Rheem RCBH-L199I ThermaForce Super High-Efficiency User Manual

INSTALLATION AND OPERATING INSTRUCTIONS

HIGH EFFICIENCY CONDENSING

COMBI BOILER

99,000 & 125,000 Btu/hr Models

160,000 & 199,000 Btu/hr Models

(Natural Gas or Propane)

WARNING: If the information in this manual is not followed exactly, a re or

explosion may result causing property damage, personal injury, or loss of life.

Do not store or use gasoline or other ammable vapors and liquids or other

combustible materials in the vicinity of this or any other appliance.

WHAT TO DO IF YOU SMELL GAS:

• Do not try to light any appliance.

• Do not touch any electrical 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 re department.

Installation and service must be performed by a qualied

licensedlicensed installer,

service agency or the gas supplier.

INSTALLATION AND OPERATION INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

SAFETY CONSIDERATIONS

Installation, start-up and servicing of the unit must be done with due

care and attention, and must only be performed by competent, qualied,

licensed and trained heating technicians. Failure to read and comply with

all instructions and applicable National and local codes may result in

hazardous conditions that could result in property damage and injury to

occupants which in extreme cases might result in death.

HAZARDS & PRECAUTIONS

Supplied with the unit - The unit is shipped with an accessory parts kit

consisting of the following items:

• 1 x Wall Mounting Bracket Kit - Part # P-081344

• 1 x Condensate Trap Assembly

• 1 x Pressure Relief valve, ¾" NPT, 30psi

• 1 x Outdoor Temperature Sensor

• 1 x Cascade/Indirect Temperature Sensor (160,000 & 199,000 Only)

• 1 x Documentation set

• 1 x Propane Conversion Kit:

Part # P-081034 (99,000 Btu/hr) or

Part # P-081054 (125,000 Btu/hr) or

Part # P-081744 (160,000 Btu/hr) or

Part # P-081014 (199,000 Btu/hr)

WARNING

If the information in this

manual is not followed

exactly, a re or explosion

may result causing property

damage, personal injury, or

loss of life.

CAUTION

Points out a potentially

hazardous situation which

must be avoided to prevent

possible moderate injury and/

or property damage

NOTE

Points out installation,

maintenance and operation

details that will result in

enhanced e󰀩ciency, longevity

and proper operation of your

boiler.

DANGER

Points out an imminently

hazardous situation which

must be avoided in order to

prevent serious injury or

death.

BEST PRACTICES

Points out recommendations

for better installation.

WARNING

Points out a potentially

hazardous situation which

must be avoided to prevent

serious injury or death.

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

SPECIFICATION 99,000 BTU 125,000 BTU 160,000 BTU 199,000 BTU

CSA Input (Natural Gas or Propane*) – MBH 15.5 - 99 16.5 - 99 23 - 125 28.5 - 125

CSA Input (Natural Gas or Propane*) – KW 4.5 - 29.0 4.8 - 29.0 6.7 - 36.6 8.4 - 36.6

CSA Output – MBH

14.8 - 89 15.8 - 89 22 - 111 27.1 - 111

CSA Output - KW 4.3 - 26.1 4.6 - 26.1 6.4 - 32.5 7.9 - 32.5

DHW - CSA Input (Natural Gas or Propane*) -

MBH

15.5 - 99 16.5 - 125 23 - 160 28.5 - 199

DHW - CSA Input (Natural Gas or Propane*) - KW 4.5 - 29.0 4.8 - 36.6 6.7 - 46.9 8.4 - 58.3

A.F.U.E 96% 95% 94% 95%

Min Gas Pressure (Nat. Gas or Propane*) – inch

w.c.

Max Gas Pressure (Nat. Gas or Propane*) – inch

w.c.

Power (120Vac/60Hz) - Watts @ full re with

internal pump

120

Weight (empty) – lbs/Kg 85 / 39 84 / 38

Pressure Vessel water content – USG/Liters 0.5 / 1.9 0.19 / 0.72

Max boiler ow rate - GPM (LPM) 10 (37.9) 11 (41.6) 12 (45.4)

Min boiler ow rate - GPM (LPM) 2 (7.6)

Max Operating Pressure – Space Heating Coil -

psig

†

43.5

Max Operating Pressure – Domestic Hot Water

Coil - psig

150

Minimum water pressure - psig

Approved installation altitude - ASL 10,000 ft

Ambient Temperature – Low (°F/°C) 32 / 0

Ambient Temperature – High (°F/°C) 122 / 50

Max relative humidity (non-condensing) 90%

Min water Temperature - Space Heating (°F/°C)

51 /51 / 10

Max water Temperature – Space Heating (°F/°C) 194 / 90

Min water Temperature – Domestic Hot Water

(°F/°C)

105 / 40

Max water Temperature – Domestic Hot Water

(°F/°C)

149 / 65

Min ow rate to activate DHW heating - GPM

(LPM)

0.5 (1.9)

Max ow rate DHW heating - GPM (LPM) 4 (15.1) 7 (26.5)

Max equivalent vent length 3" (each side) 120'

Max equivalent vent length 2" (each side) 65'

* Natural Gas units require a Propane conversion kit included with unit (see page #3-2, Table 10). Propane (LP) units require a Natural Gas conversion kit (see page

#3-2, Table 10) to be ordered separately if converting a Propane unit to Natural Gas.

† units are shipped with 30 psig pressure relief valve

ǂ Theinputratewillderateasventlengthincreases.Reference Table 3: Maximum Exhaust Venting Length in section 1.4.3 for details.

SPECIFICATIONS

INSTALLATION AND OPERATION INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

BURN

HOT

DANGER

Water temperature over 125°F (52°C) can cause severe burns instantly

or death from scalds.

Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

WARNING

CAUTION

WATER HEATER INSTALLATION GUIDELINES

ADJUSTABLE TEMPERATURE SETTING

Hotter water increases the risk of scald injury. Before changing the temperature setting, see

instruction manual.

This unit must be installed in accordance with local codes, if any; if not follow the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1, as applicable.

Failure to correctly install and operate this appliance can result in severe personal injury

or death.

The unit shall have a pressure relief valve installed within 6" [152mm] of the DHW HOT

outlet connection.

Refer to the unit’s User Manual before operating the relief valve.

The unit requires a pressure relief valve identiﬁed with the ASME V or HV symbol and

set to relieve at or below 150psi of domestic water pressure and a minimum relieving capacity

of 199,000 Btu/hr with 3/4" NPT threads. For safe operation of the unit, the relief valve

must not be removed from its designated point of installation or plugged.

Read and follow warnings and instructions.

Touch the panel above the white dot , then touch the Faucet . Adjust the water temperature

with the Plus + and Minus – then touch the Return button to save the changes.

TIME/TEMPERATURE RELATIONSHIP IN SCALDS

WATER TEMPERATURE TIME TO PRODUCE A SERIOUS BURNTIME TO PRODUCE A SERIOUS BURN

120°F (49°C) More than 5 minutes

125°F (52°C) 1 ½ to 2 minutes

130°F (54°C) About 30 seconds

135°F (57°C) About 10 seconds

140°F (60°C) Less than 5 seconds

145°F (63°C) Less than 3 seconds

150°F (66°C) About 1 ½ seconds

155°F (68°C) About 1 second

Table courtesy of Shriners Burn Institute

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

CONTENTS

1.0 INSTALLATION ..........................................1-1

1.1 GENERAL........................................................1-1

1.2 CODE REQUIREMENTS ............................................1-3

1.3 LOCATION .......................................................1-3

1.3.1 Removing/installing the front panel .................................1-5

1.4 EXHAUST VENTING AND AIR INTAKE .................................1-6

1.4.1 Applications ...................................................1-9

1.4.2 Exhaust Vent Material ..........................................1-10

1.4.3 Vent Travel ...................................................1-10

1.4.4 Venting Passage Through Ceiling and Floor .........................1-12

1.4.5 Rooftop Vent Termination........................................1-12

1.4.6 Sidewall Vent Termination .......................................1-14

1.4.7 “Direct Vent” Combustion Air Intake Piping ..........................1-18

1.4.8 “Indoor Air” Combustion Air Intake .................................1-19

1.4.9 Closet Installations .............................................1-19

1.5 CONDENSATE REMOVAL ..........................................1-20

1.5.1 Condensate Trap ..............................................1-20

1.5.2 Installing the Condensate Trap....................................1-20

1.5.3 Further Installation Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-21

1.6 WATER PIPING - SPACE HEATING ..................................1-22

1.6.1 General Piping Considerations....................................1-22

1.6.2 Basic Heating Piping Arrangements................................1-26

1.7 DOMESTIC HOT WATER SYSTEM ...................................1-31

1.7.1 Domestic Hot Water System .....................................1-32

1.7.2 Domestic Hot Water Piping ......................................1-32

1.7.3 Tankless Domestic Hot Water with a Storage Tank ....................1-35

1.7.4 Domestic Hot Water with an Indirect Water Heater ....................1-35

1.8 GAS PIPING .....................................................1-36

1.9 ELECTRICAL CONNECTIONS ......................................1-37

1.9.1 120VAC Line Voltage Hook-up....................................1-37

1.9.2 Accessing Controller Terminal Strip ................................1-37

1.9.3Externalprobetypelowwatercuto󰀨device..........................1-39

1.9.4 Power Quality and Electrical Protection .............................1-40

1.9.5 Zone Valve and Zone Pump Connections ...........................1-40

1.9.6 Thermostat / Sensor Wiring ......................................1-40

2.0

UNIT SYSTEM OPERATION .....................................2-1

2.1 GENERAL........................................................2-1

2.2 CONTROL .......................................................2-2

2.3 INSTALLER INTERFACE ............................................2-2

2.3.1 Turning Appliance ON/OFF .......................................2-2

2.3.2 Programming Mode.............................................2-3

2.4 TANKLESS DOMESTIC HOT WATER MODES ...........................2-5

2.4.1 Tankless Domestic Hot Water - Standard and ECO Comfort Modes ........2-5

2.5 SPACE HEATING ..................................................2-6

2.5.1 Overview .....................................................2-6

INSTALLATION AND OPERATION INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

2.6 SEQUENCE OF OPERATION ........................................2-7

2.7 ACCESSING THE INFORMATION MENU ...............................2-8

2.8 RESETTING THE MAINTENANCE COUNTER ..........................2-10

3.0 STARTUP & COMMISSIONING ..............................3-1

3.1 LIGHTING & SHUTTING DOWN THE UNIT .............................3-1

3.2 PRIOR TO START-UP ..............................................3-2

3.2.1 Pre-Ignition Checks .............................................3-2

3.2.2TestIgnitionSafetyShuto󰀨 .......................................3-2

3.3 COMMISSIONING .................................................3-2

3.4 FUEL CONVERSION ...............................................3-4

3.4.1 Gaining access to combustion chamber, burner removal instructions .......3-5

4.0 MAINTENANCE..........................................4-1

4.1 UNIT MAINTENANCE ..............................................4-1

4.1.1 General Care ..................................................4-1

4.1.2 Inspection.....................................................4-1

4.1.3 Venting .......................................................4-1

4.1.4 Condensate Trap ...............................................4-1

4.1.5 Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.1.6 Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.1.7 Pump ........................................................4-2

4.1.8 Gas Piping ....................................................4-2

4.1.9 Control Module.................................................4-2

4.1.10 Water Heating System ..........................................4-2

4.1.11 Freeze Protection ..............................................4-2

4.1.12 System Treatment .............................................4-3

4.1.13 Relief Valve - Maintenance and Testing .............................4-3

4.1.14 Domestic Hot Water System .....................................4-3

4.1.15 DHW Coil Cleaning Instructions...................................4-4

4.1.16 DHW Filter Cleaning Instructions ..................................4-4

4.1.17 Fan removal instructions .......................................4-5

4.1.18 Fan installation instructions ......................................4-5

4.1.19 Cleaning the Condensate Trap....................................4-6

4.1.20 Reset the Maintenance Counter...................................4-7

4.1.21 Winterization..................................................4-8

5.0 TROUBLESHOOTING .....................................5-1

5.1 PRELIMINARY CHECKS ............................................5-1

5.2 ELECTRONIC COMPONENTS .......................................5-2

5.2.1 Temperature Sensors............................................5-2

5.2.2 Cabinet Sensors................................................5-3

5.2.3 Thermostat Connections .........................................5-3

5.2.4WaterPressureSensor-TypeLowWaterCutO󰀨(LWCO)................5-3

5.2.5 Flue Gas Temperature Sensor .....................................5-4

5.2.6 Domestic Hot Water Flow Sensor ..................................5-4

5.2.7 Domestic Hot Water Temperature Sensor ............................5-4

5.2.8 Domestic Hot Water Bypass Valve..................................5-4

5.2.9 Domestic Cold Water Temperature Sensor ...........................5-4

5.2.10 Outdoor Sensor ...............................................5-5

5.2.11 DHW Tank Sensor .............................................5-5

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

5.2.12 Fan/Blower ...................................................5-5

5.3 FAULTS AND NOTIFICATIONS .......................................5-6

5.3.1 Fault Codes ...................................................5-6

5.3.2NoticationCodes .............................................5-10

5.4 OTHER FAULTS ..................................................5-12

5.4.1 No heat (space heating).........................................5-12

5.4.2 Space heating does not reach the correct temperature .................5-12

5.4.3 Space heating system remains too warm ...........................5-13

5.4.4 No domestic hot water (DHW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13

5.4.5 Domestic hot water does not reach the correct temperature .............5-13

5.4.6 Burner ignites loudly............................................5-14

5.4.7 Burner resonates ..............................................5-14

6.0 REPLACEMENT KITS .....................................6-1

7.0 WIRING DIAGRAMS ......................................6-3

INSTALLATION & COMMISSIONING REPORT..............................6-5

SERVICE RECORD ...................................................6-6

NOTES ............................................................6-8

NOTES ............................................................6-9

INSTALLATION AND OPERATION INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

PRE-INSTALLATION CHECK

Carefully consider clearances and access, vent travel and termination, gas

supply, condensate removal and combustion air supply.

Consider the following:

• Install the unit in areas where the combustion air source is free of

contamination. Exposure to corrosive chemical fumes such as chlorinated

and/oruorinatedhydrocarbonscanreducethelifeofaunit.Cleaners,

bleaches,airfresheners,refrigerants,aerosolpropellants,dry-cleaninguids,

de-greasers and paint-removers all contain vapors that can form corrosive

acidcompoundswhenburnedinagasame.Avoidairbornechloridessuch

as those released with the use of laundry detergents.

• Locate the unit where water leakage will not result in damage to the area (for

example,donotinstallabovecarpeting).Ifyoucannotndasuitablelocation,

install a drain pan with an adequate drain under the appliance.

• At a new construction site, or during renovations, protect the unit from drywall

dust or other construction related contaminants (not a construction heater).

○ Ensure combustion air is drawn from a CLEAN source (outdoors).

○ Isolate the unit from interior dust sources.

• When the unit is in operation, assess the impact of the steam plume normally

experienced at the exhaust terminal of a condensing unit. Generally, intake

and exhaust pipes should terminate at a rooftop or wall location free of

obstructions. Unit condensate is corrosive. Protective measures must be

taken to prevent corrosion damage to metal roofs or other metal building

components in contact with the condensate. Keep exhaust plumes well

away from all building air intakes including those of neighboring properties

by following all requirements of the jurisdiction having authority and this

installation manual.

• Place the exhaust outlet so it reaches 12" minimum above the down-turned

intaketoavoiduegascontaminationofthecombustionair.

• For sidewall venting options: Both the inlet and exhaust terminations must

be located on the same side of the building. You can elevate both pipes

in “periscope style” after passing them through the wall to gain required

clearance above grade and snow level.

• Examine the condensate outlet to ensure proper disposal of condensate

will occur during operation. A condensate neutralizer must be installed if the

condensatewillowintoadrainsubjecttocorrosion.

• Ensure that the pressure relief valve is installed with no valves or other

means of isolation between its inlet and the unit. Pipe the relief valve with

unobstructed piping (minimum 3/4" diameter) to a safe discharge location.

• In locations where power supply quality varies or is unstable, consider

installing surge protection and power conditioners (up to and including battery

back-up uninterrupted power supply devices).

• Ensure the domestic hot water demands are considered before purchasing a

Combi Boiler. You may need to add a storage tank or an indirect tank.

CAUTION

Care must be taken to

properly size the unit for

its intended use. Prolonged

full-re run time, over-

sizing or under-sizing,

and incorrect ow rates

through the unit can lead

to increased maintenance

costs, equipment stress and

premature failure.

WARNING

Do not use this unit if any

part has been under water.

Immediately call a qualied

service technician to inspect

the unit and to replace any

part of the control system and

any gas control that has been

under water.

DANGER

Should overheating occur

or the gas supply fails to

shut o󰀨, do not turn o󰀨 or

disconnect the electrical

supply to the pump. Instead

shut o󰀨 the gas supply at

a location external to the

appliance.

1-1

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

FRONT

17.7in

[450mm]

3.1in

[79mm]

32.5in

[826mm]

1.2in

[30mm]

1.0 INSTALLATION

1.1 GENERAL

ThisHighE󰀩ciencyCondensingCombiBoilerwithvariableinputranges(see

specication chart - page 3) is designed to be used for domestic (residential)

purposes. Domestic use is considered to be an average annual gas usage of

less than 140,000 ft³ (4,000 m³) for natural gas or 1,500 gallons (5,680 L) for

propane. The units are approved as “Category IV” vented appliances using Direct

Vent (sealed combustion).

Figures 1a, 1b and 1c show outer case dimensions and piping. Use this diagram

tondasuitablelocationfortheunit.See also Section 1.3 Location.

Figure 1a: Dimensions / Connections for Combi Boiler

NOTE

When using this unit for

non-domestic purposes

the warranty conditions

and maintenance periods

described in this document

are no longer valid. Consult

the included warranty

documentation for details.

SIDE

10.9in

[278mm]

INSTALLATION AND OPERATION INSTRUCTIONS

1-2

COMBI BOILERS 99 & 125 & 160 & 199

4.7in

[120mm]

4.7in

[120mm]

TOP

B (ALTERNATE)

4.7in

[120mm]

Figure 1b: Dimensions / Connections for Combi Boiler Models 99 - 125

DESCRIPTION DIMENSIONS

A Exhaust Outlet 2" Schedule 40 PVC

B Combustion Air inlet 2" Schedule 40 PVC

Cold Domestic Water

Connection&inletlter

3/4" Male NPT

Hot Domestic Water

Connection

3/4" Male NPT

E Heating Water Inlet (Return) 1" Male NPT

Heating Water Outlet

(Supply)

1" Male NPT

G Gas Inlet 3/4" Male NPT

H Condensate Outlet 3/4" Hose

I Control Wiring Entrance 7/16” Rubber Plug

Table 1: Connections

3.7in

[95mm]

2.6in

[65mm]

2in

[50mm]

3.5in

[90mm]

6.1in

[155mm]

BOTTOM

16in

[406mm]

BRACKET

BOTTOM

2.6in

[65mm]

2.6in

[65mm]

10.2in

[260mm]

5.1in

[130mm]

0.4in

[9mm]

1.3in

[34mm]

2.0in

[50mm]

2.6in

[65mm]

3.7in

[95mm]

Figure 1c: Dimensions / Connections for Combi Boiler Models 160 - 199

1-3

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

1.2 CODE REQUIREMENTS

TheCombiBoileriscertiedunderCSA4.9/ANSIZ21.13andWaterHeater

CSA 4.3 / ANSI Z21.10.3.

The installation 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, (latest edition) in the US or Natural Gas

and Propane Installation Code, CSA B149.1 (latest edition) in Canada. The

installation must also conform to the Canadian Electrical Code Part 1 in Canada

or the National Electrical Code ANSI/NFPA 70 (latest edition) in the US. Where

required by the authority having jurisdiction, the installation must conform to the

Standard for Controls and Safety Devices for Automatically Fired Boilers, ANSI/

ASMECSD-1.Ifthereisanyconict,thenthemorestringentwillapply.

1.3 LOCATION

All Combi boiler models are designed and approved for indoor installation. Its

ventingoptionsprovideexibilityoflocation;forexample,placementinanalcove,

basement, utility room or closet. The unit is approved for installation in a closet

(see Table 2 for clearances to combustibles).

Conditions for safe installations

Ensure that the surrounding conditions are between 32°F [0°C] and 122°F [50°C]

and less than 90% relative humidity.

Install the unit in areas where the combustion air source is free of

contamination.

Exposure to corrosive chemical fumes such as chlorinated and/or

uorinated hydrocarbons can reduce the life of a unit. Cleaners, bleaches,

airfresheners,refrigerants,aerosolpropellants,dry-cleaninguids,de-greasers

and paint-removers contain vapors that can form corrosive acid compounds

whenburnedinagasame.Alsoavoidairbornechloridessuchasthose

released with the use of laundry detergents.

This unit must not be installed in an area where water leakage will result in

damage to the areas adjacent or below the unit. When such areas cannot be

avoided, a suitable drain pan with adequate drain must be installed under the

unit.

Unit fastening

Approximate weight for the unit

85 lbs / 39 kg. For support fasteners, use at

least two of the four supplied ¼" x 1¾" long lag screws. Installers must supply 1/4"

bolts if metal mounting systems are used. Attach the wall mounting bracket to a

structurally sound wall that is capable of supporting the combined weight of the unit

and piping components which can exceed 150 lbs. (68kg).

Unit clearance

Otherfactorsa󰀨ectingpotentialmountingsites:

• Ensure minimum clearance requirements for combustible materials (see

Table 2)aresatised.

• For ease of access, we recommend a minimum 24" clearance at the front and

24" above. Check local codes for additional access and service clearance

requirements.

•

At a new construction site, or during renovations, protect the unit from

drywall dust or other construction related contaminants. Combustion air

must be drawn from a CLEAN source (e.g. outdoors) and the unit must be

isolated from interior dust sources.

WARNING

- Keep the unit area free

and clear of combustible

materials, gasoline, and other

ammable vapors and liquids.

- C

ombustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air

directly next to outdoor pools

and spas.

- T

he unit must not be exposed

to water leaks from piping or

components located overhead.

This includes condensation

dropping from un-insulated

cold water lines overhead.

Ensure the gas ignition

system components are

protected from water (dripping,

spraying, rain, etc.) during

appliance operation and when

servicing (pump replacement,

condensate trap servicing,

control replacement, etc.)

- California Proposition 65

This product contains

chemicals known to the

state of California to cause

cancer, birth defects, or other

reproductive harm.

INSTALLATION AND OPERATION INSTRUCTIONS

1-4

COMBI BOILERS 99 & 125 & 160 & 199

SURFACE

DISTANCE FROM

COMBUSTIBLE

SURFACES

RECOMMENDED DISTANCE

FOR INSTALLATION AND

SERVICE

Front 2" 24"

Rear 0" 0"

Left Side 1.5"

6"(labelsmaybedi󰀩culttoreadwith

reduced clearance)

Right Side 4"

6"(labelsmaybedi󰀩culttoreadwith

reduced clearance)

Top 2" 24"

Bottom 8" 24"

Table 2: Clearance from the unit cabinet

You must provide a minimum distance below the unit of 8" to allow

clearance for the supplied condensation trap assembly. More clearance will

typically be required to accommodate associated water and gas piping.

MOUNT BRACKET TO WALL,

HOOK UNIT OVER TOP.

FOR BRACKET USE TWO ¼” X 1¾” LAG

SCREWS WITH FLAT WASHERS INTO

STUDS. FOR METAL MOUNTING SYSTEM

USE ¼” BOLTS WITH FLAT WASHERS.

Figure 2: Wall mounting of unit

WARNING

- Exposed water piping and

associated components

(relief valves, circulators, etc.)

must not be in contact with

combustible materials. Check

local codes for required

clearances and/or provide

adequate insulation.

- DO NOT MOUNT THIS UNIT

TO A HOLLOW SHEET ROCK

WALL USING ANCHORS. The

wall mounting bracket must

be bolted to wall studs or a

solid wall structure to support

the combined weight of the

unit which can exceed 150

lbs. (68kg) once installed.

- Take precautions to avoid

injury during the installation

of this unit.

1-5

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

1.3.1 Removing/installing the front panel

•

The front panel of the unit must be removed to perform various maintenance

activities.

•

Loosen both screws (1) under the unit by using a 5 mm allen key. (They are

captive and therefore will not drop out of the lower housing).

•

Slide the front panel (2) upward and then remove it by pulling it towards you.

To replace the front panel, proceed as follows:

• Position the front panel (3) against the unit and slide it downwards until it is

correctly connected to the lower fascia panel.

• Hand tighten screws under the unit using a 5 mm allen key (do not over

tighten)

Figure 3: Loosen screws Figure 4: Frontpanel upward

Figure 5: Positioning the frontpanel

CAUTION

The front panel has a rubber

seal around the inner edge

sometimes making it very sti󰀨

to slide o󰀨 so please ensure

the unit is secured to the wall

correctly before attempting

this procedure!

WARNING

This is a room sealed cover

and therefor extremely

important that it is tted

correctly, failure to do so can

result in ue gas spillage and

carbon monoxide emissions,

causing severe personal

injury or death.

INSTALLATION AND OPERATION INSTRUCTIONS

1-6

COMBI BOILERS 99 & 125 & 160 & 199

1.4 EXHAUST VENTING AND AIR INTAKE

When you plan the installation, ensure that you consider appropriate venting

materials, travel and termination decisions.

Consider the following when selecting a vent termination location:

• Select a location where the units exhaust will not damage nearby plants,

shrubs, air conditioning equipment or be objectionable to the homeowner.

• Exhaust gases will form a visible plume during cold weather. Avoid areas

where the plume could obstruct window views.

• Prevailing winds could cause water/ice buildup on nearby objects including

building surfaces.

• Avoid locations where people or pets could come in contact with exhaust

gases.

• Avoid locations such as inside building corners, near adjacent buildings or

surfaces, window wells, stairwells, alcoves, courtyards, or other recessed

areaswherewindcoulda󰀨ecttheunit’sperformanceorcauseexhaustgas

recirculation.

• Select a location where the termination is not likely to be damaged by foreign

objects such as stones or balls, or is subject to buildup of debris such as

leaves.

Combi Boiler

FLUE GAS

EXHAUST TO

OUTDOORS

Figure 6: Basic exhaust vent assembly

Install venting in accordance with the requirements of the jurisdiction having

authority: in Canada, Part 8, Venting Systems of the B149.1-10 Code and any

other local building codes are to be followed. In the USA the National Fuel Gas

Code, ANSI 223.1, latest edition, prevails. Where there is a discrepancy between

the installation instructions below, and the code requirements, you must apply the

more stringent of the two requirements.

Provisions for combustion and ventilation air in accordance with the section “Air

for Combustion and Ventilation”, of the National Fuel Gas Code, ANSI Z223.1/

NFPA 54 (latest edition) in the US or Clause 8.2, 8.3 or 8.4 of Natural Gas

and Propane Installation Code, CAN/CSA B149.1 (latest edition) in Canada or

applicable provisions of the local building codes.

WARNING

- Venting, condensate

drainage, and combustion

air systems for all units

must comply with applicable

codes and the instructions of

their respective Installation

manuals.

- Inspect nished vent and air

piping thoroughly to ensure

all are airtight and comply

with the instructions provided

and with all requirements of

applicable codes.

- Failure to follow all

instructions can result in

ue gas spillage and carbon

monoxide emissions, causing

severe personal injury or

death. Failure to comply will

result in severe personal

injury or death.

DANGER

Failure to properly vent

the unit to the outdoors

as outlined in this Venting

section will result in death

or serious personal injury.

To avoid the risk of re,

explosion, or asphyxiation

from carbon monoxide,

NEVER operate the unit

unless it is properly vented

and has adequate air supply

for proper operation as

outlined in this Venting

section. This unit must have

air supply connected and

terminated to the outdoors.

DANGER

Do not common vent this

Combi Boiler with any other

existing or new appliance,

except as outlined in

this units Common Vent

Installation Instructions.

1-7

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

In the Commonwealth of Massachusetts

The Commonwealth of Massachusetts requires compliance with regulation 248

CMR 4.00 and 5.00 for installation of through-the-wall vented gas appliances as

follows:

(a) For all side-wall, horizontally vented, gas-fueled equipment installed in every

dwelling, building, or structure used in whole or part for residential purposes,

including those owned or operated by the Commonwealth and where the side-

wallexhaustventterminationislessthanseven(7)feetabovenishedgrade

in the area of the venting, including but not limited to decks and porches, the

followingrequirementsshallbesatised.

1. INSTALLATION OF CARBON MONOXIDE DETECTORS. At the time of

installation of the side-wall, horizontally vented, gas-fueled equipment, the

installingplumberorgasttershallobservethatahard-wiredcarbonmonoxide

detectorwithanalarmandbatterybackupisinstalledontheoorlevelwherethe

gasequipmentistobeinstalled.Inaddition,theinstallingplumberorgastter

shall observe that a battery-operated or hard-wired carbon monoxide detector

with an alarm is installed on each additional level of the dwelling, building, or

structure served by the side-wall, horizontally vented, gas-fueled equipment.

It shall be the responsibility of the property owner to secure the services of

qualiedlicensedprofessionalsfortheinstallationofhard-wiredcarbonmonoxide

detectors.

a. In the event that the side-wall, horizontally vented, gas-fueled equipment is

installed in a crawl space or an attic, the hard-wired carbon monoxide detector

withalarmandbatterybackupmaybeinstalledonthenextadjacentoorlevel.

b. In the event that the requirements of this subdivision cannot be met at the time

of completion of installation, the owner shall have a period of thirty (30) days to

comply with the above requirements, provided, however, that during said thirty

(30) day period, a battery-operated carbon monoxide detector with an alarm shall

be installed.

2. APPROVED CARBON MONOXIDE DETECTORS. Each carbon monoxide

detector as required in accordance with the above provisions shall comply with

NFPA720andbeANSI/UL2034-listedandIAS-certied.

3.SIGNAGE.Ametalorplasticidenticationplateshallbepermanentlymounted

to the exterior of the building at a minimum height of eight (8) feet above grade

directly in line with the exhaust vent terminal for the horizontally vented, gas-

fueled heating appliance or equipment. The sign shall read, in print size no less

than one-half (1/2) inch in size, “GAS VENT DIRECTLY BELOW. KEEP CLEAR

OF ALL OBSTRUCTIONS.”

4. INSPECTION. The state or local gas inspector of the side-wall, horizontally

vented, gas-fueled equipment shall not approve the installation unless, upon

inspection, the inspector observes carbon monoxide detectors and signage

installed in accordance with the provisions of 248 CMR 5.08 (2)(a)(1 through 4).

(b) EXEMPTIONS: The following equipment is exempt from 248 CMR 5.08 (2)(a)

(1 through 4):

1. The equipment listed in Chapter 10 entitled “Equipment Not Required To Be

Vented” in the most current edition of NFPA 54 as adopted by the Board, and

2. Product-approved side-wall, horizontally vented, gas-fueled equipment

installed in a room or structure separate from the dwelling, building, or structure

used in whole or in part for residential purposes.

NOTE

For the State of

Massachusetts, use only

plastic piping, ttings

and vent terminations as

specied in this manual

which are approved by the

Massachusetts Board of State

Examiners of Plumbers and

Gas for venting of appliances

(see hyperlink below):

https://licensing.reg.state.

ma.us/pubLic/pl_products/

pb_pre_form.asp

INSTALLATION AND OPERATION INSTRUCTIONS

1-8

COMBI BOILERS 99 & 125 & 160 & 199

SYSTEM PROVIDED. When the manufacturer of product-approved side-wall,

horizontally vented, gas-fueled equipment provides a venting system design or

venting system components with the equipment, the instructions provided by

the manufacturer for installation of the equipment and the venting system shall

include:

1. Detailed instructions for the installation of the venting system design or the

ventingsystemcomponents;and

2. A complete parts list for the venting system design or venting system.

(d) MANUFACTURER REQUIREMENTS – GAS EQUIPMENT VENTING

SYSTEM NOT PROVIDED. When the manufacturer of product-approved side-

wall, horizontally vented, gas-fueled equipment does not provide the parts for

ventingtheuegases,butidenties“specialventingsystems,”thefollowing

requirementsshallbesatisedbythemanufacturer:

1. The referenced “special venting systems” instructions shall be included with

the appliance or equipment installation instructions, and

2. The “special venting systems” shall be product-approved by the Board, and

the instructions for that system shall include a parts list and detailed installation

instructions.

(e) A copy of all installation instructions for all product-approved side-wall,

horizontally vented, gas-fueled equipment, all venting instructions, all parts lists

for venting instructions, and/or all venting design instructions shall remain with

the appliance or equipment at the completion of the installation.

1-9

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Removal of Existing Unit from Common Venting

When an existing unit 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 unit, the following steps must 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.

• Seal any unused openings in the common venting system.

• Visually inspect the venting system for proper size and horizontal pitch, and

determine that there is no blockage or restriction, leakage, corrosion and

otherdecienciesthatcouldcauseanunsafecondition.

• 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replacedampers.

• Place in operation the appliance being inspected. Follow the lighting

instructions. Adjust the thermostat, so that the appliance operates

continuously.

• Test for spillage at the draft hood relief opening after 5 minutes of main

burneroperation.Usetheameofamatchorcandle,orsmokefroma

cigarette, cigar, or pipe.

• 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,replacedampersandanyothergas-

burning appliance to their previous conditions of use.

• Any improper operation of the common venting system must be corrected

so the installation conforms with the National Fuel Gas Code, ANSI Z223.1/

NFPA 54, (latest edition) in the US or the Natural Gas and Propane

Installation Code, CSA B149.1 (latest edition) in Canada. When resizing any

portion of the common venting system, the common venting system must be

resized to approach the minimum size as determined using the appropriate

tables in the National Fuel Gas Code, ANSI Z223.1/NFPA 54 (latest edition)

in the US or the Natural Gas and Propane Installation Code, CSA B149.1

(latest edition) in Canada.

1.4.1 Applications

All Combi Boiler models must be installed as a Direct Vent venting system.

The combustion air must be piped in from the outdoors and connected directly

totheunit’scombustionairconnection.See section 1.4.7 for air intake piping

requirements.

NOTE

The ue gas temperature

sensor reports the current

ue gas exhaust temperature

to the unit’s controller. If

necessary, the controller

will reduce the input of the

appliance to meet the ue

gas exhaust temperature

requirements of PVC material.

The controller locks out the

unit if this temperature is

exceeded, and displays F003.

CAUTION

- The minimum wall thickness

for venting penetration is

1" and the maximum wall

thickness for venting is 14".

- Do not connect this Combi

Boiler to a chimney ue

serving a separate appliance

designed to burn solid fuel.

- The air intake tting can be

moved to the left or to the

right of the exhaust tting.

INSTALLATION AND OPERATION INSTRUCTIONS

1-10

COMBI BOILERS 99 & 125 & 160 & 199

1.4.2 Exhaust Vent Material

Use of ABS, cellular core PVC (ASTM F891), cellular core CPVC, or Radel®

(polyphenolsulfone) in venting systems is prohibited.

Exhaust Vent Material – CANADA

Use only PVC, CPVC, Polypropylene (PPS), or stainless steel* vent components.

Venting components must be approved for use with a Category IV appliance,

listed under ULC S636 and must comply with CSA B149.1 (latest edition).

• PVC (ULC-S636)

• CPVC (ULC-S636)

• Polypropylene (ULC-S636)

• Stainless steel* (ULC-S636)

Exhaust Vent Material – USA

Use only PVC, CPVC, Polypropylene (PPS), or stainless steel* vent components.

Venting components must be approved by the authority having jurisdiction and as

follows:

• PVC (Schedule 40 ASTM D1785)

• CPVC (Schedule 40 ASTM F441)

• Polypropylene (UL1738 / ULC-S636)

• Stainless Steel* (Type BH), DuraVent FasNSeal, HeatFab Saf-T Vent, Z-Flex

Z-Vent

This unit is equipped with a top mounted 2" vent connection. Wet the vent

connection gasket and pipe with clean water prior to assembly. Insert 2" PVC or

CPVC directly into the units vent connection and secure the pipe by tightening

the clamp.

Polypropylene venting will require an adapter from the venting manufacturer

to transition from the 2" vent connection to the venting system. Centrotherm

InnoFlue polypropylene venting requires adapter part number ISAAL0202. Wet

the vent connection gasket and adapter with clean water prior to assembly.

Insert the polypropylene adapter into the units vent connection and secure by

tightening the clamp.

*Manufacturers of stainless steel Type BH venting systems must submit

their approved transition tting to us for evaluation and written approval.

1.4.3 Vent Travel

The maximum exhaust venting length is dependent upon the vent pipe size (2"

or 3") and the venting material (PVC, CPVC, PPs). See Table 3 for maximum

exhaustventinglengthsandtherequiredventinglengthreductionforeachtting

in the venting system.

Example: When using 6 x 90º CPVC elbows, the maximum lineal measure of

pipe allowed using 3" pipe is 72 feet (120' – (6 x 8' = 48') = 72').

For 3" Flexible PPs, up to 35 actual lineal feet are allowed in a nominally vertical

orientation (>45°). The equivalent length of 3" Flexible PPs is calculated using

a multiple of 1.4:1, e.g. 35' x 1.4 = 49' equivalent. The balance of the venting

allowance is still available for use with rigid PPs piping material.

2" Flexible PPs is not allowed.

WARNING

- Do not mix venting materials

from di󰀨erent venting

manufacturers.

These venting materials are

designed to be installed as

part of a complete system.

Failure to comply may result

in severe personal injury or

death.

- Fully insert the approved

venting material into the

unit’s exhaust outlet and

tighten clamp to ensure the

venting connection is locked

in place.

Figure 7 Inlet and outlet vent

connections. Note the ue

exhaust test port.

NOTE

For the State of

Massachusetts, use only

plastic piping, ttings

and vent terminations as

specied in this manual

which are approved by the

Massachusetts Board of State

Examiners of Plumbers and

Gas for venting of appliances

(see hyperlink below):

https://licensing.reg.state.

ma.us/pubLic/pl_products/

pb_pre_form.asp

1-11

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

EXHAUST PIPE SIZE/

FITTINGS

MAXIMUM EQUIVALENT LENGTH

Schedule 40 PVC, CPVC or PPs – Allowances are for each side separately.

2" 65'*

3" 120'

2" or 3" 90° Long Sweep Vent Elbow Allow 5 equivalent feet

2" or 3" 90° Short Sweep Vent Elbow Allow 8 equivalent feet

2" or 3" 45° Vent Elbow Allow 3 equivalent feet

PPS

PPs 87-90° Elbow Allow 8 equivalent feet

Flex PPS

2" PPs Flex Not Allowed

3" PPs Flex 35' Actual (Equivalent = Actual x 1.4)

* The input rate will derate as vent length increases. See table below for

approximate derate at 2" maximum vent length.

MAXIMUM FIRING RATE APPROXIMATE DERATE

99,000 5 - 8%

125,000 - 199,000 10 - 16%

Follow all installation instructions supplied by the pipe and tting

manufacturer. Prior to assembly, ensure all venting components are clean of

burrs/debris which could clog the fan, burner, and heat exchanger.

General Venting/Piping Requirements

If the vent length requires increasing the vent pipe size to 3", the transition from

the2"ventconnectorto3"ventingmustoccurwithintherst18"ofthetopofthe

unit and must be done in a vertical section to avoid pooling of condensate. Slope

exhaust venting back towards the unit with a pitch of at least 1/4" per foot. Follow

venting manufacturer pitch requirements, so condensate runs back towards the

trap. Support air intake and vent piping per local code and vent manufacturers

requirements. In the absence of support requirements, support the air intake and

vent piping at every vertical and horizontal transition as well as every 5' of run.

Begin the vent system installation at the unit and work towards the outdoor

termination. We recommend using a bird screen of 1/4" stainless steel or plastic

mesh (e.g., IPEX System 636 drain grate for CPVC systems) to guard against

foreign objects.

BEST PRACTICES

To reduce the possibility of

expansion noise, allow a 1/4"

gap around the exhaust and

air intake piping.

NOTE

The bird screen is optional

for exhaust piping in cold

weather climates.

WARNING

ombustion air must not be

drawn from areas containing

corrosive air from swimming

pools or spas, including air

directly next to outdoor pools

and spas.

Table 3: Maximum Exhaust Venting Length

Figure 8

INSTALLATION AND OPERATION INSTRUCTIONS

1-12

COMBI BOILERS 99 & 125 & 160 & 199

Secure joints using appropriate solvent cement to bond the respective pipe

material (Canada: PVC/CPVC cement approved under ULC-S636, in accordance

with its manufacturer instructions; USA: PVC (ASTM D2564), or CPVC (ASTM

F493). Use transition cement anywhere that PVC and CPVC are joined. Follow

thecementmanufacturer’sinstructionscloselywhenjoiningvariouscomponents.

For PPs, connections must be secured using approved retainer clips supplied by

the respective PPs manufacturer.

Ensurethatallventconnectionsareliquidandpressuretight.Priortoringthe

unit, and before any of the venting run is concealed by the building construction,

youmusttesttheexhaustjointswithasoap/watersolution.Youmustllthe

condensate trap before testing.

1.4.4 Venting Passage Through Ceiling and Floor

• Conrmmaterialmeetslocalcodesincludingrestoppingrequirements.

Some local jurisdictions require that a minimum initial length of pipe be

exposed or accessible for inspection.

•

Pipe clearances - best practice allows a minimum 1/4" gap around the pipe to

prevent binding and expansion noise. Follow local codes.

• All piping must be liquid and pressure tight.

1.4.5 Rooftop Vent Termination

Direct Vent - Two Pipe

Rooftop vents must terminate as follows:

•

The exhaust pipe can terminate in an open vertical orientation without concern

aboutraininltration;rainwilldrainawaythroughthecondensatetrap.

•

The intake air pipe is not typically drained, so it must be terminated with a down-

turned elbow (see Figure 10). The intake pipe does not need to penetrate the

roofatthesameelevationastheexhaust(asshown);lowerdowntheroofis

OK.

WARNING

Condensate can cause

corrosion of metal roong

components and other

roong materials. Check

with the builder or roong

contractor to ensure that

materials are resistant to

acidic condensate. pH levels

can be as low as 3.0

[18" (457 mm) Canada] MIN.

NOTE: THE BIRD SCREEN

IS OPTIONAL IN COLD

WEATHER CLIMATES

CAUTION

Vent termination clearances

in this section are code

minimum, or recommended

minimum requirements,

and may be inadequate for

your installation. You must

examine building envelope

details, and take measures to

avoid admission of moisture

into building structures.

Serious structural damage

may occur if adequate

precautions and clearances

are not allowed for.

These precautions are to be

observed for neighboring

structures as well as for

the structure the unit(s) are

installed in.

Figure 10: Rooftop vent terminal congurations

Figure 9: Rooftop vent terminal

congurations

1-13

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

• The air intake pipe may terminate on the side wall of the building as long as

the air intake terminal is turned down and the side wall of the building is not

exposed to large wind loads i.e.,: prevailing wind (see Figure 9).

• Optionalbirdscreenmaybeplacedinaterminationtting.Leaveunglued,

and hold in place with a short nipple to allow easy access for cleaning.

• For roof top venting of multiple unit sets, group all intake terminals together

for a common penetration through a custom cap. Alternatively, place in

theclosestproximityachievableusingcommonlyavailablepipeashing.

Similarly, group the exhaust pipes and place the 2 separate groups of pipes

at least 3' apart (the closest intake and exhaust pipes must be 36" - or more -

apart). Use the same 12" (minimum) vertical separation for 2 pipe option.

• DO NOT exhaust vent into a common venting system, except as outlined

in this units Common Vent Installation Instructions.

DIRECT VENT CONCENTRIC ROOF TOP TERMINATION

Roof Top Concentric Termination kits are approved for use with this unit.

For vertical roof top concentric terminations, you must follow the installation

instructions supplied by the manufacturer. Care must be taken to install the

termination kit a minimum horizontal distance of 10' (305cm) away from any

portion of the building and a minimum of 12" (305 mm) [18" (457 mm) Canada]

above the roof line plus the anticipated snow line (see Figures 11 and 12).

Figure 11: Vertical Concentric Termination - Two Kits

Figure 12: Vertical Concentric Termination - Single Kit

INSTALLATION AND OPERATION INSTRUCTIONS

1-14

COMBI BOILERS 99 & 125 & 160 & 199

1.4.6 Sidewall Vent Termination

Direct Vent - Two Pipe

Sidewall direct vent applications must be vented as follows:

• Both the inlet and exhaust terminations must bemust be located on the same plane

(side) of the building.

• The exhaust outlet is to be placed so as to reach 12" minimum above the

down-turned intake - to avoid intake re-ingestion of exhaust gases.

• The elevation of both pipes can be raised in “periscope style” after passing

throughthewall,thenconguredasinFigure 13, to gain required clearance.

• Usea45°elbowontheexhaustterminationtolaunchtheplumeupando󰀨

the sidewall, for protection of wall.

• Optionalbirdscreenmaybeplacedinaterminationtting.Leaveunglued,

and hold in place with a short nipple to allow easy access for cleaning.

SNOW + 12"

[305mm]

MIN.

SNOW + 12"

[305mm]

MIN.

SNOW + 12"

[305mm]

MIN.

Figure 13: Sidewall vent termination - piping conguration

WARNING

- You must maintain at least

the minimum separation of

exhaust vent termination from

unit’s intake air as illustrated

in gures 9, 10, 13 and 15.

Failure to do so can result

in a dangerous situation

where exhaust gases are

pulled in with combustion air.

Damage to the unit can result

from a failure to maintain

these separations. Improper

installation will void the

warranty.

- You must not cover non-

metallic vent pipe and ttings

with thermal insulation.

- In areas of high snowfall,

users must be advised to

check side wall vent and

air intake terminations on

a regular basis to ensure

blockage does not occur.

WARNING

The vent for this appliance The vent for this appliance

must not terminate:must not terminate:

1. Over public walkways in 1. Over public walkways in

the US. In Canada 7’ above the US. In Canada 7’ above

public walkways.public walkways.

2. Near so󰀩t vents or crawl 2. Near so󰀩t vents or crawl

space vents or other areas space vents or other areas

where condensate or vapor where condensate or vapor

could create a nuisance or could create a nuisance or

hazard or cause property hazard or cause property

damage.damage.

3. Wherever condensate 3. Wherever condensate

vapor could cause damage vapor could cause damage

or could be detrimental to the or could be detrimental to the

operation of regulators, relief operation of regulators, relief

valves, or to other equipment.valves, or to other equipment.

Figure 14Figure 14: Prohibited installation

1-15

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

For sidewall venting of multiple units, group all intake terminals together with 6"

(minimum) lateral spacing, and similarly group the exhaust pipes. Place the 2

groups on the same plane of the building (e.g., north facing wall). Place the 2

groups of pipes at least 3' apart (the closest intake and exhaust pipes must be

36" - or more – apart). Use same 12" (minimum) vertical separation (see A in

Figure 15). Alternatively, as long as the units are identical models - intake and

exhaust terminals can maintain a minimum of 12" of separation horizontally from

any exhaust or inlet termination of an adjacent unit (see B in Figure 15).

DIRECT VENT SIDE WALL TERMINATION KITS

The Side Wall Termination kits approved for use with the Combi Boilers are

subject to restrictions. NOTE: Some jurisdictions may not allow this type of side

wall termination due to close proximity to the neighboring properties. See Figures

16, 17 and 18 on page 1-15, 1-16.

You must follow the installation instructions, clearances and wall thickness

requirements of the approved vent termination manufacturer.

Approved Side Wall Termination Kits are listed below:

• 2"PVClowproleterminationkit-Part#P-741

• 3"PVClowproleterminationkit-Part#P-742

Vent on Left or Right Side

[305mm]

[152mm]

12" [305mm] MIN.

[915mm]

Figure 16 PVC low prole termination acceptable orientations

Figure 15: Sidewall vent termination - multiple vent piping conguration

INSTALLATION AND OPERATION INSTRUCTIONS

1-16

COMBI BOILERS 99 & 125 & 160 & 199

Concentric SideWall Termination Kits

Concentric Sidewall Termination kits approved for use with the Combi boiler

are subject to restrictions. NOTE: Some jurisdictions may not allow this type of

sidewall termination due to close proximity to the neighboring properties.

You must follow the installation instructions, clearances, and wall thickness

requirements of the approved vent termination manufacturer.

Approved Concentric Sidewall Termination kits are:

• 3" PVC (UL 1738) – Ipex #397006

• 3" PVC (ULC-S636) – Ipex #196006

• 3" CPVC (ULC-S636) – Ipex #197009

• 2"CentrothermInnouePPs-#ICWT242(Termination)

#ICTCR24 (2 Pipe Adapter)

• 3"CentrothermInnouePPs-#ICWT352(Termination)

#ICCT3503 (2 Pipe Adapter)

Installation of multiple Concentric Side Wall Termination kits must be:

• On the same horizontal line (not stacked)

• With a minimum horizontal separation of 12" center to center

12" + Allowance

for Snow Level

Figure 17: Horizontal Polypropylene Concentric Termination - Two Kits

Figure 18: Horizontal Polypropylene Concentric Termination - Single Kit

1-17

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Vent terminal clearance minimums are as follows:

VENT TERMINAL MINIMUM CLEARANCES

CANADIAN

INSTALLATIONS

1, 3

US INSTALLATIONS

A= Clearance above grade,

veranda, porch, deck, or

balcony

12 in (30 cm) 12 in (30 cm)

B= Clearance to window or

door that may be opened

12 in (30cm) for appliances

below 100,000 Btuh (30 kW)

36 in (91 cm) for appliances

over 100,000 Btuh (30 kW)

12 in (30 cm)

C= Clearance to permanently

closed window

* (Recommend minimum 1 ft

(30 cm))

* (Recommend minimum 1

ft (30 cm))

D= Vertical clearance to

ventilatedso󰀩tlocatedabove

the terminal within a horizontal

distance of 2 ft (61 cm) from

the center line of the terminal.

* (Recommend minimum 2 ft

(61 cm))

* (Recommend minimum 2

ft (61 cm))

E= Clearance to unventilated

so󰀩t

* (Recommend minimum 1 ft

(30 cm))

* (Recommend minimum 1

ft (30 cm))

F= Clearance to outside corner * (Recommend minimum 4 ft

(122 cm))

* (Recommend minimum 4

ft (122 cm))

G= Clearance to inside corner * (Recommend minimum 4 ft

(122 cm))

* (Recommend minimum 4

ft (122 cm))

H= Clearance to each side of

center line extended above

meter/regulator assembly

3 ft (91 cm) within a height of

15 ft (4.6m)

I= Clearance to service

regulator vent outlet

3 ft (91 cm) *

J= Clearance to nonmechanical

air supply inlet to building or

the combustion air inlet to any

other appliance

12 in (30cm) for appliances

below 100,000 Btuh (30 kW)

36 in (91 cm) for appliances

over 100,000 Btuh (30 kW)

12 in (30cm)

K= Clearance to a mechanical

air supply inlet

6 ft (1.83 m) 3 ft (91 cm) above if within

10 ft (3 m) horizontally

L= Clearance above paved

sidewalk or paved driveway

located on public property

7 ft (2.13 m) † Vents cannot be located

above public walkways

or other areas where

condensate or vapor

can cause a nuisance or

hazard.

M= Clearance under veranda,

porch, deck, or balcony

12 in (30 cm) ‡ *

Clearance to adjacent wall 6 ft (1.83 m) 6 ft (1.83 m)

1 In accordance with the current CSA B149.1 Natural Gas and Propane Installation Code

2 In accordance with the current ANSI Z223.1 / NFPA 54 National Fuel Gas Code

3Iflocallyadoptedinstallationcodesspecifyclearancesdi󰀨erentthanthoseillustrated,thenthemoststringentshall

apply.

† A vent shall not terminate directly above a sidewalk or paved driveway that is located between two single family

dwellings and serves both dwellings.

‡ Permittedonlyifveranda,porch,deck,orbalconyisfullyopenonaminimumoftwosidesbeneaththeoor.

* Clearance in accordance with local installation codes and the requirements of the gas supplier. The minimum distance

from adjacent public walkways, adjacent buildings, openable windows, and building openings shall not be less than

thosevaluesspeciedintheNationalFuelGasCode,ANSIZ223.1/NFPA54,and/ortheNaturalGasandPropane

Installation Code, CSA B149.1

WARNING

- In addition to preventing

ingestion of chemical

contaminants, care must

be taken to ensure air

intake terminals are not

installed in locations

where contamination might

occur due to ingestion of

particulate foreign material

(dust, dirt and debris).

- Intake air openings must

be congured such that

rain or other forms of

moisture cannot enter the

air intake piping system.

Otherwise serious damage

to the unit may result.

NOTE

Care must be taken when

installing air intake piping

to ensure that a “trap” is

not formed in the piping

so as to allow a build-up

of water, and blockage of

intake air.

Such blockage will result

in a unit’s safety shut-

down.

INSTALLATION AND OPERATION INSTRUCTIONS

1-18

COMBI BOILERS 99 & 125 & 160 & 199

1.4.7 “Direct Vent” Combustion Air Intake Piping

The unit must always be installed as a Direct Vent venting system with the

combustionairpipeddirectlyfromtheoutdoorstotheunit’scombustionair

connection. Provisions for combustion and ventilation air are in accordance with

the section “Air for Combustion and Ventilation”, of the National Fuel Gas Code,

ANSI Z223.1/NFPA 54 (latest edition) in the US or Clause 8.2, 8.3 or 8.4 of

Natural Gas and Propane Installation Code, CAN/CSA B149.1: (latest edition) in

Canada or applicable provisions of the local building codes.

FLUE GAS

EXHAUST TO

OUTDOORS

COMBUSTION

AIR FROM

OUTDOORS

ALTERNATIVE

COMBUSTION AIR

CONNECTION

“DIRECT VENT”

INSTALLATION

CHECK AIR INTAKE

OUTSIDE TO MAKE SURE

IT IS CLEAR OF

OBSTRUCTIONS

Combi Boiler

Figure 20: Direct vent combustion air intake

Figure 19: Vent Terminal Clearance

Vent terminal

Air supply inlet

Area where terminal is not permitted

NOTE

Combustion air connection

may be moved from one side

to the other:

- Remove the retaining clip

screws then lift tab at back of

plug and rotate 1/8

of a turn

counter-clockwise to remove

from top of cabinet.

- Remove the retaining clip by

removing both screws then

lift tab at back of combustion

air connection and rotate

1/8th of a turn counter-

clockwise to remove from top

of cabinet.

- Reinstall plug and

combustion air connection

in the desired locations then

rotate 1/8

of a turn clockwise

until tab latches into the top

of the cabinet.

- Reinstall the retaining clip

over the combustion air

connection tab and secure

with two screws. Reinstall

two screws in the top of the

cabinet near the plug.

1-19

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Intake Pipe Sizing

For 3" Flexible PPs, you can use up to 35 actual linear feet in a nominally vertical

orientation (>45°). The equivalent length of 3" Flexible PPs must be calculated

using a multiple of 1.4:1, e.g. 35' x 1.4 = 49' equivalent. The balance of the

venting allowance is still available for use with rigid PPs piping material.

2" Flexible PPs is not allowed.

INTAKE PIPE SIZE/FITTINGS MAXIMUM EQUIVALENT LENGTH

Schedule 40 PVC, ABS, CPVC or PPs – Allowances are for each side separately.

65'65'**

3" 120'

2" or 3" 90° Long Sweep Vent Elbow Allow 5 equivalent feet

2" or 3" 90° Short Sweep Vent Elbow Allow 8 equivalent feet

2" or 3" 45° Vent Elbow Allow 3 equivalent feet

PPS

PPs 87-90° Elbow Allow 8 equivalent feet

Flex PPS

3" PPs Flex 35' Actual (Equivalent = Actual x 1.4)

Table 4: Maximum intake piping length.

* The input rate will derate as intake length increases. See table below for

approximate derate at 2” maximum intake length.

MAXIMUM FIRING RATE APPROXIMATE DERATE

99,000 5 - 8%

125,000 - 199,000 10 - 16%

For air intake, you can use Schedule 40 PVC, CPVC, ABS or PPs piping of any type. Use

the same diameter as vent piping.

Insertcombustionairpipingdirectlyintothe2"femaleplasticttingonthetopoftheunit,

and run it horizontally or vertically to the outdoors. We recommend using a bird screen of

1/4" stainless steel or plastic mesh (eg. IPEX System 636 drain grate for CPVC systems)

to guard against foreign objects.

Care must be taken to ensure adequate separation is maintained between the air intake

inletandtheventtermination.Refertotheventterminationcongurationdrawingsinthe

“Vent Termination” section above.

Support air intake and vent piping per local code and vent manufacturers requirements.

In the absence of support requirements, support the air intake and vent piping at every

vertical and horizontal transition as well as every 5' of run.

1.4.8 “Indoor Air” Combustion Air Intake

The use of indoor air for combustion is prohibited. Combustion air must be piped in from

theoutdoorsandconnecteddirectlytotheunit’scombustionairconnection

1.4.9 Closet Installations

Forinstallationsinaconnedspace(suchasacloset),ventilationopeningsmaybe

needed through a door or wall to prevent build-up of excessive heat from inside the space.

The unit must not be exposed to surrounding conditions above 122°F (50°C) or below

32°F (0°C).

INSTALLATION AND OPERATION INSTRUCTIONS

1-20

COMBI BOILERS 99 & 125 & 160 & 199

1.5 CONDENSATE REMOVAL

Thespeciedventcongurationpromotesthesafedrainageofmoisturefromthe

unitandexhaustventingwithoutowingliquidsbackthroughtheheatexchanger.

Reliable system operation requires (1) proper design and installation of

exhaustventingtoallowcondensatetorunbacktothedrain/trap;(2)acidpH

neutralization as appropriate. To achieve these:

1. Allow for a 1/4" per foot slope back to the vent connection, with appropriate

hangers to maintain that gradient.

2. Ensurethesuppliedtrapiscorrectlyinstalledandlledwithwater.

3. When required, add (and maintain in good condition) a neutralization tank.

1.5.1 Condensate Trap

The condensate trap cup must be installed on the bottom of the condensate trap

at the base of the unit.

1.5.2 Installing the Condensate Trap

1. Fill the condensate trap cup with water.

2. Install the condensate trap cup on the condensate trap base and twist toward

the right.

3. Attach the drain hose to the condensate trap outlet located to the left of the

condensate trap cup.

Figure 21: Condensate trap installation

WARNING

Fill the trap with water before

initial startup of the unit to

prevent exhaust fumes from

entering the room. Never

operate the unit unless the

trap is lled with water.

Failure to comply will result

in severe personal injury or

death.

NOTE

It is the responsibility of

the installing and/or service

Contractor to advise and

instruct the end user on how

to perform the Trap cleaning

procedure, and to advise

that the trap be checked at

least every two months and

cleaned as required.

1-21

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

1.5.3 Further Installation Details

•

Pipe the condensate drain tube to within 1" of a drain, or connect it to a

condensate pump.

• Slope the drainage line down to the drain at a pitch of 1/4" per foot, so that the

condensate runs towards the drain.

• Checkthecondensatetrapevery2months,andcleanandrellasnecessary.

Figure 22: Condensate trap drainage

Figure 23: Condensate neutralization tank

Combi Boiler

WARNING

If discharging condensates into

building drain piping materials

that are subject to corrosion,

you must use a neutralization

package.

CAUTION

When a condensate

neutralization package

is installed, the pH of the

condensate discharge must

be measured on a regular

schedule to ensure the

neutralizing agent is active

and e󰀨ective.

DANGER

The water in the condensate

neutralizer can cause severe

burns to the skin. Use extreme

caution when servicing the

condensate neutralizer. Wear

protective gloves and eyewear.

INSTALLATION AND OPERATION INSTRUCTIONS

1-22

COMBI BOILERS 99 & 125 & 160 & 199

1.6 WATER PIPING - SPACE HEATING

1.6.1 General Piping Considerations

The Combi boiler includes a factory installed, integral heating pump. The pump is

designedtoprovideadequateowthroughtheunitandnearunitpiping.

Primary/secondarypipingortheuseofabu󰀨ertank/hydraulicseparatoris

recommendedformaximumexibilityinmultizone/loadapplications.Piping

loadsinparallelisonlyacceptableinsystemswheretheminimumowrateis

guaranteedtobehigherthantheminimumfortheunitandwheretheunit’spump

isadequatetoprovidetherequiredowrateandpumpheadforthesystem.

A=boiler pressure drop

The unit is designed for use within a closed loop, forced circulation, low pressure

system. A 30 PSI pressure relief valve (3/4" NPT) is supplied.

Combi Boiler

DHW

DCW

Figure 24: Overview of piping

connections

100%

25%

50%

75%

Graph 1: Boiler pressure drop models 99-125 Btu/hr and 160-199 Btu/hr models- Pump

runs between 50% to 100% capacity to establish pressure dierence across boiler circuit

1-23

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Figure 25: Relief Piping

System Piping

Systempipingisconnectedtotheunitusingthe1"NPTMalethreadedttings

locatedonthebottomoftheunit.Usetwowrencheswhentighteningeldpiping

ontotheboiler.Useonewrenchtoholdtheboilerttingstillwhiletighteningwith

another wrench. We recommend using unions and gate or ball valves at the

unit’ssupplyandreturnwaterconnectionstosimplifyservicing.Un-insulatedhot

water pipes require a minimum 1/4" clearance from combustible materials.

Fluidllismostoftenaccomplishedbyusingaregulator&llvalvesetat12psig

ormore,withappropriatebackowpreventiondeviceasrequiredbylocalcode.

This is acceptable in areas where municipal water or well water has been treated

andlteredtoremoveexcessivemineralsandsediment,andwaterchemistry

is known to be suitable for closed-loop hydronic systems. When water quality is

unknown, or when chemical treatment or glycol is required, you should consider

other options. Follow applicable Codes and good piping practice.

Other feed and pressurization devices on the market today may be a better

choicethanarawwaterllfromthemains.Whenregularmaintenancerequires

reliefvalveblow-o󰀨,thedischargemaybedirectedbackintothepressurization

unitforrecyclingofunituidandchemicalsbackintothesystem.Inbuildingsthat

may be unoccupied for long periods of time, pressurization units are useful to

preventooddamageshouldleakageoccurfromanycomponentinthesystem.

Anadditionalbenetisthatbackowpreventiondevicesarenotrequiredwhen

using these devices.

Do not place any water connections above the unit. Leaks can damage the

fan and controls. If needed, create a shield over the top of the cover, but allow

clearanceforairowandserviceaccess.

WARNING

Failure to support the boiler

tting with a second wrench

while tightening eld piping

may lead to boiler damage.

INSTALLATION AND OPERATION INSTRUCTIONS

1-24

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Figure 26: Boiler trim basic options – concept drawing is only a simple schematic guide

Forbestresults,useaprimary/secondarypipingsystem,withaboiler’sloop

using 1" piping (see section 1.6.2). The unit comes with the primary pump

installedandgenerallyprovidesadequateowfortheunitandprimaryloop

piping only.

Combi Boiler

Combi Boiler Combi Boiler

Combi Boiler

Figure 27: Permitted and prohibited space heating combi boiler piping

WARNING

During operation, the relief

valve may discharge large

amounts of steam and/or hot

water. To reduce the potential

for bodily injury and property

damage, a discharge line

MUST be installed that:

1. Is connected from the

valve outlet with no

intervening valve and

directed downward to a

safe point of discharge.

2. Allows complete drainage

of both the valve and the

discharge line.

Is independently supported

and securely anchored to

avoid applied stress on the

valve.

4. Is as short and straight as

possible

5. Terminates freely to

atmosphere where any

discharge is clearly

visible and is at no risk of

freezing.

6. Terminates with a plain

end which is not threaded.

7. Is constructed of a material

suitable for exposure to

temperatures of 375°F

(190°C) or greater.

8. Is, over its entire length,

of a pipe size equal to or

greater than that of the

valve outlet.

DO NOT CAP, PLUG OR

OTHERWISE OBSTRUCT THE

DISCHARGE PIPE OUTLET!

CAUTION

Installers should inquire of

local water purveyors as to the

suitability of their supply for use

in hydronic heating systems. If

water quality is questionable,

a local water treatment expert

must be consulted for testing,

assessment and, if required,

treatment.

Alternatively, water or hydronic

uid of known quality can be

brought to the site.

1-25

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

WARNING

- Close ll valve after any

addition of water to the

system, to reduce risk of

water escapement.

- Ensure the gas ignition

system components are

protected from water (dripping,

spraying, rain, etc.) during

appliance operation and when

servicing (pump replacement,

condensate trap servicing,

control replacement, etc.)

NOTE

- The piping system of a

hot water unit connected

to heating coils located in

air handling units where

they may be exposed to

refrigerated air circulation

must be equipped with

ow control valves or

other automatic means to

prevent gravity circulation

of the unit’s water during the

cooling cycle.

- The unit, when used

in connection with a

refrigeration system, must

be installed so the chilled

medium is piped in parallel

with the unit with appropriate

valves to prevent the chilled

medium from entering the

unit.

Figure 27 illustrates that the integral space heating pump can be hydraulically

separated from the distribution pump by (A) closely-spaced tees, or by (B) a

low-loss header. Although best practice is primary/secondary, in some cases

(C)theintegralpumpwillbeadequatetoprovideowthroughthebuildingheat

emitters. The installer / designer must ensure that if the integral pump is used for

the space-heating emitters it is powerful enough for system distribution. Avoid

(D) where an external pump is placed in series with the integral pump because

the external pump runs when the Combi boiler is serving DHW. It will strongly

compromise DHW response.

The unit is designed to supply the heating load with temperatures within the

range of 86°F to 194°F (30° to 90°C). Use closely-spaced tees to connect

each pumped space heating load to the primary loop. As an option, a hydraulic

separatororbu󰀨ertankcanbeusedtoseparatetheheatingloadsfromtheunit.

Ensure that the pump is rated for the design circulating water temperatures.

Some pumps have a minimum water temperature rating above the low

temperaturepotentialoftheunit.Followinginstallation,conrmtheperformance

bymeasuringΔT(underhighandlowowconditions)afterestablishingthe

correctringrate.

Werecommendwaterowafterburnershutdowntouselegacyheat–thisis

signicantduetothemassoftheheatexchanger.Thepumpisunderthecontrol

of the unit to allow pump purge after burner shut-down. Default software values

willruntheunit’spumpfor1minuteaftertheburnershutsdown.

18po minimum

Figure 28: Basic Primary/Secondary piping with closely-spaced tees concept – concept

drawing. This drawing is only a simple schematic guide.

INSTALLATION AND OPERATION INSTRUCTIONS

1-26

COMBI BOILERS 99 & 125 & 160 & 199

Schematics for several piping layouts are provided herein. You must conform

thepipingdesigntooneoftheprovidedcongurationstosimplifythecontrol

application,promotegoodloadsandowmanagement.

Thisunitsringratemodulationo󰀨ersexceptionalmatchingofheatgenerationto

radiation.Thelowminimumringisbettersuitedtolowthermalloadspresented

in a typical multi-zoned radiation system. However, where individual zones in

aheatingsystemhaveloadsunder10,000Btu/hr,thesystemwillstillbenet

throughtheuseofabu󰀨ertanktoensureacontrolledsupplytemperature,andto

preventshort-cycling.Bu󰀨eringshouldbeaddedonthesecondarypipingofthe

relevant load, to avoid bulking up the thermal mass of the primary piping circuit

(and potentially lengthen the duration of the transition from hot to cool loads).

Propylene glycol solution is commonly used in a closed loop where freeze

protection is required. Its density is lower than that of water, resulting in lower

thermalperformanceatagivenowandpressure.Asolutionofpropyleneglycol

and water will require an increased system circulation rate and system head to

provide performance equivalent to straight water.

1.6.2 Basic Heating Piping Arrangements

Primary/Secondary Piping - Benets and installation rules

Theprimary/secondaryconguration:

• Ensuresgoodcirculatingwaterowthroughtheunitirrespectiveofloador

radiation system head.

• AllowsexibleΔT°controlinsecondaryloops.

• Addstothesystem’sthermalbu󰀨ering,toassistinhandlingsmallloadsand

temperature transition.

Aprimary/secondarypipingcongurationrequiresanextrapump,independent

of any secondary load pumps. This Combi Boiler includes a pre-wired integral

Primary Pump.

For optimal performance, place pumps on the supply side of secondary loops

to facilitate air evacuation. Use pumps with internal check valves to avoid ghost

owsandthermalsiphoning.

This unit is designed to be piped in a primary/secondary piping arrangement. In

some cases the unit can be piped in series with the heating load if the pump is

capableofprovidingtheowandheadthesystemrequires.Forexample,this

unit and an air handler can be installed together without the use of an additional

pump if the air handler is installed within close proximity of the unit and with

properly sized supply and return piping (see Figure 33).

If the installation involves small loads, as in typical zoned baseboard heating

applications,werecommendusingabu󰀨ertank.

To aid in temperature transition from hot to cool loads, place a 3-way mixing

valveattheentrancetothecoolload(thiswillalsoprovideoorprotection).This

typeofinstallationallowsimmediatecirculationofmixedowintothecoolloop.

WARNING

Water quality has a signicant

impact on the lifetime and

performance of the unit’s heat

exchanger.

Improperly prepared water in

a heating circuit may cause

damage to the heat exchanger

through corrosion or fouling.

Repeated or uncontrolled

water lls will increase the

potential for damage.

High levels of dissolved

solids or minerals may

precipitate out of the uid

onto the hottest part of the

heat exchanger, impairing

heat transfer and resulting in

overheating and premature

failure. The amount of solids

that may form on the heat

exchanger will depend on

the degree of hardness and

the total water volume in

the system. A high water

volume system with a low

hardness count may cause

as much damage as a system

with less volume and higher

hardness. We recommend

treating water to remove all

dissolved solids. Other water

chemistry allowable limits are

as follows:

• Acidity pH is to be between

6.5 and 8.5

• Chloride is to be less than

125 mg/l

• Iron is to be less than 0.3

mg/l

• Cu less than 0.1 mg/l

• Conductivity is to be less

than 400μS/cm (at 25°C)

• Hardness is to be 7 Grains

or less

IMPORTANT: Ensure that

these limits are acceptable

for the other water-side

components in the system.

1-27

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Combi Boiler Combi Boiler

Figure 29: Multiple combi boiler piping concept – concept drawing. This drawing is only a

simple schematic guide.

Multiple unit piping - Benets and installation rules

Multiple Combi boilers can be installed in a single heating system to provide

redundancy, increased output, and greater heating plant turn-down capabilities.

Primary/Secondary piping must be used. This approach provides constant head

andowateachunit,regardlessofowvariationsinthemainbuildingloop.

Eachunitcontrolsitsownpump,turningito󰀨oronwhenheatisrequired.This

approach saves electricity by reducing the pumping power required as load

conditions are reduced.

The Combi Boilers controller includes a cascade function which allows up to

8 Combi Boilers or Heating Boilers to operate together to satisfy a common

demand. See included Controller Manual for details.

Usecheckvalvesineachunit’spipingtopreventreverseowwhentheunitis

o󰀨.

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of

any kind. This may result

in severe unit damage. It

is the responsibility of the

Installer to ensure that glycol

solutions are formulated to

inhibit corrosion in hydronic

heating systems of mixed

materials. Improper mixtures

and chemical additives may

cause damage to ferrous and

non-ferrous components as

well as non-metallic, wetted

components, normally found

in hydronic systems. Ethylene

glycol is toxic, and may be

prohibited for use by codes

applicable to your installation

location. For environmental

and toxicity reasons, we

require only using non-toxic

propylene glycol.

NOTE

- The piping drawings in this

manual are simple schematic

guides to a successful

installation.

- There are many necessary

components not shown, and

details such as thermal traps

are left out so the drawings

have greater clarity.

- We require that our units

be installed by licensed and

experienced trades people

who are familiar with the

applicable local and national

codes.

- System design is to be

completed by an experienced

hydronic designer or

Engineer. It is necessary to

carefully read and follow

these installation instructions

along with the application

drawing that ts your system.

INSTALLATION AND OPERATION INSTRUCTIONS

1-28

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Figure 31: Space heating piping concept with closely-spaced tees on secondary loop.

Combi Boiler

Figure 30: Typical one temperature space heating piping concept with direct domestic hot

water – concept drawing. This drawing is only a simple schematic guide.

1-29

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Figure 32: Typical two temperature space heating piping concept with domestic hot water

– concept drawing. This drawing is only a simple schematic guide.

Combi Boiler

Figure 33: Air handler and direct domestic hot water – parallel piping for low loss heat

emitter concept drawing. This drawing is only a simple schematic guide.

INSTALLATION AND OPERATION INSTRUCTIONS

1-30

COMBI BOILERS 99 & 125 & 160 & 199

Combi Boiler

Figure 34: Air handler and direct domestic hot water – primary/secondary concept drawing.

This drawing is only a simple schematic guide.

1-31

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

1.7 DOMESTIC HOT WATER SYSTEM

BURN

HOT

DANGER

Water temperature over 125°F (52°C) can cause severe burns instantly

or death from scalds.

Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

WARNING

CAUTION

WATER HEATER INSTALLATION GUIDELINES

ADJUSTABLE TEMPERATURE SETTING

Hotter water increases the risk of scald injury. Before changing the temperature setting, see

instruction manual.

This unit must be installed in accordance with local codes, if any; if not follow the National

Fuel Gas Code, ANSI Z223.1/NFPA 54, or the Natural Gas and Propane Installation Code,

CAN/CSA B149.1, as applicable.

Failure to correctly install and operate this appliance can result in severe personal injury

or death.

The unit shall have a pressure relief valve installed within 6" [152mm] of the DHW HOT

outlet connection.

Refer to the unit’s User Manual before operating the relief valve.

The unit requires a pressure relief valve identiﬁed with the ASME V or HV symbol and

set to relieve at or below 150psi of domestic water pressure and a minimum relieving capacity

of 199,000 Btu/hr with 3/4" NPT threads. For safe operation of the unit, the relief valve

must not be removed from its designated point of installation or plugged.

Read and follow warnings and instructions.

Touch the panel above the white dot , then touch the Faucet . Adjust the water temperature

with the Plus + and Minus – then touch the Return button to save the changes.

INSTALLATION AND OPERATION INSTRUCTIONS

1-32

COMBI BOILERS 99 & 125 & 160 & 199

1.7.1 Domestic Hot Water System

ThisCombiboilerhasanindependentpipingcircuitfore󰀩cientlygenerating

DomesticHotWater.Whenafaucetisopenedtodrawhotwater,waterowis

detectedwithaowsensorandtheunitresuptobegingeneratingdomestichot

water.Duetotheuniquedesignoftheunit’sheatexchanger,theunitcanrewith

eithernowaterinthespaceheatingcircuitorwithoutowofwaterifpressurized

with the domestic heating system water.

The heat exchanger has two separate copper water passageways encased in the

aluminum heat transfer block. Each copper passageway is completely isolated

from the other to eliminate cross contamination in the event of a leak. This heat

exchanger complies with the double wall heat exchanger requirements in many

regional jurisdictions.

Theuniquedesignofthecastaluminumheatexchangeractsasaheatbu󰀨er,

eliminatingthecoldsandwiche󰀨ectwhenturningonando󰀨thewaterrepeatedly.

While the unit is less susceptible to lime scale build-up than other units on the

market, always consider water quality in the installation. We strongly recommend

treating hard water and adjusting the pH between 6.5 and 8.5. As a reference,

Table 5 represents some of the drinking water guidelines published by the US

EPA. Consult a water treatment adviser in your area to assess your local needs.

Proper water treatment will aid in the longevity of the unit and ensure maximum

e󰀩ciencies.

DESCRIPTION MAX MIN

Water Pressure 150 PSI 40 PSI

Programmable water temperature 149°F (65°C) 105°F (40°C)

Minimum Flow Rate to Activate DHW Sensor N/A 0.5 GPM

Acceptable pH range 8.5 6.5

Total Dissolved Solids 500 mg/l

Total Hardness 200 mg/l 11.68 gr/gal

Aluminum 0.2 mg/L 0.05 mg/L

Chlorides 250 mg/lL

Copper 1 mg/lL

Iron 0.3 mg/lL

Manganese 0.05 mg/lL

Zinc 5 mg/lL

Table 5: Domestic Water Quality Guidelines

1.7.2 Domestic Hot Water Piping

The domestic water piping connections are located at the bottom of the unit, see

Figure 1b. The connections are 3/4" male NPT threads. The cold water inlet is on

the right side and the hot water outlet is on the left side.

Usetwowrencheswhentighteningeldpipingontotheboiler.Useonewrenchto

holdtheboilerttingstillwhiletighteningwithanotherwrench.

An installer supplied pressure relief valve meeting the following requirements must

be installed:

• Maximum pressure rating of 150 PSI.

• Minimum capacity of 200,000 Btu/hr.

• On the domestic hot water outlet prior to any isolation valve.

WARNING

HOT WATER CAN SCALD!

Water Temperatures over 125°F

/ 52°C can cause severe burns

instantly or death from scalds.

Children, disabled, and elderly are

at highest risk of being scalded.

• Never leave them unattended

in or near the shower, bathtub

or sink.

• Never allow small children to

use a not water faucet or draw

their own bath.

To avoid any potential scald

hazard or if codes require specic

water temperatures at the hot

water faucet, the installer may:

• Install a eld supplied

thermostatic mixing valve at

this appliance and ensure it is

working properly.

AND

• Set the thermostatic mixing

valve to the lowest temperature

which satises your hot water

needs.

TO AVOID INJURY:

• Feel and adjust water

temperature before bathing or

showering.

•

Water drained from the system

drain valve may be extremely

hot.

• Make sure all connections are

tight.

• Direct water ow away from

any person.

NOTE

The limited warranty provided

with the water heater does not

cover defects, malfunctions

or failures resulting from

water conditions that are

not in accordance with the

specications in table 5.

1-33

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

WARNING

- Bacteria growth can develop

in domestic hot water tanks

and indirect water heaters if the

minimum water temperature is

not set high enough to prevent

its growth.

- A potentially hazardous

situation, which can cause

serious injury or death, can

exist if the unused domestic

water connections are capped

o󰀨. The unused domestic water

connections must be left open if

not used to allow for the air in the

coil to expand and contract as

the unit is in operation.

- Failure to support the boiler

tting with a second wrench

while tightening eld piping may

lead to boiler damage.

Installation of a tankless water heater service valve kit with pressure relief valve is

recommended for ease of servicing the DHW coil in the future.

Ifrequiredbylocalcode,youcaninstallaeld-supplieddomestichotwater

thermostatic mixing valve on the outlet of the unit to prevent excessively hot water

from reaching a faucet if the unit is used in a high temperature heating system. If

theunitisbeingusedtoheatalowtemperatureheatingsystemlikearadiantoor

at temperatures at or below 120°F/49°C then the thermostatic mixing valve may not

be needed.

Do not cap o󰀨 the hot and cold piping connections if they are not being used.

The Combi boiler should be connected to the cold water supply piping and the

domestic hot water piping in the home. The minimum domestic water pressure

required is 40PSI and recommended to be 50PSI or higher. Generating domestic

hot water with a water pressure lower than 40PSI reduces the amount of hot water

generated and increases the risk of scaling in the heat exchanger.

Thermal expansion of the water in the domestic hot water (DHW) system can occur

whentheCombiboilerreswithoutDHWusagesuchasinDHWComfortMode.

As the small volume of DHW in the heat exchanger is heated, it expands in volume

and creates an increase in the pressure within the water system. Check with your

local water utility company to determine if a check valve has been installed in the

cold water line. If a check valve has not been installed, the expanding water volume

owsbackintothemain,dissipatingpressure.Ifacheckvalvehasbeeninstalled,

the expanding water volume will increase the pressure within the homes water

system. A DHW expansion tank is typically not required due to the low volume

of DHW in the heat exchanger. If the pressure increase causes operation of the

pressure relief valve, a DHW expansion tank must be installed.

Thecoldwaterinletincludesaltertopreventcontaminantsfromfoulingthe

owsensorandheatexchanger.Seemaintenancesection4.1.15forcleaning

procedure.

Combi 160-199

Combi 99-125

Graph 2: Water Heater Pressure Drop

NOTE

See Domestic Hot Water

Warnings on page 1-32.

INSTALLATION AND OPERATION INSTRUCTIONS

1-34

COMBI BOILERS 99 & 125 & 160 & 199

Aquastat

Combi Boiler

Figure 35: Tankless DHW Piping Options – concept drawing. This drawing is only a simple

schematic guide.

DOMESTIC HOT WATER

DELIVERY

@ 67°F / 37.2°C temperature

rise

99,000 Btu/hr 2.4 GPM

125,000 Btu/hr 3.2 GPM

160,000 Btu/hr 4.1 GPM

199,000 Btu/hr 5 GPM

CAUTION

A eld supplied thermostatic

mixing valve may be installed

on the direct domestic hot

water piping connections at

the unit or at the outlet of a

domestic hot water storage

tank if using the domestic

hot water function. Failure

to install the thermostatic

mixing valve may result in a

hazardous situation which

can cause serious injury or

death. See section 1.7.2.

1-35

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

WARNING

The correct 10KΩ temperature

sensor (or aquastat) must be

used to operate the indirect

water heater properly. If the

incorrect sensor is used

the domestic hot water may

overheat causing serious

injury or death.

1.7.3 Tankless Domestic Hot Water with a Storage

Tank

The Combi boiler has the ability to connect a domestic hot water storage tank to

the unit to provide larger volumes of domestic hot water during peak demands.

Thestoragetankispipedtotheunit’sdomestichotandcoldwaterpiping

connections (see B in Figure 35). You must install a bronze or stainless steel

pumptocirculatewaterfromthestoragetankthroughtheunit’sdomestichot

water coil.

Thestoragetankaquastatwillenablethepumpcausingtheunittorewhenthe

temperature drops below the aquastat setpoint. The units DHW setpoint must

be set higher than the storage tank aquastat setpoint. Once the storage tank

temperature has reached its setpoint, the aquastat will disable the pump and the

unit can return to space heating operation.

1.7.4 Domestic Hot Water with an Indirect Water

Heater

You can connect the Combi boiler to an indirect water heater. Connect the

indirectwaterheater’ssupplyandreturnconnectionstotheunit’sprimaryloop

using a hydraulic separator or closely-spaced tees. Properly sized piping must

be installed. A properly sized pump must also be installed between the unit and

the indirect water heater. The pump can be wired to the included junction box to

provide DHW priority.

Some models (160,000 & 199,000) include a temperature sensor which can be

installed in the well of an indirect water heater. The temperature sensor wire

should be run through both ends of the installation rod. The sensor can then be

installed in the well using the installation rod to ensure the sensor reaches the

bottom of the well.

Figure 36: Indirect Temperature Sensor & Installation Rod

INSTALLATION AND OPERATION INSTRUCTIONS

1-36

COMBI BOILERS 99 & 125 & 160 & 199

1.8 GAS PIPING

The unit must have an inlet gas pressure of at least 4.0" w.c. for natural gas and

propane. For either fuel, the inlet pressure shall be no greater than 14.0" w.c.

Conrmthispressurerangeisavailablewithyourlocalgassupplier.

Theinletgasconnectionoftheunit’sgasvalveis3/4"NPT(male).

Usetwowrencheswhentighteningeldpipingontotheboiler.Useonewrenchto

holdtheboilerttingstillwhiletighteningwithanotherwrench.

Adequate gas supply piping must be provided with no smaller than 1/2" Iron Pipe

Size (IPS) and a 1" w.c. pressure drop in accordance with the following chart:

MODEL 1/2" IPS 3/4" IPS 1" IPS

99,000 Btu/hr (Natural gas) 40' 175' 500'

125,000 Btu/hr (Natural gas) 20' 100' 350'

99,000 Btu/hr (Propane) 100' 450' 1,400'

125,000 Btu/hr (Propane) 70' 300' 1,000'

160,000 Btu/hr (Natural gas) 10' 70' 200'

199,000 Btu/hr (Natural gas) 10' 40' 150'

160,000 Btu/hr (Propane) 50' 175' 600'

199,000 Btu/hr (Propane) 30' 125' 400'

Table 6: Maximum Pipe Length (ft)

Gaspipingmusthaveasedimenttrapaheadoftheunit’sgasvalve(see Figure

37). Amanualshuto󰀨valvemustbelocatedoutsidetheunit,inaccordancewith

local codes/standards. All threaded joints in gas piping must be made with an

approved piping compound resistant to the action of natural gas/propane. Use

proper hangers to support gas supply piping as per applicable codes.

Before placing the boiler into operation, the boiler and all gas connections must

be checked for leaks.

• Closethegasshuto󰀨valveduringanypressuretestingequaltoorlessthan½

psi (3.5 kPa).

• Disconnecttheboilerandgasshuto󰀨valvefromthegassupplyduringany

pressure testing greater than ½ psi (3.5 kPa).

The gas valve is provided with pressure taps to measure gas pressure upstream

(supply pressure) and downstream (manifold pressure) of the gas valve (see

Figure 37).Notethatmanifoldpressurevariesslightlyinaccordancewithring

rates with the modulating series units, but will always be close to 0" w.c.

WARNING

This appliance can burn

either natural gas or propane.

Refer to section 3.3 for further

instruction. If converting a

unit from one fuel to another,

you must order a conversion

kit prior to the conversion.

Install the conversion kit

according to the detailed

instructions supplied with

the kit. Failure to perform

the required fuel conversion

correctly can result in serious

injury or death.

NOTE

It is essential to check gas

supply pressure to each

unit with a manometer or

other high-quality precision

measuring device. Pressure

should be monitored before

ring the unit, when the

regulator is in a “lock-up”

condition and during operation,

throughout the unit’s full

modulation range.

Pay special attention to retrot

situations where existing

regulators may have an over-

sized orice and/or worn seats,

causing pressure “creep” and

high lock up pressures.

WARNING

Failure to support the boiler

tting with a second wrench

while tightening eld piping

may lead to boiler damage.

WARNING

Do not check for gas leaks

with an open ame, use the

bubble test. Failure to use the

bubble test or check for gas

leaks can cause substantial

property damage, serious

injury, or death.

Figure 37: Gas Valve

CHECK LOCAL CODE FOR

SIZE REQUIREMENTS

Figure 38: Gas Piping

1-37

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

1.9 ELECTRICAL CONNECTIONS

Electrical wiring to the unit (including grounding) must conform to local electrical

codes and/or National Electrical Code, ANSI/NFPA No. 70 – latest edition in the

US or The Canadian Electrical Code, C22.1 - Part 1 in Canada.

1.9.1 120VAC Line Voltage Hook-up

(Refer to Section 6.2.Wiring Diagram on page 6-7). Connect the unit to the grid

power, using the supplied appliance plug in a separate, non GFCI fused circuit

andon/o󰀨switchwithinsightoftheunit.

The unit is equipped with 3 x 1/2” electrical knock-outs for control wiring located

behind the power supply terminal strip.

The unit includes a factory installed and pre-wired pump. The pump may not be

abletosupplyadequateowfortheheatemittercircuits.Asystemheatingpump

switched through a separate relay or control box may be needed.

WARNING

Do not apply power to any

connection point on the

controllers terminal strips.

A hazardous situation could

occur resulting in possible

serious injury or death.

Figure 39: Pullling out the tray

INSTALLATION AND OPERATION INSTRUCTIONS

1-38

COMBI BOILERS 99 & 125 & 160 & 199

1.9.2 Accessing Controller Terminal Strip

Pulloutonthetwocontrolmoduleretainingtabsthenipdownthecontrolto

access the terminal strip.

Field Wiring Junction box

Theunitshipswithanoptionaleld-wiringjunctionbox.Thisboxprovideswiring

connections for a space-heating pump, a DHW pump, and an outlet for unit

power.Acertiedharnessfromthewiringboxconnectstothemovablecontroller

tray. You do not require a junction box if:

1. External pumps do not need to be controlled for space heating

2. There are no DHW indirect or storage tanks.

Figure 40: Junction box schematic

To install an external junction box to supply power and access the two pump

relays:

1. Pull out the controller as shown in Figure 39.

2. At the back of the tray, knock out the hole nearest to the power cord using a

atheadscrewdriver.

3. Feed the junction box cable through the hole and secure to the tray with the

connector nut.

4. Connect the blue wire to the X4 terminal, position 3.

5. Connect the brown (or red) wire to the X3 terminal, position 3.

NOTE

- This unit (like any modern

appliance that contains

electronic equipment), must

have a “clean” power supply,

and can be disabled by power

surges and spikes, lightning

strikes and other forms of

severe electrical “noise”.

Power conditioning equipment

(surge protectors, APC or UPS

devices) may be required in

areas where power quality is

suspect.

- The control typically uses a

true dry contact closure as a

call for heat. A signal from an

Open Therm device can also

be used. Thermostats and

other devices that use a “Triac”

output cannot be used as a call

for heat without the installation

of an intervening relay with

dry contacts to connect to the

terminal strip.

- A Combi boiler installed

above radiation level or as

required by the Authority

Having Jurisdiction, must

be provided with a low water

cut-o󰀨 device at the time of

unit installation. Refer to 1.9.3

External probe type low water

cuto󰀨 device for installation

instructions.

Figure 41: Junction box

1-39

INSTALLATION

COMBI BOILERS 99 & 125 & 160 & 199

6. Screw the junction box to the wall within six feet of the tray.

• Allow clearance for plug use.

• Allow wire enough slack for easy removal of the tray.

7. Drill out both holes in the junction box.

8. Connect 120VAC power to terminals labelled Power Inlet.

9. Wire the pump(s) to the junction box.

• Wire the space heating pump to terminals labeled Relay 1.

• Wire the DHW pump to terminals labeled Relay 2.

If using both relays, wire the pumps to the box with a duplex connector.

10. Install the junction box cover.

Note: If the junction box is installed, 120VAC power must be supplied to the

Combi boiler through the junction box. Do not plug the unit in elsewhere.

1.9.3 External probe type low water cutoff device

Youcanlinkaeld-supplied,externalsafetydevicetotheunitbyconnectingthe

safetydeviceinserieswiththeunit’s120Vmainpowersupply.

If the unit is being used only as a direct domestic hot water unit an external low

watercut-o󰀨deviceisnotrequired.However,ifrequired,werecommendusing

an electronic probe style device:

• Installtheprobetypelowwatercut-o󰀨devicewithaTeeconnectionatalevel

above the top of the unit.

•Wiretheprobetypelowwatercut-o󰀨deviceinserieswiththe120VACpower

supply, so that when the device trips on a low water condition the power

supply to the unit is interrupted.

Heating Boiler

Combi Boiler

Figure 42: External Probe Type Low Water Cuto Device

INSTALLATION AND OPERATION INSTRUCTIONS

1-40

COMBI BOILERS 99 & 125 & 160 & 199

Figure 43: Terminal strip for connection of the DHW Aquastat (optional), thermostat or end switch(es) (mandatory), outdoor sensor

(optional)

3 2 1

5 4 3 2 1

4 3 2

3 2 1

2 1

X15

Fuse inside

X2 X1

X14

X11

X10

X4 (120 V ~ )

120 V ~ , 60 Hz

24 V =

120 V ~

2 1

F1 (5 AT)

junction box

859904.01

N L

3 2 1

X3 (120 V ~ )

junction box

X13

DHW Aquastat

or Sensor

10kΩ

Outdoor Sensor

12kΩ

Space Heating

Demand

(dry contact)

1.9.4 Power Quality and Electrical Protection

In areas of unreliable power, appropriate surge protectors and / or power

conditioning equipment should be installed to protect the unit.

1.9.5 Zone Valve and Zone Pump Connections

Zoning can be accomplished with either zone pumps or zone valves. If zoning by

multiple pumps, we recommend using an external pump module.

Zone valve end switches can be wired together in parallel, and connected to X13

terminals 1 and 2. Do not apply power to the X13 terminal strip. Alternatively, you

can connect the zone valves and thermostats to a zoning panel control system

(available from your local heating wholesaler).

You can connect zone pumps to the unit with a zone pump control, available from

your local heating wholesaler.

1.9.6 Thermostat / Sensor Wiring

A thermostat from a single zone heating system can be connected directly to the

controller’sX13terminals1and2.DonotapplypowertotheX13terminalstrip.

An outdoor sensor is not required for the unit to operate. If an outdoor sensor is

not connected, the unit will operate as a set point unit and operate at its design

supply temperature.

If outdoor reset functionality is desired connect the supplied Outdoor sensor to

X13terminals3and4.Theoutdoorsensorisa12KΩthermistortypesensor.

The sensor should be installed:

• On the exterior of the building on the north side.

• Ensure the outdoor sensor is shielded from direct sunlight and not near any

buildingexhaustswhichcoulda󰀨ectitstemperaturereading.

DHWAquastator10KΩsensorcanbeconnectedtothecontroller’sX13

terminals 4 and 5. Do not apply power to the X13 terminal strip.

2-1

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

2.0

UNIT SYSTEM OPERATION

2.1 GENERAL

The Combi boiler is designed to heat both your indoor space and your domestic

hotwater.Theunit’suniqueheatexchangerdesignincorporatesseparatecopper

waterways for space heating and for domestic hot water generation.

Withtheinstallationoftheprovidedoutdoorsensor,theunit’scontrollercan

provide outdoor reset control for the space heating load. The built-in control

provides a set point for water temperature for the domestic load. Installing the

outdoor sensor is optional, but recommended for higher e󰀩ciency.

Alternatively, the controller can provide a set-point water temperature for the

space heating load.

The unit is equipped with a factory-installed pump. The pump is pre-wired and

will operate with any call for space heating or when heating an indirect water

heater. The pump will not operate with a call for domestic hot water using the

unit’sinternaldomestichotwatertanklesscoil.

The pump operates for 10 seconds every 24 hours to prevent it from seizing. The

pump is energized 24 hours after the last call for heat and every 24 hours after

that until the next call for heat.

The Combi boiler can generate domestic hot water in several ways. The unit can

be used as a tankless water heater, with or without a storage tank, and also with

an indirect water heater.

The unit is equipped with an electronic unit controller that ignites the burner and

continuouslymonitorstheamethroughouteachcallforheat.Thecontrolalso

displays the current operating conditions of the unit and any error messages

should a problem occur.

Theunit’scontrolleralsoprovidesfrostprotection.Whentheunit’sheat

exchanger temperature becomes too low the burner switches on to keep the heat

exchanger warm. Ensure that the condensate trap is protected from freezing. The

unit must be installed indoors.

BURN

HOT

DANGER

Water temperature over 125°F (52°C) can cause severe burns instantly

or death from scalds.

Children, disabled, and elderly are at highest risk of being scalded.

See instruction manual before setting temperature at water heater.

Feel water before bathing or showering.

Temperature limiting valves are available, see manual.

INSTALLATION AND OPERATION INSTRUCTIONS

2-2

COMBI BOILERS 99 & 125 & 160 & 199

2.2 CONTROL

ICON FUNCTION

Numerical Display Main Display

Plus & Minus Temperature Adjustment

Flame Burner ON Indicator

Dot Power ON Indicator

Faucet DHW Indicator

Radiator Heating Indicator

Wrench Service / Reset

Return Arrow Enter / Save

Numerical Display Service Display

Table 7: Controller Indicators and Touch Pad

2.3 INSTALLER INTERFACE

2.3.1 Turning Appliance ON/OFF

To turn on the unit, touch the area above the dot for 2 seconds. Now only the dot is

illuminated.

Toturno󰀨theunit,touchtheareaabovethedotfor2seconds.Adashappearsto

the right and the space heating water pressure displays to the left.

2-3

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

2.3.2 Programming Mode

There are two parameters available in the User Setup Menu.

Thecontrollerhasvelevels:UserMenu,InstallerMenu(code15),aMaster

Installer Menu (code 20), RF Menu (code 30) and Cascade Menu (code 35). See

included Controller Manual for details.

Adjusting the Space Heating Water Temperature

To access the main menu:

1. Touch the area above the dot.

2. Touch the Radiator button.

3. To change the space heating target temperature, touch the Plus or Minus

buttons.

• To save the changes, touch the Return button.

• To exit without saving the changes, touch the area above the dot.

“P” to the right of the screen indicates that the changes have been saved.

INSTALLATION AND OPERATION INSTRUCTIONS

2-4

COMBI BOILERS 99 & 125 & 160 & 199

Adjusting the Domestic Hot Water Temperature

To access the main menu:

1. Touch the area above the dot.

2. Touch the Faucet button.

3. To change the DHW target temperature, touch the Plus or Minus buttons.

2. To alter this value, touch the Plus or Minus buttons.

• To save the changes, touch the Return button.

• To exit without saving the changes, touch the area above the dot.

“P” to the right of the screen indicates that the changes have been saved.

NOTE

The domestic hot water

thermostat is adjusted to its

lowest temperature position

when shipped from the

factory. It’s recommended to

set the domestic hot water

thermostat to 120°F/49°C as

an initial setting and further

adjust as required. For

energy e󰀩cient operation,

this setting should be set

as low as practical for the

consumer’s needs.

2-5

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

2.4 TANKLESS DOMESTIC HOT WATER

MODES

2.4.1 Tankless Domestic Hot Water - Standard and

ECO Comfort Modes

Standard Mode (OFF): The unit will respond to a call for domestic hot water as

a priority over the space heating demand. When the domestic hot water demand

issatisedtheunitwillreturntothespaceheatingloadiftheloadisstillcalling.

The heat exchanger will not maintain its domestic hot water temperature between

demands for hot water.

Comfort Mode (ON): The heat exchanger is maintained at the DHW

temperature.

ECO Comfort Mode (ECO): This mode operates like the Comfort Mode but has

the added advantage of learning when the domestic hot water is used. During the

low use periods, the heat exchanger is allowed to cool.

To switch between the 3 modes:

1. Touch the area above the dot.

2. Touch the Faucet button twice.

3. To change the DHW mode, touch the Plus or Minus buttons.

• To save the changes, touch the Return button.

• To exit without saving the changes, touch the area above the dot.

“P” to the right of the screen indicates that the changes have been saved

INSTALLATION AND OPERATION INSTRUCTIONS

2-6

COMBI BOILERS 99 & 125 & 160 & 199

2.5 SPACE HEATING

2.5.1 Overview

The Combi boiler is designed to be installed in a primary/secondary type

piping system. The unit comes complete with a factory-installed pump, which is

designedtocirculateheatingsystemwaterthroughtheunit’sheatexchangerand

primarylooppipingonly.Thebuilding’sdistributionpipingsystemmayrequirea

dedicated pump or pumps to circulate space heating water through the heating

system. The unit can operate a separate building pump (120V 1.0 AMP max).

There are various ways to zone a space heating system. Local wholesalers sell

controlpackagesthato󰀨ereasymethodstoconnectthezoningsystemtothe

unit.

The unit supplies heat to the space using an outdoor reset function. With an

outdoor sensor installed, the unit automatically adjusts its space heating water

temperature based on the parameters programmed into the unit. See separate

controller manual for parameter information. If the Outdoor sensor is not installed,

the unit uses the temperature set in the “User Set Up” menu “Boiler Supply

Temperature” to supply hot water to the space heating system.

2-7

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

2.6 SEQUENCE OF OPERATION

The unit operates in a similar way for both a space heating and a domestic hot

water call for heat. When the unit is powered up the controller enters a self-

diagnostic mode, and displays the controller software version in the main display.

The sequence of operation is as follows:

1. The unit receives a call for heat from a dry contact closure on terminals

X13.1 and X13.2 (24 volts section). The unit can also receive a call forfor

domestichotwaterheatingfromtheinternalowsensor,orfroma10KΩ

sensor or aquastat wired to terminals X13.4 and X13.5 (24 volts section).

2. The unit performs a safety check and energizes the fan for a pre-purge

(Service Display = 3).

3. Once the 5-second pre-purge is complete, the unit enters a 5-second trial for

ignition (Service Display = 4). If the unit fails to ignite, the unit will complete

another 5-second pre-purge then 5-second trial for ignition. This is repeated

4 times before a hard lock-out occurs. The Return button must be pressed to

reset the controller and begin another trial for ignition.

4. Oncetheburnerislitandamehasbeenproventheunitoperatesasitis

programmed (Display = for space heating or for domestic hot water).

5. If the unit exceeds its target temperature and there is still a call for heat or

hotwatertheburnerwillturno󰀨(integralpumprunsunlesscallison-demand

DHW). (Service Display = 1)

6. Afteraspaceheatingcallforheatissatised,theunit’spumpwilloperatefor

an adjustable amount of time (Service Display = 0).

7. If the burner is on to maintain the heat exchanger temperature for DHW

Comfort mode (Service Display = 7).

8. If the burner is on for frost protection (Service Display = 9).

MAIN

DISPLAY

SERVICE

DISPLAY

DESCRIPTION

[pressure] P - The unit is OFF. Press the space above the Dot for 2

seconds to turn on the unit

(blank) (blank) No Call for Heat - Standby

XXX 0 Unit pump running – pump post purge

XXX 1 Unit water temperature exceeds target – unit pump is

energized, call still present

XXX 2 Self-test – When power is applied to the unit the

controller enters a self diagnostic mode for 5 seconds

XXX 3 Fan Pre-purge and Post-purge

XXX 4 Trial for Ignition and Flame Proving

XXX + Heating – Space Heating

XXX +

Heating – DHW

XXX 7 Burner on for DHW Comfort mode

XXX

Freeze Protection mode

Table 8: Operating Display and Service Display Codes.

NOTE

The unit is equipped with

a frost protection feature.

This feature operates the

unit’s built-in pump and the

burner to help protect the

unit from freezing. If the

unit is in a hard lock-out

condition the burner will not

operate, but the unit’s built-

in pump will operate. We are

not responsible for damages

to the unit, and/or related

components, nor property

damages that may result from

freezing conditions.

INSTALLATION AND OPERATION INSTRUCTIONS

2-8

COMBI BOILERS 99 & 125 & 160 & 199

2.7 ACCESSING THE INFORMATION MENU

The Information menu provides real time operating information to assist with

troubleshooting.

To access the Information menu:

1. Touch the area above the Dot.

2. Touch and hold the Wrench button for two seconds, let go when the minus,

plus, and wrench are displayed.

3. Again, touch and hold the Wrench button for two seconds to enter the

information menu.

See table 9 for a list of codes and corresponding description.

4. To scroll through the list of codes, use the Minus or Plus button.

5. To exit the information menu and return to the Service menu, press the area

above the Dot.

2-9

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

See below for a description of the codes:

Space heating setpoint

Table 9: Information Menu

Notethatdisplayparametersmaydi󰀨erdependingontheconguration.Where

there is no DHW sensor, the display reading can be ignored.

INSTALLATION AND OPERATION INSTRUCTIONS

2-10

COMBI BOILERS 99 & 125 & 160 & 199

2.8 RESETTING THE MAINTENANCE

COUNTER

Inspectionoftheunitmustbeperformedannuallybyaqualiedservice

technician. This unit includes a maintenance counter which tracks the amount of

fuel burned within a two year period to ensure maintenance is performed if usage

exceeds typical residential usage. When above average usage occurs within a

twoyearperiod,anoticationcodewillbedisplayed.

Toresetthemaintenancecounterandclearamaintenancenoticationcode:

1. Touch the area above the dot.

2. Touch the wrench for two seconds until the return button appears.

3. Touch wrench and return buttons together.

CAUTION

The maintenance counter

must only be reset after

performing the maintenance

procedures in Section

4.0 Maintenance of this

manual. Failure to perform

maintenance can result in a

hazardous condition.

2-11

UNIT SYSTEM OPERATION

COMBI BOILERS 99 & 125 & 160 & 199

The code numbers are displayed in the left numerical display.

4. Change C000 to C090 by touching the + button.

5. Touch wrench to enter the maintenance menu.

The current maintenance counter value is displayed in the left numerical display.

INSTALLATION AND OPERATION INSTRUCTIONS

2-12

COMBI BOILERS 99 & 125 & 160 & 199

INSTALLATION AND OPERATION INSTRUCTIONS

2-12

COMBI BOILERS 99 & 125 & 160 & 199

Thefollowingnoticationswillbedisplayedasthetimeformaintenance

approaches.

MAINTENANCE COUNTER NOTIFICATION CODE

80 n120 - Maintenance recommended

100 n121 - Maintenance required, limited DHW output

120 n122 - Maintenance required, no DHW output

Thenoticationcodewillbedisplayedfor30secondsandthewrenchwillash.

Pressthewrenchbuttontoseethenoticationcodeagainafter30seconds.

6. Touch the wrench to reset the maintenance counter to 0.

7. Touch return to resume normal operation.

“P”willbebrieydisplayedontherightscreentoindicatethechangehasbeen

stored.

3-1

STARTUP AND COMMISSIONING

COMBI BOILERS 99 & 125 & 160 & 199

3.0 STARTUP & COMMISSIONING

3.1 LIGHTING & SHUTTING DOWN THE

UNIT

(LP)

INSTALLATION AND OPERATION INSTRUCTIONS

3-2

COMBI BOILERS 99 & 125 & 160 & 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-2

COMBI BOILERS 99 & 125 & 160 & 199

3.2 PRIOR TO START-UP

3.2.1 Pre-Ignition Checks

1. Fill the condensation trap. Ensure the venting system is complete and seal-

tested.Conrmthatanycommonventingsystemattheinstallationsiteis

isolated and independent of the unit, that any holes left from removal of a

previousunithavebeensealed,andthatanyresizingoftheolduehas

been done.

Checkthatthewaterpipingsystemisfullyushedandlled,andthatall

air has been discharged. Use a minimum water pressure of 12 psig and

conrmthatthepressurereliefvalveisinstalledanddischargelineisdirected

downward to a safe point of discharge

3. Check to see that adequate gas pressure is present at the inlet gas supply

testport.Withtheunitgasvalveshuto󰀨,usingaTorx15screwdriver,open

the test port by turning 1 full turn counterclockwise. Connect a manometer

and open the manual gas valve. Requirements are minimum 4" w.c. and

maximum 14" w.c. Check that there are no gas leaks.

4. Performanalcheckofelectricalwiringandprovidepowertotheunitto

initialize operation.

5. The installer must verify that at least one carbon monoxide alarm has

been installed within a residential living space or home following the alarm

manufacturer’sinstructionsandapplicablelocalcodesbeforeputtingthe

appliance into operation.

3.2.2 Test Ignition Safety Shutoff

Withtheunitinoperation,testtheignitionsystemsafetyshuto󰀨deviceby

shuttingo󰀨themanualgasvalveimmediatelyoutsidetheunitcase.Ensurethat

theunithasshuto󰀨andthattheappropriateerrorinformationisdisplayedonthe

main display screen. To restart the unit, press the Reset button.

3.3 COMMISSIONING

The Combi Boiler is factory calibrated to operate with natural gas at sea level.

HighFirecombustionissetbytheoriceinstalledandisnoteldadjustable.

Alowcaloricvaluenaturalgasorice(SeeTable10)isavailableforlocations

wherethenaturalgascaloricvaluefallsbelowtheexpectedrangeof950-1100

BTU/Ft3.Consultyourlocalfuelproviderforyourfuel’scaloricvalue.Low

reiseldadjustableviathelowreadjustmentonthegasvalvebutmustbe

done with caution. No mixture adjustment may be performed unless done by

aqualiedtechnicianusingaproperlyfunctioningandcalibratedcombustion

analyzer.

This unit can burn either natural gas or propane if equipped with the

correct specied orice. Examine the rating plate of the unit to ensure it

is congured for the fuel you are using. If the unit is to be converted from

natural gas to propane or from propane to natural gas a fuel conversion kit

must be installed. For the correct fuel conversion kit part number, see the

table on the next page:

DANGER

- Fill trap with water before

unit is rst red to prevent

exhaust fumes from entering

room. Never operate the unit

unless the trap is lled with

water.

Failure to comply will result

in severe personal injury or

death.

- It is forbidden to make

adjustments to the gas

valve except with a properly

calibrated gas combustion

analyzer by persons who

are trained and experienced

in its use. Failure to use an

analyzer can result in an

immediate hazard.

3-3

STARTUP AND COMMISSIONING

COMBI BOILERS 99 & 125 & 160 & 199

MODEL NATURAL GAS

TO PROPANE

PROPANE TO

NATURAL GAS

LOW CALORIFIC

NATURAL GAS

99,000 Btu/hr P-081034 P-081044 P-081364

125,000 Btu/hr P-081054 P-081064 P-081374

160,000 Btu/hr P-081744 P-081754 P-081764

199,000 Btu/hr P-081014 P-081024 P-081414

Table 10: Fuel conversion kits

The gas valve will automatically de-rate the maximum input by approximately 2%

per1,000'abovesealevel.Thegasvalve’szerogovernorwillensurethatthe

gas-airmixtureisnota󰀨ectedataltitude.

Toverifytheproperoperationofthegasvalveintheeld,thefollowingprocedure

canbecarriedoutbyaqualiedtechnician(see diagrams on this page).

1. Turno󰀨theunit’smanualgasvalve.WithaTorx15screwdriver,open

the inlet gas supply pressure test port by turning its screw 1 full turn

counterclockwise. Attach a manometer to the pressure test port. Turn on

gas to the appliance. Static manometer reading should be ideally 7" w.c.,

for natural gas and 11" w.c. for propane. Minimum and maximum static

pressure must be between 4" and 14" w.c. Monitor pressure throughout the

commissioningprocedure.Pressuremaydroopupto1"athighre.

2. Allowtheunittoignite/runagainstalargeload.Tomaintainhighre,press

theameicon,thenpressandholdthe Wrench icon for two seconds.

Then while holding the Wrench icon press the Plus button twice. “H” will

showintheservicedisplayastheunitentershighre.

NOTE:Allowtheunittooperateathighrefor3minutestostabilize.

(The unit operates in manual mode for 10 minutes then switches back to

the normal operating mode. To extend manual mode operation, press the

Wrench and Plus together twice while the unit is operating in manual

mode to reset the timer for 10 more minutes.) Do not take measurements if

the Service display shows an “h”.

3. Clockthenaturalgasmetertoconrmfullmaximumratingplateinput.With

acombustionanalyzerprobeintheuegastestport,checkthemeasured

results against Table 11- High Fire. If the results are outside the permitted

range,checktheinletpressure,andconrmthatthecorrectoriceand

venturi are installed. High Fire CO

issetbytheoriceinstalledandisnot

eldadjustable.Forareasoflowercaloricvaluenaturalgas,installthe

alternativeoricelistedinTable10.

4. Switchtheunittolowrebypressingthe Wrench button and Minus

buttonsatthesametime.Theunitwilldroptolowre.“L”willshowonthe

service display. Compare the readings with Table 11 - Low Fire. If adjustment

isnecessary,removethelowreadjustmentcaptorevealaTorxheadscrew.

Make minimal adjustments, typically less than 1/8th of a turn at a time. Turn

the screw clockwise to increase CO

and counter-clockwise to reduce CO

If the target cannot be met, even after a full turn, contact the factory. When

nished,replacethelowrecap,andleavethemanualmodebypressing

Plus

AND Minus simultaneously.

5. Switcho󰀨the unit by pressing the space above the dot for two seconds. Turn

o󰀨thegasattheunit’smanualgasvalve.Removetheuegasanalyzer

from the test port and reinstall the test port cap. Remove the gas pressure

manometer from the gas valve and fully close the test port. Turn on the gas

attheappliance’sgasshuto󰀨valve.Ensurethattherearenogasleaksand

reinstall the front cover. Turn on the unit by pressing the space above the dot

for two seconds.

Figure 44 Gas Valve Adjust

Figure 45: Flue gas test port plug

WARNING

Check the rating plate of the

unit to ensure it is congured

for the fuel you are using. If

the fuel is incorrect for the

appliance, a conversion kit

must be installed as listed in

Table 10 and the gas valve

adjusted accordingly.

Failure to perform the

required fuel conversion can

result in an immediate hazard.

DANGER

Attempting to change high

re combustion by adjusting

the low re combustion

adjustment could lead to

unstable operation, failed

ignitions, or dangerous

operating conditions.

INSTALLATION AND OPERATION INSTRUCTIONS

3-4

COMBI BOILERS 99 & 125 & 160 & 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-4

COMBI BOILERS 99 & 125 & 160 & 199

3.4 FUEL CONVERSION

Theunitisfactoryre-testedtooperate with natural gas as shown on the rating

plate. Firing a unit with a fuel other than what is listed on the rating plate is

prohibitedunlessthefollowingconversionprocedureiscompletedbyaqualied

technician.

Fuelconversionrequireshardwareadjustments(oricereplacement)aswellas

measurementandpossibletuningofthelowremixture.Detailedinstructions

including parts and labeling are found in Fuel Conversion kits. Refer to Table 10

for the correct kit number.

NATURAL GAS PROPANE

VALUE

(

)

AT HIGH FIRE WITH THE FRONT COVER OPEN¹

Max. CO

value 10.3% 11%

Min. CO

value 8.7% 9.8%

CO LIMIT

(

PPM

)

AT HIGH FIRE WITH THE FRONT COVER OPEN²

Max. CO limit < 150ppm <250ppm

VALUE

(

)

AT LOW FIRE WITH THE FRONT COVER OPEN

Max. CO

value =ActualvalueatHighre =ActualvalueatHighre–0.3%

Min. CO

value 8.7% 9.5%

Table 11: Acceptable High and Low Fire Combustion Values

¹ High Fire

issetbytheoriceinstalledandisnoteldadjustable.

² If the CO reading exceeds the limit in this table, the unit must be shut down until the

cause of excessive CO readings is corrected.

Thefollowingproceduremustbecarriedoutbyaqualiedtechnician.

1. Ensurethatthegassupplyisturnedo󰀨atthemanualgasvalve.

2. Disconnect the electrical power.

3. Disconnect the nut at the gas valve outlet (top of the gas valve) and remove

theoriceandO-ring.

4. InsertthecorrectoriceintotheO-ring,andre-installintothenutatthegas

valve outlet (top of the gas valve) and then tighten the nut.

5. Restore the gas supply by opening the manual gas valve.

6. Test for leaks by using an approved leak detection solution on all joints.

7. Carefully follow the “Prior to Start-Up” – Section 3.2 and “Commissioning” –

Section 3.3 procedures on the preceeding page 3-2.

DANGER

Operating any unit using

a fuel other than the fuel

listed on its rating plate is

prohibited. If the information

in this section related to

conversion to alternative

fuels is not followed exactly,

a dangerous situation can

result, leading to re or

explosion, which may cause

property damage, personal

injury, or loss of life.

Figure 46: Orice and O-ring

PROPANE ORIFICE CHART

MODEL

ORIFICE

SIZE

99,000 Btu/hr 327

125,000 Btu/hr 392

160,000 Btu/hr 440

199,000 Btu/hr 535

WARNING

Ensure the part kit and

orice are correct for the

appliance model and fuel type

prior to performing the fuel

conversion.

NATURAL GAS ORIFICE

CHART

MODEL

ORIFICE

SIZE

99,000 Btu/hr 415

125,000 Btu/hr 480

160,000 Btu/hr 580

199,000 Btu/hr 660

3-5

STARTUP AND COMMISSIONING

COMBI BOILERS 99 & 125 & 160 & 199

Figure 47: Back Flow Valve

Figure 48: Blower and Gas Valve Assembly

WARNING

Each unit is equipped with

a back ow valve installed

at the outlet of the fan.

Inspect the back ow apper

annually.

3.4.1 Gaining access to combustion chamber, burner

removal instructions

DISASSEMBLY

1. Turno󰀨themainpowerswitchtotheunit.

2. Turno󰀨thegassupplyvalvetotheunit.

There is no need to drain the unit unless the unit will be exposed to freezing

conditionswhileo󰀨.

3. Remove the front cover, and allow the unit to cool.

4. Unplug the electrical connector at the gas valve and fan.

5. Loosen the lower gas valve connection nut.

NOTE: There is an O-ring in the lower gas connection. Cover the gas piping

connections to prevent debris from entering the gas piping.

6. Remove all 6mm Allen bolts from the heat exchanger cover and carefully

remove the front cover complete with the fan and the gas valve attached.

7. Place the heat exchanger cover in a safe location.

NOTE

The Caution regarding burner

refractory on page 4-2 of this

manual must be observed.

CAUTION

When removing the heat

exchanger cover in step 6,

be careful not to damage the

burner and refractory material

located on the opposite side

of the heat exchanger cover.

Use caution when handling

refractory materials. See

Caution on page 4-2.

INSTALLATION AND OPERATION INSTRUCTIONS

3-6

COMBI BOILERS 99 & 125 & 160 & 199

INSTALLATION AND OPERATION INSTRUCTIONS

3-6

COMBI BOILERS 99 & 125 & 160 & 199

REASSEMBLY

1. Replace the heat exchanger gasket. Inspect, and when needed change other

gaskets. If necessary, inspect and clean the gasket mating surface.

2. Place the heat exchanger cover onto the heat exchanger and loosely install

the 6mm Allen bolts removed in step 6. Tighten the 6mm Allen bolts in a

cross pattern as shown in the Figure 49.

3. Connect the gas line to the gas valve ensuring the O-ring is in place. Tighten

the gas valve nut. Ensure the upper gas valve connection is tight. Re-connect

the gas valve electrical connection.

4. Re-connect the electrical connection to the fan.

5. Inspect the condensate trap for debris. Remove and clean if necessary. Fill

the condensate trap with water.

6. Turn on the gas supply valve to the unit and inspect for gas leaks. Use an

approved leak detection solution. Soap test all joints.

7. Ensure the unit is full of water and purged of air if the unit was drained during

disassembly.

8. Turn on the power to the unit and create a call for heat or for domestic hot

water.

9. Inspect the gasket around the unit cover.

10. Checkuegasesforpropercombustion.See Section 3.3 Commissioning for

proper adjustments.

11. Re-installtheunit’scoverandsettheunitintonormaloperation.

Figure 49: Tighten Allen bolts in

cross pattern direction.

4-1

MAINTENANCE

COMBI BOILERS 99 & 125 & 160 & 199

4.0 MAINTENANCE

4.1 UNIT MAINTENANCE

4.1.1 General Care

•

Keepcombustiblematerialsandammableliquidsandvaporsawayfromtheunit.

• Keep vent terminals clear of obstructions (snow, dirt, etc.).

4.1.2 Inspection

•

Inspectionoftheunitmustbeperformedannuallybyaqualiedservice 

technician.

4.1.3 Venting

•

Check vent terminals for any obstructions (e.g. leaves, dust, other debris).

• Check and clean or replace intake screens as required.

• Check for holes or leaks in venting. Replace venting as needed.

• Examine for any signs of moisture caused by sweating intake air pipes.

Insulate as required.

• Ensure proper resealing or reinstallation of venting at each servicing.

4.1.4 Condensate Trap

•

Examine the condensate trap every two months to see if cleaning is

necessary (refer to trap cleaning instructions, section 4.1.18 of this manual).

Ensurethatthetraphasbeenre-lledcompletelybeforeringtheunit.

• Check the pH level of the condensate discharge if using condensate

neutralization.

4.1.5 Burner

•

Attherstannualservice,removetheburnertoinspecttheextentoffouling

(refer to burner removal and reassembly instructions, section 3.4.1 of this

manual). Blow clear using compressed air. Evaluate the magnitude of

cleaning required, and establish a reasonable burner inspection schedule.

Some installations may call for annual service, others showing clean burners

will only need attention every 2 years. In alternate years, visually inspect

burnerthroughthesightglass.Ensuretheameisstableandwithout

excessiveuttering.Normalamepatternisevenlydistributedovertheburner

surface.

• If the burner is operating improperly, remove and clean or replace. Use a

combustion analyzer to determine proper combustion. See Table 11 for

correct values.

CAUTION

- The owner is responsible

for general care of the unit.

Improper maintenance of the

unit may result in a hazardous

condition.

- Periodic inspection of the

low water cut-o󰀨 device,

including ushing of oat

types, is required, if installed

as an accessory to the unit.

- When servicing controls,

label all wires prior to

disconnection. Wiring errors

can cause improper and

dangerous operation.

- When removing a burner,

a new burner gasket is

required.

WARNING

- Fill the trap with water

before the unit is rst red to

prevent exhaust fumes from

entering the room. Never

operate the unit unless the

trap is lled with water.

Failure to comply will result in

severe personal injury or death.

Whenever the burner is

removed for inspection or

unit servicing, examine the

sealing gaskets and replace if

damaged.

Figure 50: Checking igniter gap using 251-001 Ignitor Gapping Tool

3/16" / 4.5MM

INSTALLATION AND OPERATION INSTRUCTIONS

4-2

COMBI BOILERS 99 & 125 & 160 & 199

4.1.6 Heat Exchanger

During annual inspection (with the heat exchanger cover removed), examine

the heat exchanger for signs of contamination and clean if necessary. In areas

of poor gas quality or contaminated combustion air, there may be a build-up of

black plaque (typically sulfur). Other fouling agents are airborne dust, debris and

volatiles.Cleantheheatexchangersurfacewithasti󰀨plasticbristlebrushonly.

During maintenance, the heat exchanger gasket must be replaced. Inspect other

gaskets, and change when needed. Refer to the heat exchanger cover removal

instructions in Section 3.4.1 for access to the combustion chamber and heat

exchanger. Observe the safety warning regarding the burner refractory on

this page.

4.1.7 Pump

Check that the pump is on in normal space heating operation, and that the water

ΔT is reasonable for the heating application.

4.1.8 Gas Piping

Check for damage or leaks, and repair as needed.

4.1.9 Control Module

•

Check that unit operation is consistent with the steps in Section 2.6 Sequence

of Operation.

• Check that water temperature targets and setpoint are satisfactory, and have

not been adversely adjusted.

4.1.10 Water Heating System

• Check water pressure and temperature. There should be no noticeable

change if the unit and system components are functioning normally. Check for

any noise in the system.

• Check heating system water piping for damage or leaks, and repair as

needed.

• Check for 12-15 psig in normal operation, and look to ensure pressure does

not run up toward 30 psig at high temperature. If pressure rises sharply,

considerreplacementoftheexpansiontank.Checkalsofornoiseathighre

that may signal water quality problems.

• Water chemistry must be of a quality generally accepted as suitable for

hydronic applications. See Section 1.6 for details.

• Ensurethatanydirect“cityll”waterconnectionsareleftintheclosed

positiontominimizeexposuretoleaksandooding.

4.1.11 Freeze Protection

Theunit’scontrolleroperatestheunitasneededtoprotectitfromfreezing.Ifthe

unit and system components are vulnerable to freezing we recommend using a

freezeprotectionsolution.Useantifreezemadespecicallyforhydronicsystems.

We recommend inhibited propylene glycol. Antifreeze concentration must be

between 25% and 50% of the total volume of water in the system.

CAUTION

The heat exchanger has a

small amount of combustion

chamber insulation

(refractory), that contains

ceramic bers.

When exposed to extremely

high temperatures, the

ceramic bers, which contain

crystalline silica, can be

converted into cristobalite,

classied as a possible

human carcinogen.

Avoid disturbing or damaging

the refractory. If damage

occurs, contact the factory for

directions.

Avoid breathing in fumes and

contact with skin and eyes.

Follow these precautions:

1. For conditions of frequent

use or heavy exposure,

you need a respirator.

For respirators certied

by NIOSH, refer to the

“NIOSH Guide to the

Selection and Use of

Particulate Respirators

Certied under 42 CFR

84".

For current information,

contact NIOSH on 1-800-

356-4676 or on the web at

www.cdc.gov/niosh.

2. Wear long sleeved, loose

tting clothing, gloves

and eyes protection.

3. Assure adequate

ventilation.

4. Wash with soap and water

after contact.

5. Wash potentially

contaminated clothes

separately from other

laundry, and rinse clothes

thoroughly.

6. Discard used insulation in

an air tight plastic bag.

NIOSH rst aid guidelines:

• Eye contact - Irrigate and

wash immediately.

• Breathing in fumes -

Provide fresh air.

4-3

MAINTENANCE

COMBI BOILERS 99 & 125 & 160 & 199

4.1.12 System Treatment

• Check consistency of any system treatment used, for appropriate mixture.

Chemical inhibitors are consumed over time, lowering their density.

• Verify proper operation after servicing.

4.1.13 Relief Valve - Maintenance and Testing

The relief valve manufacturer requires that under normal operating conditions a

“try lever test” must be performed quarterly. Under severe service conditions, or

if corrosion and/or deposits are noticed within the valve body, you must test more

often. Also perform a “try lever test” at the end of any non-service period.

Test at or near maximum operating pressure by holding the test lever fully open

foratleast5secondstoushthevalveseatfreeofsedimentanddebris.Then

release the lever and permit the valve to snap shut.

If the lever does not activate, or there is no evidence of discharge, discontinue

useofequipmentimmediately,andcontactalicensedcontractororqualied

service personnel.

Ifthereliefvalvedoesnotcompletelyseal,anduidcontinuestoleakfrom

thedischargepipe,performthetestagaintotryandushanydebristhatmay

be lodged in the valve. If repeated attempts fail to stop the leakage, contact a

licensedcontractororqualiedservicepersonneltoreplacethevalve.

Whileperforminga“trylevertest”,aquantityofheattransferuidwillbe

dischargedfromthepipingsystem,andthesystempressurewilldrop.Thisuid

must be replaced. We highly recommend using a system pressurization unit

such as an Axiom Industries model MF200torellandpressurizeyoursystem.

Capturethedischargeduidinacontainerandrecycleitbyreturningittothe

system feeder unit. This is particularly important when your system contains

treatment chemicals or glycol solutions. If the system employs plain water, turn

ontheunit’sautollvalvetorechargethelostuid.

4.1.14 Domestic Hot Water System

Check that the domestic hot water generation is performing as expected. Fouling

of the interior of the domestic heating coil can cause poor performance. Clean

domestic heating coil with nontoxic tankless water heater solution as required.

Quality of the domestic cold water is very important to the longevity of the

unit. The recommended pH of the domestic water is between 6.5 and 8.5. The

internaldomesticwaterheatexchangertubingandtheowsensoraresubjectto

fouling if exposed to hard water (over 11.68 grains of hardness) or has a TDS of

500mg/L or higher. See Table 12.

CAUTION

Before testing the relief valve,

make certain the discharge

pipe is properly connected to

the valve outlet, and arranged

to contain and safely dispose

of equipment discharge.

NOTE

Installers should contact the

local water supplier about

the suitability of their water

for use in hydronic heating

systems.

If water quality is questionable,

a local water treatment expert

must be consulted for testing,

assessment and, if required,

treatment.

Alternatively, water or hydronic

uid of known quality can be

brought to the site.

WARNING

Do not use automotive-type

ethylene or other types of

automotive glycol antifreeze,

or undiluted antifreeze of

any kind. This may result

in severe unit damage. The

installer is responsible

in ensuring that glycol

solutions are formulated to

inhibit corrosion in hydronic

heating systems of mixed

materials. Improper mixtures

and chemical additives may

cause damage to ferrous and

non-ferrous components as

well as non-metallic, wetted

components, normally found

in hydronic systems. Ethylene

glycol is toxic, and may be

prohibited for use by codes

applicable to your installation

location. For environmental

and toxicity reasons, we

require only using non-toxic

propylene glycol.

INSTALLATION AND OPERATION INSTRUCTIONS

4-4

COMBI BOILERS 99 & 125 & 160 & 199

4.1.15 DHW Coil Cleaning Instructions

Clean the DHW coil as follows:

1. These instructions assume that a set of service valves have previously been

installed.

2. Theseinstructionsassumetheuseofatanklesswaterheaterushkit.

3. Turno󰀨theunitbytouchingtheareaabovethedotfor2seconds.

4. Openahotwaterfaucetuntiltheheatexchangerissu󰀩cientlycool.

5. Close the gas valve and DHW hot and cold water isolation valves.

6. Attach two hoses to the DHW hot and cold water service valve hose

connections.

7. Attachthecoldwaterhosetotheushkitpumpandplaceina5gallon

bucket.

8. Place the loose end of the hot water hose in the bottom of the 5 gallon

bucket and open the DHW hot and cold water service valves.

8. Pour 2 gallons of nontoxic tankless water heater cleaning solution in the

bucket.

9. Plug in the pump and allow the cleaning solution to circulate in accordance

withthemanufacturer’sinstructions.

10. AftercleaningtheDHWcoil,disconnectthewireharnessfromtheuegas

temperature sensor on models equipped with an internal domestic hot water

bypass valve. The lockout will cause the internal domestic hot water bypass

valve to send cleaning solution through the bypass line.

11. Allowthecleaningsolutiontocirculateinaccordancewiththemanufacturer’s

instructions.

12. After cleaning the bypass line, unplug the pump and close the DHW cold

water service valve.

13. Remove the hot water hose from the 5 gallon bucket and route to a suitable

drain.

14. OpentheDHWcoldwaterisolationvalveandushoutthebypasslinefor

about 5 minutes.

15. Reconnectthewireharnesstotheuegastemperaturesensorandresetthe

lockout by pressing the wrench for 2 seconds.

16. Flush out the DHW coil for about 5 minutes then close the DHW hot water

service valve and open the DHW hot water isolation valve.

17. Disconnect the two hoses from the DHW hot and cold water service valve

hose connections.

18. Open the gas valve and turn on the unit by touching the area above the dot

for 2 seconds to resume normal operation.

4.1.16 DHW Filter Cleaning Instructions

CleantheDHWwaterlterduringannualmaintenanceasfollows:

1. Turno󰀨theunitanddisconnectpower.

2. Turno󰀨theDHWhotandcoldisolationvalves.

3. Place a bucket under the drain and drain the DHW water from the unit.

4. Unscrewthewaterlterfromtheunit’scoldwaterinlet.

5. Cleanthewaterlterunderrunningwater.Useasoftbrushifnecessary.

6. Reinstallthewaterlterintheunit’scoldwaterinlet.

7. Open the DHW hot and cold isolation valves.

8. Reconnect the power and return the unit to operation.

4-5

MAINTENANCE

COMBI BOILERS 99 & 125 & 160 & 199

DESCRIPTION MAX MIN

Water Pressure 150 PSI 40 PSI

Programmable water temperature 149°F (65°C) 105°F (40°C)

Minimum Flow Rate to Activate DHW Sensor N/A. 0.5

Acceptable pH range 8.5 6.5

Total Dissolved Solids 500mg/L

Total Hardness 200 mg/L 11.68 gr/gal

Aluminum 0.2 mg/L 0.05 mg/L

Chlorides 250 mg/L

Copper 1 mg/L

Iron 0.3 mg/L

Manganese 0.05 mg/L

Zinc 5 mg/L

Table 12: Domestic Water Quality Guidelines

4.1.17 Fan removal instructions

1. Turno󰀨thepowerandthegassupplytotheunit.

2. Remove the front cover, and allow the unit to cool down.

3. Disconnect the electrical plug attached to the fan.

4. Loosentheunionnutatthetopofthegasvalve.Carefullyremovetheorice

and O-ring, and keep in a safe place for re-installation later. Ensure you

protect the gas valve outlet from dust and debris.

Remove the 2 hex nuts connecting the fan to the burner housing, and

carefullyremovethefan.Youwillndagasketattachedtothefanoutletas

well as an internal check valve. Keep these items in a safe place for re-

installation.

6. If the removed fan is to be re-installed, ensure the fan and venturi are clean

and dust free.

4.1.18 Fan installation instructions

1. Place the fan gasket on the outlet of the fan housing. The gasket has 2

locator pins to ensure the gasket does not move during installation.

2. Reinstall the check valve in the burner housing and attach the fan to the

burner housing with the 2 hex nuts. Tighten the 2 hex nuts with a wrench.

3. InserttheoriceandO-ringbetweenthegasvalveoutletandthegaslineto

the fan. Tighten the gas valve union nut with a wrench. Ensure that the gas

valve inlet (lower) nut is tight.

4. Connect the electrical plug to the fan.

5. Restore the gas supply to the unit, and test the gas valve inlet for gas leaks.

6. Restore the power to the unit, and create a call for heat or hot water.

7. Check for leaks at the gas valve outlet and the connection between the fan

and the burner housing.

8. Install the cover to the unit.

9. Return the unit to normal operation.

DANGER

When servicing or replacing

the fan, you must transfer the

venturi from the old fan to the

new fan.

Failure to relocate the venturi

to the new fan may cause

an immediately hazardous

situation which must be

avoided in order to prevent

serious injury or death.

INSTALLATION AND OPERATION INSTRUCTIONS

4-6

COMBI BOILERS 99 & 125 & 160 & 199

4.1.19 Cleaning the Condensate Trap

1. Turno󰀨thepowerandthegassupplytotheunit.

2. Remove the front cover, and allow the unit to cool down.

3. Removetheexiblehose(1)fromthecondensatetrapanddrain.

4. Detach the condensate trap cup (2) by rotating it to the left (counter-

clockwise) and then pulling it downwards.

5. Empty the condensate trap cup (3).

6. Detach the condensate trap base (4) by pressing the three securing clips in,

while simultaneously pushing the condensate trap base downwards (4).

7. Remove the circlip and the plastic ball from the condensate trap base (5).

8. Clean the following components with water:

● the inside of condensate trap base

● plastic ball

● circlip

● condensate trap cup

● openingoftheuepipe

9. Return the plastic ball to the condensate trap base and attach the circlip.

1 2

3 4

2 ¼"

(60 mm)

5 6

4-7

MAINTENANCE

COMBI BOILERS 99 & 125 & 160 & 199

10. Check that the ball and circlip have been installed correctly (6). Make sure

that the top of the circlip is about 2 1/4” (60 mm) below the edge of the

condensate trap base.

11. ReplacetheO-ring(part#150-367)atthebottomoftheuepipe.

12. Attach the condensate trap base to the bottom by pushing it high enough so

that the securing clips click over the lip (8).

4.1.20 Reset the Maintenance Counter

The maintenance counter should be reset after all maintenance items in this

section have been completed. Refer to Resetting the Maintenance Counter,

section 2.8 of this manual.

–

14. Slidetheexiblehoseontothecondensatetrapbaseandintothedrain(10)

9 10

DANGER

Make sure that the

condensate trap base is

returned to its original

position, rmly locked into

the bottom with no gaps.

Incorrectly attaching the

condensate trap base (or not

attaching it at all) will result

in products of combustion

leaking into the room creating

a dangerous situation.

13.Makesurethecondensatetrapcupis¾lled

with water (7) before installation, slide it into the

condensate trap base and rotate it to the right

(clockwise) until it is correctly secured (9).

CAUTION

The maintenance counter

must only be reset after

performing the maintenance

procedures in Section

4.0 Maintenance of this

manual. Failure to perform

maintenance can result in a

hazardous condition.

INSTALLATION AND OPERATION INSTRUCTIONS

4-8

COMBI BOILERS 99 & 125 & 160 & 199

4.1.21 Winterization

The Combi Boiler must be winterized along with the rest of the heating and

domestic water systems when the systems will be shut down for an extended

period of time and be subject to freezing conditions.

1. Turno󰀨thepowerandthegassupplytotheunit.

2. If the heating system does not contain the proper level of propylene glycol to

prevent freezing, drain the units space heating coil along with the rest of the

heating system.

3. Drain the units domestic hot water coil along with the rest of the domestic

water system.

4. Remove the condensate trap cup and empty.

5. If present, empty condensate pump.

NOTE

Damage to the Combi Boiler

caused by freezing water is

not covered by the warranty.

5-1

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

5.0 TROUBLESHOOTING

The troubleshooting section is divided into four sections:

5.1 Preliminary Checks

5.2 Electronic Components

5.3 Faults and Notications

5.4 Other Faults

Often, you can identify and solve a problem through simple checks of the basics:

conrmingtheelectricalpowersupply,gasowandresettingthethermostat

control.Tohelpwithpreliminarychecks,theunit’scontrolmoduleo󰀨ersaclear

visual display of the status of the various control circuit components.

Should a problem remain unsolved after applying the preliminary checks,

proceed to the detailed system review in this guide. The Troubleshooting chapter

covers potential error conditions, grouped into the following categories:

5.3.1 Fault Codes

5.3.2 Notication Codes

5.4.1 No heat (space heating)

5.4.2 Space heating does not reach the correct temperature

5.4.3 Space heating system remains too warm

5.4.4 No domestic hot water (DHW)

5.4.5 Domestic hot water does not reach the correct temperature

5.4.6 Burner ignites loudly

5.4.7 Burner resonates

Below each section is a list of symptoms, diagnoses, and solutions.

Some diagrams (see Section 6.0) are included for use with troubleshooting

including:

• Electrical Wiring Diagrams

• Unit Component Layout Diagrams

5.1 PRELIMINARY CHECKS

Asarststepintroubleshooting,youshouldreviewthecontroller’sdisplay

screen. Diagnostic features evaluate system integrity, display error conditions,

and indicate initial troubleshooting action.

Inadditiontocheckingthecontroller’sdisplay,trythesetroubleshootingsteps:

1. Conrmpowertotheunit:checkthatcontrolmoduledisplayison(e.g.,

display is lit).

2. Check that unit is not in a safety lockout.

3. Ensure that wiring is secure and properly terminated.

4. Check that gas is reaching the unit.

Conrmthatthewatersystemisproperlypressurizedto12psigandthatthe

pump is operating.

NOTE

This unit is equipped with a

blocked vent shut-o󰀨 system

that closes the gas supply

when it detects an irregular

venting condition.

INSTALLATION AND OPERATION INSTRUCTIONS

5-2

COMBI BOILERS 99 & 125 & 160 & 199

5.2 ELECTRONIC COMPONENTS

This section details the method for troubleshooting the non-standard electronic

components on the unit, including the electronic water pressure sensor-type

LWCO and the temperature sensors.

5.2.1 Temperature Sensors

The resistance of the temperature sensors varies inversely with temperature. To

test, measure the temperature of the sensed environment and compare with the

value derived from the measurement of the resistance (obtained by connecting a

goodqualitytestmetercapableofmeasuringupto5,000KΩ(5,000,000Ω)atthe

controller end of the sensor lead).

To obtain a resistance reading, remove power to the unit. For the supply water

and return water temperature sensors, remove the wire leads by disconnecting

theirrespectiveMolexconnectors.Placemulti-meterprobesintothesensor’s

male Molex connector socket. Do not apply voltage to the sensor as damage

may result.

12KΩ temperature sensors are supplied with the unit. See Table 14 for resistance

values.

SENSOR TYPE PURPOSE LOCATION

S0 NTC12KΩ Heat Exchanger

Temperature

Left Side of Heat

Exchanger

S1 NTC12KΩ Heating Supply

Temperature

Heating Supply Pipe

S3 NTC12KΩ Domestic Hot Water DHW Supply Pipe

S4 NTC12KΩ Domestic Cold Water DCW inlet Pipe

S5 NTC12KΩ Flue Gas Temperature Top of rear Flue passage

S6 NTC12KΩ Outdoor Sensor Outdoors (North side)

S7 NTC10KΩ Hot Water Tank External Water Heater

PTC1

PTC2

PTC Cabinet Temperature

Left and right Side top of

inner cabinet

Water Pressure Heating Supply Pipe

Table 13: Temperature and Pressure Sensors

Figure 52: Heating Supply

Temperature Sensor S1

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

F / C Ω-ohm F / C Ω-ohm F / C Ω-ohm

5F / -15C 76,020 77F / 25C 12,000 149F / 65C 2,752

14F / -10C 58,880 86F / 30C 9,805 158F / 70C 2,337

23F / -5C 45,950 95F / 35C 8,055 167F / 75C 1,994

32F / 0C 36,130 104F / 40C 6,653 176F / 80C 1,707

41F / 5C 28,600 113F / 45C 5,522 185F / 85C 1,467

50F / 10C 22,800 122F / 50C 4,609 194F / 90C 1,266

59F / 15C 18,300 131F / 55C 3,863 203F / 95C 1,096

68F / 20C 14,770 140F / 60C 3,253 212F / 100C 952

Table 14: Temperature Sensor Resistance Values – 12KΩ sensors.

Figure 51: Heat exchanger

Temperature Sensor S0

5-3

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

5.2.2 Cabinet Sensors

The Cabinet temperature sensors ensure that the unit shuts down if the

temperature inside the cabinet is above normal.

The Cabinet temperature sensors are located on the left and right side at the top

of the cabinet. To remove the sensors, unclip the wiring harness and unscrew

from the top cabinet.

5.2.3 Thermostat Connections

Theunit’scontrollerisdesignedtoheatasinglespaceheatingload.Theloadcan

consistofasinglezoneorseveralzones.Ineithermethod,the‘CallforHeat’must

be from a device providing a dry contact and connected to X13.1 and X13.2. The

use of power-robbing thermostats directly will cause the unit to operate erratically.

If using a power-robbing thermostat, you will need to isolate it through a relay. An

Open Therm device can also be used across X13.1 and X13.2.

5.2.4 Water Pressure Sensor-Type Low Water Cut Off

(LWCO)

Theunitisequippedwithapressuresensorthatservesasalow-watercut-o󰀨.

The water pressure is displayed in the main display when the pressure is low. For

example, a system water pressure of 4.6psi would be displayed as 4.6P. If the

pressureistoolowthecontrollerashesanerrormessageinthemaindisplayby

toggling between the actual pressure and LO. To correct this error, increase the

system pressure. The water pressure in the heating system must be higher than

8psifortheunittoreachmaximumringrate.Whenthewaterpressureisless

than8psi,theunitrestrictsitsringrate.Ifthepressureislessthan4psithenthe

unitwillnotreatall.

To test the operation of the pressure sensor – type LWCO

1. Turno󰀨theunitatthecontrollerbypressingtheareaabovethedot.The

current system pressure is displayed.

Isolate the space heating circuit, and reduce the water pressure. The

displayed water pressure should drop as the system water is being removed

(expansion tank isolated). If the pressure remains steady the pressure sensor

maybeblockedorfaulty.Ifitremains“xed”,draintheunitandreplacethe

sensor, or dislodge any blocking debris from the sensor inlet channel and

reinsert.

3. IfthepressuresensorisOKrelltheunitandopentheclosedvalves.Ensure

the system pressure is adequate for the heating system.

PRESSURE SENSOR LWCO REPLACEMENT

1. Turno󰀨thepowertotheunit.

2. Isolate and drain the unit.

3. Disconnect the electrical connection to the sensor.

4. Carefully remove the pressure sensor by loosening it, turn the nut counter

clockwise until it can be removed. If there is some water leakage, ensure the

water does not spill into the controller.

5. Push the new sensor into the socket while twisting slightly. Take care to avoid

damage to the O-ring.

6. Connect the electrical connector to the sensor.

7. Restore water pressure to the unit.

8. Restore power to the unit.

Cabinet sensors

Figure 53: Cabinet Temperature

Sensors

Figure 54: Water Pressure Sensor

Type LWCO

Figure 55: Pump

INSTALLATION AND OPERATION INSTRUCTIONS

5-4

COMBI BOILERS 99 & 125 & 160 & 199

5.2.5 Flue Gas Temperature Sensor

Thissensorensuresthattheunitshutsdownsafelyiftheuetemperature

isabovenormal.Highuetemperaturescanbeanindicationthattheheat

exchanger requires cleaning.

Theuegastemperaturesensorislocatedatthetopoftherearuepassage,

below the top panel. To remove the sensor, unclip from the wiring harness and

unscrewfromtherearuepassage.

5.2.6 Domestic Hot Water Flow Sensor

TheCombiboilerisequippedwithaowsensortomeasurewaterowthrough

thedomestichotwatercircuitinthewaterheater.Theowsensorconsistsoftwo

parts, the mechanical turbine in the cold water inlet and the external inductive

sensorsurfacemountedontheoutsideofthecoldwaterinlet.Theminimumow

required to activate the water heater is 0.5 GPM or 2 L/min.

To service or replace the mechanical turbine:

1. Disconnect power to the unit.

Turno󰀨thecoldandhotwatervalvesbelowtheunit,releasethewater

pressure and then drain the domestic hot water circuit. Leave the drain valves

open.

5.2.7 Domestic Hot Water Temperature Sensor

The Combi boiler is equipped with a domestic hot water temperature sensor. The

sensor is surface-mounted on the hot water outlet pipe.

5.2.8 Domestic Hot Water Bypass Valve

Combi boiler models 160,000 & 199,000 are equipped with a domestic hot water

bypass valve which allows cold water to bypass the heat exchanger to temper

the domestic hot water temperature.

To service or replace the bypass valve:

1. Turno󰀨theunitanddisconnectpower.

2. Close the DHW hot and cold isolation valves.

3. Place a bucket under the drain and drain the DHW water from the unit.

4. Disconnect and remove the bypass tube.

5. RemovetheretainingclipundertheunitattheDHWlter.

6. Disconnect the bypass valve from the heat exchanger using two wrenches

5.2.9 Domestic Cold Water Temperature Sensor

The Combi boiler is equipped with a domestic Cold water temperature sensor. The

sensor is surface-mounted on the Cold water inlet pipe.

Figure 57: Domestic Hot Water

Flow Sensor

Figure 56: Flue Gas Temperature

Sensor S5

Figure 58: Domestic Hot Water

Temperature Sensor S3

5-5

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

5.2.10 Outdoor Sensor

An outdoor sensor is supplied with each unit. The sensor should be mounted

on the north side of the building away from any direct sunlight. Keep the

sensor away from any heat sources such as exhaust fan outlets, dryer outlets,

mechanical room ventilation grills etc.

TheOutdoorsensorisa12KΩsensorwithresistancevaluesaslistedinTable

14.Ifthesensorisnotconnectedtotheunit,theunitoperatesattheunit’ssupply

temperature set in the User Setup menu, and operates as a set point load.

5.2.11 DHW Tank Sensor

The Combi boiler allows the use of a tank sensor for controlling the domestic

hotwatertanktemperature.A10KΩsensororanaquastatcanalsobeusedto

operate the Combi boiler.

Ifaeldsupplieddomestichotwatersensorisused,itmustbea10KΩsensor

matching the following table.

TEMPERATURE RESISTANCE TEMPERATURE RESISTANCE

°F °C Ω °F °C Ω

0 -18 85,362 100 38 5,828

5 -15 72,918 105 41 5,210

10 -12 62,465 110 43 4,665

15 -9 53,658 115 46 4,184

20 -7 42,218 120 49 3,760

25 -4 39,913 125 52 3,383

30 -1 34,558 130 54 3,050

35 2 29,996 135 57 2,754

40 4 26,099 140 60 2,490

45 7 22,763 145 63 2,255

50 10 19,900 150 66 2,045

55 13 17,436 155 68 1,857

60 16 15,311 160 71 1,689

65 18 13,474 165 74 1,538

70 21 11,883 170 77 1,403

75 24 10,501 175 79 1,281

80 27 9,299 180 82 1,172

85 29 8,250 185 85 1,073

90 32 7,334 190 88 983

95 35 6,532 195 91 903

Table 15: Temperature Sensor resistance values – 10KΩ sensor

5.2.12 Fan/Blower

Control and power to the fan is provided via a single wiring harness to the

controller.

Figure 61: Outdoor air Temperature

Sensor S6

Figure 59: Domestic Hot Water

Bypass Valve

Figure 60: Domestic Cold Water

Temperature Sensor S4

INSTALLATION AND OPERATION INSTRUCTIONS

5-6

COMBI BOILERS 99 & 125 & 160 & 199

5.3 FAULTS AND NOTIFICATIONS

5.3.1 Fault Codes

During operation the controller can detect unusual situations and can take action to avoid damage to the heat

exchanger or other unsafe operations. During these situations, the controller limits the temperature and power output

of the burner, or temporarily disables operation entirely.

Thesefaultsareshownashingandvisibleonthemaindisplay,anddisplayedonlywhenanunusualreadingis

currently detected. Fault Codes can be reset by touching the wrench for 2 seconds after the cause of the fault has

been resolved.

FAULT CODE DESCRIPTION POSSIBLE CAUSE / SOLUTION

F000 Heat exchanger temperature sensor

fault.

• Verify wire harness connections at heat exchanger

temperature sensor and control module are tight.

• Replace heat exchanger temperature sensor.

F001 High heat exchanger temperature

during central heating demand.

• Verify all air has been bled/purged from the heat

exchanger central heating coil

• Replace internal pump if it is not operating during a

central heating demand.

• Verify the unit has been converted to propane if operating

on propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Clean heat exchanger central heating coil.

• Cleanresideofheatexchanger.

F002 High heat exchanger temperature

during DHW demand.

• Verify the unit has been converted to propane if operating

on propane

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Clean heat exchanger DHW coil.

• Cleanresideofheatexchanger.

F003 Highuetemperature.

• Verify the unit has been converted to propane if operating

on propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

5-7

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

F004 Noamedetectedduringfourignition

trials.

• Verifyexternalgasshuto󰀨valveisopen.

• Verify gas inlet pressure is at least 4” during igntion trial.

• Verify condensate drain is not blocked.

• Check vent and combustion air piping for blockage.

• Verify internal and power supply grounding.

• Verify ground spring is in contact with burner head screw.

• Verify ignitor to ignition module connection is tight.

• Check ignitor condition and clean/replace as necessary.

• Verifyoperationofthebackowapperinthefanoutlet.

• Verify ignitor is not in contact with burner and gap is

correct.

• Replaceignitionmoduleifunitlightsbutameicon

doesn’tilluminate.

• Replace ignition module if spark is not present and

110VAC is present on ignition module black and gray

wires.

• Replace control module if spark is not present and

110VAC is not present on ignition module black and gray

wires.

• Replace gas valve if gas inlet pressure does not drop

during trial for ignition and 24VDC is present at gas valve

harness.

• Replace control module if gas inlet pressure does not

drop during trial for ignition and 24 VDC is not present at

gas valve harness.

F005 Noamedetectedduringoperation.

• Verify condensate drain is not blocked.

• Check vent and combustion air piping for blockage.

• Checkforuegasrecirculation.

• Ifventterminationissubjecttohighwinds,recongure/

relocate as necessary.

• Verify gas inlet pressure is at least 4” at both low and high

re.

• Verifylowandhighrecombustionreadingsarewithin

specications.

• Check ignitor condition and clean/replace as necessary.

F006 Flamedetectedwhenburneriso󰀨.

• Verify good internal and power supply grounding.

• Verifyamegoesoutatconclusionofdemand,ifnot

replace gas valve.

• Replace ignition module.

• Replace control module.

F007 Lowamesignal.

• Verify ignitor to ignition module connection is tight.

• Check ignitor condition and clean/replace as necessary.

• Verifylowandhighrecombustionreadingsarewithin

specications.

F008 Incorrect fan speed

• Verify wire harness connections at fan and control

module are tight.

• Replace fan.

• Replace control module.

F009 Control module internal fault.

• Removealleldwiringfromunitthenresetfault.

• CheckeldwiringforvoltagebackfeedifF009faultdoes

not return.

• Replace control module if F009 fault code returns.

INSTALLATION AND OPERATION INSTRUCTIONS

5-8

COMBI BOILERS 99 & 125 & 160 & 199

F010 Heat exchanger temperature sensor

open.

• Verify wire harness connections at heat exchanger

temperature sensor and control module are tight.

• Check resistance of each heat exchanger temperature

sensor (center pin is common), replace sensor if open

circuit is found.

• Check resistance of each heat exchanger temperature

sensor (center pin is common) at control module harness

connector, repair wire harness if open circuit is found.

F011 Heat exchanger temperature sensor

short

•

Check resistance of each heat exchanger temperature

sensor (center pin is common), replace sensor if short

circuit is found.

• Check resistance of each heat exchanger temperature

sensor (center pin is common) at control module harness

connector, repair wire harness if short circuit is found.

F012 Flue temperature sensor open.

• Verifywireharnessconnectionsatuetemperature

sensor and control module are tight.

• Checkresistanceofuetemperaturesensor,replace

sensor if open circuit is found.

• Checkresistanceofuetemperaturesensoratcontrol

module harness connector, repair wire harness if open

circuit is found.

F013 DHW inlet temperature sensor

open/short

•

Verify wire harness connections at DHW inlet temperature

sensor and control module are tight

• Check resistance of DHW inlet temperature sensor,

replace sensor if open/short circuit is found.

• Check resistance of DHW inlet temperature sensor at

control module harness connector, repair wire harness if

open/short circuit is found.

F014 Heat exchanger temperature sensor

mounting fault.

• Heat exchanger temperature is not changing while unit is

red.

• Verify heat exchanger temperature sensor is properly

mounted on the heat exchanger.

F015 High cabinet temperature

• Checkheatexchangerforuegasleakage

• Checkventpipeforuegasleakage

F016 DHW outlet temperature sensor

mounting fault

• DHWoutlettemperatureisnotchangingwhileunitisred

• Verify DHW outlet temperature sensor is properly

mounted on the DHW outlet pipe

F017 DHW bypass valve fault

• Verify wire harness connections at DHW bypass valve

and control module are tight.

• Check resistance of DHW bypass valve at control module

harness connector:

Green-Purple=30to40Ω

Green-Blue=30to40Ω

Green-Yellow=30to40Ω

Green-Orange=30to40Ω

Red-Black=5.5to6.5MΩ

Red-Brown=17to21MΩ

If any resistance value is outside of these ranges, check

and repair any wire harness open/short circuit before

replacing DHW bypass valve.

F018 Flue/Combustion Air blockage.

• Check the vent and combustion air pipes for blockage.

• Verifyoperationofthebackowapperinthefanoutlet.

5-9

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

F019 Boiler Memory Module (BMM) fault.

• Verify wire harness connections at boiler memory module

and control module are tight.

• Verify wire harness continuity between boiler memory

module and control module .

• Replace boiler memory module.

F021 Critical parameter changed

• Factory reset required.

F027 Outdoor temperature sensor short.

• Check resistance of outdoor temperature sensor, replace

sensor if short circuit is found.

• Check resistance of outdoor temperature sensor at

control module harness connector, repair outdoor sensor

eldwiringifshortcircuitisfound.

F028 Reset button fault.

• Check the reset button for unintentional operation such

as during cleaning.

• Replace control module.

F029 Gas valve fault.

• Verify wire harness connections at gas valve and control

module are tight

• Replace gas valve if upper coil resistance is not 35 to 45

Ω.

• Replace gas valve if lower coil resistance is not 20 to 30

Ω.

• Check resistance of gas valve at control module harness

connector, repair wire harness if open/short circuit is

foundorifresistanceisnotwithin60to70Ω

• Replace control module.

F031 Supply temperature sensor open/

short.

• Verify wire harness connections at supply temperature

sensor and control module are tight.

• Check resistance of supply temperature sensor, replace

sensor if open/short circuit is found.

• Check resistance of supply temperature sensor at control

module harness connector, repair wire harness if open/

short circuit is found.

F040

Cabinet temperature sensor open.

• Verify wire harness connections at cabinet temperature

sensors and control module are tight.

• Check resistance of cabinet temperature sensors, replace

sensor if open circuit is found.

• Check resistance of cabinet temperature sensors at

control module harness connector, repair wire harness if

open circuit is found.

F041

Cabinet temperature sensor short.

• Check resistance of cabinet temperature sensors, replace

sensor if short circuit is found.

• Check resistance of cabinet temperature sensors at

control module harness connector, repair wire harness if

short circuit is found.

F042 Cascade DHW not available

• Resolve any other lockouts in the cascade system.

• Verify Leader cascade parameter settings are correct.

• Verify Follower(s) cascade parameter settings are

correct.

• Check cascade communication status in the information

menu of both Leader and Follower.

INSTALLATION AND OPERATION INSTRUCTIONS

5-10

COMBI BOILERS 99 & 125 & 160 & 199

-- (Blinking)

Water presssure sensor fault.

• Verify wire harness connections at water pressure sensor

and control module are tight.

• Check resistance of water pressure sensor at control

module harness connector:

Black-Orange=7.5to9.5KΩ

Black-Yellow=7.5to9.5KΩ

• If any resistance value is outside of these ranges,

check and repair wire harness open/short circuit before

replacing water pressure sensor.

5.3.2 Notication Codes

Duringoperationthecontrollercanalsodetectunusualsituationsanddisplayanotication,usuallywithoutsignicant

interruption of the normal operation of the appliance.

Thesenoticationsareshownonthemaindisplay,anddisplayonlywhenanunusualreadingiscurrentlydetected.

Once the error has been resolved, the operation will be restored

Note that these notications only appear on controllers installed with software versions after 1.80. The software

version of the controller will appear upon the controller’s initial start up.

NOTIFICATION

CODE

DESCRIPTION POSSIBLE CAUSE / SOLUTION

n030 DHW outlet temperature sensor

open/short

• Verify wire harness connections at DHW outlet temperature

sensor and control module are tight.

• Check resistance of DHW outlet temperature sensor, replace

sensor if open/short circuit is found.

• Check resistance of DHW outlet temperature sensor at control

module harness connector, repair wire harness if open/short

circuit is found.

n040

Cascade communication lost

•

Verify Leader is powered on and cascade parameter settings are

correct.

• Verify Follower(s) cascade parameter settings are correct.

• Check cascade communication status in the information menu of

both Leader and Follower.

n041

Cascade system sensor open

•

Verifysystemsensoreldwiringisterminatedatthechoosen

input (X13-3&4 or X13-4&5).

• Check resistance of system temperature sensor, replace sensor if

open circuit is found.

• Check resistance of system temperature sensor at control

moduleharnessconnector,repairsystemsensoreldwiringif

open circuit is found.

n120 Maintenance recommended

• Maintenance is recommended based on hours of use.

n121 Maintenance required, limited DHW

output

• Maintenance is required based on hours of use.

• DHW output will be limited until maintenance is performed.

n122 Maintenance required, no DHW

output

• Maintenance is required based on hours of use.

• DHW output is disabled until maintenance is performed.

5-11

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

n150 High heat exchanger temperature,

limited output

• Verify all air has been bled/purged from the heat exchanger

central heating coil.

• Replace internal pump if it is not operating during a central

heating demand.

• Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

n151 Highuetemperature,limited

output

• Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger.

• Clean heat exchanger central heating and DHW coils.

n152

Flue temperature sensor

mounting fault

•

Fluetemperatureisnotchangingwhileunitisred.

• Verifyuetemperaturesensorisproperlymountedonthevent

pipe.

n201 Heat exchanger air purge function

activated

• Air trapped in the heat exchanger

• Closed boiler isolation valve

• Defective boiler pump

n202

Highuetemperature,burner

disabled

•

Verify the unit has been converted to propane if operating on

propane.

• Verifycombustionreadingsatlowandhighrearewithin

specications.

• Cleanresideofheatexchanger

• Clean heat exchanger central heating and DHW coils.

n245 Fluegasbackow,fanonlow

speed

• Verify vent and combustion air piping and terminations are

installed according to this manual.

• Verifyoperationofthebackowapperinthefanoutlet.

INSTALLATION AND OPERATION INSTRUCTIONS

5-12

COMBI BOILERS 99 & 125 & 160 & 199

5.4 OTHER FAULTS

5.4.1 No heat (space heating)

POSSIBLE

CAUSES

ANALYSIS POSSIBLE SOLUTION

The power LED is not

shown.

→Yes

↓No

• Check the power supply.

• Check the fuse (see Electrical schematic).

• Check wiring for breaks.

The right display

shows a line (–).

Theunitiso󰀨.

→Yes

↓No

• Switch on the unit by touching just above the power LED and

holding for 2 seconds.

Room thermostat

/ zone control not

enabling unit.

→Yes

↓No

• Check the wiring.

• Verify room thermostat / zone control is providing dry contact to enable unit for

space heating.

No electricity (24V). →Yes

• Check the wiring according to the schematic.

• Check Connector X13.

5.4.2 Space heating does not reach the correct temperature

POSSIBLE

CAUSES

ANALYSIS POSSIBLE SOLUTION

Water pressure in the

system is too

low.

→Yes

↓No

Top up the system.

Room thermostat is not

calling for heat.

→Yes

↓No

Check the setting and adjust it if necessary.

Temperature is set too

low.

→Yes

↓No

Increase the space heating temperature (see 2.3.2)

If an outdoor sensor is present. Check the outdoor sensor.

Noowinthesystem. →Yes

↓No

ChecktheΔT±36°F/±20°Cbetweenthecentralheatingsupplyandthe

return.Ensureacorrectowinthesystem.

Theunit’scapacityis

not correctly

set.

→Yes

↓No

Adjusttheunit’scapacity.

No heat transfer due to

contamination in the

unit/system.

→Yes

↓No

Flush the unit/system.

Flue and/or air supply

duct is blocked.

→Yes Checkand(ifnecessary)cleantheueandtheairsupplyduct.

5-13

TROUBLESHOOTING

COMBI BOILERS 99 & 125 & 160 & 199

5.4.3 Space heating system remains too warm

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

Room thermostat / zone

control is defective or has

a short circuit.

→Yes

↓No

• Check the wiring.

• Check room thermostat / zone control for a short circuit.

There is thermo-siphon in the central

heating circuit.

→Yes Place a check valve (in the case of thermo-siphon) or a

two-way valve (if there is a second pump in the central

heating circuit).

5.4.4 No domestic hot water (DHW)

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

The power LED is not shown. →Yes

↓No

• Check the power supply.

• Check the fuse (see electrical schematic).

Flow sensor does not work. →Yes

↓No

Replacetheowsensor.

Domestichotwaterow<0.5gpm →Yes

↓No

Increasethedomestichotwaterow.

Domestic hot water sensor S3 is

defective.

→Yes

↓No

Replace the domestic hot water sensor S3.

Noelectricityontheowsensor(5V

DC).

→Yes Check the wiring according to the schematic. CK THE

WIRING ACCORDING TO THE SCHEMATIC.

5.4.5 Domestic hot water does not reach the correct temperature

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

Domestichotwaterowistoohigh. →Yes

↓No

Reducethedomestichotwaterow.

Setting for domestic hot water

temperature is too low.

→Yes

↓No

Increase the domestic hot water temperature.

Insu󰀩cientheattransferduetocalciumor

contamination in the domestic hot water-sided

central heating unit.

→Yes

↓No

De-calcifyorushthedomestichotwater-sidedcentral

heating unit.

The central heating system becomes

warm while tapping water.

→Yes

↓No

Undesirable circulation during domestic hot water demand

in the central heating circuit due to thermo-siphon of the

second pump in the central heating circuit. Place a check

valve (in the case of thermo-siphon) or a two-way valve (if

there is a second pump).

INSTALLATION AND OPERATION INSTRUCTIONS

5-14

COMBI BOILERS 99 & 125 & 160 & 199

POSSIBLE CAUSES ANALYSIS POSSIBLE SOLUTION

Central heating pressure is too low. →Yes

↓No

Topo󰀨thecentralheatingsystemuntilthecentralheating

pressure is between 1 and 2 bar.

Theueisblocked. →Yes Checktheue.

5.4.6 Burner ignites loudly

POSSIBLE CAUSES ANALYSIS SOLUTION

Inlet pressure is too high. →Yes

↓No

The gas pressure regulator may be defective. In that case,

contact the energy company.

Ignition distance is incorrect. →Yes

↓No

Replace the ignitor including the ignition cable.

Gas-air control is not correctly

adjusted.

→Yes Check and/or adjust combustion with a calibrated

combustion analyzer.

5.4.7 Burner resonates

POSSIBLE CAUSES ANALYSIS SOLUTION

Gas inlet pressure lower than 4“ w.c.

or sometimes disappears.

→Yes

↓No

The gas pressure regulator may be defective. Contact the

energy company.

Thereisrecirculationofuegases. →Yes

↓No

Checktheueandairsupplyduct.

Gas-air control is not correctly adjusted. →Yes

↓No

Check and/or adjust combustion with a calibrated

combustion analyzer.

Burner seal is defective. →Yes

↓No

Replace the burner seal.

Burner is defective. →Yes Replace the burner.

6-1

REPLACEMENT KITS

COMBI BOILERS 99 & 125 & 160 & 199

6.0 REPLACEMENT KITS

Replacement

Kit Numbers

Replacement Kit Description

MODELS

99,000 125,000 160,000 199,000

P-081014 Conversion To Propane - Venturi 375

P-081024 Conversion To Natural Gas - Venturi 375

P-081034 Conversion To Propane - Venturi 528

P-081044 Conversion To Natural Gas - Venturi 528

P-081054 Conversion To Propane - Venturi 500

P-081064 Conversion To Natural Gas - Venturi 500

P-081364 Conversion To Low Caloric Gas - Venturi 528

P-081374 Conversion To Low Caloric Gas - Venturi 500

P-081414 Conversion To Low Caloric Gas - Venturi 375

P-081744 Conversion To Propane - Venturi 456

P-081754 Conversion To Natural Gas - Venturi 456

P-081764 Conversion To Low Caloric Gas - Venturi 456

P-081134 Replacement kit: Flue Temperature Sensor

x x x x

P-081144 Replacement kit: Ignitor

x x x x

P-081154 Replacement kit: Burner 99 - 125

x x

P-081174 Replacement kit: EBM Fan

x x x x

P-081224 Replacement kit: Boiler Pump

x x x x

P-081234 Replacement kit: Gas Valve

x x x x

P-081264 Replacement kit: Flow Sensor Complete (99-

125)

x x

P-081294 Replacement kit: Temperature Sensor Heat

Exchanger

x x x x

P-081314 Replacement kit: Pressure Sensor

x x x x

P-081334 Replacement kit: Controller Box White

x x x x

P-081384 Replacement kit: Burner 160 - 199

x x

P-081444 Replacement kit: Flow Sensor (Clip only)

x x x x

P-081454 Replacement kit: Maintenance Set Heat

Exchanger

x x

P-081494 Replacement kit: Bypass Wiring

x x

P-081504 Replacement kit: Ignition Wiring

x x x x

P-081534 Replacement kit: Sensor Wiring Tankless

x x

P-081574 Replacement kit: Ignition Line Complete

x x x x

P-081654 Replacement kit: Condensate Trap Boiler

x x x x

P-081694 Replacement kit: Temperature Sensor Clip

22mm

x x x x

P-082424 Replacement kit: Bypass Valve

x x

P-081784 Replacement kit: Temperature Sensor DHW

(Clip 15mm)

x x x x

P-081794 Replacement kit: Controller Box Black

x x x x

P-081814 Replacement kit: Strainer

x x x x

INSTALLATION AND OPERATION INSTRUCTIONS

6-2

COMBI BOILERS 99 & 125 & 160 & 199

PAGE INTENTIONALLY LEFT EMPTY

6-3

WIRING DIAGRAMS

COMBI BOILERS 99 & 125 & 160 & 199

7.0 WIRING DIAGRAMS

Diagram 6.2-1: Schematic wiring diagram 99 &

125 models

X2 X1

X9 X8

X14

X15

X2X8

5 4 3 2 1

2 1

X14

X15

16 15

14 13

12 11

8 7 6

2 1

Aquastat or

DHW Sensor

Outdoor Sensor

Thermostat

(by others)

Ignition

Power Plug

120V

Boiler

Pump

Blower

Motor

Flue Sensor

Cabinet Sensor

Heat ex. Sensor

Space Heating

Presure Sensor

DHW Hot NTC

CH Supply NTC

DHW Flow Sensor

Gas valve

BMM

G/Y GY

BL R O BK

Motor

Blower

R O BK

Pump

Boiler

snoitpO snoitpO

Power Plug

120V

W BK

Ignition

R O G/Y

GY BK

BMM

GY BK

Gasvalve

Space Heating

Pressure Sensor

DHW Flow Sensor

Heatex. Sensor

DHW Hot Sensor

CH Supply NTC

Cabinet Sensor

Flue Sensor

860004.02

Combi Boiler 99, 125 Ladder Wiring Diagram

Control Module

Notes:

Wire Color Code Key:

Combi Boiler 99, 125 Schematic Wiring Diagram

BK - Black

- Original wiring as supplied with the appliance must be replaced with type T wire or

its equivalent.

- The wiring for the 120V field connections to the appliance shall have a minimum

size of 14 AWG and a temperature rating of at least 194 °F (90°C).

W - White

G - Green

BL - Blue

R - Red

O- Orange

V - Violet

BR - Brown

Y - Yellow

GY - Gray

Control ModuleLow Voltage

High Voltage

Control Module

Y G W

OBL

GY BK

BR RR

5 4 3 2 1

Aquastat or

DWH Sensor

Outdoor Sensor

Thermostat

(by others)

X2 X1

X9 X8

X14

X15

X1X2X8

X3X9

2 1

5 4 3 2 1

5 4

26 13 2 1

X14

X15

16 15

14 13

12 11

8 7 6

2 1

Aquastat or

DHW Sensor

Outdoor Sensor

Thermostat

(by others)

3-wayvalve

Ignition

Power Plug

120V

Boiler

Pump

Blower

Motor

Flue Sensor

Cabinet Sensor

Heat ex. Sensor

Space Heating

Presure Sensor

DHW Cold NTC

DHW Hot NTC

CH Supply NTC

DHW Flow Sensor

Gas valve

BMM

G/Y GY BL R O BK

Motor

Blower

R O BK

Pump

Boiler

snoitpO snoitpO

Power Plug

W BK

Ignition

R O G/Y

GY BK

3-wayvalve

Aquastat or

DWH Sensor

Outdoor Sensor

Thermostat

(by others)

BMM

GY BK

Gas valve

Space Heating

Pressure Sensor

DHW Flow Sensor

DHW Hot Sensor

CH Supply NTC

Cabinet Sensor

Heatex. Sensor

DHW Cold Sensor

Flue Sensor

860124.02

Combi Boiler 160, 199 Ladder Wiring Diagram

Control Module

Notes:

Wire Color Code Key:

Combi Boiler 160, 199 Schematic Wiring Diagram

BK - Black

- Original wiring as supplied with the appliance must be replaced with type T wire or

its equivalent.

- The wiring for the 120V field connections to the appliance shall have a minimum

size of 14 AWG and a temperature rating of at least 194 °F (90°C).

W - White

G - Green

BL - Blue

R - Red

O- Orange

V - Violet

Y - Yellow

BR - Brown

GY - Gray

Control ModuleLow Voltage

High Voltage

Control Module

Y G W

OBL

GY BK

BR R

5 4 3 2 1

Diagram 6.2-2: Schematic wiring diagram 160 &

199 models

INSTALLATION AND OPERATION INSTRUCTIONS

6-4

COMBI BOILERS 99 & 125 & 160 & 199

120V~ / 60Hz

DHW Sensor / Aquastat

Diagram 6.2-3: Electrical wiring diagram

6-5

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

INSTALLATION & COMMISSIONING REPORT

Unit Details:

Model Number _____________________ Serial Number ______________________________________________

Date of Installation ______________ Address of installation __________________________________________

_____________________________________________________________________________________________

User contact information _______________________________________________________________________

Installer Information Company ___________________________________________________________________

Address ______________________________________________________________________________________

Phone/Fax/E mail ____________________________________________________________________________

Fuel

Natural Gas

Propane

Gas Supply Pressure (high re) _______ Inches w.c. Measured Rate of Input (high re) ____________ Btu/hr

Installation instructions have been followed and completed (Section 1 of Installation and Operating Instructions).

Check-out procedures have been followed and completed (Section 3 of Installation and Operating Instructions).

Leak testing completed

gas piping

venting system

Fan and combustion components

System Cleaned and Flushed (type of cleaner used) ________________________________________________

System Filled (type/concentration of any glycol/chemicals used) _______________________________________

Air purge completed

Relief Valve correctly installed and piped

Relief valve “try lever” test performed

Condensatetraplled

Condensatedrainclearandfreeowing

Condensate Neutralization? Yes/No

IgnitionSafetyShuto󰀨testcompleted.Flamecurrentreading-Highre_______µA-Lowre_______µA

Owner advised and instructed in the safe operation and maintenance of the unit and system.

Information regarding the unit and installation received and left with owner

Combustion Readings - recommended, but optional (required for fuel

conversion):

_____________ % O

______________ % CO ____________ ppm

Fluetemperature_________Returnwatertemperature(measuresimultaneouslywithuetemp.)_______________

Commissioning has been completed as listed on this report - Installer Signature _____________________________

This installation & commissioning report should remain with the Combi boiler for future reference during

maintenance and repair.

INSTALLATION AND OPERATION INSTRUCTIONS

6-6

COMBI BOILERS 99 & 125 & 160 & 199

SERVICE RECORD

DATE LICENSED CONTRACTOR DESCRIPTION OF WORK DONE

6-7

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

IMPORTANT

Thisunitisequippedwithafeaturethatsavesenergybyreducingtheunit’swater

temperature as the 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theunit’swater

temperature as the heating load decreases.

• This unit is not used for any space heating.

• This unit is part of a modular or multiple unit system having a total input

300,000 BTU/hr or greater.

• This unit is equipped with a tankless coil.

INSTALLATION AND OPERATION INSTRUCTIONS

6-8

COMBI BOILERS 99 & 125 & 160 & 199

NOTES

6-9

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

NOTES

INSTALLATION AND OPERATION INSTRUCTIONS

6-10

COMBI BOILERS 99 & 125 & 160 & 199

This page is intentionally left blank.

6-11

INSTALLATION AND OPERATING INSTRUCTIONS

COMBI BOILERS 99 & 125 & 160 & 199

This page is intentionally left blank.

84156404

Rheem Sales Co.

Montgomery, AL.

(833) 212-9276

IBC Technologies Inc.

8015 North Fraser Way

Burnaby, BC Canada V5J 5M8

(844) HEAT-IBC / (844) 432-8422

IBC Technologies USA Inc.

121 Walter A Gaines Way

Lawnside, NJ 08045

(856) 887-0544

Rheem RCBH-L199I ThermaForce Super High-Efficiency Condensing Combi Boilers

Product's Documents

Installation and Operating Instructions

Specifications

Rheem RCBH-L199I Questions and Answers