listed)
Manufacturer DuraVent Centrotherm Selkirk
Model Polypropylene Single Wall Rigid PolyPro Flex InnoFlue Single Wall Rigid InnoFlue Flex PolyFlue Single Wall Rigid PolyFlue Single Wall Flex
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 manufacturer’s
instruction being sure to provide for thermal expansion. Clamp sections
together as directed by vent manufacturer.
8. All air piping may be PVC or polypropylene. PVC to polypropylene adapter
required at boiler connection if using polypropylene air piping.
9. Vent and air can be up-sized to 3 in. for longer runs. Requires 2 x 3 in.
polypropylene increaser. Vent increaser must be directly attached to boiler
vent connector and must be installed in vertical section of pipe. If using
polypropylene air piping, increaser must be directly attached to PVC to
polypropylene adapter and must be installed in vertical section of pipe. See
Figure 7-19.
10. If using flexible polypropylene:
A. Maximum length of corrugated flexible venting will be reduced vs. rigid
pipe due to higher pressure drop of flexible venting. See Table 7-10.
B. Store vent material in ambient space 41°F (5°C) or warmer before beginning
installation. Observe vent manufacturer’s instructions for storing and
handling this pipe.
C. Use only in vertical or near vertical installations with bends no greater
than 45°. Maximum two offsets (four bends).
20
110332-01 – 1/22
7 General Venting (continued)
PHTM II Installation, Operating & Service Instructions
Table 7-17: Listed Polypropylene Vent Fittings
Joint Connector Increaser
Length
2 in. (60 mm) 3 in. (80 mm) 2 in. (60 mm) to 3 in. (80 mm)
DuraVent PolyPro 2PPS-LC 3PPS-LC
2PPS-X3L
PVC to PP Adapter 2 in. (60 mm)
2PPS-ADL
Centrotherm InnoFlue
IANS02 IANS03
ISIA0203
ISAGL0202 adapter + IAFC02 clamp
Selkirk PolyFlue
PF-LB PF-LB or 4PF-LB 2PF-2I3 + PF-LB
locking band
N/A
Joint connector required at all joints in venting system
Clamp
Vent Air
PVC to polypropylene adapter required when using polypropylene air piping
Joint connector required at all joints in venting system
2in X 3in (60mm X 80mm) increaser
Clamp
Vent Air
PVC to polypropylene adapter required when using polypropylene air piping
Figure 7-18: Near Boiler Polypropylene Venting
Figure 7-19: Near Boiler Polypropylene Venting with Increaser
110332-01 – 1/22
21
8 Sidewall Direct Venting
PHTM II Installation, Operating & Service Instructions
Determine Terminal Location
! 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. · A gas vent extending through an
exterior wall shall not terminate adjacent to a wall or below building
extensions such as eaves, parapets, balconies, or decks.
1. Do not exceed maximum equivalent vent and air pipe length in Table 7-7.
2. Consider surroundings when selecting terminal location:
A. Locate terminal so flue gas will not damage nearby plants or air
conditioning equipment or be objectionable to building owner.
B. During cold weather, a visible cloud of flue gases will be emitted from
terminal. Avoid areas where this could obstruct window view or be otherwise
objectionable.
C. Flue gas may condense or freeze causing water or ice buildup on objects
surrounding structure. Move or protect these objects if they are subject to
damage from condensate.
D. Avoid possibility of accidental contact of flue gas with people or pets.
E. Avoid locating terminal where wind currents could affect performance or
cause recirculation. Areas to avoid include inside building corners, near
adjacent buildings or surfaces, windows wells, stairwells, alcoves,
courtyards, or other recessed areas.
3. Locate terminals so they are not likely to be damaged by foreign objects
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 required when window and/or air inlet is within 4 ft. (1.2 m)
of inside corner.
D. Do not locate terminal above a public walkway.
E. Minimum 12 in. (305 m) below roof overhang. Close proximity to overhang
and/or a deep overhang requires vent terminal to protrude farther from wall.
F. Minimum 4 ft. (1.2 m) in USA or 6 ft. (1.8 m) in Canada from any electric
meter, gas meter, regulator, or relief equipment. Never terminate above or
below any of these within 4 ft. (1.2 m) horizontally.
G. Vent and air terminals minimum 12 in. (305 mm) above grade or normal snow
line, if applicable.
5. Do not locate vent terminal under decks or similar structures.
6. Avoid locating combustion air terminal in an area with or likely to have
contaminants. See Table 5-2.
NOTICE: Minimize lengths of piping outside building to reduce risk of
condensate freezing in vent pipe causing boiler shutdown.
Prepare Wall Penetrations
1. Use base plate (if applicable) to determine air and vent pipe hole
centerline locations.
2. Cut hole for air pipe as close as desired to pipe outside diameter.
3. Cut hole for vent pipe at least 1 in. (25 mm) larger than pipe outside
diameter following required clearance per Figure 5-1.
4. Ensure vent wall penetration and methods of securing and sealing around
terminal allow for thermal expansion.
22
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
8 Sidewall Direct Venting (continued)
Figure 8-1: Vent Terminal Clearances (Air Terminal not Shown for Clarity)
110332-01 – 1/22
23
PHTM II Installation, Operating & Service Instructions
8 Sidewall Direct Venting (continued)
CPVC/PVC or Polypropylene Fittings Terminal
! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage.
! WARNING
Asphyxiation Hazard. All propylene vent systems rely on gaskets for sealing.
Ensure gaskets are installed in each female end of vent pipe or fitting.
Failure to make proper joint connections could cause products of combustion
and/or carbon monoxide to enter building, resulting in severe personal injury,
death or substantial property damage.
Table 8-3: Polypropylene Sidewall Terminal Fittings
DuraVent PolyPro
Centrotherm InnoFlue
Selkirk PolyFlue
UV resistant single wall pipe + two 2PPSE90BC elbows + 2PPS-BG screen
UV stabilized end pipe + two ISELL0287UV elbows + IASPP02 screen
UV resistant pipe + two 2PF90UV elbows + 2PF-HVST screen
Note: 2 in. (60 mm) components shown. Replace “2”
with “3” for 3 in. (80 mm) component part numbers.
From boiler vent connection
PVC coupling or polypropylene end pipe
To boiler air connection
7′ (2.1m) Max.
12″ (305mm) Min. 12″ (305mm) Min.
1. Vent terminates outside building in elbow, coupling, or end pipe pointing
outward away from wall and air terminal. Air terminates outside building in
downward-facing elbow. Air terminal may be to left or right of vent terminal.
See Figures 8-2 and 8-4.
2. Screens on vent and air intake terminals are generally recommended. Use
1/2 in. (12 mm) mesh stainless steel for CPVC/PVC or listed screens for
polypropylene.
3. Vent terminal minimum 12 in. (305 mm) above air terminal.
4. Required CPVC/PVC vent pipe and fittings listed in Table 7-11.
Polypropylene listed in Tables 7-16 and 7-17.
To boiler vent connection
To boiler air connection
12″ (305mm) Min. 7′ (2.1m) Max.
Grade or Snow line
Figure 8-4: Alternate Fittings Terminal
5. Assembly
A. Use appropriately sized wall thimble or a sheet metal plate on building exterior to maintain proper clearance and provide weather tight seal.
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.
From boiler vent connection
To boiler air connection
Elbow
Screen
12″ (305mm) Min.
Grade or snow line
Figure 8-2: Fittings Terminal 24
Elbow
Screen Wall Thimble
Figure 8-5: CPVC/PVC Fittings Terminal Assembly 110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
8 Sidewall Direct Venting (continued)
From boiler vent connection
To boiler air connection
Wall Thimble
DuraVent & Selkirk: Remove gasket to install screen
Elbow
Table 8-7: CPVC/PVC Low Profile Terminal Kits
Length
Ipex
Diversitech
2 in. (60 mm)
397984
HVENT-2
3 in. (80 mm)
397985
HVENT-3
Elbow
Joint Connector
Screen
3. Follow terminal manufacturer’s instructions for assembly.
NOTICE: Ensure outer terminal orientation per Figure 8-8.
! WARNING
Asphyxiation Hazard. Ensure outer terminal cover is installed before operating
boiler. Operation without outer cover installed could cause product damage or
improper operation resulting in severe personal injury, death or substantial
property damage.
Figure 8-6: Polypropylene Fittings Terminal Assembly
CPVC/PVC Low Profile TPeorsmsibilenOarlientations ! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage.
1. Low profile terminals listed in Table 8-7 may be used to terminate air and
vent outside building per Figure 8-8. Both air and vent pipes must attach to
terminal kit.
2. Required vent pipe and fittings listed in Table 7-11.
From boiler vent connection
To boiler air connection
12″ (305mm) Min.
Grade or Snow line
Possible Orientations
To boile air connec
Gra Sno
Figure 8-8: Low Profile Terminal
110332-01 – 1/22
25
PHTM II
8 Sidewall Direct Venting (continued)
CPVC/PVC Concentric Terminal
! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage.
1. Concentric vent terminals listed in Table 8-9 may be used to terminate air
and vent outside building per Figure 8-10. Both air and vent pipes must attach
to terminal kit.
! WARNING
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 in. (60 mm) PVC
397005
CVENT-2
2 in. (60 mm) CPVC 197040
N/A
3 in. (80 mm) PVC
397006
CVENT-3
3 in. (80 mm) CPVC 197009
N/A
Note: Additional Ipex concentric terminal kits with different lengths may also be used.
Elbow (field supplied) Combustion
air
Clamp or Strap (field supplied) Outer Pipe Inner Pipe
Installation, Operating & Service Instructions
3. Follow terminal manufacturer’s instructions and Figure 8-11 for assembly.
4. If needed, terminal can be shortened. Follow terminal manufacturer’s
instructions and Figure 8-12.
! WARNING
Asphyxiation Hazard.
Ensure rain cap is installed before operating boiler. Operation without rain
cap installed could cause product damage or improper operation resulting in
severe personal injury, death or substantial property damage.
If using stainless steel screw to attach rain cap, always drill clearance hole
in rain cap and pilot hole in vent pipe appropriate for screw size to avoid
cracking PVC components. Failure to comply may cause product damage or
improper operation, resulting in severe personal injury, death, or substantial
property damage.
From boiler To boiler vent connection air connection
IPEX or Diversitech Concentric Terminal
1″ (25mm) Min. 2″ (50mm) Max.
Grade/ Snow line
12″ (305mm) Min.
Figure 8-10: CPVC/PVC Concentric Terminal
Combustion air
Rain Cap
Vent
Vent
Wye Fitting
Sidewall
Location of optional screen 12″ (305mm) Min above grade/snow line
1″ (25mm) Min 2″ (50mm) Max
Figure 8-11: CPVC/PVC Concentric Terminal Installation
26
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
8 Sidewall Direct Venting (continued)
*Overall length of inner pipe to be ‘A’ longer than overall length of outer pipe.
Concentric Wye Fitting
Kit Size
*’A’
‘B’
‘C’
7-3/8″ (187mm) 1-3/4″ (44mm)
2″
3-1/2″ (89mm)
12-3/16″ (310mm) 3/4″ (19mm)
8-3/4″ (222mm) 2-1/4″ (57mm)
3″
4-1/2″ (114mm)
12-3/16″ (310mm) 1″ (25mm)
Manufacturer IPEX
DIVERSITECH IPEX
DIVERSITECH
12″ (305mm)
Min
‘C’
‘B’
To install stainless steel screw and nut locate drill location dimple on
outside of rain cap and drill a 3/16″ (4.8mm) hole through cap and inner pipe
wall ensuring path of hole is perpendicular to inner pipe. Do not overtighten
screw.
*Inner Vent Pipe
Outer Air Intake Pipe
Rain Cap
Notes: 1. All cuts must be square and deburred. 2. Lengthening of terminal is
not permitted.
Figure 8-12: CPVC/PVC Concentric Terminal Dimensions
Polypropylene Concentric Terminal
! WARNING
Asphyxiation Hazard. All polypropylene vent systems rely on gaskets for
sealing. Ensure gaskets are installed in each female end of vent pipe or
fitting. Failure to make proper joint connections could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
1. Concentric terminals listed in Table 8-13 may be used to terminate air and
vent outside building per Figure 8-14. Both air and vent pipes must attach to
terminal kit.
Table 8-13: Polypropylene Concentric Sidewall Terminal Components
2. Required vent pipe and fittings listed on Tables 7-16 and 7-17.
3. One polypropylene to PVC adapter required. Install at terminal air pipe
connection if using PVC air pipe. Install at boiler air connection if using
polypropylene air pipe.
4. Follow terminal manufacturer instructions for assembly.
From boiler vent connection
To boiler air connection
Polypropylene Concentric Sidewall Terminal (DuraVent shown)
Length
2 in. (60 mm)
3 in. (80 mm)
DuraVent PolyPro 2PPS-HKC
3PPS-HKC
Centrotherm InnoFlue
ICWT242 terminal + ICTCR24 two-pipe
adapter
ICWT352 terminal + ICCT3503 two-pipe
adapter
110332-01 – 1/22
Selkirk PolyFlue
2PF-HCT terminal + 2PF-CTA twopipe adapter
3PF-HCT terminal + 3PF-CTA twopipe adapter
12″ (305mm) Min.
Grade/ Snow line
Figure 8-14: Polypropylene Concentric Terminal 27
9 Vertical Direct Venting
PHTM II Installation, Operating & Service Instructions
Determine Terminal Location
! 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 least 2 ft. (610 mm) above any part of the building
within 10 ft. (3.1 m) horizontally.
3. Avoid locating combustion air terminal in an area with or likely to have
contaminants. See Table 5-2.
NOTICE: Minimize lengths of piping outside building to reduce risk of
condensate freezing in vent pipe causing boiler shutdown.
Prepare Roof Penetrations
1. Cut hole for air pipe as close as desired to pipe outside diameter.
2. Cut hole for vent pipe at least 1 in. (25 mm) larger than pipe outside
diameter following required clearance per Figure 5-1.
3. Ensure vent roof penetration and methods of securing and sealing around
terminal allows for thermal expansion.
4. Use roof flashing and storm collars to ensure a weather tight seal and
prevent moisture from entering building.
5. Follow all local codes for isolation of vent pipe and fire stops when
passing through floors, ceilings, and roofs.
CPVC/PVC or Polypropylene Fittings Terminal
! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage..
! WARNING
Asphyxiation Hazard. All polypropylene vent systems rely on gaskets for
sealing. Ensure gaskets are installed in each female end of vent pipe or
fitting. Failure to make proper joint connections could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
1. Vent terminates outside building in coupling or end pipe pointing upward.
Air terminates outside building in downward-facing elbow. Use two 90° elbows
or 180° bend for air terminal. Air terminal may be to left, right, or below
vent terminal as long as clearances in Figure 9-1 are maintained.
2. Screens on vent and air intake terminals are generally recommended. Use
1/2 in. (12 mm) mesh stainless steel for CPVC/PVC or listed screens for
polypropylene.
3. Vent terminal minimum 12 in. (305 mm) above air terminal.
4. Required CPVC/PVC vent pipe and fittings listed in Table 7-11.
Polypropylene listed in Tables 7-16 and 7-17.
5. Alternate terminal arrangement with vertical vent and sidewall air intake
is permitted. See Figure 9-5.
24″ (610mm) Min.
10′ (3.1m) 0″
Min.
12″ (305mm) Min. 12″ (305mm) Min.
Roof or Snow line
From boiler vent connection
To boiler air connection
Figure 9-1: Fittings Terminal
28
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
9 Vertical Direct Venting (continued)
Table 9-2: Polypropylene Vertical Terminal Fittings
DuraVent PolyPro
Centrotherm InnoFlue
Selkirk PolyFlue
UV resistant single wall pipe + 2PPS-BG screen
UV stabilized UV resistant
end pipe +
pipe + 2PF-
IASPP02 screen HVST screen
Note: 2 in. (60 mm) components shown. Replace “2” with “3” for 3 in. (80 mm) part numbers.
DuraVent & Selkirk: Remove gasket to install screen
Screen
Elbow
Joint Connector
Coupling Screen
Elbow Screen
Roof Flashing
From boiler vent connection
To boiler air connection
Figure 9-3: CPVC/PVC Fittings Terminal Assembly
6. Assembly
A. Use appropriately sized roof flashing to maintain proper clearance and
provide weather-tight seal.
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.
7. Brace exterior vertical runs of piping as required.
Roof Flashing
From boiler vent connection
To boiler air connection
Figure 9-4: Polypropylene Fittings Terminal Assembly
10′ (3.1m) 24″ (610mm) Min
PVC Coupling or Polypropylene end pipe with screen
Fire Stop listed for use with vent system
Normal snow line on roof
Vent Pipe
Boiler
Air Intake Pipe
Elbow with screen
12″ (305mm) Min
Grade/Snow Line
110332-01 – 1/22
Figure 9-5: Alternate Vertical Vent/Sidewall Air Terminal
29
PHTM II
9 Vertical Direct Venting (continued)
CPVC/PVC Concentric Terminal
! WARNING
Asphyxiation Hazard. All CPVC/PVC vent joints must be glued. Failure to comply
could cause products of combustion and/or carbon monoxide to enter the
building, resulting in severe personal injury, death or substantial property
damage.
1. Concentric vent terminals listed in Table 8-9 may be used to terminate air
and vent outside building per Figure 9-6. Both air and vent pipes must attach
to terminal kit.
2. Required vent pipe and fittings listed in Table 7-11.
3. Follow terminal manufacturer’s instructions and Figure 9-7 for assembly.
Installation, Operating & Service Instructions
! WARNING
Asphyxiation Hazard. If using stainless steel screw to attach rain cap, always
drill clearance hole in rain cap and pilot hole in vent pipe appropriate for
screw size to avoid cracking PVC components. Failure to comply may cause
product damage or improper operation, resulting in substantial property
damage, or death.
Vent
Location of optional screen
Combustion air Roof Line
Rain Cap
Outer Pipe Inner Pipe Storm collar and Roof Flashing or equivalent (field
supplied)
12″ (305mm) Min. (USA) 18″ (460mm) Min. (Canada) 24″ (610mm) Max.
Roof or snow line
From boiler vent connection
To boiler air connection
Figure 9-6: CPVC/PVC Concentric Terminal
4. If needed, terminal can be shortened. Follow terminal manufacturer’s instructions and Figure 8-12.
! WARNING
Asphyxiation Hazard. Ensure rain cap is installed before operating boiler.
Operation without rain cap installed could cause product damage or improper
operation, resulting in severe personal injury, death or substantial property
damage.
Clamp or Strap (field supplied)
Wye Fitting
Elbow (field supplied)
Vent
Combustion air
Figure 9-7: CPVC/PVC Concentric Vertical Installation
! WARNING
Do not install U-bend or any other fittings on terminal rain cap. Failure to
comply could cause product damage or improper operation, resulting in severe
personal injury, death or substantial property damage.
Figure 9-8: Do Not Install U-bend or any other
Fittings on Terminal Rain Cap
30
110332-01 – 1/22
PHTM II
9 Vertical Direct Venting (continued)
Polypropylene Concentric Terminal
! WARNING
Asphyxiation Hazard. All polypropylene vent systems rely on gaskets for
sealing. Ensure gaskets are installed in each female end of vent pipe or
fitting. Failure to make proper joint connections could cause products of
combustion and/or carbon monoxide to enter the building, resulting in severe
personal injury, death or substantial property damage.
Installation, Operating & Service Instructions
Abandoned B-vent Chase
! WARNING
Asphyxiation Hazard. · Only abandoned (unused) B-vent may be used as a chase.
Failure to comply may cause product damage or improper operation resulting in
severe personal injury, death or substantial property damage. · Do not use
flexible polypropylene outside of B-vent chimney. Failure to comply may cause
product damage or improper operation resulting in severe personal injury,
death or substantial property damage.
1. Concentric terminals listed in Table 9-9 may be used to terminate air and
vent outside building per Figure 9-10. Both air and vent pipes must attach to
terminal kit.
2. Required vent pipe and fittings listed in Tables 7-16 and 7-17.
3. One polypropylene to PVC adapter required. Install at terminal air pipe
connection if using PVC air pipe. Install at boiler air connection if using
polypropylene air pipe.
4. Follow terminal manufacturer instructions for assembly.
Table 9-9: Polypropylene Concentric Vertical
Terminal Components
Length
DuraVent PolyPro
Centrotherm InnoFlue
Selkirk PolyFlue
2 in. (60 mm)
2PPS-VKC (black) or 2PPS-VK-TCC (terracotta)
ICRT2439 terminal + ICTCR24 twopipe adapter
2PF-VCT terminal + 2PF-CTA twopipe adapter
3 in. (80 mm)
3PPS-VKC (black) or 3PPS-VK-TCC (terracotta)
ICRT3539 terminal + ICCT3503 twopipe adapter
3PF-VCT terminal + 3PF-CTA twopipe adapter
Polypropylene Concentric Vertical Terminal (DuraVent shown)
12″ (305mm) Min.
Roof or Snow line
From boiler vent connection
To boiler air connection
Figure 9-10: Polypropylene Concentric Terminal
110332-01 – 1/22
1. Abandoned B-vent may be used as an air chase with flexible polypropylene
vent pipe only if all of the following conditions are met:
A. B-vent must be clean and in good condition.
B. B-vent inside diameter 6 in. (150 mm) or larger.
C. All B-vent joints and seams must be sealed with RTV silicone.
Use DuraVent or Centrotherm concentric terminal and flexible polypropylene
listed in Table 9-11 to terminate air and vent outside building per Figure
9-12 and 9-13.
NOTICE: Selkirk components may only be used with a sidewall air termination.
2. If any of above conditions is not met, terminate air piping through
sidewall using PVC or polypropylene fittings per Figure 9-14.
3. Required vent pipe and fittings listed in Tables 7-16 and 7-17.
4. Do not count concentric termination when calculating equivalent length.
5. Follow terminal manufacturer instructions for assembly.
6. Air connection for B-vent air chase:
A. Install tee same size as B-vent on base of B-vent with cap in side of tee.
Connect PVC air pipe to side of tee using a PVC socket x male thread adapter.
Cut clearance hole in cap, insert PVC adapter, and install electrical conduit
locknut to secure. Seal all joints with RTV silicone.
B. DuraVent: Install PolyPro lower B-vent adapter in base of tee.
C. Centrotherm: Install cap in base of tee. Route smooth section of InnoFlue
flex through cap in base of tee. Use wall plate and RTV silicone to seal this
penetration.
31
PHTM II
9 Vertical Direct Venting (continued)
Table 9-11: Polypropylene B-vent Chase Components
DuraVent PolyPro
2PPS-VFTC flex termination cap + 2PPSBV* adapter + 2PPS-FLEX** flex length
Centrotherm InnoFlue
Selkirk PolyFlue
IFBK02** B-vent kit + IAWP02BP wall plate
2PF-10UV or 2PF-39UV rigid pipe + 2PFHVST screen + 2PF-FLEX flex length + 2PFBVSC storm collar
- Size of B-vent (in.), e.g. 2PPS-BV6 for 6 in. B-vent ** 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.
Installation, Operating & Service Instructions
10′ (3.1m)
Centrotherm Innoflue IFBK02 or IFBK03 B-Vent Kit
24″ (610mm) Min 12″ (305mm) Min
B-Vent Flashing
Normal snow line on roof
PPs Flex
Fire Stop listed for use with B-Vent
B-Vent
Centrotherm Innoflue Vent Pipe
B-Vent tee with cap and PVC thread adapter (See Text)
Base PVC Air Intake Pipe
IACGE02 or IACGE03 Gasket in B-Vent Cap
Support Bracket
Boiler
10′ (3.1m)
24″ (610mm)
Min
12″ (305mm)
Min
PPs Flex
Fire Stop listed for use with B-Vent
Duravent Polypro Vent Pipe
Duravent Polypro 2PPS-VFTC or 3PPS-VFTC Vertical Flex Termination Cap
B-Vent Flashing Normal snow line on roof
B-Vent
B-Vent tee with cap and PVC thread adapter (See Text)
Flex Male Adapter
Air Intake Pipe
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 9-12: DuraVent Polypropylene B-vent Air Chase System
Figure 9-13: Centrotherm Polypropylene B-vent Air Chase System
10′ (3.1m)
24″ (610mm) Min 12″ (305mm) Min
PPs Flex Fire Stop listed for
use with B-Vent
Duravent Polypro 2PPS-VFTC or 3PPS-VFTC Vertical Flex Termination Cap
B-Vent Flashing Normal snow line on roof
B-Vent
Duravent Polypro Vent Pipe
Air Intake Pipe
Note: Duravent Polypro Flex components shown.
Outside Wall
Elbow with Screen
12″ (305mm) Min
Boiler
Grade/Snow Line
Figure 9-14: Polypropylene B-vent Chase with Sidewall Air Terminal
32
110332-01 – 1/22
PHTM II
9 Vertical Direct Venting (continued)
Abandoned Chimney Chase
! WARNING
Asphyxiation Hazard. Only abandoned (unused) masonry chimney may be used as a
chase. If chimney contains multiple flues, all flues must be abandoned.
Failure to comply could cause product damage or improper operation resulting
in severe personal injury, death or substantial property damage.
! WARNING
Asphyxiation Hazard. Do not use flexible polypropylene outside of masonry
chimney. Failure to comply could cause product damage or improper operation
resulting in severe personal injury, death or substantial property damage.
Installation, Operating & Service Instructions
Vent
Note: Duravent Polypro Flex components shown.
Clean, tight unused chimney
Base support and elbow for PPs flex pipe
Exterior Wall Plate
PPs Flex
Duravent Polypro Vent Pipe Air Intake Pipe
Boiler
Outside Wall Elbow with screen 12″ (305mm) Min
Grade/Snow Line
Figure 9-16: Masonry Chimney Chase System
1. Abandoned chimney may be used as a chase with flexible polypropylene vent pipe only if all of the following conditions are met:
A. Chimney is structurally sound and in good condition.
B. No other appliances or fireplaces are vented into chimney or adjacent flues.
Use concentric terminal and flexible polypropylene listed in Table 9-15 to terminate vent outside building. Terminate air through sidewall using PVC or polypropylene fittings. See Figure 9-16.
2. Follow vent system manufacturer’s instructions for assembly.
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.
WITH CROWN 45° MAX
BOILER
CHIMNEY AND FOUNDATION ARE STRUCTURALLY SOUND
Figure 9-17: Masonry Chimney Chase Requirements
BOILER
110332-01 – 1/22
Figure 9-18: Masonry Chimney Chase and Any Adjacent Flues must be Abandoned 33
10 Heating System Piping
PHTM II Installation, Operating & Service Instructions
General System Piping Precautions
! WARNING
Asphyxiation Hazard.
· Failure to properly pipe boiler could cause improper operation and damage to
boiler or building resulting in severe personal injury, death or substantial
property damage.
· Protect gas ignition system components from water (dripping, spraying, rain,
etc.) during boiler operation and service (circulator replacement, condensate
trap cleaning, control replacement etc).
· Oxygen contamination of boiler water will cause corrosion of iron and steel
boiler components and could lead to premature boiler failure. Warranty does
not cover problems caused by oxygen contamination of boiler water or scale
(lime) build-up caused by frequent addition of water.
· Maintain clearances to system piping per Figure 5-1.
! CAUTION
Toxic Material. The heat transfer medium must be water or other nontoxic fluid
having a toxicity rating or Class of 1, as listed in Clinical Toxicology of
Commercial Products, 5th edition.
B. Pipe outlet of safety relief valve to location where water or steam will
not create a hazard or cause property damage if valve opens. (The end of
discharge pipe must terminate in unthreaded pipe.)
C. If safety relief valve discharge is not piped to drain, it must terminate
within 6 in. (150 mm) of floor.
D. Do not route discharge piping through an area that is prone to freezing
temperature.
E. Termination of safety relief valve must be in an area where it is not
likely to become plugged by debris.
F. If replaced, replacement must have a setting less than or equal to maximum
allowable working pressure (MAWP) shown on ASME data plate located on left
side of heat exchanger (50 psig [345 kPa]).
! 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.
Standard Piping Components
1. Safety relief valve (required).
A. Shipped loose in parts carton (30 psig [207 kPa]).
Table 10-1: Head Loss at Selected Flow Rates
Boiler Supply Boiler Model Conncection
inch, FPT
Boiler Return Connection inch, FPT
T = 35°F
Minimum Required
Flow (GPM)
Boiler Head Loss, (Ft.)
PHTM2180H
1
1
6.4
11.2
PHTM2150H
1
1
8.1
8.2
PHTM2180H
1
1
9.7
11.6
2. Pump (required) Boiler loop pump is supplied with this boiler and sized for near boiler piping equivalent length of 50 ft. See Table 10-1 for flow range through boiler. At least one additional pump is required on system side.
T = 30°F
T = 25°F
T = 20°F
Minimum Required
Flow (GPM)
Boiler Head Loss, (Ft.)
Minimum Required Flow (GPM)
Boiler Head Loss, (Ft.)
Minimum Required
Flow (GPM)
Boiler Head Loss, (Ft.)
7.5
14.6
9.0
20.0
11.2
29.7
9.4
10.9
11.3
15.3
14.1
23.4
11.3
15.5
13.5
21.8
16.9
33.5
Notes: 1. Required Flow (GPM) = Output (MBH) x 1000/(500 x T) Output (MBH) – select value for specific boiler model from Table 3-1. Using boiler antifreeze will result in higher pressure drop and may require larger circulators. 2. Boiler head loss includes 50 eq. ft. near boiler piping. [Approximately 20 ft. straight pipe, (4) 90° elbows and (2) full port ball valves]
34
110332-01 – 1/22
PHTM II
10 Heating System Piping (continued)
Installation, Operating & Service Instructions
Pressure Drop vs. Flow
30
120
25
150/180
20
Pressure Drop (Feet of Head)
15
10
5
0
0
2
4
6
8
10
12
14
16
Flow Rate (GPM)
Figure 10-2: System Curve w/ 50 equivalent ft. of piping
4. Fill valve (required) A. Either a manual or automatic fill valve may be
used, but a manual valve is preferred because it eliminates unmonitored
additions of make-up water to the system. B. Ideal location for fill valve is
at expansion tank. C. If using antifreeze with automatic fill valve, it is
recommended to install a water meter to monitor make-up water. Antifreeze
concentration will decrease as make-up water is added. If using antifreeze,
local codes often require a backflow preventer or disconnect from city water.
110332-01 – 1/22
3. Expansion tank (required)
A. If this boiler is replacing an existing boiler with no other changes in
system, old expansion tank can generally be reused.
B. If expansion tank must be replaced, consult expansion tank manufacturer’s
literature for proper sizing.
C. If using antifreeze, account for additional expansion of glycol solution
when sizing an expansion tank. In a typical residential heating system, a
glycol mixture has an expansion rate of 1.2 times that of water alone,
therefore a tank for an anti-freeze system should be at least 1.2 times
greater in size. Antifreeze should be stainless steel compatible.
35
PHTM II Installation, Operating & Service Instructions
10 Heating System Piping (continued)
5. Automatic air vent (required)
Manual air vents are required to remove air during initial fill.
6. Manual reset high limit (required by some codes i.e. ASME CSD-1)
A. Install high limit in boiler supply piping just above boiler with no
intervening valves.
B. Set manual reset high limit to 200°F. Wire limit to “external limit”
terminal on low voltage connection board per Section 12 Field Wiring.
7. Isolation valves are useful when boiler must be drained, as they will
eliminate having to drain and refill entire system.
8. Dirt and magnetic filter (strongly recommended)
A. Install a dirt/magnetic filter to prevent any system debris from entering
boiler and fouling of water passages.
B. Note that some filters have a significant pressure drop, which may impact
ability of system pump to obtain required flow.
9. Drain valve (required)
Install drain valve as shown in Figures 10-3 and 10-4.
10. Low water cut-off (LWCO) (may be required by local jurisdiction)
A. Protection of this boiler against low water and/ or inadequate flow is
provided by UL353 listed flow switch built into boiler.
B. This is a water tube boiler and this flow switch 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 to Section 12 Field Wiring and LWCO manufacturer’s instructions
for proper wiring.
· Auto reset 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 is used, be certain that it is located at a point in
piping from which air can escape to an automatic air vent.
G. Generally, this means there should be no down-turns in piping between LWCO
and point where automatic air vent is installed.
H. Failure to do this may result in nuisance boiler shut-downs due to small
amounts of air trapped around probe.
11. Primary-secondary piping is required for this boiler.
· Webstone primary/secondary manifold kit: 111577-01
36
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
10 Heating System Piping (continued)
4
3
2
1
REVISIONS
REV.
EN
DATE
DESCRIPTION
110332-01 – 1/22
A. At least eight pipe diameters upstream of first tee. B. No further apart than 12″ (305mm) (or four pipe diameters), whichever is smaller.
From System
To System
Hydraulic Separator may be substituted for tees
A
Dirt & Magnetic Filter (highly recommended)
B
Flow Check
Valves
Optional Full Port Isolation Valves
Heating Circulators
Close Nipple (locate Header Sensor as close as possible to downstream tee)
Air Separator
Expansion Tank
B
Header Temperature Sensor (when used)
Optional Full Port Isolation Valves
To System
Fill Valve
Backflow Preventer
Cold Water Line
System Zone Valves
Heating System Circulator A
Drain Valve Circulator
Tee & Plug (Recommended for future Heat Exchanger service)
Unions
Full Port Isolation Valves
Optional Zone Valve Controlled System
4
NOTICE: Installer is responsible for piping configurations to provide proper flow rates and
meet local codes.
NOTICE: Primary-secondary piping is reqUNuLiErSeS dOT.HERWISE NOTED: THIRD ANGLE MATERIAL:
! CAUTION ALL DIMENSIONS IN INCHES. PROJECTION
TOLERANCES:
ITEM NUMBER:
Burn Hazard. Property Damage.
X.X ±.1 X.XXX ±.005 X.XX ±.03 ANGLE ±1°
FIRST USE:
Under some conditions this boiler can deliver wPRaOtPeERrTYtoOFheating systTeITLAmEL:TAthat is significantly
higher than boiler setpoint. Where suUc.hS.oBveorihleeraCt coomulpdacnauys, eInpce.rsonal injury or property
damage (e.g. temperatures
low temperature using tempering
radiant floor zoLnAeNCsA),STpERr,oPAtect system THIS DOCUMENT CONTAINS
CONFIDENTIAL INFORMATION
valves or other means. AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER
COMPANY, INC. ANY REPRODUCTION IN PART OR AS A WHOLE WITHOUT THE WRITTEN
PERMISSION OF U.S. BOILER
from
ePxNRcIeEMAsAsRiRvBYeO-SILEECROPNIPDINAGRY HEAT ONLY
COMPANY, INC. IS STRICTLY PROHIBITED.
Fig3ure 10-3: Heating System Piping
2
DES: EJ CHK: APVD: DATE:
09/0 DRAWI
1
37
PHTM II Installation, Operating & Service Instructions
10 Heating System Piping (continued)
38
4
3
A. At least eight pipe diameters upstream of first tee. B. No further apart than 12″ (305mm) (or four pipe diameters), whichever is smaller.
Dirt & Magnetic Filter (highly recommended)
2
From System
REV.
EN
Flow Check Valves
To System
Hydraulic Separator may be substituted
A
for tees
Close Nipple
(locate Header Sensor
as close as possible
B
to downstream tee)
DATE
1 REVISIONS
DESCRIPTION
DWN CHK APVD
Optional Full Port
B
Isolation Valves
Air Separator
Header Temperature Sensor
B
Expansion Tank
(when used)
Heating Circulators
Optional Full Port Isolation Valves
Fill Valve
Cold Water Line
Backflow Preventer
Drain Valve
Circulator
Full Port Isolation
Valve
Indirect Circulator
Flow Check Valve
Tee & Plug (Recommended for future Heat Exchanger service)
Unions
Full Port Isolation Valves
To System
Indiect Domestic Water Heater (IWH)
System
Zone Valves
A
Heating System
Circulator
NOTICE: Installer is responsible for piping configurations to
provide proper flow rates and meet local codes.
A
NOTICE: Primary-secondary piping is required.
Indirect
! CAUTION
Optional Zone Valve Controlled System
4
Supply
UNLESS OTHERWISE NOTEDB: uTrHnIRDHANaGzLEardMA.TEPRIArLo: perty Damage.
DES: EJL
SCALE: 1:15
ALL
Under some conditions DIMENSIONS IN INCHES. PROJECTION
TOLERANCES:
ITEM NUMBER:
this
boiler
can
deliveCrHKw: ater
to
SIZE: B
Indirect Return
X.X ±.1 X.XX ±.03
X.XXX ±.005 ANGLE ±1°
PROPERTY
hsOeeF taptoiningt.sWyshtTFeIIeTRLASmErTL:eTUAStEsh: uact hisosvigernhifeicaat nctolyulhdigchaeurstehaADpPAneVTEDr:b:sooinlearl
SHEET: 1 OF 1 REVISION:
U.S.
Boiler Cominpjaunryy,oIrnpcr.operty LANCASTER, PA
dNaEmAaRgBeOI(LeE.RgP.IPloINwGtemperatu0r9e/13r/2a0d21iant
A
floor zones), protect system from excessive temperatures THIS DOCUMENT
CONTAINS CONFIDENTIAL INFORMATION
AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER
PRIMARY-SECONDARY
DRAWING NUMBER:
using tempering valves or other means. COMPANY, INC. ANY REPRODUCTION IN PART
OR AS A
WHOLE WITHOUT THE WRITTEN PERMISSION OF U.S. BOILER
W/ INDIRECT WATER HEATER
TS-103-66
COMPANY, INC. IS STRICTLY PROHIBITED.
Figure 10-4:3Heating System Piping with Indirect Wat2er Heater
1
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
10 Heating System Piping (continued)
110332-01 – 1/22
4
3
A. At least eight pipe diameters upstream of first tee B. In lieu of Webstone
Kit, primary/secondary manifold can be fabricated out of
copper piping.
To System
2
REV.
EN
DATE
1 REVISIONS
DESCRIPTION
From System
B
Flow Check Valves
Optional Full Port Isolation Valves
Heating Circulators
Optional Full Port Isolation Valves
Circulator
Union Close Nipple (locate Header Sensor as close as possible to downstream
tee)
Air Separator
A
Union
Primary/Secondary Manifold Kit B
Header Temperature Sensor (when used)
Fill Valve
Dirt & Magnetic Filter (highly recommended)
Cold Water Line Backflow Preventer
To System
Expansion Tank
NOTICE: Installer is responsible for piping configurations to
provide proper flow rates and meet local codes.
System
A
Zone
Valves
NOTICE: Primary-secondary piping is required.
! CAUTION
Burn Hazard. Property Damage.
Heating System Circulator
Under some conditions this boiler can deliver water to
UNLEhSeS OaTtHinERgWIsSEyNsOtTeEmD: thTHaIRtDisANsGigLEnifMicAaTEnRItAlyL: higher than boiler
ALL XDsin.IXMeTj±uOEt.pN1LrSEyoIROXAi.onNXNXSrtCX.INpE±WS.Ir:0No0Ch5pHeEerSer. tysPudRcOaJhmECoaTIvOgeNerh(eeITEa.Mgt .NcUlooMuwBEldRt:ecmapueseraptuerresorandailant
X.fXloX ±o.0r3zAoNnGeLsE ±)1,°protect systemFIfRrASoTLTmUASE:excessive temperatures
U.uSs. iBnogilteePrmRCOpPeoERrmTiYnOgpFavanlyv,esInocr. oTtIhTLeE:r means.
LANCASTER, PA
NEAR BOILER PIPING
DES: EJL CHK: APVD: DATE:
01/0
39
Optional Zone Valve Controlled System
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION
Figure
10-5:
Heating
System
Piping
with
Primary/Secondary Manifold AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER COMPANY, INC. ANY REPRODUCTION IN PART OR AS A
WHOLE WITHOUT THE WRITTEN PERMISSION OF U.S. BOILER
COMPANY, INC. IS STRICTLY PROHIBITED.
PRIMARY-SECONDARY W/HEADER, HEAT ONLY
DRAWIN
4
3
2
1
PHTM II Installation, Operating & Service Instructions
10 Heating System Piping (continued)
Boiler Supply Connection (1″ NPT)
B
B
Safety Relief Valve*
3
(3/4″ NPT)
4
T/P Gauge* (1/4″ NPT)
Boiler Return Connection (1″ NPT) 1 2
Boiler Pump*
3
5
18″
6
(Req’d Clearance)
- Supplied with boiler 7
Figure 10-6: Webstone Primary-Secondary Manifold Kit Recommended Installation
A
A
Table 10-7: Recommended Piping Configuration
Item No.
Item Description
Qty.
1 1″ NPT Copper Adapter
1
UNLESS OTHERWISE NOTED: ALL DIMENSIONS IN INCHES.
TPHRIORDJ2EACNTIGOLNE1″
MATERIAL:
NPT x 5″ Lg.
Copper
Tube*
1
TOLERANCES: X.X ±.1 X.XXX ±.005
3
1″ xIT3EM-3N/8U”MLBgE.RC: opper Tube*
2
X.XX ±.03 ANGLE ±1°
4
1″ xFI9RAS0TLºTUACSEo:pper Elbow
2
PROPERTY OF
5
1″ xTI4TL”EL: g. Copper Tube*
1
U.S.
Boiler Company6, LANCASTER, PA
IncW. ebstone
AdapLOterWH-LHOCES-S94HEADER
1
RECOMMENDED INSTALLATION 7 Webstone Manifold H-58754-54
1
THIS DOCUMENT CONTAINS CONFIDENTIAL INFORMATION
8 Nipple, AND ITS CONTENTS ARE THE SOLE PROPERTY OF U.S. BOILER
COMPANY, INC. ANY REPRODUCTION IN PART OR AS A
3/4″
NPT
x
2″
Lg.
Steel
Nipple
2
WHOLE WITHOUT THE WRITTEN PERMISSION OF COMPANY, INC. IS STRICTLY PROHIBITED.
9U.S. BOILER
Elbow,
3/4″
NPT
x
90º
Steel
Elbow
1
*Pip2e lengths are approx. based on thread engagement
DES: EJL
SCALE: 1:4
CHK:
SIZE: A
APVD: DATE:
10/12/2021
SHEET: 1 OF 1 REVISION:
A
DRAWING NUMBER:
TS-103-68
1
40
110332-01 – 1/22
11 Gas Piping
PHTM II Installation, Operating & Service Instructions
! WARNING
Explosion Hazard. · Failure to properly pipe gas supply to boiler could cause
improper operation or leaks of flammable gas resulting in severe personal
injury, death or substantial property damage.
· Gas supply to boiler and system must be shut off prior to installing or
servicing boiler gas piping.
1. Gas piping must be sized to deliver adequate gas for boiler operation.
Consider the following:
A. If gas pressure in building is above 1/2 psig (3.4 kPa), an additional gas
pressure regulator is required. If additional regulator is used to reduce
boiler inlet pressure, it must be at least 6 to 10 ft. (1.8 to 3.0 m) upstream
of boiler.
B. Pressure drop from point of delivery to boiler. See Table 3-4 for inlet gas
pressure requirements.
C. Existing and expected future gas using equipment (i.e. water heater,
cooking equipment, etc.).
2. Use methods and materials in accordance with local plumbing codes. In
absence of such requirements, follow NFPA 54/ANSI 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 liquefied petroleum gas.
B. A sediment trap must be installed upstream of 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 piping independently from boiler gas connection.
3. Boiler and its gas connection must be leak tested before placing boiler in
operation.
A. For pressure testing at equal to or less than 1/2 psig (3.4 kPa) close
manual shut-off valve.
B. For pressure testing above 1/2 psig (3.4 kPa) disconnect boiler and manual
shut-off valve.
! DANGER
Explosion Hazard. Do not use matches, candles, open flames or other ignition
sources to check for leaks. Failure to comply could result in severe personal
injury, death or substantial property damage. C. Locate leaks using listed
combustible gas
detector, a non-corrosive leak detection fluid or other listed leak detection
method. Repair any leaks found immediately.
Gasket Gas Valve Adapter (1/2″ NPT) Ground Joint Union
Direction of Gas flow Manual Shutoff Valve
3″ Min. Drip Leg
Cap
Figure 11-1: Gas Piping
110332-01 – 1/22
41
12 Field Wiring
PHTM II Installation, Operating & Service Instructions
! DANGER
Electrical Shock Hazard. · Disconnect electrical supply before installing or
performing maintenance. · Electrical power may be supplied from more than one
circuit. ·Lock out all electrical boxes with padlock once power is turned off.
! WARNING
Electrical Shock Hazard. All wiring and grounding must conform to requirements
of authority having jurisdiction or, in absence of such requirements, to
National Electrical Code/NFPA 70 or Canadian Electrical Code, Part 1 (CSA
C22.1 – latest edition). · Make electrical connections according to boiler’s
wiring diagram and instructions. Failure to properly wire electrical
connections to the boiler may result in severe personal injury, death or
substantial property damage. · Protect each boiler circuit with a properly
sized over-current device. · Never jump out or bypass any safety or operating
control or component of this boiler.
NOTICE: Internal wiring diagrams contained in this manual are for reference
only. Each boiler is shipped with a wiring diagram sheet within boiler
literature packet. Read, understand and follow this wiring diagram and wiring
diagrams of any 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. 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 12-3.
Locating Field Connection Terminal Strips
Field connection terminal strip locations are shown in Figure 12-1. To access
terminal strips:
1. Remove front door. Front door is removed by first loosening two thumb
screws located under front of door.
2. Disconnect igniter wire at burner door.
3. Pull control enclosure forward, then to the left and allow it to swing
down into the service position.
Low Voltage Connection Board 120 VAC Connection Board
Jacket Knockouts
Jacket Knockouts
Opened Control Enclosure
Figure 12-1: Location 120VAC and low voltage connection boards
Field 120VAC Connections
1. Provide a dedicated circuit for boiler of 15A or greater. A service switch
is recommended and is required by many local codes. Locate this switch in
accordance with local codes or, in absence of such requirements, in a location
where it can be safely accessed in an emergency.
2. All 120VAC connections to boiler are made on 120VAC Connections terminal
strip (see Figure 122) located on right side of bottom panel. Route all 120
VAC wiring through conduit knock out holes located on right side in front of
terminal strip.
42
110332-01 – 1/22
12 Field Wiring (continued)
LN 120V
Line
LN Boiler
Pump
LN System
Pump
LN Aux
Pump
PHTM II Installation, Operating & Service Instructions
D. Maximum combined current draw for all circulators is 5A.
Low Voltage Connections
1. All low voltage field connections to boiler are made on Low Voltage
Connections terminal strip (see Figure 12-3) located on left side of bottom
panel. Route all low voltage wiring through conduit knock out holes located on
left side in front of terminal strip.
Service Switch
Overcurrent Protection/ Disconnect
GND
L1 L2 Power Supply
120/60/1
Figure 12-2: 120 VAC Connections
From left to right, connections on terminal strip are:
Terminal
Description
120VAC L
Hot
120VAC N
Neutral
Boiler Pump L
Hot
Boiler Pump N System Pump L System Pump N
Neutral Hot
Neutral
Auxiliary Pump L
Hot
Auxiliary Pump N
Neutral
3. Pump outputs
A. Boiler Pump (supplied with boiler). Circulates water through boiler. Boiler
pump is always on when boiler is responding to heating demand. See Table 15-15
for alternate boiler pump output functions. Maximum recommended current draw
for boiler pump is 2.0A.
B. System Pump: (field supplied) Circulates water through radiation. System
pump is always on when boiler is responding to heating demand. Refer to Table
15-15 for alternate system pump output functions. Maximum recommended current
draw for system pump is 1.5A.
C. Auxiliary Pump: (field supplied) Auxiliary pump output can be used for 2nd
zone or indirect pump. Refer to Table 15-15 for more information and alternate
auxiliary pump outputfunctions. Maximum recommended current draw for auxiliary
pump is 1.5A.
110332-01 – 1/22
Low Voltage Connections
24 VAC R W C
LWCO
Heat
T’stat
RW Aux T’stat
Ext. Limit
+0-10V 4-20mA
Header Sensor
Outdoor Sensor
Outdoor Sensor
Header Sensor
Wired Connection
External Limit (if needed)
Auxilliary Thermostat
24 Volt Heating Thermostat
LWCO (if needed)
Figure 12-3: Low Voltage Connections
From left to right, connections 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 V 4-20mA
Optional remote modulation control* (+)
0-10 V 4-20mA
Optional remote modulation control* (-)
Header Sensor
Optional Header* Temperature Sensor (1)
Header Sensor
Optional Header* Temperature Sensor (2)
Outdoor Sensor
Optional Outdoor Temperature Sensor (1)
Outdoor Sensor
Optional Outdoor Temperature Sensor (2)
*Available when Lead Lag Master Enabled.
43
12 Field Wiring (continued)
PHTM II Installation, Operating & Service Instructions
2. External power must not be applied to any low voltage terminals – doing so
may damage boiler control. Note following:
A. Heat T’Stat (field supplied) – Connect room thermostat or zone panel end
switch (isolated contact only) to “Heat T’stat” terminals.
B. Aux T’Stat – Auxiliary T’Stat can be used for 2nd zone or indirect demand.
Refer to Table 15-13 for explanation.
C. External Limit: External limit terminals are intended for use with field
supplied safety device, such as a manual reset high limit or LWCO. When an
external limit is used, jumper between these two terminals must be removed.
D. Outdoor Sensor – Use only Tasseron TSA00AA (P/N 108681-01) 10k outdoor
sensor. When optional sensor is connected, boiler control will provide outdoor
air sensor based freeze protection interlocks. When placing sensor, consider
following:
i. Locate sensor on outside of building.
ii. Avoid placing sensor in areas where it may be covered with ice or snow.
iii. Avoid direct radiation 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 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. Header Temperature Sensor – Use only Honeywell 32003971-003 (P/N 108703-01)
sensor. Optional header sensor is required to enable Lead/Lag sequencer.
Locate sensor as shown in Figures 10-3, 10-4 and 10-5. Wire sensor using a 2
conductor, UL Type CM, AWM Style 2092, 300Volt 60°C shielded cable. Connect
one end of shielding
on this cable to ground.
F. LWCO wiring – Although not necessary to protect this boiler, some
jurisdictions may require installation of LWCO with this boiler.
i. Refer to Section 10 Heating System Piping for LWCO kits available from
manufacturer.
ii. LWCO from these kits is installed to 4 pin connector on Low Voltage
Connections terminal strip.
G. RJ45 Connections – Boiler-to-Boiler communication network is used for
multiple boiler (“Lead-Lag”) installations.
Note: Combi boilers may only be used as slaves in such a system. Refer to
Table 15-16 for information on enabling this feature.
Boiler lead/lag sequencer connection is made directly to control. Refer to
Figure 12-4.
RJ45 Connections (2)
X6 X5
BCC
X4 X3
XB-2 XB-1
X1 Fuses
X2
Figure 12-4: Boiler-to-Boiler Connections
44
110332-01 – 1/22
13 Condensate Disposal
PHTM II Installation, Operating & Service Instructions
! WARNING Asphyxiation 2Hazard.
Failure to install condensate drain in
accordance with instructions outlined below
could cause products of combustion and/or carbon monoRxEiVde. to enter
buildEiNng, resulting in severe personal injury, death or substantial
property damage.
DATE
1. This high efficiency boiler produces condensate.
NOTICE: Condensate is corrosive. Use only materials listed by authority having
jurisdiction. In absence of such requirements, PVC and CPVC pipe may be used.
2. 3/4″ PVC condensate drain connection can be solvent welded.
3. Condensate disposal considerations:
A. If required by local codes, install neutralizing filter. Neutralizing 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.
C. If point of condensate disposal is above trap,
it will be pump to
nmeocveesscaornydteonussaeteaf1rcoomndbeonilseartteo
drain. IRnEsVucIShIOcaNsSes, select a condensate pump that
is listed DfoEr SuCseRIwPiTthIOcNondensing boilersD. WN
Select a pump with an overflow switch to
prevent property damage from condensate.
D. Barbed fitting on bottom panel is connected to trap vent and must be unobstructed for trap to work properly.
NOTICE: If condensate drain line becomes obstructed, boiler may leak from condensate trap vent. Consider installing drain pan directly below boiler if such a leak could cause property damage. Pipe drain pan drain to suitable location.
CHK
110332-01 – 1/22
Condensate Trap Vent 3/4″ PVC Connection Condensate Trap Cleanout
Figure 13-1: Condensate Trap 45
14 Start-Up and Checkout
PHTM II Installation, Operating & Service Instructions
Heating System Cleaning and Treatment
! CAUTION
Component Damage. Proper flushing, cleaning, and water side maintenance is
highly recommended to protect boiler heat exchanger. Scaling and sediment
build up may not be covered under warranty.
1. Prior to fill, flush entire heating system to remove sediment, flux, and
traces of boiler additives.
2. Clean with approved cleaners such as the following or its equivalent: ·
Fernox Cleaner F3 (for new heating systems) · Sentinel x300 System cleaner
(for new heating systems) · Sentinel X400 System Restorer (for old closed loop
hydronic systems) Refer to instructions supplied with cleaner for proper
dosage and use.
NOTICE: Cleaning system prior to removing old boiler or by isolating new
boiler from system while cleaning will yield best results.
3. After system has been cleaned, recommend using approved inhibitors such as
the following or its equivalent:
· Fernox F1 Protector
· Sentinel X100 Inhibitor
Refer to instruction supplied with inhibitor for proper dosage and use.
Fill Water Quality
NOTICE: Make sure system is filled with water meeting the following criteria:
· Hardness less than 7 grains/gallon.
· pH between 6.5 and 9.5 (for systems containing aluminum components, between
6.5 and 8.5)
· Chlorides less than 200 PPM. If fill water is drawn from a system containing
a water softener, test a sample of the water to confirm that this criteria is
met.
Following appropriate water chemistry guidelines will help extend the life of
appliance by reducing effects of lime scale buildup and corrosion, which are
not covered by warranty.
NOTICE: Minimize introduction of make-up water, dissolved oxygen, and
contaminants into boiler by following installation guidelines outlined in
Appendix B: Water Quality and Boiler Additives.
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.
! CAUTION
Component Damage. Avoid use of petroleum based boiler additives and ester-
based oils/lubricants. These could attack seals in both boiler and system
which could result in property damage.
1. Fill system ensuring water quality meets requirements of this manual.
2. Pressurize system to at least 12 psig (83 kPa) at boiler. Pressure will
vary with each application.
3. Verify air pressure in expansion tank is equal to system pressure.
4. Eliminate air in boiler by bleeding from heat exchanger manual air vent on
top left side of heat exchanger (Figure 14-1).
46
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
14 Start-Up and Checkout (continued)
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 to vent until a steady
stream of water is observed.
C. Close vent and remove hose.
5. Isolate each zone to purge air confirming that heating system and boiler
are completely filled.
Confirm 1/4″ ID tubing is connected to hose barb. Route tubing to a safe place away from controls before opening vent.
Manual Air Vent
Final Check Before Starting Boiler
! WARNING
Asphyxiation Hazard. Burn Hazard. Completely read, understand and follow all
instructions in this manual before attempting start-up.
1. Verify that venting, water piping, gas piping and electrical system are
installed properly.
2. Confirm vent system is complete and free of obstructions before attempting
to fire boiler.
3. Inspect all wiring for loose, uninsulated or miswired connections.
4. Verify boiler and system are full of water and pressurized.
Detail A (Scale 2:1)
A
Flame Rod
Figure 14-1: Manual Air Vent Location
NOTICE: When boiler is first powered, control will automatically run a pump
purge sequence (status 10) for 2 minutes.
5. Check all gas piping before boiler manual shut-off valve for leaks and
purge sections that are filled with air. Refer to NFPA 54/ANSI Z223.1 National
Fuel Gas Code and/or CAN/CSA B149.1 Natural Gas and Propane Installation Code
for additional information on testing and purging gas lines.
! DANGER
Explosion Hazard. Do not use matches, candles, open flames or other ignition
source to check for leaks. Failure to comply could result in severe personal
injury, death or substantial property damage.
6. If using LP gas, perform conversion stated below, otherwise skip to Step 7.
110332-01 – 1/22
47
PHTM II Installation, Operating & Service Instructions
14 Start-Up and Checkout (continued)
LP Conversion
! WARNING
Asphyxiation Hazard. · Do not attempt to operate this boiler on LP gas without
making proper adjustments to gas valve and control. Do not convert this boiler
to LP gas without using a combustion analyzer to verify CO is below 200 ppm
air free. (In event of high CO, consult section 18 Troubleshooting). · Failure
to properly convert this boiler for use on LP gas could cause unreliable
operation at elevated carbon monoxide (CO) levels, resulting in severe
personal injury, death or substantial property damage.
LP conversion requires (2) steps: gas valve setting adjustment and control
parameter change.
A. Use 2.5 mm hex wrench to adjust gas valve setting from “1” to “2” (Figure
14-2).
C. Apply yellow LP gas conversion label, supplied with boiler literature
packet, to jacket beside rating label.
7. Start boiler using lighting instructions in Figure 14-8. With boiler
powered up, and with no call for heat, display should look like Figure 14-3.
Once a call for heat is present, it will look like Figure 14-4.
Figure 14-3: Home screen at power up (no call for heat)
Figure 14-2: Gas Valve Fuel Setting
B. Use keypad to enter adjust mode and change parameter A06 from “0” to “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 reached and press “enter”.
Press and hold for five seconds to adjust by increments of 10. · Press “menu”
button until PAS is 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.
48
Figure 14-4: Home screen with CH and DHW demands
8. Boiler should attempt to fire several seconds after a call for heat
appears. With front door removed, try for ignition will appear as an audible
spark (lasting approximately 4 seconds).
9. Upon initial start-up, gas train will be filled with air. Even if gas line
has been completely purged of air, it may take several tries for ignition
before a flame is established.
10. If boiler does not light after 2 retries for ignition, it will enter a
“soft lockout” and will wait for one hour before attempting another ignition
sequence. This soft lockout can be reset by interrupting power to boiler.
11. Once a flame has been established for first time, subsequent calls for
burner operation should result in a flame on first try.
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
14 Start-Up and Checkout (continued)
12. If there is a problem, display will show error code (Figure 14-5). Refer
to label on access door and Section 18 Troubleshooting to diagnose error.
Figure 14-5: Home screen with error 13. If successful ignition, display will
show flame icon
(Figure 14-6)
Figure 14-6: Home Screen While Running 14. Boiler will automatically perform a
calibration to
properly set its air-fuel ratio (i.e. O2 or CO2 and CO levels).
15. Check inlet gas pressure (Figure 14-7). Verify inlet gas pressure is
between upper and lower limits shown on rating label with all gas appliances
on and off. Be sure to close this pressure tapping when gas pressure check is
complete.
16. Perform combustion test.
! WARNING
Asphyxiation Hazard. Use a combustion analyzer to verify proper operation by
checking carbon monoxide (CO) levels. Failure to use a combustion analyzer
could cause operation of boiler with elevated CO levels resulting in severe
personal injury, death or substantial property damage.
A. Boiler is equipped with a screw cap in vent adapter. Be sure to replace
this cap when combustion testing is complete.
B. Measure carbon monoxide (CO) level after 5 minutes of operation above 50%
firing rate. Ensure door is sealed before taking combustion readings.
C. CO should not exceed 200 ppm air free. (in event of high CO, see Section 18
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 14-1). Burner should shut off immediately.
18. Test any external limits or other controls in accordance with
manufacturer’s instructions.
19. Refer to Section 15 Operation to set-up control for system in which
boiler is installed. Some common set-up tasks include:
A. Setting CH temperature setpoints.
B. Defining boiler and system pump operation.
20. Review User’s Information Manual and system operation with homeowner.
Inlet Pressure Tapping
Figure 14-7: Gas valve inlet pressure tap
110332-01 – 1/22
49
PHTM II Installation, Operating & Service Instructions
14 Start-Up and Checkout (continued)
FOR YOUR SAFETY READ BEFORE OPERATING/POUR VOTRE SECU× RITE L× ISEZ× AVA×NT DE
METTRE EN MARCHE
WARNING: If you do not follow these instructions exactly, a fire or explosion
may result
causing property damage, personal injury or loss of life.
AVERTISSEMENT: Quiconque ne respecte pas à la lettre les instructions dans
la présente notice risque de déclencher un incendie ou une explosion
entraînant des dommages, des blessures ou la mort.
A. This appliance does not have a pilot. It is equipped with an ignition
device which automatically lights the burner. Do not try to light the burner
by hand.
B. BEFORE OPERATING smell all around the appliance area for gas. Be sure to
smell next to the floor because some gas is heavier than air and will settle
on the floor.
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’air et peuvent s’accumuler au niveau du sol.
WHAT TO DO IF YOU SMELL GAS:
QUE FAIRE SI VOUS SENTEZ UNE ODEUR DE GAZ:
– Do not try to light any appliance. – Do not touch any electric switch; do
not use any
phone in your building. – Immediately call your gas supplier from a neighbor’s
phone.
Follow the gas supplier’s instructions. – If you cannot reach your gas
supplier, call the fire department.
C. Use only your hand to turn the gas control valve. Never use tools. If the
valve will not turn by hand, don’t try to repair it, call a qualified service
technician. Force or attempted repair may result in a fire or explosion.
D. Do not use this appliance if any part has been under water. Immediately
call a qualified service technician to inspect the appliance and to replace
any part of the control system and any gas control which has been under water.
– Ne pas tenter d’allumer d’appareil. – Ne touchez à aucun interrupteur ; ne
pas vous servir des
téléphones se trouvant dans le bâtiment. – Appelez immédiatement votre
fournisseur de gaz depuis un
voisin. Suivez les instructions du fournisseur. – Si vous ne pouvez rejoindre
le fournisseur, appelez le service des
incendies.
C. Ne poussez ou tournez la manette d’admission du gaz qu’à la main ; ne
jamais utiliser d’outil. Si la manette reste coincée, ne pas tenter de la
réparer ; appelez un technicien qualifié. Le fait de forcer la manette ou de
la réparer peut déclencher une explosion ou un incendie.
D. N’utilisez pas cet appareil s’il a été plongé dans l’eau, même
partiellement. Faites inspecter l’appareil par un technicien qualifié et
remplacez toute partie du système de contrôle et toute commande qui ont été
plongés dans l’eau.
OPERATING INSTRUCTIONS/ INSTRUCTIONS DE FONCTIONNEMENT
1. STOP! Read safety information above on this label. 2. Set the thermostat
to lowest setting. 3. Turn off all electric power to the appliance. 4. This
appliance is equipped with an ignition device which
automatically lights the burner. Do not try to light the burner by hand. 5.
Turn the external boiler manual gas valve
handle clockwise to close the gas supply (OFF Position). 6. Wait five (5)
minutes to clear out any gas. Then smell for gas,
including near the floor. If you smell gas, STOP! Follow “B” in the safety
information above on this label. If you don’t smell gas, go to the next step.
7. Turn the external boiler manual gas valve handle counterclockwise to open
the gas supply (ON Position). 8. Turn on all electric power to the appliance.
9. Set the thermostat to the desired setting. 10. If the appliance will not
operate, follow the instructions
“To Turn Off Gas To Appliance” and call your service technician or gas
supplier.
OPEN/OUVERT CLOSED/FERME
1. ARRÊTEZ ! Lisez les instructions de sécurité sur la portion supérieure
cette étiquette.
2. Réglez le thermostat à la température la plus basse. 3. Coupez
l’alimentation électrique de l’appareil. 4. Cet appareil est équipé de l’
dispositif d’allumage qui automobile
allume maticallyle brûleur. Ne tentez pas d’allumer le brûleur manuellement.
5. Tourner la chaudière externe manuelle poignée en clapet à gaz dans le sens
des aiguilles d’une montre pour fermer l’offre de gaz (Position OFF). 6.
Attendre cinq (5) minutes pour laisser échapper tout le gaz. Reniflez tout
autour de l’appareil, y compris près du plancher, pour déceler une odeur de
gaz. Si vous seutez une odeur de gaz,
ARRÊTEZ ! Passez à l’étape B des instructions de sécurité sur la portion
supérieure de cette étiquette. S’il n’y a pas d’odeur de gaz, passez à l’étape
suivante. 7. Tourner la chaudière externe manuelle compteur de poignée
en clapet à gaz ouvrir dans le sens des aiguilles d’une montre le gaz
approvisionnement (Position ON). 8. Mettez l’appareil sous tension. 9. Réglez
le thermostat à la température désirée. 10. Si l’appareil ne se met pas en
marche, suivez les instructions intitulées « Comment couper l’admission de gaz
de l’appareil » et appelez un technicien qualifié ou le fournisseur de gaz.
EXTERNAL BOILER MANUAL GAS VALVE
LA CHAUDIÈRE EXTERNE MANUELLE DE CLAPET A` GAZ
TO TURN OFF GAS TO APPLIANCE/ COMMENT COUPER L’ADMISSION DE GAZ DE L’APPAREIL
1. Set the thermostat to lowest setting. 2. Turn off all electric power to
the appliance if service is to be
performed. 3. Turn the external boiler manual gas valve handle clockwise
to close gas supply (OFF Position).
1. Réglez le thermostat à la température la plus basse. 2. Coupez
l’alimentation électrique de l’appareil s’il faut procéder à l’entretien. 3.
Tourner la chaudière externe manuelle poignée en clapet à gaz dans le
sens des aiguilles d’une montre pour fermer l’offre de gaz (Position OFF).
101607-04
Figure 14-8: Lighting and operating instructions
50
110332-01 – 1/22
PHTM II Installation, Operating & Service Instructions
14 Start-Up and Checkout (continued)
Boiler Sequence of Operation
Table 14-9: Boiler Sequence of Operation
Status Screen Display
Priority: Standby Status: Standby
Priority: Standby Status: Pump Purge
Priority: Central Heat Status: Standby
Priority: Central Heat
Status: Prepurge
Priority: Central Heat
Status: Burner Ignition
Priority: Central Heat
Status: Calibration
Priority: Central Heat
Status: Run
Priority: DHW Status: Run
Priority: Standby Status: Post-purge
Priority: Standby Status:
Hold
Priority: Standby Status: Lockout
Description
Burner – Off
Pump(s) – Off
There is no call for heat, boiler is not firing and priority is “standby”. Boiler is ready to respond to a call for heat. Additionally, boiler and pumps remain off when Warm Weather Shut Down is active or “Boiler Switch” (A01) is set to “Off”.
Burner – Off
Pump(s) – Cycle
Pump Air Elimination (Pump Purge) is entered when power is cycled or when
there has been a supply high limit hold. During this state boiler pump cycles
on and off every 5 seconds for two minutes to help remove air from boiler
water piping. This may be
interrupted by pressing ” ! reset” button.
Burner – Off
Pump(s) – Cycle
Boiler is not firing. There is a CH demand and supply temperature is greater than setpoint minus “Diff Below”.
Burner – Off
Pump(s) – On
When supply temperature drops, burner demand continues with following status shown: Waiting For Limit To Close: blower started, air pressure switch is checked. Prepurge: blower is driven to prepurge speed to empty chamber of flue products.
Burner – On
Pump(s) – On
After prepurge is complete following status is shown: Burner Ignition: Spark and fuel valve are energized.
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, ionization setpoint is calibrated, next blower drives to low fire and fuel valve output is calibrated (runs for 1 minute).
Burner – On
Pump(s) – On
After burner ignition (following calibration), the following status is shown: Low Fire Hold: modulation rate held at low fire to allow initial home heating Run (Modulate): Burner rate modulates to match home heat requirements.
Burner – On
Pump(s) – On
If CH demand is active and a DHW demand is received, DHW demand becomes “priority” and modulation rate, setpoint, “Diff Above” and “Diff Below” are based on DHW settings.
Burner – Off
Pump(s) – Off
If there is no call for heat, fuel valve is closed and blower is driven to post-purge speed to empty combustion chamber of flue products.
Burner – Off
Pump(s) – Off
Hold status is entered when a delay is needed before allowing burner to fire. See user display door label or section 18 Troubleshooting to determine cause of the Hold.
Burner – Off
Pump(s) – Off
A lockout status is entered to prevent boiler from running due to a detected problem. See user display door label or section 18 Troubleshooting to determine cause of Lockout. Last 8 Lockouts are recorded in Lockout History.
110332-01 – 1/22
51
15 Operation
User Display Overview
+
PHTM II Installation, Operating & Service Instructions
reset
Figure 15-1: Display Icons
Table 15-2: Display descriptions
180°F
When not flashing or alternating display temperature is boiler supply temperature.
Visible when 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.
Combi boilers only.
Visible when CH setpoint reset is enabled.
Visible when adjust mode is active. Icon will flash if manual mode is enabled.
Visible when manual reset lockout is active.
52
110332-01 – 1/22
PHTM II
15 Operation (continued)
Operating Mode
Basic boiler status is displayed and DHW setpoint may be adjusted.
reset
+
Figure 15-3: Viewing boiler status
Press “” or “” buttons to cycle through Status List. Each item will alternate
between status code and its corresponding value.
Table 15-4: Status List
Display
Description
StA Status (see Table 15-5)
SP Active, Operating Setpoint
bt Boiler Supply Temperature
rt Boiler Return Temperature
Ft Flue Temperature
ot Outdoor Air Temperature*
ht Header* 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
Installation, Operating & Service Instructions
The STA (status) display code contains below listed values.
Table 15-5 Managing of Status Numbers
Display
Description (see Section 18 Troubleshooting for explanation)
0
Self Check
1
Standby
2
Waiting For Air Pressure Switch To Close
3
Prepurge
4
Burner Ignition
5
Calibration
6
Low Fire Hold
7
Rate Limit
8
Run (Modulate)
9
Postpurge
10 Pump Air Elimination (2 minutes)
11 Standby Delay
12 Lockout
13 Boiler On/Off Switch (A01)
14
Warm Weather Shutdown*
- Not available with local user display.
reset
+ 120
Figure 15-6: Adjusting DHW Setpoint
Press “+” or “-” buttons to immediately change the DHW setpoint. Faucet and DHW Setpoint flash while editing.
110332-01 – 1/22
53
15 Operation (continued)
PHTM II Installation, Operating & Service Instructions
Adjust Mode Menu
Diagnostic information and Quick Menu parameters are available without
entering a password. Press and Hold “menu” button for 3 seconds to access
Adjust Mode.
reset
Press buttons
to adjust
parameters.
Press buttons to view next menu or parameter.
Press and hold for three seconds to access Adjust Mode
Press to exit current menu or cancel current editing session
Press to select menu or parameter to edit.
Figure 15-7: Adjusting Parameters
Press “” or “” buttons to switch between menus A, b, C, and PAS, press “enter” to Select. The following items are available in the A menu. Menu A, Quick Menu
Table 15-8: Quick Menu (with no password entered)
Display
Range
Description
A01
On/Off Boiler On/Off Switch
A02
On/Off DHW Comfort Mode*
A03
60 -190°F (16 – 88°C)
DHW Setpoint
A04
60 – 190°F (16 – 88°C)
Central Heat 1 Setpoint
A05
60 -190°F (16 – 88°C)
Central Heat 2 Setpoint
Menu c, Diagnostic Menu
Table 15-9: Diagnostic Menu
Display
Description
C01 Active Detailed Fault Code (see Table 18-6)
Demand Source
1 Standby
2 Central Heat 1
3 Central Heat 2
4 Domestic Hot Water C02
5 Sequencer Control
6 CH Frost Protection
7 DHW Frost Protection
8 Boiler On/Off Switch
*Combi boilers only.
A01 Boiler Switch Allows an installer to prevent boiler starts while reviewing
boiler settings.
A02 DHW Comfort Mode Combi boilers only.
9 Warm Weather Shutdown C03 Fan Speed Demanded (RPM x 100) C04 Fan Speed Feedback (RPM x 100) C05 Three-way valve status (0) DHW, (1) CH* C06 System Pump On/Off Status C07 Boiler Pump On/Off Status
A03 DHW Setpoint Desired boiler water temperature during DHW demand.
A04 Central Heating 1 Setpoint Desired water temperature of Central Heat 1
(CH1).
A05 Central Heating 2 Setpoint Desired water temperature of Central Heat 2
(CH2).
C08 Auxiliary Pump On/Off Status C09 Flame Signal C10 Safety Software Revision
C11 Application Software Revision C12 Parameter Revision
Boiler Size Status: (1) 136 combi (2) 200 combi
Menu b, Lockout/Hold History Menu
C13
b01 to b08 are Lockout or Hold history records. b01 is
latest entry.
(3) 080 (4) 120 (5) 150 (6) 180
54
110332-01 – 1/22
15 Operation (continued)
PHTM II Installation, Operating & Service Instructions
Accessing Password Protected Menus
Password protected parameters are available by entering a password.
reset
+
Figure 15-10: Menu Structure
Press and hold the “menu” for 3 seconds, Press “” or “” buttons until PAS is
visible and press “enter”. Press “enter” while PA1 is visible. Press “+” or
“-” buttons until desired value is reached (password is 86).
(Press and 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.
“” or “”
Menu Structure
- Only shows when comminicating Zone Panel connected
IMPORTANT
This boiler is equipped with a feature that saves energy by reducing boiler
water temperature as heating load decreases. This feature is equipped with an
override which is provided primarily to permit the use of an external energy
management system that serves the same function. THIS OVERRIDE MUST NOT BE
USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE:
· An external energy management system is installed that reduces boiler water
temperature as heating load decreases.
· This boiler is not used for any space heating. · This boiler is part of a
modular or multiple
boiler system having total input of 300,000 BTU/hr or greater. · This boiler
is equipped with a tankless coil.
110332-01 – 1/22
! WARNING
Asphyxiation Hazard. · Parameter changes should only be made by a qualified
installer, service agency or gas supplier. · Fuel Gas Selection (parameter
A06) must match fuel gas supply AND gas valve fuel setting (see Figure 14-2).
· Altitude Selection (parameter A07) must match boiler installation location.
Only change these settings if required to match site conditions. These
settings determine minimum and maximum blower speeds. · Incorrect fuel gas and
altitude settings could cause unreliable operation at elevated carbon monoxide
(CO) levels, resulting in severe personal injury, death or substantial
property damage.
55
15 Operation (continued)
PHTM II Installation, Operating & Service Instructions
Table 15-11: Menu A, Quick Menu (items A06, A07, A08 and A09 visible only after password entered)
Default
Range/ Choices
Parameter and Description
A01 Boiler On/Off Switch
On
On/Off
Boiler switch allows an installer to prevent boiler starts while boiler powered and reviewing boiler
settings. Control is factory set with boiler switch in “On” position.
A02 DHW Comfort Mode
Off
On/Off
Combi boilers only.
170°F
60°F – 190°F A03 DHW Setpoint (16°C – 88°C) Desired boiler water temperature to IWH produced during DHW demand.
180°F 83°C
60°F – 190°F A04 Central Heat 1 Setpoint (16°C – 88°C) Desired water temperature of CH1.
180°F 83°C
60°F – 190°F A05 Central Heat 2 Setpoint (16°C – 88°C) Desired water temperature of CH2.
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
0
0, 1
· changing gas valve setting from position “1” to position “2” . If conversion to LP Gas is required,
refer to manual Section 14 Startup and Checkout for complete instructions.
(0) Natural Gas
(1) LP Gas
A07 Altitude Selection (visible only after password entered):
0
0
Boiler is shipped from factory configured for sea level (0 to 2000 ft. / 0 to 610 Meters).
(0) 0 to 2000 feet (0 to 610 Meters)
A08 Calibrate (visible only after password entered):
Setting to “On” enables a manual calibration to be attempted at next boiler start. For immediate
Off
On/Off
calibration cycle CH demand normal periodic calibrations are not affected by this setting.
On Manual calibration is requested
Off Manual calibration is not requested
A09 Gas Valve Offset (visible only after password entered):
29
13-46
Gas valve offset is set automatically during calibration. When replacing an old gas valve with a new
gas valve, it is possible boiler will not start unless this value is changed. For this situation, set Gas
Valve Offset to 30 to allow the boiler to start.
A10 Factory Default (visible only after password entered):
Returns all parameters back to the orig
References
Read User Manual Online (PDF format)
Read User Manual Online (PDF format) >>