Home

Service & Installation Manual

1. 6 1 POSSIBLE PROBLEMS AND SOLUTIONS When the service display or the operating panel is flashing the burner controller has detected a fault If multiple faults exist the temperature display shows an additional code Refer to table 12 After the fault has been resolved the burner controller can be restarted by pressing the reset button on the operating panel Table 12 Fault Codes Fai Possible problem solution e Check the wires for continuity e Replace S1 e Heat exchanger block temperature greater than 266 F 130 C 10 11 12 13 14 S1 CH sensor fault 20 21 22 23 24 1S2 CH sensor fault e Check the wires for continuity e Replace S2 e Check the wires for continuity nu CH Sensor fault after set check Replace CH sensor 1 and or 2 e Airin system e Pump does not run Temperature too high e Water flow rate too low in CH system radiators closed pump setting too low Ss e Check the cable harness 2 PCCM CIMA TOS ene e Correct the connections of S1 or S2 l e Check setting of gas valve 3 Flue gas temperature too high Replace sensor S8 Manual gas valve is not open Incorrect spark probe gap Gas inlet pressure too low No power to gas valve or ignition unit Nia Henne Sianeli aren restan e Condensate discharge blocked 2 l g e Flue or Air intake tube blocked tries i e Check setting of gas valve e Replace ignition cable and spark probe Flame detection fault e Replace ignition unit e Replace burner c
2. Figure 29 Manual air vent 44 HSE Installation and Service Manual 4 Check that the electrical wiring matches the wiring diagram in this manual or on the appliance 5 Operate circulating pump and vent the system at the highest points of the piping system Fill the CH system again if the pressure has dropped too low as a result of the de aerating 3 2 2 DHW SYSTEM 1 The DHW system can be connected to a storage hot water tank However do not connect it with an indirect hot water tank or closed system 2 De aerate the heat exchanger and the pipe system by opening hot water taps Leave the tap open until all the On 3 air has been released from the system eel lina 2 Check all joints for leaks N 3 2 3 GAS SUPPLY 1 This appliance is equipped for operation on Natural Gas If propane is used convert the appliance using the propane conversion kit and following the conversion instructions in section 3 5 2 De aerate the gas pipe at the inlet pressure measuring nipple which is located on the upstream of the gas valve Do not release gas to the room Remember that propane does not vent upward naturally 3 Use a soap solution to check for leaks in gas piping between the meter and appliance gas valve Repair and retest if necessary 4 Check that the inlet gas pressure matches with information on the rating plate Figure 30 Condensate trap 3 3 STARTUP WARNING The following instructions are intended as a gui
3. Appliance with piping for central heating boiler CH system Appliance with piping for domestic hot water heating DHW system ICONS The following symbols may be used in this manual AN DANGER indicates a potentially hazardous situation which if not avoided will DANGER result in death or serious injury AN WARNING WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION CAUTION indicates a potentially hazardous situation which if not avoided could result in minor or moderate injury CAUTION indicates a potentially hazardous situation which if not avoided may CAUTION result in property damage Special instructions which are important but not related to personal injury or NOTICE property damage TECHNICAL SUPPORT For information about specific adjustments installation maintenance and repair activities please contact Allied Engineering Company HSE Installation and Service Manual TECHNICAL SPECIFICATIONS HSE 125 N HSE 125 P Technical data NaturalGas Propane Maximum CH operating temperature F C DHW domestic hot water HEATER Nominal input rate 1000 Btu h kW Nominal output rate 1000 Btu h kW Energy Factor EF 0 91 DHW minimum flow rate USGPM I min DHW continuous delivery at 135 F with 77 F water temperature rise USGPM l min 2 8 10 7 DHW continuous delivery at 120 F with 60 F water temperatur
4. for appliances gt 10 000 cm for appliances gt 10 000 Btuh other appliance Btuh 3 kW and lt 100 000 Btuh 3 kW and lt 50 000 Btuh 15 30 kW 36 inches 91 cm for kW 12 inches 30 cm for appliances gt 100 000 Btuh 30 appliances gt 50 000 Btuh 15 kW kW Clearance to a mechanical air 6 feet 1 83 m 3 feet 91 cm above if within 10 supply inlet feet 3 m horizontally Clearance above paved 7 feet 2 13 m t sidewalk or paved driveway located on public property Clearance under veranda 12 inches 30 cm M porch deck or balcony In accordance with the current CSA B149 1 Natural Gas and Propane Installation Code In accordance with the current ANSI 2223 1 NFPA 54 National Fuel Gas Code Tt 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 floor For clearances not specified in ANSI 2223 1 NFPA 54 or CSA B149 1 one of the following shall be indicated a A minimum clearance value determined by testing or b A reference to the following footnote Clearance in accordance with local installation codes and the requirements of the gas supplier 25 HSE Installation and Service Manual 1 7 5 DIRECT VENT CONFIGURATIONS WARNING Failure to ensure that tubes are connected seated or sealed properly may result
5. water flow rate rating l 28 700 BTU H 8 4 kW 0 9 GPM 200 I h 90 000 BTU H 26 2 Wl 3 3 GPM 750 I h Flow Ipm Head feet Head meters Flow gpm Line A Pressure drop of CH heat exchanger boiler Line Total pressure head for pump stage 1 Line II Total pressure head for pump stage 2 Line III Total pressure head for pump stage 3 X axis Water flow rate through CH heat exchanger Y axis Pump pressure head and or pressure drop of CH H E Figure 27 CH HE A Pump head vs water flow 42 HSE Installation and Service Manual 2 4 6 OUTDOOR RESET FUNCTION When the outdoor temperature sensor is connected the appliance uses the outdoor reset function to control the CH supply water temperature Outdoor reset automatically and continuously adjusts the CH supply temperature based on the outdoor air temperature following the reset ratio curve The reset ratio is determined from entering the following parameters in the operating panel 1 CH supply temperature at minimum outdoor temp see section 2 4 1 2 a 2 minimum CH supply water see Table 8 parameter 5 3 minimum outdoor temperature see Table 8 parameter 6 4 maximum outdoor temperature see Table 8 parameter 7 Figure 28 shows examples of the outdoor reset curves Note Outdoor Reset Function cannot operate unless an outdoor temperature sensor is connected If an outdoor temperature sensor is not connected the o
6. B149 1 current edition and or local code requirements for use of plastic venting Plastic vents shall be installed such that the first 3 feet 92 cm or total vent run if less than 3 feet 92 cm from the appliance flue outlet is readily accessible for visual inspection CAN CSA B149 1 clause 8 9 5 Location of the venting terminal for vertical venting system has to be determined based on the applicable code before installing the terminals Total Concentric Horizontal or Vertical Connection Figure 21 and 24 Figures 21 and 24 are typical installations for the total concentric horizontal and vertical venting systems with a combined terminal cap and a concentric adapter for air inlet and flue outlet on the appliance The adapter installation which requires change of the sealing ring referred to in section 1 7 5 2 Combination Twin Tube and Concentric Connection Figure 23 and 24 Figures 22 and 23 are typical installations for combination twin tube to concentric pipe using a twin tube to concentric adapter and concentric terminal cap 32 HSE Installation and Service Manual Max 27 6 700mm 2 0 50mm CONC C Z 4 3 110mm AR SE f CONCENTRIC 4 7 120mm PIPE ADAPTER see note AIR INTAKE PIPE VENT OUTLET PIPE BOILER MOUNTING CONCENTRIC Sg FRAME OPTIONAL TERMINATION CAP BOILER 8 3 210mm 9 5 240mm Figure 22 Horizontal Twin Pipe to Concentric CONCEN
7. CH supply temperature Press and hold the CH HW temp W button on the operating panel until the temperature display flashes Pressing the CH HW temp W button again will switch between CH and DHW the CH LED should be on The CH supply temperature can be changed using the D and buttons The CH supply temperature can be changed between 86 F 30 C and 194 F 90 C After completing the change confirm the change by pressing the Reset button if no other changes are required If no button is pressed after a period of 30 seconds the parameter change menu is closed automatically with any changed settings stored Note If an outdoor reset sensor is connected the displayed CH temperature is not a set temperature b Change domestic hot water DHW temperature Press and hold the CH HW temp W button on the operating panel until the temperature display flashes Pressing the CH HW temp W button again will switch between CH and DHW the DHW LED should be on The DHW supply temperature can be changed using the and buttons The DHW supply temperature can be changed between 104 F 40 C and 149 F 65 C After completing the change confirm the change by pressing the Reset button if no other changes are required If no button is pressed after a period of 30 seconds the parameter change menu is closed automatically with any changed parameters stored c Domestic hot water comfort The comfort function of domestic hot water c
8. MinimuminputrateHW 1 20 Setting range 25to50 e Min supply temperature 40 C Setting range 10 C to 60 C 50 F to 140 F If the OT during OT demand 104 F thermostat demands a supply temperature that is OT OpenTherm stat elow this set value the heat demand cannot be met OT response a if OT demand lt par E then OT demand par E 2 Enable 2l F Tonon blower speed 1 70 _ Setting range 50 to 99 E ppw oer In setingrange soto 99 SERRE Ee input rating 42 4200 rpm 52 5200 rpm Set point CH flow temperature e heating DE a Setting range 60 C to 90 C 140 F to 194 F external DHW tank SS ecm satisfied e J samaritan oor 40 HSE Installation and Service Manual Table 8a Installer parameters description and default settings for HSE 145 Parameter Default service Description setting Optional Setting of parameter display temp display emen Lee service code 15 0 Standard CH DHW operation System type 1 CH ee Indirect hot water tank 2 DHW operation only 3 CH operation only 0 pump overrun only 2 CH pump continuous 1 pump continuously active 2 n a 3 pump on off with external economy switch CH input rating 99 Setting range parameter c to 100 HW input rating Setting range parameter d to 85 of outdoor reset curve 77 F Outdoor temperature reset control outdoor reset curve 20 F Outdoor temperature reset control outdoor reset curve 77 F
9. Outdoor temperature reset control Bee 1 sempre osm OOO operation o s ee external hw tank operation Three way or two way valve 0 confirmed during CH n a position 1 confirmed during hw operation n a 1 DHW booster function on l i 0 modulation off during CH operation voaN atngoption 1 modulation on during CH operation Minimum input rate CH Setting range 20 to 50 d Minimum input rate HW Setting range 20 to 50 Min supply temperature 40 C Setting range 10 C to 60 C 50 F to 140 F If the OT during OT demand 104 F thermostat demands a supply temperature that is OT OpenTherm stat eow this set value the heat demand cannot be met Ignore OT demand if lt value par E OT response lt If OT demand lt par E then OT demand par E 2 Enable OT B Ignition blower speed CH Setting range 35 to 85 Ignition blower speed DHW Setting range 35 to 85 only Blower speed for Setting range 52 to 60 max determining input rating 52 5200 rpm 60 6000 rpm Set point CH flow temperature dote heating SC A Setting range 60 C to 90 C 140 F to 194 F external DHW tank po Gel Ime EE Setting range 0 15 minutes satisfied Minimum off time after CH l re satisfied r boiler off Setting range 0 to 10 minutes anti cycling function 41 HSE Installation and Service Manual 2 4 4 SETTING CH amp DHW OPERATING INPUT RATING CH and DHW operating input rating are determined ba
10. defective controller Ves Replace sensor S1 or S2 eee gt See Fault code display 1 or 2 Dy Ne Burner does not ignite gt Yes See section 6 2 burner fails to ignite 6 6 REDUCED OUTPUT Possible problems Solutions At maximum input rating setting the 1 Adjust the air gas ratio input rating should not decrease by 2 Check venting system for blockage more than 5 3 Check heat exchanger for soot by measuring emissions 64 HSE Installation and Service Manual 6 7 CH SUPPLY WATER DOES NOT REACH CORRECT TEMPERATURE Possible problems Solutions Room thermostat settings not correct C gt Yes Check the setting and adjust if necessary Q No 1 Correct the temperature setting Supply water temperature set too low gt Yes see section 2 4 1 item 2 a 2 Check the outdoor reset sensor for short circuit Jb No Pump speed not correct or faulty L Yes i pump setting or replace Lb No No water circulation in the system gt Ves Check for water circulation at least one heating loop must be open Lb No RE a Adjust the input rating setting ee boiler input rating is not set proper gt TER parameter see section 2 4 3 Lb No Scale in or soot on the heat exchanger gt Yes e a or clean outside of the 6 8 NO DOMESTIC HOT WATER DHW Possible problems Solutions Flow switch is faulty or not enough Sy 1 Water flow lt 2 0 l
11. high fire setting Important the CO level at low fire setting must never be below 9 5 For example natural gas setting The CO level at high fire setting is 9 5 _ the CO level at low fire setting is 9 2 9 5 The CO level at high fire setting is 9 0 the CO level at low fire setting is 8 9 9 0 For example propane setting The CO level at high fire setting is 10 5 the CO level at low fire setting is 9 9 10 2 The CO level at high fire setting is 10 0 the CO level at low fire setting is 9 5 9 7 3 6 1 ADJUST THE GAS AIR RATIO BY MEASURING THE CO PERCENTAGE OF THE FLUE WARNING Always use a calibrated combustion analyzer to perform the adjustment Notes for Figure 32 A Setting screw cover B Screw for low fire adjustment socket head wrench 4 mm C Nipple for measuring offset pressure gas outlet pressure D Nipple for measuring gas inlet pressure E Throttle screw for high fire adjustment F Nipple for measuring manifold pressure Adjust the gas air ratio as follows 1 Switch off the appliance using the On Off button f on service display 2 Turn the external manual gas shutoff valve off Remove the front cover of the appliance Loosen the screw in the nipple D on the gas valve with two turns and connect a pressure Figure 32 Gas Valve manometer on it to measure gas inlet pressure gt w 5 Turn the external manual gas shutoff valve on 50 HSE I
12. in leakage and eventual failure of the sealing gasket Five venting configurations are available for the appliance Twin Tube e 3inch CPVC twin tube venting system with 80 mm to 3 inch CPVC adapters e 3 inch stainless steel twin tube venting system with 80 mm to 3 inch stainless steel adapters e 80mm PP twin tube venting system adapter not required Concentric e 80mm 125 mm PP concentric venting system with a concentric adapter Combination e 80mm PP twin tube venting joined to 80 mm 125 mm PP concentric venting system using a twin tube to concentric adapter 1 7 5 1 TWIN TUBE TO APPLIANCE CONNECTION Refer Figure 14 1 Right hand air supply is for standard installation The sealing cap must be removed pop ects seang i ring by 116x110mm if there is one el 4 6x4 3 sealing ring for concentric 2 Install the tubes or adapters if required into connection air supply opening and the flue collar on the top of the appliance The built in sealing rings provide airtight connections The joints of air supply tubes should be sealed by silicone or other means The flue tubes should be sealed following flue tube suppliers installation instructions 1 7 5 2 CONCENTRIC TO APPLIANCE CONNECTION Refer to Figure 15 1 Properly seal the air supply opening on the appliance with the sealing cap supplied with the set item B in Figure 14 Figure 14 Air supply and flue openings 2 Replace the existing sealing ring item A on
13. key el Domestic hot water operation The hot water supply HW has priority over CH heating When the flow switch detects a domestic hot water demand of more than 0 53 USGPM 2 I min the CH heating demand is interrupted After starting the blower Code E and ignition of the burner code Ah the controller goes to domestic hot water operation code 6 During domestic hot water operation the blower speed and hence the input rate of the appliance is controlled based on the set domestic hot water temperature The domestic hot water temperature can be set between 104 F 40 C and 149 F 65 C During DHW operating mode the set domestic hot water temperature is displayed on the operating panel and the actual domestic hot water supply temperature can be read by pressing and holding the service key Supply domestic hot water without time delay For a quick supply of domestic hot water a comfort function has been provided in the controller This function keeps the heat exchanger at the correct temperature This comfort function is set as per section 2 4 1 c Code 7 is also displayed when appliance frost protection is active see code BS Off 36 HSE Installation and Service Manual 2 2 PC INTERFACE The controller has an interface for a PC With a special cable and accompanying software a PC can be connected This provision makes it possible to follow the behaviour of the controller the appliance and the heating system
14. or sodium chloride e leaking refrigeration equipment e Freon from common aerosol dispensers These chemicals are especially common near swimming pools beauty shops dry cleaning establishments laundry areas workshops and garages The warranty is void when failure is due to corrosion AIR INTAKE SYSTEM For a direct vent system DWV drains waste vents PVC CPVC ABS galvanized steel tube and flex aluminum tube can be used for the air intake system Do not use these materials for the exhaust vent system ULC S636 PVC and CPVC or stainless steel tube may also be used for the air intake system The air intake tube and its joints should be sealed using appropriate sealants when necessary EXHAUST VENT SYSTEM WARNING Failure to comply with these instructions may result in a failure of venting system and leakage of flue products to the living space Only certified PP CPVC or stainless steel may be used to vent this appliance Do not use cellular core for vent piping Follow vent manufacturer s recommendations for vent installation WARNING Venting and components e g elbows primer cement are to be installed as a system as per the vent manufacturer s installation instructions Do not mix and match components from different vent systems This appliance will produce some condensate with a positive vent static pressure during operation and therefore an air tight and anti corrosion venting system must be used Use only certifi
15. technician should the appliance or systems exhibit any unusual behavior r HSE Installation and Service Manual 4 3 LI UU LI LI UU LU SERVICE CHECKLIST Do not store anything against the appliance or allow dirt or debris to accumulate in the area immediately surrounding the appliance The flow of air supply and exhaust must not be obstructed Check air openings are not restricted and complies with applicable code s Adequate supply air is necessary for combustion and ventilation Check all gasket joints for leakage and tighten bolts or replace gaskets if necessary When the appliance has operated for several minutes check for leakage around appliance along vent and other areas susceptible to leakage Check for dislodged venting Inspect the flue ways and terminal cap for the presence of soot rust scale or blockage The presence of soot rust scale or corrosion indicates misadjustment Clean the Terminal Cap Screen Inspect and if necessary clean the main burner Check burners to see that they are not cracked or dislodged Visually check the main burner flames A yellow flame caused by improper adjustment is always accompanied by formation of soot which if allowed to continue will partially restrict free passage of products of combustion to the flue Check that gas piping is secured Smell for gas leaks around appliance and gas piping connections Gas leaks can also be checked for using a soap solution do not
16. that vents do not leak 4 2 4 CHECK THE PRESSURE RELIEF VALVES d 2 Before manually operating the pressure relief valves make sure that the discharge pipes are directed to a suitable place of disposal to avoid a potential scald hazard Make sure that the discharge pipes of relief valves are full size without any restriction and installed to permit complete drainage of both the valve and discharge line Check the pressure relief valve and lift the lever to verify the flow at least annually or as recommended on the warning tag of the valve System has to be refilled after lifting the lever If the valve fails to seat properly or continually weeps after closing replace it Make sure that the weeps are caused by a faulty valve and not by over pressurized system due to the expansion tank which is waterlogged undersized or damaged 4 2 5 CHECK ALL WIRING 1 2 Remove the front cover Check the ignition cable connecting terminals and ground wiring to ensure all in good condition and connected securely and properly Check ground continuity of wiring using continuity meter and replace ground wire if ground continuity is not satisfactory 4 2 6 SERVICE THE VENTING SYSTEM 1 2 3 Inspect flue and air passages for any blockages cracks and joint leakages If necessary use a brush and vacuum to clean and remove any blockages and seal the joints and cracks Replace any parts which have severely corroded or cracked Rea
17. the spark ignition probe and gently clean any deposits if necessary As the spark gap cannot be checked directly use a flat surface across the corner of the heat exchanger to measure the distance to the probe See the picture in section 6 3 The distance should be in the range of 1 1 16 in to 1 9 64 inch 27 to 29 mm Replace the probe if necessary If necessary clean the fins of the heat exchanger from top to bottom with a brush or compressed air If necessary clean the bottom side of the heat exchanger and the condensate discharge at the bottom of the flue discharge behind the heat exchanger After cleaning fill the condensation trap with water Check the silicone gasket of the front cover for damage cracks and or discolouring and replace if necessary Reinstall the heat exchanger cover on the heat exchanger by screwing in the socket screws with spring washers Crosswise tighten the socket screws evenly by hand Then using an Allen key to tight the screws all around the edge Make sure that the silicon gasket is well placed around the heat exchanger cover Check the gas pipe gasket for damage and reconnect the gas pipe to the inlet of the gas valve Re plug the wire connectors to the blower and the ignition module to the gas valve Open the external manual gas shutoff valve and check the gas pipes and gas valve for leaks Check the CH and hot water supply systems for leaks Switch on the electrical power to the appliance and then push
18. until an appears on the service display Measure the CO value again at high fire Ensure that the CO value is within the range listed in table 11 If the CO value does not match the value in Table 11 Please contact the manufacturer To exit the test mode simultaneously press the D and buttons on the operating panel Switch off the appliance using the On Off Y button a on service display Turn off the external manual gas shutoff valve Remove the combustion analyzer probe and plug the opening Remove the pressure manometer and tighten the screw in nipple D without leakage 22 23 24 Switch on the appliance using the On Off button Turn the external manual gas shutoff valve on Replace the front cover of the appliance After the appliance has been adjusted the input rating must be verified following the input rating test as described in Section 3 8 3 7 APPLIANCE FOR USE AT HIGH ALTITUDE The appliance is factory equipped for operation at altitudes ranging from 0 to 2 000 feet 0 to 609 m above sea level for USA and 0 to 4 500 feet 0 to 1370 m above sea level for Canada The appliance can be used for any altitude without changing any part however some adjustments may be required The conversion of an appliance from sea level to high altitude must be performed by a qualified heating installer service technician or gas supplier and in accordance with the requirements of Section 1 2 of this manual A conver
19. vent joints and seams be properly cleaned and sealed gas tight by following the vent manufacturer s instructions Also seal the joints of tube storm collar and flashing storm collar with waterproof caulking for a vertical venting installation Increasing the length of the exhaust vent run will increase the amount of condensate The condensate of the exhaust is acidic and can cause severe corrosion of ordinary venting materials Also appliance operation can be affected by restrictive vent or combustion air supply piping Therefore venting lengths must be within the specified minimum and maximum equivalent venting system length in Table 3 Slide the adapters if required or air supply and flue tubes into the combustion air intake and flue outlet of the appliance so that the gaskets seal snugly around the adapter Ensure that there are no gaps or leaks Connect the required combustion air and vent tubes to the adapters if installed by following the vent manufacturer s instructions and applicable code s 29 HSE Installation and Service Manual 10 Generally all vent tubes must be adequately supported with vent supports no less than five feet 1 5 m apart or as per the vent system manufacturer s instructions or applicable code s and at smaller intervals if necessary to ensure that there are no sagging sections along the horizontal runs Do not use the appliance to support the weight of the venting Noncombustible tube strap or hangers suit
20. Figure 7 1 Use the compression fittings supplied with the appliance to connect the heating system supply and return pipes Check whether the compression rings are straight in the connectors All pipes must be installed tension free in order to avoid ticking of the pipes The connections must not be twisted in order to avoid leaks at the joint points 2 The CH system is recommended with e A make up water loop in the system below the appliance as shown in figure 8 e A drain tap at the lowest point of the system e An expansion tank Follow section 1 4 1 4 e A check valve when pipes are running upward at a short distance from the appliance This prevents gravity circulation during domestic hot water operation of the appliance 3 Flush the CH system thoroughly after finishing the piping installation and purge trapped air 22mm TO 4 NPT 15mm TO Ap NPT CH COMPRESSION FITTING __ Les DHW COMPRESSION FITTING e pe pp g AVAILABLE WITH DHAN KIT E XH X BY TEE a mi n 22mm TO 34 NPT DHW PRESSURE ne weem ett d CH COMPRESSION FITTING RELIEF VALVE 125 5 AW AILABLE WITH GHW IT CH PRESSURE RELIEF gl VALVE 30PSI _ UDO 4s MANUAL GAS 3i TEE Si 8 z a donald T E LE VALVE AE ei HF a 3 DRAIN VALVE DHW PRW DISCHARGE PIPE MANUAL SHUTOFF VALVE a ee To HEATING SUPPLY HOT DOMESTIC WATER DOMESTIC WATER OUTLET HOT INLET COLD HEATING RETURN COLD Note Install pressure re
21. GPM l min 3 6 13 7 Maximum DHW temperature F C 150 65 Electrical data Mains voltage frequency Vac Hz 120 60 Consumed power full load W Consumed power standby W Height inch mm 31 9 810 270 Weight Connections CH supply inch NPT male CH return inch NPT male DHW supply inch NPT male Cold water for DWH inch NPT male Gas inch NPT male Condensate drain flexible pipe outside diameter inch mm Air supply inlet without adapter installed m Flue gas outlet without adapter installed m Air supply inlet with adapter installed inch Flue gas outlet with adapter installed inch The CH input rate is set to 100 amp DHW to 85 by default see Setting CH A DHW input rating The energy factor EF is the ratio of energy delivered to the water as compared to the total energy consumed The DHW Booster function operates at an input rate of 145 000 Btu h 42 5 kW for the first 2min after which the DHW input rate drops to 124 000 Btu h 36 3 kW Note NPT National Pipe Thread HSE Installation and Service Manual MAJOR COMPONENTS CH pump M Gas valve N Burner controller with operating panel O Supply sensor S1 P Return sensor S2 Q Blower R DHW Flow switch S CH Pressure gauge T N A U CH manual air vent V Sight glass and mirror for checking flame W Air supply TACT TATMIMVOWSY Additional Components supplied with appliance Flue discharge Wiring connecting block terminal C
22. H OO ap SUPPLY INLET AREA WHERE TERMINAL IS NOT PERMITTED Fiqure 13 Direct Vent Terminal Clearances 24 HSE Installation and Service Manual Table 2 Direct Vent Terminal Clearances Refer to Figure 13 Canadian Installations US Installations Clearance above grade 12 inches 30 cm 12 inches 30 cm veranda porch deck or balcony Clearance to window or door 6 inches 15 cm for appliances lt 6 inches 15 cm for appliances lt that may be opened 10 000 Btuh 3 kW 12 inches 10 000 Btuh 3 kW 9 inches 23 30 cm for appliances gt 10 000 cm for appliances gt 10 000 Btuh Btuh 3 kW and lt 100 000 Btuh 3 kW and lt 50 000 Btuh 15 30 kW 36 inches 91 cm for kW 12 inches 30 cm for appliances gt 100 000 Btuh 30 appliances gt 50 000 Btuh 15 kW kW Clearance to window or door S P that may be opened Clearance to permanently S R closed window Clearance to unventilated x n soffit Clearance to outside corner R Clearance to inside corner S S Clearance to each side of 3 feet 91 cm within a height 15 center line extended above feet above the meter regulator meter regulator assembly assembly Clearance to service 3 feet 1 83 m e regulator vent outlet Clearance to non mechanical 6 inches 15 cm for appliances lt 6 inches 15 cm for appliances lt air supply inlet to building or 10 000 Btuh 3 kW 12 inches 10 000 Btuh 3 kW 9 inches 23 the combustion air inlet to any 30 cm
23. O OI EE 5 Technical Specifications EE 6 Major 0 99 666 a1 9 amp eee eee ee ere ee AEEA EErEE EnEn eee eee 8 Bil wee 9 Description Regele le 10 Section 1 Installation Instructions 00 0 0 eee eeee eee ee ence ee eeeae eases esses eeseaaeeseaaeesaaaseaaasesaaesesanseessanessons 11 1 1 Receiving Moving ANd Unpacking nnsnnnsensnennnsnnneneesnrrsrrrnrrrrsnrrsrrrntrrrsrrrsrrrnnrrrsrtrntrrrntr rtre rteern ne 11 1 2 Installation Codes and Heourements 11 1 3 Location and Installations cccccceccccecccececeee ee eeceeeeseeeeseeesee esse eeseeeesaeeeseeeseaeeseeesseeeseeeeeseeesaeeess 12 kad TOCA OM EE 12 13 2 Minimum Service CIC ee 12 1 3 3 Installation in a Kitchen Cupboard or Closet 12 1 3 4 Installation in an Airing Cupboard or Close 12 1 3 5 Remove Front Panel cccccccccseccsseecesceceuceceeecseecaeeccseeceaceceueesaueesseeseueeseueesaaeesaeesueeeesseeseeeenaaes 13 US MONU WE 13 1 3 7 Install the Condensate EE degen eendeitege 14 1 4 Water Piping Systems E 14 1 4 1 CH Piping Systemi Boiler scossi iomeisneineniidnannneniani nananana a a a 15 PALI CH PIDDI CONNECCION senerara AEE EEA AEE E ER EEE 15 14 1 2 Pressure Relef E EE 16 1 4 1 3 Manual Shutoff Valve S a ere naia E a A AE A E E aa EEEE en 16 1 4 1 4 Expansion Tank and Make Up Water 16 1 4 1 5 System Bypass and Pressure Head losses 16 1 4 1 6 Corrosion Prevention ntemal 17 1 4 2 DHW Piping System Water Heater 0 ccccccccccsecceeceeee
24. PN7362112 INSTALLATION AND SERVICE MANUAL ___ AN Gas fired Condensing Boller and INTERGAS nee e te pf Hot WARNING If the information in this manual is not followed exactly a fire or explosion may result causing property damage personal injury or loss of life e Do not store or use gasoline or other flammable vapors and liquids in the vicinity of this or any other appliance e 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 fire department Installation and service must be performed by a qualified installer service agency or the gas supplier Improper installation adjustment alteration service or maintenance can cause property damage personal injury or loss of life Read all instructions before installation or service Save this manual for future reference Allied Engineering Company Division of E Z Rect Manufacturing Ltd Manufacturers of Gas and Electric Boilers Stainless Steel Tanks Heat Exchangers and Electric Boosters 94 Riverside Drive North Vancouver BC V7H 2M6 e Tel 604 929 1214 e www alliedboilers com HSE Installation and Service Manual Table of Contents Section Page AOUT OOF EE 5 AbDreviations and Names SCG WEE 5 Jee ler 5 SCH MAG AN SUD
25. RNER IGNITES WITH NOISE Possible problems Solutions Gas inlet pressure too high C Yes a A may be faulty Contact Lb No 1 Replace the spark probe Incorrect spark probe gap gt ues 2 Adjust the spark probe gap Lb No Gas air ratio not adjusted properly gt Yes Make the adjustment see section 3 6 Jb No ER Replace the spark probe Weak spark C gt Yes 2 Replace the ignition unit on the gas valve 3 Adjust the spark probe gap Drawing for spark probe gap Le MEN H Spark gap distance approx 4 5 mm 0 18 6 4 BURNER RESONATES Possible problems Solutions Gas inlet pressure too low C gt Yes The gas regulator may be faulty Contact the gas company Lb No Re circulation of the flue gases gt Yes Check the venting system Cu Gas air ratio not adjusted properly gt Yes Make the adjustment see section 3 6 63 HSE Installation and Service Manual 6 5 NO HEATING CH Possible problems Solutions Room thermostat not closed or outdoor 1 Check the wiring reset sensor faulty gt Yes 2 Replace the thermostat 3 Replace the outdoor reset sensor 1 Check the wiring according to the No voltage 24 V output from the diagram burner controller Check the connector x4 Replace defective burner controller Check the voltage to the pump Pump is not operating Check the connector x4 Replace defective pump Replace
26. SC EE 4 2 6 3 4 3 10 4 2 3 4 2 4 3 2 HSE Installation and Service Manual 4 4 CAUTION WATER REPLENISHMENT Avoid unnecessary replenishment of water in the CH system It can allow oxygen to enter the system and cause serious corrosion problems for system components which are not anti corrosion type As well an excessive amount of minerals may be deposited in the heat exchanger Do not draw water from the CH system for cleaning flushing etc Any audible sounds in the boiler system may be indications of scaling or lack of sufficient water flow and the system should be checked without delay Scaling is due to improper maintenance It is not the fault of the appliance Scale damage is not covered by warranty 45 REFRACTORY HANDLING PROCEDURE WARNING The mineral block used in this product are RCFs Refractory Ceramic Fibers RCFs pose a possible cancer hazard by inhalation and can cause respiratory skin and eye irritation After mineral block has been fired it will produce increased levels of nuisance dust and poses increased carcinogenic risk Follow the precautionary measures below before attempting service or access PRECAUTIONARY MEASURES e Avoid breathing fibers and contact with skin and eyes e Use a National Institute for Occupational Safety and Health NIOSH approved dust mist respirator e Wear long sleeved loose fitting clothing gloves and eye protection e Wash work clothes separately from other clot
27. TRIC VENT TERMINATION ROOF FLASHING ROOF CONCENTRIC CONCENTRIC AIR amp VENT PIPE VENT ADAPTER s E BOILER BOILER CS 7 ae OPTIONAL WALL Concentric Pipe Adapter Figure 23 Vertical Twin Pipe to Concentric Venting Figure 24 Vertical Concentric Venting 33 HSE Installation and Service Manual Controller Section 2 2 1 CONTROLLER OPERATION The appliance uses a microprocessor based controller to manage all functions including ignition and flame supervision continuously modulating monitoring each heat demand from the heating system or from the domestic hot water supply The pump starts running when there is a heat demand from the heating system The overrun time which has a default of one minute can be changed from O to 15 minutes if necessary see setting and adjustment of section 2 4 refer to parameter 8 Also the controller will automatically run the pump for 10 seconds once every 24 hours to prevent it from getting seized There are two supply temperatures set with a default in the controller memory one is for Central Heating CH and the other for Domestic Hot Water supply DHW If an outdoor temperature sensor is connected to the appliance the CH heating supply set point will automatically adjust as the outdoor temperature changes For more information about the outdoor reset feature see the section 2 4 3 and 2 4 6 The controller modulates the appliance input rate by ch
28. U 5 ft 60 ft 5 ft 60 ft 1 52 m 20 m 1 52 m 20 m 1 52 m 20 m 1 52 m 20m FLUE TUBE 5 ft 60 ft 5ft 60 ft 5 ft 60 ft 5 ft 60 ft 1 52 m 20 m 1 52 m 20 m 1 52 m 20 m 1 52 m 20 m Choose the right appliance vent outlet adapter if required for plastic or stainless steel vent tube for twin tube or concentric tube venting Reduce the equivalent length by 6 5 feet 2 m for each 90 degree elbow added and by 3 5 feet 1 1 m for each 45 degree elbow for your estimating the equivalent venting lengths Always confirm with the selected venting manufacturer for the actual equivalent length of elbows 1 7 7 EXAMPLE OF 3 INCH DIAMETER TWIN TUBE CALCULATION Table 4 Example Calculation Refer to Figure 15 TUBE TYPE TUBE LENGTHS TOTAL TUBE LENGTHS Flue Tube L1 L2 L3 2x6 5feet 40 feet 12 2 m Air Supply Tube L4 L5 L6 2x6 5feet 40 feet 12 2 m Total Length 80 feet 24 4 m 1 7 8 EXAMPLE OF 3 5 INCH 80mm 125mm DIAMETER CONCENTRIC TUBE CALCULATION With 3 elbows at 90 degree the maximum straight length of concentric tube that can be used is 85 feet 3 x 2 x 6 5 feet 46 feet 14 m 28 HSE Installation and Service Manual 1 7 9 The following installation procedure is a guide for all vent installations 1 VENT INSTALLATIONS The appliance must be vented to the outdoors Do not install the vent into a common venting system The venting system does not require a vent damper When the straight flue
29. a call for heat the controller checks whether the supply water temperature is below the set point If it is the blower will be energized and speed up to perform the pre purge The pump is also activated 4 After the pre purge the controller energizes the spark then gas valve If the flame is proved the controller enters the normal operating condition If the flame is not proved the controller will retry to light 3 more times If a flame is still not established the controller will lockout 47 HSE Installation and Service Manual 5 After flame is established the controller will modulate the firing rate depending upon the sensed difference between the supply and return water temperatures and the set point of supply temperature If an outdoor temperature sensor is connected to the appliance the heating supply water temperature setting will automatically adjust as the outdoor temperature changes 6 Once the call for heat is satisfied the controller shuts the burner off and after performing a post purge shuts the pump off 7 A demand for domestic hot water is given priority If a call for DHW is received while the appliance is responding to a call for heat the heating pump is de energized until the call for DHW is satisfied 3 4 CHECK BURNER SYSTEM To maintain safe and efficient operation examine the burner system regularly through the inspection window item K on the Major Components diagram on the left side of
30. able for the weight can be used to support horizontal runs and maintain vent location 11 Horizontal venting tube runs must always be installed with a slope upwards not less than in ft 2 cm m from the appliance to the vent terminal This is to ensure that any condensate in the venting flows back towards the appliance so that the condensate can be disposed of through the condensate trap system installed on the bottom of appliance or at the down end of the horizontal portions of the venting system This will prevent condensation from gathering in the venting tube and will also reduce the chance of icicles forming over horizontal tube ends in the winter 1 7 9 1 HORIZONTAL TWIN TUBE SIDE VENTING WITH TWIN TERMINAL CAPS Figure 16 is a typical installation for a side venting installation using two 45 elbows as twin terminal caps and adapters if required for air inlet and flue outlet on the appliance A space between the two terminal Caps is required as shown in Figure 16 AIR INTAKE 180 ELBOW WITH SCREEN FACE DOWN MIN 12 305MM kb SAHUARITA age ell AIR PIPE VENT PIPE VENT ADAPTER A EE BE VENT ADAPTER VENT ADAPTER BIRD SCREEN lt Ge Pa 45 ELBOW El BOILER KLE gt AIR INTAKE e MOUNTING FRAME BOILER BIRD SCREEN 77 SZ FRONT VIEW all d Figure 16 Side Venting Figure 17 Termination Installations adapter on inl
31. ackaged in the carton with the appliance The appliance mounting strip condensate trap installation instructions and warranty card are included in the carton Refer to Figure 1 Figure 1 Appliance with parts 1 2 INSTALLATION CODES AND REQUIREMENTS All applicable national provincial state and local codes laws regulations and ordinances must be followed They expand on and take precedence over any recommendations in this booklet Authorities having jurisdiction shall be consulted before installations are made In Canada the installation must conform to the requirements of the authority having jurisdiction or in the absence of such requirements to the Natural Gas and Propane Installation Code current edition CAN CSA B149 1 All electrical wiring and grounding must be in accordance with the Canadian Electrical Code CSA C22 1 Part 1 current edition and applicable local codes In the United States of America 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 current edition All electrical wiring and grounding must be in accordance with the National Electrical Code ANSI NFPA 70 current edition and applicable local codes Where required by the authority having jurisdiction follow the Standard for Controls and Safety Devices for Automatically Fired Boilers ANSIVASME CSD 1 current edition If th
32. ally when not properly used or maintained Corrosion is a preventable condition and is not covered by the product warranty 1 4 2 DHW PIPING SYSTEM WATER HEATER The appliance includes standard parts for connection to a central heating CH system For connection to domestic hot water heating DHW system the DHW kit must be used with the appliance and can be supplied upon request 1 4 2 1 DHW PIPING CONNECTIONS 1 Piping and components connected to the water heater shall be suitable for use with potable water 2 Flush the hot and cold water system thoroughly to clean out metal powder sand and dirt before connecting it 3 Use compression fittings supplied to connect the DHW supply and return pipes refer to Figure 7 Check whether the compression rings are straight in the connectors All pipes must be installed tension free in order to avoid ticking of the pipes The connections must not be twisted in order to avoid leaks at the joint points 4 Test that there are no water leaks from the cold and hot water supply pipes and then insulate all water piping especially the hot supply and recirculation water lines and cold water pipe according to the climate of the region or local code to prevent the pipe from freezing Do not cover the drain or pressure relief valve WARNING Potential Scald Hazard A thermostatic mixing valve must be used to prevent potential scalding hazards that may result in severe personal injury or death W
33. ameter pipe g CH supply fitting is 22mm to 3 4 NPT male V deeg 22mm diameter pipe 2 NPT male S Cold water 15 mm diameter pipe for DHW fitting is 15mm to 2 NPT male E 15 mm diameter pipe E DHW fitting is 15mm to 14 NPT male 1 25mm diameter flexible tube 80 mm diameter with vent adapter 3 Air supply inlet Z Flue gas outlet 80 mm diameter g with vent adapter 3 HSE Installation and Service Manual DESCRIPTION OF THE APPLIANCE The Super Hot Intergas HSE is a combined high efficiency condensing boiler and instantaneous water heater that is designed for providing Central Heating CH and or Domestic Hot Water DHW The actual required input rate for CH and DHW can be independently programmed lower than the maximum input rate to match the user s design heating load and required DHW supply During operation the input rate will be automatically modulated to satisfy the central heating or domestic hot water demand The heat exchanger is constructed of two separated copper tube circuits i e CH and DHW embedded in high pressure cast aluminium This design protects against corrosion by using copper tube to contain system water and aluminium to condense flue gases The DHW system eliminates typical standby heat losses as compared to hot water tanks isolates the domestic hot water from potential contamination as compared to a single wall indirect tank or flat plate heat exchanger and has a highe
34. an be set by using the Comfort button as follows e Eco x LED on The comfort function is self learning The appliance is deactivated during the night or after a long absence The appliance adjusts to the user s pattern of domestic hot water use e On DO LED on The comfort function of the appliance is continuously activated to keep the heat exchanger warm The appliance always supplies domestic hot water immediately e Off Both LED s off The heat exchanger is not kept warm delaying the supply of hot domestic hot water When there is no demand for hot domestic water the comfort function can be switched off 38 HSE Installation and Service Manual d Temperature selection F C The temperature selection on the display can be toggled between Fahrenheit and Celsius as follows e Fahrenheit F Press the F C button The Fahrenheit F LED will turn on and the Celsius C LED will turn off e Celsius C Press the F C button The Celsius C LED will turn on and the Fahrenheit F LED will turn off 3 Reset button When a lock out occurs a figure is flashing on the service display figure 25 item 9 the appliance can be restarted by pressing the Reset button for 5 seconds Check the possible cause of the fault listed in table 12 of section 6 to determine and resolve the problem before resetting the appliance Note After 30 seconds of no action the changes will automatically be stored and the contr
35. ance is factory equipped for natural gas An optional propane conversion kit included with conversion instructions can be supplied upon request The appliance includes standard parts for connection to a central heating CH system For connection to domestic hot water heating DHW system the DHW kit must be used with the appliance and can be supplied upon request Using the appliance for any other application which is outside of the scope is not covered by the warranty HSE Installation and Service Manual Installation Instructions Section 1 1 1 RECEIVING MOVING AND UNPACKING INSPECT SHIPMENT FOR POSSIBLE DAMAGE All goods are carefully manufactured inspected checked and packed by experienced workers The manufacturer s responsibility ceases upon delivery of goods to the carrier in good condition Any claims for damage and or shortage in shipment or non delivery must be filed immediately against the carrier by the consignee Use care when receiving moving and unpacking the appliance Dropping the appliance may cause damage and prevent safe and proper operation Only transport the appliance using the right transportation equipment such as a hand truck with a fastening belt or special equipment for maneuvering steps During transportation observing the transportation markings on the packaging and securing the appliance on the transportation equipment to prevent it from falling off Unpacking the appliance and check the parts p
36. anging the blower speed based on both the difference between supply and return temperatures and the set point temperature The amount of gas induced into the blower will depend on the blower speed that has been designed to maintain an approximately constant air fuel ratio The minimum input rate is 23 of the maximum input rate In addition all other safety controls including safety high limit and DHW flow switch are connected to the controller The controller will shut down the appliance when an unsafe condition exists or in some cases corrects the problem based on the sensor switch signal Step modulation is set on factory setting so that the power speed is increased gradually This provides the best CH operation However if the appliance is being used for heating an indirect hot water tank the step modulation can be set off The appliance will then start almost immediately at the maximum setting and the system will heat up faster The operating and display panel is shown in Figure 25 The display panel has three primary modes of operation These are e Standby Mode displays appliance s current status This is the default operating condition e Parameter Mode used to change control settings e Information Mode displays appliance operating temperatures The display and operating controls are summarized in Table 5 and operating condition codes are summarized in Table 6 34 HSE Installation and Service Manual Super Hot Int
37. aping to the appliance room The condensate trap must always be filled with water or condensate so that it forms a liquid filled trap Check the trap and if low fill it until water begins to pour out of the drain Install the condensate trap to the condensate outlet pipe C and tighten union The flexible tube A from the condensate trap should be inserted into an open waste pipe B of not less than 1 1 4 inch 32 mm diameter or a neutralization unit If connected to a soil pipe or waste system the waste pipe must have a trap similar to the arrangement for washing machine The condensate formed both in the appliance and the venting system is collected in the collector at the bottom of heat exchanger and is discharged into the public sewage system through the condensate trap The condensate produced by the gas combustion products typically has a pH value between 3 and 4 Some local codes may require that the aggressive and corrosive condensate be Figure 6 Install condensate trap neutralized before discharging it into the public sewage system If a neutralization unit is installed all condensate passes through the neutralization unit and is neutralized to a pH value of above 6 5 before release to the public sewage system It is advisable to contact your local authority responsible for waste water regulations before commencing with the installation of the neutralization unit The amount of neutralizer needed will depend on the opera
38. ce to overheat resulting in severe personal injury death or substantial property damage Carbon monoxide is a lethal colorless and odorless gas For safety the input rating shown on the rating plate or specified input rating for high altitude as described in Section 3 7 must not be exceeded Input Rating Test Consult the local Gas Company to determine the high heating value of the gas supplied in Btu per cubic feet Operate appliance for 15 minutes starting with all parts at room temperature and check input by clocking gas meter with all other gas appliances turned off including their pilot flames Use the following formula 3600 x High Heating Value of Gas in Btu cu ft x Volume of Cubic Feet Timed INPUT Btu h Clocked Time in Seconds To ensure accuracy clock enough cubic feet of gas so that there is at least one revolution of the test dial and the clocked time is at least 60 seconds 3 9 CHECK FOR CONTROLS After the unit has been operated for a while set the appliance to the maximum input rating as described in Section 3 6 1 step 15 and lower the water supply temperature setting below the actual appliance water temperature The burner should shut off Return the settings to their required design set points and make sure the appliance cycles normally Repeat this type of check on the safety high limit aquastat thermostat and other system controls to ensure all work satisfactorily If any of the safety controls do not fu
39. ch or deck is greater than 1 foot 300 mm Do not locate the vent terminal directly under roof or deck overhangs to prevent icicles from forming Due to the low flue gas temperature pluming will occur at the flue terminal Care should be taken to ensure that the discharge plume will not cause annoyance to the neighbors Therefore never allow vent terminal towards neighbor s windows or where personal injury or property damage can occur The terminal shall not be installed in any area which is not allocated to the occupancy in which the appliance is installed In a structure with three walls and a roof the terminal shall not be installed 23 HSE Installation and Service Manual a more than 72 inches 1 8 m from the outside opening b on any wall that has an opening between the terminal and the open side of the structure It is highly recommended that the vent terminal be located where it will not be exposed to normal prevailing winds The vertical termination shall extend to the required height above the highest point where it passes through the roof of the building and located higher than any portion of a building within a horizontal distance of the required distance or specified as local jurisdiction The vent terminal shall be located at a certain distance from any building opening and above any mechanical air supply inlet to any building Gas service meters The vent shall not terminate within 3 feet 0 9 m of any gas s
40. cseeeeeeeeeeeeeseeseeeeeeuseesaeeeeeeseaeeeesaeeeeeesaeees 17 1421 BP le e e SOIC GU OM EE 17 1 4 2 2 DHW Piping with a Backflow Dreventer AAA 18 1 4 2 3 Pressure Relief Valve or Temperature and Pressure Relief Valve cccccccecseeeeeeeeeeeeeeesseees 18 1 4 2 4 Cathodic Protection Devices ccc cecccceecccceececeeeeceeeeesececeucesseeeessaeceseaeeeseaeeeseueessaueessseesseeessaaees 18 1 4 3 Appliance Used with Solar System cccccccccccecccceececeecececeeseeeesaeeceseeeeeseueeeseeeeseucesseeesseaeeesgeees 18 1 5 Gas Service PD IAG D 18 1 6 Seege ed EE 19 1 7 le an COMBUSTION ET 21 1 721 Corrosive ne Ce 22 L2 PAVIA UAC S LO aiee ere eee eterna Gaui are sce Seve avenge bale ode dapsone Galeton Dea ET NEEN Sean doting 22 bo Exhaust Vent Sy E 22 Lk Vent TermmallNornatOMs sssi seisin aia a ie a aaa a i eaaa a A seca 23 1 7 5 Direct Vent Configurations ccccccccccseeceeceeeeeeeeeeeeeseeeeeesaeeeeeseeeeeeseeeeeeseeeeeeseeeeesaaseseeeseeeeesaeeeees 26 1 7 5 1 Twin Tube to Appliance Connechon 26 1 7 5 2 Concentric to Appliance Conpnechon 26 1 7 6 Equivalent Vent Air Intake Tube Length and Dameters 27 1 7 7 Example of 3 Inch 80 mm Diameter Twin Tube Calculation ccccccccccceeeeeeseeeeeeeaeeeeeeaeeees 28 1 7 8 Example of 3 5 Inch 80 mm 125mm Diameter Concentric Tube Calculation cccceeeeeee 28 HSE Installation and Service Manual Le WGMG eege eege eege 29 1 7 9 1 Horizontal Twin Tube S
41. ctrical service panel through a fused disconnect switch to the appliance This appliance must be electrically bonded to ground in accordance with the requirements of the authority having jurisdiction local codes or in the absence of such requirements with the National Electrical Code ANSI NFPA 70 current edition and or the Canadian Electrical Code CSA C22 1 Part 1 current edition Field wiring shall conform to Section 2 2 and to the temperature limitations of Type T 63 F 35 C rise or better Make wiring connections as follows 1 Unscrew the screws A in order to gain access to the space of the appliance controller B Refer to Figure 11 2 The cover plate display hinges open downwards to access to the controller and electrical connections 3 Refer to electrical wiring diagram in Figure 12 to make the electrical connections 4 After making the required connections replace the appliance controller Figure 11 Open control panel HSE Installation and Service Manual Dm CO Ww gt Connector X4 24V Connector X2 115V Connector X5 9 10 11 12 2 4 7 8 Ground terminal heat exchanger Cable of ignition flame sensor Burner controller Ground terminals burner controller zI A AVAVA VAVA VATA TAT 45 6 7 8 9 101112 F Fuse 3 15A T P1 CH pump S3 DHW sensor G Gas valve R Resistor S5 Flow switch DHW lonisation Ignition probe S1 CH Flow sensor S7 High limit M Power
42. de for qualified persons Before lighting the appliance the pre startup instructions of Section 3 2 MUST be performed If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life 45 HSE Installation and Service Manual 3 3 1 LIGHTING INSTRUCTIONS WARNING Should appliance overheat or the gas supply fail to shut off do not turn off or disconnect the electrical supply to the circulating pump Instead shut off the gas supply at a location external to the appliance pe FOR YOUR SAFETY READ BEFORE OPERATING Fo This appliance does not have a pilot It is e If you cannot reach your gas supplier equipped with an ignition device which call the fire department automatically lights the burner to light the burner by hand Do not try C Use only your hand to turn the manual gas valve Never use tools If the valve will not BEFORE OPERATING smell all around the turn by hand don t try to repair it call a appliance area for gas Be sure to smell qualified service technician Force or next to the floor because some gas is attempted repair may result in a fire or heavier than air and will settle on the floor explosion WHAT TO DO IF YOU SMELL GAS D Do not use this appliance if any part has e Do not try to light any appliance been under water Immediately call a e Do not touch any electrical switch do qualified service technician to inspect the n
43. ds will restore factory parameter settings and E Ger will appear on the temperature display 39 HSE Installation and Service Manual 2 4 3 SETTING AND DESCRIPTION OF PARAMETERS The factory default settings and setting ranges for all parameters are shown in Table 8 The CH operating input rating can be changed by adjusting the CH input rating and or blower speed following the sections 2 4 2 and 2 4 4 Table 8 Installer parameters description and default settings for HSE 125 Parameter Default service Description setting Optional Setting of parameter display temp display ep Liese 0 Standard CH DHW operation Eerst 1 CH aa Indirect hot water tank y yP 2 DHW operation only 3 CH operation onl 0 pump overrun 2 CH pump continuous 1 pump continuously active 2 n a 3 pump on off with external economy switch CH input rating 99 Setting range parameter c to 100 HW input rating 99 Setting range parameter d to 100 Clesse re E e T O of outdoor reset curve tas F Outdoor E reset control outdoor reset curve 20 F Outdoor temperature resel control Clesse on Soleo outdoor reset curve 77 F Outdoor temperature r reset control E Lemmer operation REES external hw tank operation Three way or two way valve o 0 confirmed during CH m e n a position 1 confirmed during hw operation n a ee 0 modulation off during CH operation 1 modulation on during CH operation d
44. during a long period 2 3 2 3 1 2 3 2 TEST PROGRAMS AND FROST PROTECTION TEST PROGRAMS In the burner controller there is a provision for putting the appliance into a test status This test can be done with heat demand on or off By activating a test program the appliance will become active with a fixed blower speed without intervention of the control functions The safety functions remain active though Simultaneously press D and on the temperature display of the operating and display panel to switch off the test program The test program will automatically switch off after 10 minutes Table 7 Test Programs Description of program Press buttons on display DIETI EVAT aS panel simultaneously Set burner on with maximum CH input A and H 1x Set burner on with maximum DHW input and 2x H Switch off test program and or automatically Current operating off after 10 minutes condition FROST PROTECTION The appliance has provision for protecting its heat exchanger as described below NOTE To avoid the condensate freezing the appliance must be installed in a FROST FREE room A e n order to avoid appliance heat exchanger freezing an appliance frost protection has been built in When the temperature of the heat exchanger drops to 41 F 5 C the burner will be activated and the pump starts running until the heat exchanger temperature reaches 50 F 10 C Code is given when the appliance frost
45. e rise USGPM l min 3 6 13 7 Maximum DHW temperature F C 150 65 Electrical data Mains voltage frequency Vac Hz 120 60 Consumed power full load W Consumed power standby W Height inch mm 31 9 810 270 Weight Connections CH supply inch NPT male CH return inch NPT male DHW supply inch NPT male Cold water for DWH inch NPT male Gas inch NPT male Condensate drain flexible pipe outside diameter inch mm Air supply inlet without adapter installed m Flue gas outlet without adapter installed m Air supply inlet with adapter installed inch Flue gas outlet with adapter installed inch The CH amp DHW input rate is set to 100 by default see Setting CH amp DHW input rating The energy factor EF is the ratio of energy delivered to the water as compared to the total energy consumed Note NPT National Pipe Thread HSE Installation and Service Manual TECHNICAL SPECIFICATIONS HSE 145 N HSE 145 P Technical data Natural Gas Propane Si O 0 C Maximum CH operating temperature DHW domestic hot water HEATER Nominal input rate 1000 Btu h kW 33 145 9 7 42 5 Nominal output rate 1000 Btu h kW 29 128 8 5 37 4 Energy Factor EF 0 91 DHW minimum flow rate USGPM l min 0 53 2 0 DHW continuous delivery at 135 F with 77 F water temperature rise USGPM l min 2 8 10 7 DHW continuous delivery at 120 F with 60 F water temperature rise US
46. e tube and neutralizer are properly connected and filled A manometer has been used to check the gas inlet pressure against requirements printed on appliance rating plate All applicable venting codes have been met Air tube openings sized to provide adequate supply air for combustion and ventilation and will not be blocked off The gas air ratio has been checked Operate the appliance for 15 minutes then clock and calculate Btu h input rate The input rate must not exceed that specified on the appliance rating plate or specified for high altitude Clocked BTU H Input Rate Perform check of temperature controls high limit aquastat and thermostat Test any other controls as specified by the manufacturer Visually inspect main burner to ensure proper flame operating characteristics and ignition extinction is ok Allow the appliance to cycle a few times to ensure functions are operating correctly Close external manual shut off valve and check burner flame extinguishes Clearly identify emergency shut off devices and make the user or owner aware of their location and method of operation Fill in the contact information on the cover of the User s Information Manual and leave both manuals in the envelope adjacent to the appliance Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Combustible materials gasoline and other flammable vapors and liquids should not be stored
47. ected from the gas supply piping system during any Sanit pressure testing of that system at test pressures in excess of 1 2 VALVE psig 14 inches water column 356 mm water column G The appliance must be isolated from the gas supply piping Li system by closing its individual manual shutoff valve during any a ONE pressure testing at test pressures equal to or less than 14 in water column 356 mm water column GAS esl 12 psig Figure 10 Sediment trap for gas line The pipe compound used should be resistant to the action of liquefied petroleum gases Check for gas leaks in piping connection to appliance and gas valve inlet before placing the appliance in operation by using a soap and water solution Also check for gas leaks at the gas valve outlet when the appliance is on DO NOT USE AN OPEN FLAME INSTALLER MUST IDENTIFY EMERGENCY SHUT OFF DEVICES 1 6 ELECTRICAL CONNECTION WARNING Electrical shock hazard can cause severe injury or death Disconnect power before installing or servicing The appliance requires a 120 Vac 60 Hz power supply and must be grounded All electrical connections must be made in full accordance with the Code requirements listed in Section 1 2 WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Verify proper operation after servicing Run a separate electrical circuit from the ele
48. ed PP CPVC or stainless steel exhaust venting which has been approved The following manufacturers offer venting and components approved for use with this appliance CPVC schedule 40 venting tube and components e In Canada IPEX System CPVC or certified type of ULC S636 e In USA ANSI ASTM F441 CPVC schedule 40 or certified type 22 HSE Installation and Service Manual 1 7 4 PP venting tube and components e In Canada M amp G PP system certified type of ULC S636 e In USA ANSI ASTM PP system certified type Stainless steel venting tube and components certified types for Category IV e Flexmaster Canada Ltd Z Vent e Z Flex U S Inc Z Vent e Heat Fab Inc Saf T Vent e Flex L International Inc StaR 34 e Protech Systems Inc FasNSeal The use of these manufacturers venting systems for sidewall venting will require the use of a vent terminal specified by Allied Engineering Company The vent terminal for a vertical venting system should be obtained from the supplier of the venting system listed above VENT TERMINAL INFORMATION The minimum distance from the vent terminal to adjacent public walkways adjacent buildings operable windows and building openings shall be not less than those values specified in the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 Flue gas condensate can freeze on the exterior walls or on the vent termination Frozen c
49. ere is any conflict in the above requirements the more stringent requirement applies The installation and service must also conform to the additional requirements in this manual If there is any conflict with a requirement in this manual and a Code requirement the Code requirement must be followed The hot water distribution system must comply with all applicable codes and regulations When replacing an existing appliance it is important to check the condition of the entire hot water distribution system to ensure safe operation some jurisdictions may require that flue condensate be neutralized prior to disposal because flue condensate is very corrosive and will corrode most metals HSE Installation and Service Manual 1 3 1 3 1 1 3 2 1 3 3 1 3 4 LOCATION AND INSTALLATION LOCATION This appliance is intended for an indoor wall hung installation using the wall mounting strip or optional mounting frame The appliance should be mounted on a wall with sufficient bearing strength In the case of light wall constructions resonance sounds may occur In order to avoid freezing of the condensate discharge the appliance should be installed in a frost free room A hot water boiler installed above radiation level or as required by the authorities having jurisdiction must be provided with a low water cutoff device at the time of boiler installation This appliance must be installed such that gas ignition system components are protec
50. ergas Figure 25 Operating and Display Panel Table 5 Operating and Display Panel Display Operating Controls 1 Power On Off LED 7 DHW Eco mode LED A Power On Off button E F C button 2 CH LED 8 DHW Comfort function LED 6 CH HW Temp button F Comfort button 3 DHW LED 9 Service display C button G Service button 4 Temperature display 10 Fault LED D button H Reset button 5 Fahrenheit LED 11 CH pressure gauge 6 Celsius LED Notes An illuminated LED indicates ON or active status When the red Fault LED above the Reset button flashes on the burner controller has detected a fault In the Temperature display 4 a fault code appears Table 6 Operating Condition Codes Operating condition codes shown in item 9 in Figure 25 L off frost protection active Self test CH operating L Stand by Blower on el Domestic hot water operating o Pump overrun Ignition Comfort function is on or Set temperature reached internal frost protection The code shown in item 9 in Figure 25 indicates the following operating condition Off The appliance is not operating but the power supply is connected to the appliance There is no response to any demand for DHW or CH however the frost protection is active If the temperature of the water in the heat exchanger drops below 41 F 5 C the pump starts running the heat exchanger is heated code 7 appears on the service display Stand by After press
51. ervice Manual 3 3 2 STARTUP INSTRUCTIONS In the event of failure of any component either the system will not operate or it will go into safety lockout After placing the appliance in operation the ignition system safety shutoff device must be tested The method of testing is specified as follows 1 Make sure the gas valve and all electrical power to the appliance is OFF 2 Set room thermostat to the lowest setting 3 Connect a manometer to the gas inlet pressure tapping located upstream of gas valve to check inlet gas pressure 4 Wait five minutes to clear out any gas If you smell gas STOP Follow the safety instructions provided in section 3 3 7 under WHAT TO DO IF YOU SMELL GAS Remember that propane does not vent upward naturally 5 Check the ignition control as follows a Switch on the electrical power to the appliance b Turn manual shut off gas valve to OFF c Set room thermostat above room temperature to call for heat and turn power on for the appliance d Watch listen for sparking in the combustion chamber from the inspection hole on the left side of appliance after a few seconds of pre purge If no flame is detected after four tries for ignition the controller will automatically lockout and only restart the ignition sequence after manual reset by pushing the reset button on the operating panel 6 Turn manual shut off gas valve to ON The burner should ignite 7 Check for gas leaks at all joints including
52. ervice regulator vent outlet and mechanical air inlet to building requires a clearance of 10 feet 3 0 m from any gas service regulator internal relief vent Vents are prohibited above the gas meter assembly not propane regulator vents within 3 feet 0 9 m horizontally of the vertical center line of the regulator to a vertical distance of 15 feet 4 6 m The bottom of the vent terminal and the air intake shall be located at least 12 inches 0 3 m above grade plus height of the normal snow line The terminal shall not be less than 7 feet 2 1 m above grade where located adjacent to a public walkway and shall not terminate over public walkways or over an area where condensate or vapor could create a nuisance of hazard or could be detrimental to the operation of regulators relief valves or other equipment The diagram as shown in Figure 13 indicates vent terminal clearances A to M for a direct vent appliance The clearance marked on the diagram are stated separately in Table 2 for US and Canadian installations and shall not be less than those specified in the current ANSI Z223 1 NFPA 54 National Fuel Gas Code or CSA B149 1 Natural Gas and Propane Installation Codes as applicable For clearances not specified in ANSI Z223 1 NFPA 54 or CSA B149 1 the clearances shall be in accordance with local installation codes and the requirements of the gas supplier SIDE coRNER DETAIL oct we SE Y M t VENT TERMINAL
53. essags 51 3 8 PSIG MOUT R UNG EE 52 3 9 EE EN S 52 2O CHECK fOr GaS EE 52 3 11 Check theCondensate Lt E a a vee al eee a A 52 212 staller S SCI EE 53 Section 4 Service amp Maintenance Instructions cccceceeeeeeee seen ee KENNEN RRR EE RRE ENER EEERR ERR EEN RRE 54 4 1 Service amp Maintenance Instructions 0 00 cece ceeccceeeccceeeeeeeeeecaeeceseeeeeseeeesseeeesseeeesuecessueeesaeeeesansees 54 4 2 SEINVICS PVOCCO EE 54 A201 Check AppllanGe Alea EE 54 4 2 2 Inspect the Condensation Trap and Discharge Tube 55 4 2 3 Check the Water and Gas Piping Gvstems E 55 4 2 4 Check the Pressure Relief Valves ccccccccccsececessceceeeeeceeeseeeceseeseeseaeeeseaeesseseseueessaseessneeessaaees 55 A2 CTS IG AUN MING EEN 55 426 Service the Venting Syste EE 55 4 2 7 Service the Heat Exchanger if necessan E 56 4 2 8 Check the Operation of the Appliance enee 56 4 2 9 CHECKING Control Settings aise cs eae iene ate acetal aersbeson dal eral E ages ada aaa adiae oak 56 HSE Installation and Service Manual 4282 Check tE GaSAN E le EE 56 e E Een E En 57 4 2 9 Completion of Inspection and Service cece ceecccceeececeeeeeceeeeseeceeaeecesseeeeseucesseeesseeeeseueesaeeeeseaeees 57 4 2 10 Review the Service with CUwner 57 4 3 SNE os Gel a2 14 EE 58 4 4 Caution Water Heniensbment 59 4 5 Refractory Handling Procedure ccccccccccsssccceceecenceeeeeeeeeeseeceaeeeseueessaeeeseacessaeessaeeessneeesenseesag
54. et 1 7 9 2 VERTICAL ROOF TOP TWIN TUBE VENTING WITH TWIN TERMINAL CAPS Figures 17 to 19 are typical installations for the vertical twin tube venting with twin terminal caps and adapters if required for air inlet and flue outlet on the appliance Location of the venting terminal has to be determined based on the applicable code before installing the terminals Keep the end opening of air terminal at least 12 inches 300 mm above the normal snow accumulation that can be expected on the roof and the top of the vent terminal at least 12 inches 300 mm above the air inlet terminal opening Support the venting on the outside of the roof if necessary or based on the code requirements 30 HSE Installation and Service Manual 1 7 9 3 VERTICAL ROOF TOP TWIN TUBE VENTING WITH AIR SUPPLY FROM SIDE WALL A typical installation of a vertical twin tube venting configuration with air supply from side wall is shown in Figure 20 Install side air supply tube terminal The air supply terminal A in Figure 20 can be located on the outside wall Location of the venting terminal must be determined based on the applicable code before installing the terminals Se l Figure 20 Vertical Single Figure 18 Vertical Tw Figure 19 Vertical Twin Tube Venting with Side Air Venting Venting Supply 31 HSE Installation and Service Manual 1 7 9 4 CONCENTRIC CONNECTIONS WITH A COMBINED TERMINAL CAP CAUTION In Canada follow CAN CSA
55. hen the appliance is used for hot water supply leet umin only in the summer the CH heating function can be switched off with the service code on the operating panel If the appliance is shutdown during the winter the domestic hot water and heating water loops should be drained to prevent the pipes from freezing Also disconnect the make up water for the CH heating loop and cold water for the domestic hot water at the bottom of the appliance 02 04 06 08 10 12 14 16 18 20 bar D X Figure 9 shows the domestic hot water flow rate 2 9 5 8 87 11 6 14 5 17 4 20 3 23 2 26 1 29 0 psi versus the cold water pressure 10 Figure 9 DHW flow rate vs water pressure HSE Installation and Service Manual 1 4 2 2 1 4 2 3 1 4 2 4 1 4 3 1 5 DHW PIPING WITH A BACKFLOW PREVENTER If the water heater is installed in a closed water supply system such as one having a backflow preventer in the cold water supply line means shall be provided to control thermal expansion Contact the water supplier or local plumbing inspector on how to control this situation PRESSURE RELIEF VALVE OR TEMPERATURE AND PRESSURE RELIEF VALVE A pressure relief valve must be installed near the domestic hot water outlet If the unit is connected to a separate storage vessel the separate vessel must have its own temperature and pressure relief valve The pressure relief valve or temperature and
56. her appliance 2 Make sure that no corrosive atmospheres indicated in section 1 7 1 are in the vicinity of the air intake opening 54 HSE Installation and Service Manual 4 2 2 INSPECT THE CONDENSATION TRAP AND DISCHARGE TUBE 1 2 St Follow the maintenance schedule required by the neutralizer supplier Shut off the appliance and remove the condensate discharge tube from the outlet of condensation trap Unscrew the slip ring nut from the condensation trap to disconnect it from the appliance Remove any sediment in the trap and discharge tube and flush them with water After cleaning replace the condensation trap onto the condensate outlet of the appliance and discharge tube onto the outlet of the trap Tighten both of the slip ring nuts by hand only Fill the trap with water until the water begins to pour out of the drain 4 2 3 CHECK THE WATER AND GAS PIPING SYSTEMS 1 2 3 4 Check all pipes fittings and components for leaks and ensure they are properly supported Verify all system components are correctly installed and operating normally Verify that the pressure of the CH system matches the expansion tank pressure under cold system condition usually set at 12 psi 83 kPa Watch the pressure in the CH system does not rise too high as it heats up Excessive pressure rise indicates incorrect expansion tank sizing or a damaged expansion tank Check air vent and air separators in the heating system Make sure
57. hing Rinse washer thoroughly e Operations such as sawing blowing tear out and spraying may generate airborne fiber concentration requiring additional protection e Use a vacuum with a HEPA filter for clean up e Dispose of all RCF scrap and dust in a closed airtight plastic bag FIRST AID MEASURES e Eye contact Flush eyes with water to remove dust for at least 15 minutes If irritation persists seek immediate medical attention e Skin contact Wash affected area gently with soap and warm water after handling e Difficulty breathing Move to an area of clean fresh air Seek immediate medical attention if difficulties persist e Ingestion Do not induce vomiting Drink plenty of water Seek immediate medical attention 59 HSE Installation and Service Manual Replacement Parts Section 5 NOTE To supply the correct part it is important that you state the appliance model serial number and type of gas when applicable Any part returned for replacement under standard company warranties must be properly tagged with Return Goods Authorization Form R G A completely filled in with the appliance serial number etc and shipped to the Company freight prepaid lf determined defective by the Company and within warranty the part will be returned in kind or equal substitution freight collect Credit will not be issued Refer to Replacement Parts List 60 HSE Installation and Service Manual Troubleshootino
58. ide Venting with Twin Terminal Cape 30 1 7 9 2 Vertical Roof Top Twin Tube Venting with Twin Terminal Cape 30 1 7 9 3 Vertical Roof Top Twin Tube Venting with Air Supply from Side Wall 00 00nn0nnnn0nnnannnnannannnna 31 1 7 9 4 Concentric Connections with a Combined Terminal Cap 32 SEH Heer 34 2 1 CONTONE OD el AlN EE 34 2 2 ge Od EE 37 2 3 Fest Programs and Frost Protect OM EE 37 Zouk TES Ee elle 37 SE FrOSEPrOLOCION eniT a A E a inter 37 2 4 Seting and EE 38 24 1 User See EE 38 24 2 installer le EE e 39 2 4 3 Setting and Description of Parameters E 40 2 4 4 Setting CH and DHW Operating Input Ratmg 42 2 4 5 Pump Head and Pressure Drop Of CH H E cccccccccccseccceeeeeeceeeeceeceeeeecesseeeesseeeesseeeseeeeseeeensees 42 ZAO OUIGOOl Reset FUNGCHOM EE 43 Section 3 batterer aces ee Eed ee eege 44 3 1 CH System Operating Requirement c ccccccccsssecccesececeeeseecceseeccsegeeecseeeecseuseeessaeeessaneeesseaess 44 SES EE ee ee 44 O21 lee 44 322 WOTIVV SY un EE 45 329 Mm ele EE 45 SE 11 EE 45 Seo OMEN SMC HONG E 46 ees EECH 47 3 3 3 Sequence of Control Operation 47 3 4 Check TEE Syste Mi ees dee ee ee 48 3 5 CONMVEFSION to Propane E 49 3 6 Setting OlGas Allr RaO EE 49 3 6 1 Adjust the Gas Air Ratio by Measuring the CO Percentage of the Flue cc cecccceeceeeeeeeeees 50 Af Appliance for Use at High Altitude ec cccccccccccceececeeeeeceeeeeeeseeseaeeeseaceeseeessaeesseesaeaeeesee
59. in the area of the appliance NOTE INSTALLER S RESPONSIBILITY Before leaving installations installers shall ensure that the appliance accessory component equipment or piping and tubing they installed comply with the Code requirements and the person initially activating the appliance shall ensure that the appliance is in safe working order CSA B149 1 05 Natural Gas and Propane Installation Code 53 Reference Section 3 7 3 8 1 2 1 6 7 5 3 2 3 1 4 3 2 3 11 3 3 2 3 6 1 3 7 1 2 1 7 3 6 3 6 1 3 8 3 9 3 4 4 2 10 HSE Installation and Service Manual Service amp Maintenance Instructions 4 1 SERVICE amp MAINTENANCE INSTRUCTIONS WARNING Electrical shock hazard before servicing the appliance disconnect the appliance and heating system from the power supply by switching off the emergency power OFF button or disconnect the relevant power circuit breaker of the house power grid Turn off the gas by closing the external main manual gas shut off valve before servicing Verify proper operation after serving WARNING Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation WARNING If any part of this appliance has been under water inspect the appliance and replace any part of the control system and any gas control which has been under water WARNING Keep appliance area clear and free from combustible materia
60. ing the W button of the appliance the operating condition LED is off The LED above the on off button is on and if necessary one of the LED s item 7 and 8 of the domestic hot water comfort function is on The appliance is ready for responding to the demand for CH or DHW 0 Pump overrun After the operation of the CH the pump has an overrun This overrun time is set at the factory according to table 8 and may be changed Also the controller will automatically run the pump for 10 seconds once every 24 hours to prevent it from getting seized This activation of the pump takes place at the time of the last heat demand 24 hours later In order to change this time set the room thermostat higher for a while at the desired time 35 HSE Installation and Service Manual H Set temperature reached The burner controller can temporarily block the heat demand and stop the burner This blocking takes place because the required temperature has been reached When the temperature has dropped sufficiently the blocking is cancelled H Self test The burner controller may regularly carry out a self test and check the connected sensors During this time the controller displays code and does not carry out any other tasks H Blower on At appliance start up the blower is brought to the starting speed When this speed is reached the burner is ignited Code is also visible during blower post purge after stopping the burner 4 Ignition Whe
61. le 3 Equivalent Venting System Length for HSE 125 Direct Vent Twin Tubes Direct Vent Concentric Tubes Equivalent Length of Air and Flue Equivalent Length of Air and Flue Tubes in Feet m Tubes in Feet m 3 diameter 3 diameter A JD diameter A ID diameter 80mm 80mm 80mm 125mm 80mm 125mm vertical runs horizontal runs vertical runs horizontal runs AIR TUBE 5 ft 85 ft 5 ft 85 ft 5 ft 85 ft 5 ft 85 ft 1 52 m 26 m 1 52 m 26 m 1 52 m 26 m 1 52 m 26 m FLUE TUBE 5 ft 85 ft 5 ft 85 ft 5 ft 85 ft 5 ft 85 ft 1 52 m 26 m 1 52 m 26 m 1 52 m 26 m 1 52 m 26 m Choose the right appliance vent outlet adapter if required for plastic or stainless steel vent tube for twin tube or concentric tube venting Reduce the equivalent length by 6 5 feet 2 m for each 90 degree elbow added and by 3 5 feet 1 1 m for each 45 degree elbow for your estimating the equivalent venting lengths Always confirm with the selected venting manufacturer for the actual equivalent length of elbows 2T HSE Installation and Service Manual Table 3a Equivalent Venting System Length for HSE 145 Direct Vent Twin Tubes Direct Vent Concentric Tubes Equivalent Length of Air and Flue Equivalent Length of Air and Flue Tubes in Feet m Tubes in Feet m 3 diameter 3 diameter A JD diameter A ID diameter 80mm 80mm 80mm 125mm 80mm 125mm vertical runs horizontal runs vertical runs horizontal runs AIR TUBE 5 ft 60 TU 5 ft 60 D
62. lief valve 6 153mm below the bottom of the appliance casing to allow for controller opening Figure 7 Piping system installation 15 HSE Installation and Service Manual 1 4 1 2 1 4 1 3 1 4 1 4 1 4 1 5 PRESSURE RELIEF VALVE WARNING The pressure relief valve discharges pressurized hot water which can turn into steam Steam exiting the discharge outlet can explosively expand in all directions Always maintain a safe distance from the discharge pipe outlet in order to avoid potential contact with exiting hot water or steam and injury A pressure relief valve is supplied as standard equipment The pressure relief valve is extra protection against damage that could be caused by malfunctioning controls or excessive water pressure The pressure relief valve is a code requirement Field installation of the relief valve must be consistent with the ANSI ASME Boiler and Pressure Vessel Code Section IV The manufacturer is not responsible for any water damage If a pressure relief valve is not used the warranty is void The pressure relief valve should be installed on the boiler outlet with its spindle vertical The connection between the boiler and the relief valve must have at least the area of the relief valve inlet No valve should be installed between the pressure relief valve and the appliance or in the discharge piping A discharge pipe should be used The discharge pipe outlet should be positioned over a suitable drain a
63. ls gasoline and other flammable vapours and liquids This appliance has been designed to provide years of trouble free performance in normal installations The owner or user should conduct a general external examination covering all items on the User Checklist at the beginning of each heating season and in mid heating season In addition the owner or user should have the appliance inspected and cleaned if necessary by qualified service technician or gas suppliers service person at least once every year at the beginning of the heating season for continued safe operation Note that some operating conditions may require more frequent inspections for example check and remove any obstruction to the flow of combustion air or venting of flue gases and any combustible materials gasoline and other flammable vapours and liquids around the appliance area Periodically perform a visual check of burner flame The Service Checklist must only be used by a qualified service technician or gas supplier s service person Always verify proper operation after servicing 4 2 SERVICE PROCEDURE The appliance and the system should be checked and cleaned if necessary Verify and correct any problem reported by the owner before proceeding with the maintenance procedures 4 2 1 CHECK APPLIANCE AREA 1 Make sure that no gasoline or other flammable vapors and the liquids and combustible materials are stored in the vicinity of this appliance area or any ot
64. min water flow to trigger it SS 2 Replace the flow switch Lb No No voltage 24 V output from the y Check that wiring is according to the burner controller CA SS wiring diagram Lb No sensor S3 faulty gt Yes Replace sensor S3 Lb No Burner does not ignite gt Yes See section 6 2 burner fails to ignite 65 HSE Installation and Service Manual 6 9 DOMESTIC HOT WATER DOES NOT REACH CORRECT TEMPERATURE Possible problems Solutions Water flow rate higher than 9 I min C gt Yes Adjust water flow rate Jt No Water temperature setting too low gt Yes Set the hot water to desired temperature gwo De scale insi ide ofthe Scale in or soot on the heat exchanger gt Yes 3 S TEA ie or clean outside of the g wo Cold water temperature lt 10 C 6 10 NTC TEMPERATURE SENSORS DATA Table 13 NTC Resistances NTC 12 kOhm T C F R ohm T C F R ohm T C F R ohm 60 140 66 HSE Installation and Service Manual 67 HSE Installation and Service Manual 68
65. n the blower has reached the ignition speed the burner is ignited by means of electric spark ignition During ignition code appears If the burner is not ignited another ignition attempt is made after about 5 seconds If the burner has still not fired after the fourth ignition attempt the controller indicates a fault See section 6 1 D CH operation A room thermostat can be connected to the controller if necessary in combination with an outdoor sensor See the electric wiring diagram of section 1 6 When heat is demanded by a thermostat signal the blower runs code 3 and the burner is ignited code Ah followed by the CH operating condition code 5 During CH operation the blower speed and hence the input rate of the appliance is adjusted This is done in such a way that the temperature of the CH water is controlled towards the set CH supply temperature In the case of on off thermostat the CH supply temperature is set at the operating panel and remains fixed In the case of an outdoor sensor the CH supply temperature will automatically adjust based on the outdoor air temperature and the outdoor reset function programmed by the user The CH supply temperature can be set between 86 F 30 C and 194 F 90 C and will be displayed on the operating panel During CH operating mode the set CH supply temperature is displayed on the operating panel and the actual CH supply temperature can be read by pressing and holding the service
66. nce 2 Lift the front panel C and remove it forward e St gl 1 3 6 MOUNTING There are two types of mounting methods Wall mounting strip A is the standard appliance mounting bracket and wall mounting frame B is an optional mounting frame which holds a square expansion tank For mounting the appliance on the inside of an external wall through which sidewall venting passes Figure 3 Remove front cover wall mounting frame B is recommended to provide sufficient clearance for venting elbows Option One Wall mounting strip A Only Refer to Figure 4 1 Use the screws and plugs supplied to fasten the bracket horizontally to the wall 2 Hang the appliance by sliding it top down over the standard mounting strip 3 Install the parts of the various connecting sets Option Two Mounting frame B Refer to Figure 5 1 Use the screws and plugs supplied to fasten the mounting frame B vertically to the wall 2 Connect the expansion tank to the heating system before connecting appliance piping 3 Hang the appliance by sliding it top down over the mounting frame 4 Install the parts of the various connecting sets Figure 4 Wall mounting strip Figure 5 Mounting frame HSE Installation and Service Manual 1 3 7 1 4 INSTALL THE CONDENSATE TRAP Refer to Figure 6 WARNING Risk of exhaust gases esc
67. nction necessary corrections should be made immediately 3 10 CHECK FOR GAS LEAKS To identify gas leaks smell for gas around appliance area and gas piping connections See Section 3 3 1 To check a specific area including all pipe joints connected to the gas valve for leakage spray a mixture of soap and water onto the suspected area active bubbling indicates a gas leak The gas leaks of the joint connected to the gas valve outlet should be checked when the appliance is on DO NOT TEST FOR LEAKS WITH AN OPEN FLAME Gas leaks must be repaired immediately 3 11 CHECK THE CONDENSATE TRAP Check that the condensate drain trap neutralizer when used and condensate tube loop when used are properly connected The water should fill the trap to form a liquid filled trap and not be plugged with excessive sediment See section 3 2 52 HSE Installation and Service Manual 3 12 E D LI OOO OUD E INSTALLER S CHECKLIST The information printed on the appliance rating plate matches the application i e altitude input and fuel type All applicable electrical codes have been met Gas piping has been purged and checked for leaks with a soap solution including all joints between the gas valve outlet and gas supply pipe when the appliance is on System is filled with water and all air has been purged Only oxygen barrier tubing has been used for the system The condensing trap is filled with water When used the condensat
68. nd so arranged that there will be no danger of being scalded The discharge pipe must pitch down from the valve and should be no smaller than the outlet of the valve The end of the discharge pipe should not be concealed or threaded and should be protected from freezing Extensive runs traps or bends could reduce the capacity of the pressure relief valve MANUAL SHUTOFF VALVES Refer to Figure 7 Install the manual shut off valves on the supply and return pipes EXPANSION TANK AND MAKE UP WATER The boiler requires an expansion tank which is of the adequate volume for the heating system For larger volume systems an additional expansion tank may be required Consult heating system engineer and the expansion tank manufacturer for proper sizing information Install make up water connections as per local codes If a pressure reducing valve is used as shown in figure 8 adjust it to match the system P E REDUCING fill pressure Also adjust the diaphragm type expansion tank air pressure to match the system fill pressure In connecting the cold make up water supply to the appliance make sure that clean water supply is available When the water Figure 8 Example of make up water loop supply is from a well or pump a sand strainer should be installed at the pump SYSTEM BYPASS AND PRESSURE HEAD LOSSES A bypass primary secondary piping is not required for the safe operation of the appliance It may however be required in conjuncti
69. nstallation and Service Manual 10 11 12 13 14 15 16 17 18 19 20 21 Switch on the appliance using the On Off button Set the appliance to the maximum input rating by simultaneously pressing the Service and buttons twice on the operating display panel of the controller until an appears on the service display of the controller display panel See section 2 3 1 Measure the gas inlet pressure to match the value in table 11 and adjust it if necessary Check the CO level at high fire setting and compare with the value in Table 11 If necessary adjust the setting of throttle screw E to correct CO level at high fire Set appliance to the minimum input rating by simultaneously pressing the Service and buttons on the operating display panel of the controller until an L appears on the service display See section 2 3 1 Measure the CO value If the CO value does not match with the value in table 11 and notes proceed as follows Otherwise skip ahead to step 17 Remove the setting screw cover A with a torx T15 screwdriver Using a torx T15 screwdriver adjust the setting screw B to the correct CO value clockwise higher and counter clockwise lower After finishing measurement and setting replace the setting screw cover A Then set the appliance to the maximum input rating by simultaneously pressing the Service and buttons twice on the operating panel of the controller
70. oller will return to normal 2 4 2 INSTALLER PARAMETER SETTINGS The appliance burner controller has been set to the factory default parameters listed in Table 8 of Section 2 4 3 These parameters can only be changed with the service code Proceed as follows to activate the program memory 1 Switch off the appliance by using the On Off W button BW on the service display 2 Simultaneously press the Service and Reset buttons until a 0 appears on the service and the temperature displays 3 Using the Di and buttons set service code on the temperature display 4 Press the Service button to confirm the service code 5 Use the Service button to select the parameter to be changed the parameter will be displayed on the service display 6 Use the and buttons to set the selected parameter to the required value the value will be displayed on the temperature display 7 Repeat the steps 5 and 6 for other parameters which require change 8 After making all required changes press the Reset button until P appears on the service display 9 Switch on the appliance again using the On Off W button The controller has now been reprogrammed Notes Pressing the On Off W button before pressing the Reset button to confirm the changes takes you out of the setting menu without storing the parameter changes After entering the installer parameter setting pressing the Service button for 5 secon
71. on with certain controls on a heating system MAKE lt WATE EXPANSION TANK Pump head and pressure drop of the CH heat exchanger versus water flow rate are shown in Figure 30 To confirm if the equipped pump meets the system pressure drop or requires an additional system pump the system pressure drop must be calculated by a qualified heating system designer HSE Installation and Service Manual 1 4 1 6 CORROSION PREVENTION Internal The use of oxygen barrier tubing is recommended to protect the system and its components e g pump from corrosion Should your system include non oxygen barrier tubing please contact the factory or a heating professional for recommendations If freeze protection is required use an inhibited propylene glycol solution which is specifically designed for hydronic heating systems and always maintained at a neutral pH e g Fernox Alphi 11 or equivalent Follow the supplier s instructions for proper use and maintenance Do not use automotive antifreeze Some types of chemical additives can cause problems e g accelerated corrosion reduced efficiency etc and could result in premature failure of the boiler heat exchanger and or system components especi
72. ondensate discharge DHW sensor S3 Condensate trap Heat exchanger Operating and display panel lonisation ignition probe Front cover fixing screw High limit S7 not shown Flue sensor S8 not shown 1 Compression fittings for CH pipes 4 2 Vent adapters 80mm to 3 CPVC 5 A Outdoor sensor 6 Optional Accessories ordered separately 1 DHW kit includes compression fittings 3 for DHW pipes 125 psi PRV etc 4 2 Condensate Neutralization Kit 5 Wall mounting strip Pressure relief valve 30 psi Drain valve Propane conversion kit Mounting frame Computer interface cable for diagnostics HSE Installation and Service Manual DIMENSIONS 17 7 450mm 4 7 4 7 3 5 120mm 120mm 90mm o E NE we VO VUE COOC Tm UNS N P Y Z e 2 6 65mm 5 3 7 9 4 5 135mm 200mm 115mm 810mm 190mm 11 8 300mm 2 6 65mm A B C 2 0 50mm D E AoA Hi 2 6 2 6 ePi 1 2 1 4 30 35mm F 65Mm 65mm 80mm 10 6 270mm i g _ 22mm di
73. ondensate on the vent cap can result in a blocked flue condition and should be removed to keep the appliance operating normally Some discoloration to exterior building surfaces can be expected Adjacent brick or masonry surfaces should be protected with a rust resistant sheet metal plate To prevent discoloration and degradation of building materials by flue gases and flue gas condensation ensure that the vent terminal is installed clear of nearby obstacles In all cases installation shall be in accordance with applicable code s For proper operation the vent terminal must be kept free of snow leaf dropping and other debris at all times to ensure that no blockage occurs Do not terminate the vent in a window well stairwell alcove courtyard or other recessed area The vent cannot terminate below grade and over paved walkways or paved driveway that is located between two single family dwellings and serves both dwellings or near soffit vents or crawl space vents or other area where condensate or vapor could create a nuisance or hazard or cause property damage or where condensate or vapor could cause damage or could be detrimental to the operation of regulators relief valves or other equipment The vent shall not terminate underneath a veranda porch or deck unless the veranda porch or deck is fully open on a minimum of two sides beneath the floor and the distance between the top of the vent termination and the underside of the veranda por
74. ontroller e Check flow rate DHW temperature higher than e Ensure X4 9 10 not connected unless 105 C operating in system type 1 e Replace sensor S3 e Blower jammed by appliance front cover e Wire between blower and casing e Check the wires for poor contact tacho signal e Replace blower 47 S3 DHW sensor open circuit e Check the wires for continuity e Replace S3 E e Check the wires for continuity 18 S8 Flue gas sensor open circuit Replace 8 19 S8 Flue gas sensor short circuit CREK E WES IORS NOTLA e Replace S8 SES e Check the wires for continuity 28 S7 High limit sensor open Replace 7 Faulty gas valve relay on e Replace burner controller 29 30 controller 61 No flame signal after 4 ignition tries Blower speed incorrect HSE Installation and Service Manual 6 2 BURNER FAILS TO IGNITE Possible Problems Solutions Ee ak weesen Lb No lemer T No gt ves ea Jb No 4 Check the cabling No spark ie C gt Yes 2 Check the spark probe Ignition unit on gas unit faulty 3 Replace ie ignition Se I no Gas air ratio not adjusted properly gt Yes Make the adjustment see section 3 6 Jb No 1 Check the wiring Blower faulty 2 Check the fuse 3 Replace the blower if necessary Q Ne Blower blockage gt Yes Clean the blower Ne Gas valve faulty E Yes Replace the gas valve 62 HSE Installation and Service Manual 6 3 BU
75. ot use any phone in your building appliance and to replace any part of the e Immediately call your gas supplier from control system and any gas control which a neighbor s phone Follow the gas has been under water supplier s instructions 1 STOP Read the safety information above 7 Turn external main manual gas shut off on this label valve on Turn off all electrical power to the appliance 8 Set room thermostat to desired setting Set the room thermostat to lowest setting H Turn on all electrical power to the appliance This appliance is equipped with an ignition 10 If the appliance will not operate follow the device which automatically lights the instructions To Turn Off Gas To Appliance burner Do not try to light the burner by and call your service technician or gas hand supplier Turn external main manual gas shut off emeng valve off to CLOSE 2 to OPEN Wait five 5 minutes to clear out any gas K 2 Koa Then smell for gas including near the floor If you smell gas STOP Follow B in the safety information above on this label If ou don t smell gas go to the next step TO TURN OFF GAS TO APPLIANCE fo 1 Turn off the appliance using the ON OFF 3 Set the room thermostat other operation switch on the operating panel control to lowest setting Turn off all electrical power to the appliance 4 Close the external main manual gas shut off if service is to be performed valve 46 HSE Installation and S
76. pipe is over 9 5 feet 3 m a venting condensate drain and trap should be installed The venting condensate drain should be installed as close to the appliance as possible and must be equipped with a drain trap The drain trap can be formed by attaching 1 2 13 mm diameter flexible tubing to the drain assembly making a loop of approximately 6 diameter and securing it with a cord or tie wrap where the tube crosses over itself Do not squash the tube or over tighten it see Figure 15 or use other type of boiler condensate trap The loop or condensate trap must then be filled with water to form a liquid filled trap This trap allows condensate to drain while preventing exhaust gases from escaping The condensate should be discharged as per section 1 3 7 20 ft 6 m 22 ft 7 5m L4 L3 Always select the venting systems including the terminals approved for use with this type of appliance 5 ft 1 5m L6 Follow the vent manufacturer s instructions or applicable codes to install the venting system proper venting adapters spacers thimbles caps roof flashing storm collar supports terminal s etc and support the venting system so that its weight does not bear on the Figure 15 Sample of venting length estimate appliance Provide minimum service clearance from vent components to the wall as specified in the section 1 3 The vent system has a positive pressure in the flue requiring that all
77. pressure relief valve must be rated in accordance with and comply with the Standard for Relief Valves for Hot Water Supply systems ANSI Z21 22 CSA 4 4 or the ANSI ASME Boiler and Pressure Vessel Code Section IV Heating Boilers The location of the relief valve shall be accessible for servicing or replacement If a separate storage vessel is installed it shall have a tapping separate from the tapping for the water connections to accommodate a temperature and pressure relief valve of adequate size to protect the water heater This tapping shall be clearly identified on Class Il marking material and shall be located in the top of the tank or in the side of the tank on a centreline within the upper 6 inches of the top of the tank The tapping shall be threaded in accordance with the Standard for Pipe Threads General Purpose Inch ANSI ASME B1 20 1 The maximum Btu h discharge capacity of the pressure relief valve must be at least equal to the maximum input rating of the water heater The maximum relieving pressure setting must not exceed 150 psi 10 3 bar No valve shall be placed between the relief valve and the water heater relief valve and the storage tank or in the discharge pipe as shown in figure 7 Avoid contact with the hot water and steam discharged to prevent personal injury The discharge pipe outlet should be positioned over a suitable drain within 6 152 mm from the floor It must be arranged so that there will be no dange
78. propane and high altitude if applicable use The correct conversion information must be entered on the conversion data label by the installer 14 Replace the front cover of the appliance 3 6 SETTING OF GAS AIR RATIO The gas inlet pressure must not exceed the value specified in Table 11 The gas air ratio is set at the factory and normally does not need any adjustment for sea level application The gas air ratio can be checked by measuring the CO percentage in the flue In case of replacing the gas valve converting to another type of gas and or high altitude application the gas air ratio and other parameters listed in table 11 must be checked and adjusted The appliance is factory equipped for natural gas A conversion for propane can be supplied upon request order number 4001010 49 HSE Installation and Service Manual Table 11 Appliance setting values Gas type Natural gas H Propane 8 CO2 at low fire setting L anO with front cover off See notes below See notes below 7 CO at high fire setting H and with front cover off 9440 5 10 3 40 5 Gas inlet pressure in w c mm w c 178 11 280 4 80 NOTES A For Natural Gas The COQ level at low fire setting must be 0 to 0 3 lower than the CO level at high fire setting Important CO level at low fire setting must never be below 8 9 B For propane The CO level at low fire setting must be 0 3 to 0 6 lower than the CO level at
79. protection intervenes heating heat exchanger e When the system or a part thereof can freeze a frost thermostat should be installed in the area to be protected Connect this according to the wiring diagram See section 1 6 REMARK When the appliance is out of action on the service display the appliance frost protection is still active However there will be no response to heat demand from an external frost thermostat The external frost thermostat is not active when the appliance has been switched off at the control panel or when the main power supply has been interrupted 3 HSE Installation and Service Manual 2 4 SETTING AND ADJUSTMENT The functioning of the appliance is mainly determined by the parameter settings in the controller User parameters can be set directly through the operating panel without entering the service code while the installer parameters only can be changed by entering the service code 2 4 1 USER PARAMETER SETTINGS 1 Appliance on off The appliance is activated by means of the On Off button Figure 25 item A on the operating and display panel When the appliance is switched on by pressing the On Off button the green Power On Off LED Figure 25 item 1 will be on When switching the appliance off by pressing the On Off button code ES is shown on the service display Figure 25 item 9 to indicate it is still powered 2 Change the settings of the various functions a Change
80. r efficiency as compared to a direct fired hot water tank Because of the separated circuits for CH and DHW the heating and the hot water supply operate independently of each other The hot water supply has priority over the central heating if both systems are connected they cannot work simultaneously It is possible to use the appliance solely for hot water or solely for heating with the unused system not connected Also the DHW circuit can be connected to a storage hot water tank but cannot be connected to a closed system e g the coil of an indirect hot water tank The appliance is equipped with an electronic controller to energize the pump control the blower open the gas valve ignite the burner continuously monitor the flame and modulate the input rate to match the current heat demand The appliance is certified as a direct vent balanced flue only The combustion air supply and flue discharge can be connected to the appliance by means of two separate pipes or a concentric connection The appliance must be wall mounted and can be mounted using either the supplied wall mounting strip or the optional wall mounting frame The frame provides the spacing needed for a large elbow when venting through the sidewall on which it is mounted Also the frame can hold a square expansion tank and allows piping to pass behind the appliance for a very compact installation The wall mounting frame and expansion tank are supplied separately The appli
81. r of being scalded and the hot water cannot splash on anyone or nearby equipment The discharge pipe must pitch down from the valve and should be no smaller than the outlet of the valve The end of the discharge pipe should not be concealed or threaded and should be protected from freezing Extensive runs traps or bends could reduce the capacity of the pressure relief valve No reducing coupling or other restriction can be installed in the discharge line If a relief valve discharges periodically this may be due to thermal expansion in a close water supply system Contact the water supplier or local plumbing inspector on how to correct this situation Do not plug the relief valve CATHODIC PROTECTION DEVICES When cathodic protection devices are used in the storage tank hydrogen gas can be produced in a hot water system that has not been used for a long period of time generally two weeks or more Hydrogen gas is extremely flammable To prevent the possibility of injury under these conditions we recommend the hot water faucet be open for several minutes at the kitchen sink before you use any electrical appliance which is connected to the hot water system If hydrogen is present there will probably be an unusual sound as air escaping through the pipe as the hot water begins to flow There should be no smoking or open flame near the faucet when it is open APPLIANCE USED WITH SOLAR SYSTEMS This appliance is suitable for use with solar hot wate
82. r systems and can be buffered using a Super Hot storage tank or indirect hot water tank Contact Allied Engineering Company for details GAS SERVICE PIPING All piping and fittings must be installed as per codes in Section 1 2 Make sure the gas on which the appliance will operate is the same as that specified on the appliance rating plate Do not install the appliance if equipped for a different type gas Consult your gas supplier to get gas information HSE Installation and Service Manual To prevent damage care must be taken not to apply too much torque when connecting pipe fitting of gas supply to gas inlet pipe on the appliance A manual main shut off valve must be installed in the gas line outside the appliance jacket and as required in Section 1 2 The valve should be readily accessible for turning on and off When a vertical section of gas piping is supplied on the upstream side of the gas controls a drip pocket or sediment trap must be installed at the inlet of gas connection to the appliance in the gas supply line upstream of the gas controls and as close to the appliance as possible example shown in Figure 10 The appliance and its gas connection must be leak tested before TO GAS placing the appliance in operation The gas controls furnished PPLIANCE INLET are suitable for a maximum operating gas pressure of 1 2 psi 14 inches water column 356 mm water column ee The appliance and its individual shutoff valve must be disconn
83. rsion should only be carried out by a qualified heating installer or service technician When the appliance is connected to a type of gas other than the type specified on the rating plate the gas orifice ring must be changed and the gas inlet pressure must be adjusted The gas conversion sets for other types of gas can be ordered from manufacturer Refer to Figure 31 Conversion of the gas orifice ring 1 Switch off the electrical supply to the appliance Turn the external manual gas shutoff valve off Remove the front cover of the appliance Follow section 1 3 4 4 Disconnect the coupling 1 on the gas valve outlet and turn the gas pipe 2 backwards 5 Replace the O ring 3 and the gas orifice ring 4 with those provided with the gas conversion set Reconnect the gas pipe 2 onto the gas valve outlet Turn the external manual gas shutoff valve on Switch on the electrical supply to the appliance oo amp Check the gas connections for tightness and leaks after appliance is on 10 Change parameter h to the value for propane listed in Table 11 11 Check the gas air ratio and change gas inlet pressure as per section 3 6 1 Figure 31 Gas conversion 12 Perform a test following section 3 2 3 13 Attach the conversion data label adjacent to the appliance s rating plate The conversion data label indicates that the appliance has been converted for
84. s 59 Secon o Replacement Pars E 60 Section 6 Troubleshooting E TU TE 61 6 1 Possible Problems and Solutions geed 61 6 2 BUNGE Al LO MIE EE 62 6 3 B rner ONMeS WIN NOG searre qercanctsasduncs E E meeeamraeameen 63 6 4 Bumer ear 63 6 5 No Heatingi CH NEE 64 6 6 Reduced OUUU eoa a a A I a A 64 6 7 CH Supply Water Does Not Reach Correct Temperature 65 6 8 No Domestic Hot Water E e A EE 65 6 9 Domestic Hot Water Does Not Reach Correct Temperature ccccccceecceeeeeeeeeeeeeaeeesaeeeeeneees 66 6 10 NTC Temperature Sensors Uata 66 SECH 7 NOTES ee 67 HSE Installation and Service Manual ABOUT OUR MANUALS Your Super Hot Intergas appliance has been provided with two manuals e User s Information Manual This manual is intended for the owner or user of the appliance and provides information on routine operation and maintenance and emergency shutdown e Installation and Service Manual This manual must only be used by a qualified heating installer service technician or gas supplier Installation or service by anyone unqualified to do so may result in severe personal injury death or substantial property damage Both manuals should be kept in the envelope provided and affixed adjacent to the appliance so that they are readily available for future reference ABBREVIATIONS AND NAMES USED Description Referred to as HSE condensing boiler and water heater Appliance Central heating CH Domestic hot water DHW also HW
85. sed on the CH or DHW input rating parameter 3 amp 4 blower speed parameter h and maximum input rating Table 9 CH and DHW operating input rating CH and DHW input setting parameter 3 amp 4 DHW max 85 for HSE 145 HSE 145 Input Rate Btu h kW 145 000 42 5 130 500 38 3 116 000 34 0 ee 0 101 500 29 8 a Lemess 72 500 21 3 58 000 17 0 HSE 125 Input Rate Btu h kW 124 000 36 3 111 600 32 7 99 000 29 0 87 000 25 4 74 400 21 8 62 100 18 2 50 000 14 5 37 200 10 9 28 700 8 4 Figure 26 Pump stage adjustment 2 4 5 PUMP HEAD AND PRESSURE DROP OF CH H E If the appliance is equipped with a variable speed pump the water flow rate total pressure head can be adjusted by turning the pump switch as shown in figure 26 Set the pump stage based on the selected CH operating input rating and pressure drop of the boiler heat exchanger Figure 27 shows the relationship between pressure drop of CH heat exchanger and or the total pressure head of pump and water flow rate through CH heat exchanger The type Wilo Star S21 with three stages is equipped Measure the temperature difference between the CH supply and return of the appliance to ensure that it is about 36 F 20 C The table 10 shows an example of the minimum water flow rate required with 36 F 20 C temperature rise Table 10 CH operating input rating vs water flow rate CH operating input Min
86. sion data label provided by manufacturer must be attached adjacent to the rating plate to indicate that the appliance has been converted for high altitude use The correct conversion information must be entered on the conversion data plate by the installer To convert a sea level appliance for high altitude use the reduced high altitude input rate can be achieved by changing the gas outlet pressure to match the value of CO concentration in Table 11 following the procedure in section 3 6 1 51 HSE Installation and Service Manual Use at Altitudes above 2000 feet 609 m in U S A In USA for appliance installations at altitudes above 2000 feet 609 m above sea level the input rating of the appliance should be reduced at the rate of 4 percent for each 1 000 feet 305 m above sea level Use at Altitudes above 4500 feet 1370 m in Canada In Canada for appliance installations at altitudes above 4500 feet 1370 m the certified high altitude input rating of the appliance should be reduced at the rate of 4 percent for each additional 1 000 feet 305 m over 4500 feet 1370 m or consult local authorities for the input rate reduction After the appliance has been converted for high altitude use the input rating must be verified following the input rating test as described in Section 3 8 3 8 CHECK INPUT RATING WARNING Exceeding the allowable input rating can produce dangerous concentrations of carbon monoxide and cause the applian
87. ssemble parts removed during cleaning ensuring air tightness of flue gas and air passages by resealing the vent air intake system Inspect the terminal to ensure it is clear and unobstructed Soot can be caused by improper burner adjustment Check and adjust as necessary following sections 3 6 3 6 1 and 3 8 Return appliance to operation following lighting instructions in section 3 3 55 HSE Installation and Service Manual 4 2 7 SERVICE THE HEAT EXCHANGER IF NECESSARY 1 ee ae 10 11 12 13 14 15 16 17 18 19 20 Shutdown the appliance as described in the lighting instructions in section 3 3 1 Remove the front cover of the appliance Wait until the appliance and the burner have cooled down Remove the wire connector connecting blower and the ignition module to the gas valve Disconnect the gas pipe connected to the inlet of the gas valve Unscrew the 10 socket screws from the heat exchanger cover and remove it forward complete with gas valve and blower While removing the heat exchanger cover do not hold from the gas valve and or the blower Be careful not to damage the burner the gas valve and the blower while removing the front plate The burner does not need any maintenance Check the burner surface to make sure no plugging cracking eroding and or dislodging resulting in unsafe operation Never clean the burner with a brush or compressed air This causes damage to the metal fibre Check
88. supply S2 CH Return sensor S8 Flue sensor V Blower wf Ki X4 X 110V X2 5 24V 1 0V 6 24V 2 24V 3424 9 0V_ 3 Tacho F 2 3 G 11 0V 4 1 External economy switch When using DHW comfort function Eco or On 4 and 5 must be closed On off room thermostat 0 1A 24V and or Frost thermostat Power supply clock thermostat 6 positive 7 switched live 9 negative 24V max 3VA Outdoor sensor 12kOhm 25 C Tank Thermostat for indirect hot water tank Installer parameter 1 must be set to 1 Installer parameter n must be set DHW sensor S3 must be disconnected OpenTherm When in use 6 7 must be open Power supply 2 Live 4 Neutral CH pump 8 Live 7 Neutral Valve floor heating 3 Live 5 Switch live 6 Neutral VC4011 Honeywell 115V Three way valve 3 Live 5 Switch live 6 Neutral VC4011 Honeywell 115V PC interface Figure 12 Control Wiring Diagram 20 HSE Installation and Service Manual 1 7 VENTING AND COMBUSTION AIR DEFINITIONS A direct vent a balanced flue appliance an appliance that operates with all air for combustion obtained from the outdoor atmosphere and all flue gases discharged to the outdoor atmosphere A non direct vent appliance an appliance that operates with all air for combustion obtained from the boiler room and all flue gases discharged to the outdoor atmosphere This appliance is certified as a direct vent appliance only The
89. t As well minerals dissolved in a hard water supply will precipitate when heated and preferentially deposit in the heat exchanger Therefore do not draw water from the heating system for cleaning flushing etc The HSE is a condensing appliance with forced air combustion and therefore avoids the typical corrosion and draft problems associated with operating at a low return water temperature To achieve better appliance efficiency the system can be designed with a return water temperature of less than 135 F 57 C A lower the return water temperature will result in higher the efficiency however ensure that there is no risk of system water freezing THE APPLIANCE MUST ALWAYS BE USED FOR HEATING SYSTEMS WITH FORCED WATER CIRCULATION 3 2 PRE STARTUP Prefill the condensate trap with water as shown in Figure 30 IMPORTANT The water must form a liquid filled trap to prevent exhaust gases from escaping to the appliance room 3 2 1 CH SYSTEM 1 Fill entire heating system with water to reach appliance operating pressure see section 1 4 1 4 and purge air from appliance using the manual air vent A as shown in Figure 29 Alternatively an automatic air vent can be mounted on the appliance instead of the manual air vent Water should be of suitable quality Do not use water with high hardness 2 Check all joints and repair any leaks in water piping 3 Check for proper installation of pressure relief valve and discharge pipe
90. ted from water dripping spraying rain etc during appliance operation and service circulator replacement condensate trap control replacement etc Structure through which venting will pass must be free and clear for opening i e no hidden conduit telephone cables or other obstructions MINIMUM SERVICE CLEARANCES Minimum clearances from appliance casing to combustible materials are zero however reasonable space must be provided for ventilation Recommended minimum clearances for service are listed in table 1 Table 1 Recommended Minimum Service Clearances Recommended Minimum Service Clearances Left right side Left right side an lt with piping Flue Vent Clearance 1 inch 25 mm Hot Water Pipe Clearance 1 inch 25 mm INSTALLATION IN A KITCHEN CUPBOARD OR CLOSET Make sure there is sufficient ventilation above and below the appliance When the appliance is placed ina small cupboard ventilation openings of at least 8 i in 50 cm must be made Refer to Figure 2 INSTALLATION IN AN AIRING CUPBOARD OR CLOSET Compartment ventilation is not required for a standard airing cupboard or closet e g 24 x 24 x 91in high or 0 6 x 0 6 x 2 3m high Figure 2 Install in kitchen cupboard or closed closet HSE Installation and Service Manual 1 3 5 REMOVE FRONT COVER Remove the front cover on the appliance as follows refer to Figure 3 1 Unscrew both screws B at the bottom of the applia
91. ted to it At the time of removal of an existing appliance the following steps shall be followed with each appliance remaining connected to the common venting system placed in operation while the other appliances remaining connected to the common venting system are not in operation a Seal any unused openings in the common venting system b Visually inspect the venting system for proper size and horizontal pitch and determine there is no blockage or restriction leakage corrosion and other deficiencies which could cause an unsafe condition c Insofar as is practical close all building doors and windows and all doors between the space in which the appliances remaining connected to the common venting system are located and other spaces of the building Turn on clothes dryers and any appliance not connected to the common venting system Turn on any exhaust fans such as range hoods and bathroom exhausts so they will operate at maximum speed Do not operate a summer exhaust fan Close fireplace dampers d Place in operation the boiler being inspected Follow the lighting instructions Adjust the thermostat so the appliance will operate continuously e Test for spillage at the draft hood relief opening after 5 minutes of main burner operation Use the flame of a match or candle or smoke from a cigarette cigar or pipe f After it has been determined that each appliance remaining connected to the common venting system properly vents when
92. tested as outlined above return doors windows exhaust fans fireplace dampers and any other gas burning appliance to their previous conditions of use g Any improper operation of the common venting system should be corrected so the installation conforms with the National Fuel Gas Code ANSI 2223 1 and or the Natural Gas and Propane 21 HSE Installation and Service Manual Installation Code CAN CSA B149 1 When re sizing any portion of the common venting system the common venting system should be resized to approach the minimum size as determined using the appropriate tables in Part 11 of the National Fuel Gas Code ANSI Z223 1 NFPA 54 and or the Natural Gas and Propane Installation Code CAN CSA B149 1 1 7 1 1 7 2 1 7 3 CORROSIVE ATMOSPHERE If the appliance is to be installed near a corrosive or potentially corrosive air supply the appliance must be isolated from it and outside air must be supplied as a direct venting system Chemical vapors from products containing chlorine or fluorine must be avoided Even though these chemicals may be safe to breathe corrosive substances can become liberated when passed through a gas flame Even at low concentrations these chemicals can significantly contaminate the air supply and shorten the life of any gas fired appliance The following is a list of some of the products which should be avoided e bleaches and chlorinated cleaning products e paints and sprays e water softeners calcium
93. the ON OFF W button on the operating panel to switch on the appliance Check the CH and hot water supply systems for normal operation 4 2 8 CHECK THE OPERATION OF THE APPLIANCE Return appliance to operation following lighting instructions in section 3 3 Verify the heating water pressure in the system is correct 4 2 8 1 CHECK THE CONTROL SETTINGS 1 Following section 2 4 to check the control settings Adjust settings if necessary 2 Check the external limit controls Adjust replace if necessary 4 2 8 2 CHECK THE GAS AIR RATIO Check gas air ratio following sections 3 6 and 3 6 1 and adjust it as necessary 56 HSE Installation and Service Manual 4 2 8 3 CHECK BURNER FLAME Check the burner flame through the observation port on the left side top of heat exchanger following section 3 4 4 2 9 COMPLETION OF INSPECTION AND SERVICE 1 Replace the front cover 2 Put the appliance into operation at the maximum input and check the gasket joint of the appliance case including the gasket joints connecting air intake and flue tubes to appliance case for leaks 3 Verify the input rating following section 3 8 4 Check the CH and hot water supply systems for normal operations 4 2 10 REVIEW THE SERVICE WITH OWNER 1 Review the user s manual with the owner and make sure that the owner understands the importance to perform the periodic service and maintenance specified in the manuals 2 Remind the owner to call a licensed service
94. the appliance behind the cover Check condition of burner system It is possible for parts of the burner system to become plugged cracked eroded and or dislodged resulting in unsafe operation Check for lifting Flames should not lift excessively from the burner The flames may lift slightly during ignition or when the burner is cold Check ignition and extinction Ignition should flow quickly and smoothly across the burner Popping noises or explosions from the burner during ignition extinction or abnormal burner operation indicates the need for service Check flame color On high fire the flame should be stable and mostly blue No yellow tipping should be present however intermittent flecks of yellow or orange in the flame are normal An extremely yellow flame as seen on a burning candle or match is an indication of incomplete combustion and is usually accompanied by the formation of soot and carbon monoxide carbon monoxide is a lethal colorless and odorless gas If soot is allowed to accumulate it will partially restrict free passage of products of combustion to the flue Under typical operating conditions the flame should have a distinct bright blue inner cone and a blue light orange outer cone If any of the above problems are observed or the burner system does not operate properly immediately take corrective action 48 HSE Installation and Service Manual 3 5 CONVERSION TO PROPANE WARNING This conve
95. the top of the appliance as shown in Figure 14 by the sealing ring 116 x 110 mm 4 6 in x 4 33 in which should be provided by manufacturer 3 Fit the adapter on the flue discharge 4 The venting tubes should be sealed following venting tube supplier s installation instruction CAUTION In Canada follow CAN CSA B149 1 current edition and or local code requirements for use of plastic venting Plastic vents shall be installed such that the first 3 feet 92 cm or total vent run if less than 3 feet 92 cm from the appliance flue outlet is readily accessible for visual inspection CAN CSA B149 1 clause 8 9 5 26 HSE Installation and Service Manual 1 7 6 EQUIVALENT VENT AIR INTAKE TUBE LENGTH AND DIAMETERS The resistance of the combustion air supply and the flue gas tubes depends on the length the diameter components used and venting configuration of the venting system For the appliance to operate normally the venting system including air intake piping flue tube and terminal must not be overly restrictive Use Table 3 to determine the venting system equivalent length for a specified vent configuration The equivalent venting system length of your installation must be within the maximum and minimum allowable length specified in Table 3 Use the notes in Table 3 to calculate your venting systems equivalent length in feet based on the total centerline length and number of elbows for air supply piping and exhaust vent Tab
96. tion of the appliance To determine the required refill amount check granulate level several times throughout the year or as necessary In some cases one granulate fill may last an entire year Contact Allied Engineering Company for a condensate neutralization kit when required Never use copper or steel galvanized pipe in the construction of the condensate system Route condensate drain line in a manner such that any condensate leakage will not cause property damage Do not run flue condensate line outside A frozen or blocked drain will cause the condensate to fill the combustion chamber and cause the boiler shut down When a condensate pump is used or required select a pump that is designed for pumping the condensate of condensing residential furnaces i e corrosion resistant WATER PIPING SYSTEMS The water piping system of an appliance connected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle The appliance when used in connection with a refrigeration system must be installed so the chilled medium is piped in parallel with the appliance with appropriate valves to prevent the chilled medium from entering the appliance 14 HSE Installation and Service Manual 1 4 1 CH PIPING SYSTEM BOILER 1 4 1 1 CH PIPING CONNECTIONS Refer to
97. upstream and downstream from gas valve 8 Ensure that all other gas appliances are turned off including their pilot flames 9 Clock the input rate and adjust the inlet gas pressure to match with rating plate as described in Table 11 of section 3 6 10 Adjust gas air ratio if necessary as described in section 3 6 17 11 Check for proper burner flame characteristics as described in section 3 4 12 Heat the water in the heating system to the design temperature 13 Set the required inputs for CH and DHW based on sections 2 4 2 2 4 3 and 2 4 4 Check the temperature difference between the CH supply and return of the appliance This should be less than 77 F 25 C If necessary change the pump position if equipped with variable speed pump and or the manual shut off valve on the return or supply pipe 14 Switch off the electrical supply to the appliance 15 De aerate the appliance and the system after cooling down fill up if necessary 16 Check the heating system and the hot water supply for proper operation 17 Return thermostat and controls to normal operation settings 18 Instruct the User about filling de aerating and the operation of the heating system and the hot water supply 3 3 3 SEQUENCE OF CONTROL OPERATION The sequence of control operation is as follows 1 When power is first turned on 120 Vac is provided to the controller blower and pump 2 On power up the controller performs a self check 3 When there is
98. use an open flame to check for leaks Note Propane is heavier than air and pools in low areas in the event of a leak Inspect for leaks in the water piping and at water piping connections Circulating pumps used in CH system should be inspected for water leaks Check for weeping at pressure relief valve outlet during normal operation Listen for unusual audible sounds in the appliance Any audible sounds in the CH and hot water supply system may be indications of scaling or lack of sufficient water flow and the system should be checked without delay Scaling is due to improper maintenance It is not the fault of the appliance Scale damage is not covered by warranty Check the pressure gauge and expansion tank pressure is within an acceptable range for the CH system Keep appliance area clear and free from combustible materials gasoline and other flammable vapors and liquids Combustible materials gasoline and other flammable vapors and liquids should not be stored in the area of the appliance Check should be made on ignition system operation controls and safety shut off valves Check that the condensation trap is filled with water and not clogged including the discharge pipe Remove any sediment if necessary If applicable periodically inspect low water cutoff for proper operation The emergency shut off devices are identified and the owner is aware of their location and method of operation 58 Reference Section 4 2 1
99. utdoor reset function parameters will be ignored and the boiler will operate at the CH supply temperature setting as per section 2 4 1 2 a 43 T supply E A C 194 176 158 140 122 104 86 68 50 32 90 80 70 60 50 40 30 10 20 30 C gt 68 86 F T outside A curve factory default setting B curve an example of user setting X axis Outdoor temperature Y axis CH supply temperature Figure 28 Outdoor reset curve HSE Installation and Service Manual Startup Instructions WARNING If you do not follow these instructions exactly a fire or explosion may result causing property damage personal injury or loss of life WARNING Connect the appliance to the mains voltage only after filling and de aerating WARNING When an additive is added to the CH water it must be suitable for use with the materials used in the appliance and system such as copper brass stainless steel steel plastic and rubber 3 1 CH SYSTEM OPERATING REQUIREMENTS The CH system is designed for use in closed loop systems Operating the CH system in an open system will not result in premature failure of the heat exchanger however it will result in premature failure some of the components which are not anti corrosion type Also avoid unnecessary replenishment of CH system water It can allow oxygen to enter the system and cause serious corrosion problems for parts which are not corrosion resistan
100. venting system must be installed in accordance with this manual and the venting manufacturer s certified installation instructions Provision for combustion and ventilation air must be met in accordance with Chapter 5 3 Air for Combustion and Ventilation and Chapter 7 Venting of Equipment of the National Fuel Gas Code ANSI Z223 1 NFPA 54 in USA and Section 7 Venting Systems and Air Supply for Appliances of the Natural Gas and Propane Installation Code CAN CSA B149 1 in Canada Also applicable provisions of the local building codes must be followed Contact local building or fire officials about restrictions and installation inspection in your area If there is any conflict in the above Code requirements the more stringent requirement applies For a direct vent appliance installation sufficient air for ventilation in the appliance room or closet should be provided from indoors to reduce the room air temperature The air supply and venting terminations must always be kept clear of obstructions i e snow ice etc The responsibility of providing a suitable venting and air intake tube of adequate draft capacity and in good usable condition is that of the gas fitter installer Interference with the air supply for the appliance shall be prohibited Removal of an Existing Boiler When an existing appliance is removed from a common venting system the common venting system is likely to be too large for proper venting of the appliances connec

Service & Installation Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Service &amp; Installation Manual

Contents

Download Pdf Manuals

Related Search

Related Contents

Service & Installation Manual