EI ONEX Manuale di istruzioni

INSTALLER, THESE INSTRUCTIONS TO BE AFFIXED ADJACENT TO THE BOILER.

ASME

certiﬁed

62403535.R00 9/02/2010

Installation and maintenance

instructions for gas-ﬁred condensing

hot water boiler

OXIOM-3

SAFETY INSTRUCTIONS

- Do not store or use gasoline or other

ﬂammable vapors and liquids in the

vicinity of this or any other appliance.

- WHAT TO DO IF YOU SMELL GAS

• Do not try to light any appliance.

• Do not touch any electrical switch; do

not use any phone in your building.

• Immediately call your gas supplier from

a neighbor’s phone. Follow the gas

supplier’s instructions.

• If you cannot reach your gas supplier,

call the ﬁre department.

- Installation and service must be performed

by a qualiﬁed installer, service agency or

the gas supplier.

- Ne pas entreposer ni utiliser d’essence

ou ni d’autres vapeurs ou liquides

inﬂammables à proximité de cette appareil

ou de tout autre appareil.

- QUE FAIRE SI VOUS SENTEZ UNE ODEUR

DE GAZ:

• Ne pas tenter d’allumer l’appareil.

• Ne touchez à aucun interrupteur, ne

pas vous servir des téléphones se

trouvant dans le bâtiment

• Appelez immédiatement votre

fournisseur de gas de puis un voisin.

Suivez les instructions du fournisseur.

• Si vous ne pouvez rejoindre le

fournisseur, appelez le service des

incendies

- L’installation et l’entretien doivent être

assurés par un installateur ou un service

d’entretien qualiﬁé ou par le fournisseur

de gaz.

WARNING: If the information in these

instructions is not followed exactly, a ﬁre

or explosion may result causing property

damage, personal injury or death.

AVERTISSMENT: Assurez vous de bien

suivre les instructions données dans

cette notice pour réduire au minimum

le risque d’incendie ou d’explosion ou

pour éviter tout dommage matériel, toute

blessure ou la mort

SAFETY INSTRUCTIONS 62403535.R00

In the event of a breakdown and/or malfunction

of the boiler, turn off the unit and do not make any

attempt to repair it. The boiler must be serviced

exclusively by a qualiﬁed technician using original

spare parts. Failure to comply with this requirement

may compromise the safety of the unit and void its

warranty.

Use the service switch to disconnect the boiler

from the electrical circuit before carrying out any

service or maintenance operations.

Electrical

CAUTION: Label all wires prior to disconnection when

servicing controls. Wiring errors can cause improper

and dangerous operation. Verify proper operation after

servicing.

ATTENTION: Au moment de l’entretien des

commandes, étiquetez tous les ﬁls avant de les

débrancher. Des erreurs de câblage peuvent entraîner

un fonctionnement inadéquat et dangereux. S’assurer

que l’appareil fonctionne adéquatement une fois

l’entretirn terminé.

Correct Use:

This boiler must only be used for the purpose for which

it has been expressly designed: heating of water for

closed circuit systems for central heating and the

production of domestic hot water.

Should overheating occur or the gas supply fail

to shut off, do not turn off or disconnect the electrical

supply to the pump. Instead, shut off the gas supply at

a location external to the appliance.

En cas de surchauffe ou si l’alimentation de gaz

ne peut être coupée, ne pas couper ni débranch

l’alimentation électrique de la ponpe. Fermer plutôt le

robinet d’admission de gaz à l’extérieur de l’appareil

Do not use this appliance if any part has been

under water. Immediately call a qualiﬁed service

technician to inspect the appliance and to replace any

part of the control system and any gas control, which

has been under water.

N’utilisez pas cet appareil s’il a été plongé dans

l’eau, même partiellement. Faites inspecter l’appareil

par un tecnicien qualiﬁé et remplacez toute partie du

système de contrôle et toute commande qui ont été

plongés dans l’eau.

Do not obstruct the air intake or vent pipe

terminals. Failure to take proper precautions can

result in excessive levels of carbon monoxide which

can cause severe personal injury or death!

Any optional extras or kit ﬁtted subsequently

must be original manufacturer parts.

SAFETY INSTRUCTIONS

WARNING!!! These instructions must be read

prior to installation. If the information in these

instructions is not followed exactly, a ﬁre or

explosion may result, causing property damage,

personal injury, or death.

Liability

The manufacturer declines all liability, contractual or

otherwise, for damages resulting from the incorrect

installation of this boiler. This includes the failure

to comply with the instructions provided by the

manufacturer or from a failure to comply with the

applicable local and national regulations in force.

The manufacturer declines all liability, contractual

or otherwise, for any damage to people, animals or

property caused by the incorrect use of this boiler or

inadequate or incorrect service or maintenance.

Hazards and Your Safety - Hot Water Can Scald!

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

severe burns instantly, or death from scalds. Children,

the disabled, and the elderly are at highest risk of

being scalded; see instruction manual before setting

temperature at boiler! Feel water before bathing or

showering.

If there is a smell of combustion products, turn the

unit off, air out the room and call a licensed authorized

technician. Failure to take proper precautions can

result in excessive levels of carbon monoxide which

can cause severe personal injury or death!

Qualiﬁed Technicians:

Qualiﬁed technicians are individuals with speciﬁc,

technical training in space heating systems, domestic

hot water systems, fuel gas systems and electrical

systems. These individuals must have the legally

required qualiﬁcations.

Installation and Alterations:

Licensed, authorized personnel must carry out the

installation and calibration of the boiler. Never modify

the boiler or its ﬂue gas carrying components in any

way. This boiler must be properly vented. Failure to

follow these instructions could result in personal injury

or death!

For safety and environmental reasons, the packing

materials must be properly disposed of. Any replaced

part or packaging should never be left within the reach

of children. Failure to follow these instructions could

result in severe personal injury

Maintenance:

at least once a year the user must call in a licensed

authorized technician for routine maintenance.

TABLE OF CONTENTS

SAFETY INSTRUCTIONS .....................................................................................................................................................................2

TABLE OF CONTENTS.........................................................................................................................................................................5

1 - INSTALLATION - CODE REQUIREMENTS.....................................................................................................................................7

1.1 - National installation legislation .................................................................................................................................................7

2 - GENERAL INFORMATION...............................................................................................................................................................7

2.1 - Key to symbols used ................................................................................................................................................................7

2.2 - Description of models:..............................................................................................................................................................7

3 - MAIN COMPONENTS ......................................................................................................................................................................8

4 - FUNCTION OVERVIEW .................................................................................................................................................................10

4.1 - Intended use and functions of the boiler ................................................................................................................................12

4.2 - Setting of the boiler.................................................................................................................................................................12

4.3 - Efﬁciency up to 98%...............................................................................................................................................................13

4.4 - Characteristic curves of heating system’s residual head........................................................................................................14

4.5 - Boiler head loss curve............................................................................................................................................................14

4.6 - Characteristic curve of the domestic side...............................................................................................................................14

5 - INSTALLATION - Mounting & gas and water connections........................................................................................................15

5.1 - Clearances for installation and servicing for models..............................................................................................................15

5.2 - Clearances from combustible material...................................................................................................................................15

5.3 - Choosing the installation location...........................................................................................................................................15

5.4 - Mounting the boiler.................................................................................................................................................................16

5.5 - Gas and water connections....................................................................................................................................................16

5.6 - Condensate disposal..............................................................................................................................................................17

5.7 - Relief valve.............................................................................................................................................................................17

5.8 - Supply and return piping.........................................................................................................................................................18

5.8.1 - Converting a combi boiler into a heating only boiler.................................................................................................18

5.9 - Low temperature heating systems..........................................................................................................................................18

5.10 - Use of glycol and other chemicals........................................................................................................................................18

5.11 - Domestic hot and cold water (only for 160C model).............................................................................................................18

5.12 - Gas supply piping.................................................................................................................................................................19

5.13 - Operating at high altitudes....................................................................................................................................................19

5.14 - Suggested piping and wiring connections for the 160C and 160OC versions Boiler ...........................................................20

5.15 - Suggested piping and wiring connections for the 160B and 160OB versions Boiler............................................................21

6 - INSTALLATION - Electrical connections.....................................................................................................................................22

6.1 - Electrical connections: overview.............................................................................................................................................22

6.2 - Connecting the power supply cable........................................................................................................................................23

6.3 - Choosing the room thermostat...............................................................................................................................................23

6.4 - Thermostat wiring...................................................................................................................................................................23

6.5 - Installing the outdoor temperature sensor (optional)..............................................................................................................24

6.6 - Wiring the circulator pump for 160B and 160OB models .......................................................................................................24

6.7 - Alarm output ...........................................................................................................................................................................24

7 - INSTALLATION - Indirect storage tank connections..................................................................................................................25

7.1 - Connecting the boiler to an indirect storage tank ..................................................................................................................25

8 - INSTALLATION - Vent & combustion air .....................................................................................................................................27

8.1 - Removing of a boiler from a common venting system............................................................................................................27

8.2 - Venting systems .....................................................................................................................................................................28

8.3 - Design of the venting system .................................................................................................................................................28

8.4 - Flue terminal location in compliance with CAN/CSA B149.....................................................................................................29

9 - INSTALLATION - Split venting system........................................................................................................................................30

9.1 - Split system (polypropylene) or AL29-4C (UL 1738/UL C 636) system..................................................................................30

9.2 - Split system components........................................................................................................................................................32

9.3 - Split system components........................................................................................................................................................33

9.4 - Split system: installation examples.........................................................................................................................................33

10 - INSTALLATION - Coaxial venting system.................................................................................................................................34

10.1 - Coaxial system ....................................................................................................................................................................34

10.2 - Coaxial system components.................................................................................................................................................35

10.3 - Coaxial system components.................................................................................................................................................36

10.4 - Coaxial system: installation examples..................................................................................................................................36

11 - OPERATING .................................................................................................................................................................................37

11.1 - Operating..............................................................................................................................................................................37

11.1.1 - User instructions.....................................................................................................................................................37

11.1.2 - Filling the condensate trap .....................................................................................................................................37

11.1.3 - Filling the heating system.......................................................................................................................................37

11.1.4 - Filling the domestic hot water heat exchanger (160C and 160OC models only)....................................................38

11.1.5 - Auto-purging the heating system............................................................................................................................38

TABLE OF CONTENTS

11.2 - General warnings concerning gas supply.............................................................................................................................38

11.3 - Conﬁrming the boiler’s gas type ...........................................................................................................................................38

11.4 - Gas type conversion.............................................................................................................................................................38

11.5 - Start-up.................................................................................................................................................................................38

11.6 - Ignition control testing...........................................................................................................................................................39

11.7 - Gas supply pressure checking and adjustment....................................................................................................................39

11.8 - Check the combustion air pressure .....................................................................................................................................40

11.9 - Checking and adjusting CO2 levels......................................................................................................................................41

11.9.1 - Checking and adjusting CO2 levels without CO2 meter.........................................................................................42

11.10 - Adjusting the heating capacity ............................................................................................................................................42

11.11 - Domestic hot water ﬂow rate adjustment (160C and 160OC models only).........................................................................42

11.12 - Cold start boiler...................................................................................................................................................................42

12 - USE...............................................................................................................................................................................................43

12.1 - Check heating system pressure...........................................................................................................................................43

12.2 - Overview...............................................................................................................................................................................43

12.3 - Displays................................................................................................................................................................................43

12.4 - Start-up procedure................................................................................................................................................................44

12.5 - Summer mode......................................................................................................................................................................44

12.6 - Winter mode.........................................................................................................................................................................44

12.7 - Adjusting the domestic hot water temperature .....................................................................................................................44

12.8 - Heating system temperature adjustment..............................................................................................................................44

12.9 - Heating system type selection..............................................................................................................................................45

12.10 - Outdoor reset adjustment...................................................................................................................................................45

12.10.1 - Outdoor reset applications ...................................................................................................................................45

12.10.2 - Outdoor reset adjustment precautions.................................................................................................................45

12.10.3 - Outdoor reset: setting parameters........................................................................................................................46

12.10.4 - Outdoor reset: zone adjustments.........................................................................................................................46

12.10.5 - Outdoor reset activation.......................................................................................................................................46

12.10.6 - Outdoor reset with room compensation ...............................................................................................................46

12.11 - Boiler switch settings ..........................................................................................................................................................48

12.12 - Delays, alarms and protective actions................................................................................................................................48

12.13 - Circulator pump and three way valve protection ................................................................................................................48

12.14 - Freeze protection................................................................................................................................................................48

12.15 - Display in energy saving mode ..........................................................................................................................................48

12.16 - “Users’ menu”.....................................................................................................................................................................49

12.17 - “Installer’s menu”................................................................................................................................................................50

12.18 - Diagnostics.........................................................................................................................................................................52

12.18.1 - Diagnostics: “L” lock-outs.....................................................................................................................................53

12.18.2 - Diagnostics: “E” blocking errors ...........................................................................................................................55

13 - MAINTENANCE............................................................................................................................................................................57

13.1 - General precaution...............................................................................................................................................................57

13.2 - Removing the casing.............................................................................................................................................................57

13.3 - Cleaning the burner and primary heat exchanger, ﬂue gas side..........................................................................................58

13.4 - Correct positioning of the ignition and ﬂame detection electrodes ......................................................................................59

13.5 - Domestic hot water heat exchanger (only for 160C and 160OC model)..............................................................................59

13.6 - Condensate trap cleaning.....................................................................................................................................................60

13.7 - Circulator pump motor replacement (only for 160C and 160OC models) ............................................................................61

13.8 - Expansion tank pressure (only for 160C and 160OC models).............................................................................................61

13.9 - 3-way valve removal (only for 160C and 160OC models)....................................................................................................62

13.10 - Draining the heating side of the boiler................................................................................................................................64

13.11 - Draining the domestic hot water side of the boiler..............................................................................................................64

13.12 - Overrides............................................................................................................................................................................64

13.12.1 - Auto-purging.........................................................................................................................................................64

13.12.2 - Fan ......................................................................................................................................................................64

13.12.3 - Minimum and maximum output............................................................................................................................64

13.12.4 - Checking the ﬂame current ..................................................................................................................................65

13.13 - Water and ﬂue temperature sensor....................................................................................................................................65

13.14 - Outdoor temperature sensor (optional) ..............................................................................................................................65

13.15 - Functional wiring diagram...................................................................................................................................................66

13.16 - Multiwire wiring diagram.....................................................................................................................................................67

14 - TECHNICAL DATA ......................................................................................................................................................................68

15 - SPARE PARTS.............................................................................................................................................................................69

16 - READ OUT FLOW CHART ..........................................................................................................................................................74

17 - WARRANTY..................................................................................................................................................................................76

1 - INSTALLATION - CODE REQUIREMENTS

1.1 - National

installation

legislation

- The installation must conform to the

requirements of the authority having

jurisdiction or, in the absence of such

requirements, to the latest edition of

the National Fuel Gas Code, ANSI

Z223.1/NFPA 54 and or CAN/CSA

B149.1, Natural Gas and Propane

Installation Code.

- Where required by the authority

having jurisdiction, the installation

must conform to the Standard for

Controls and Safety Devices for

Automatically Fired Boilers, ANSI/

ASME CSD-1

2 - GENERAL INFORMATION

2.1 - Key to

symbols used

WARNING!!! Failure to follow

these indications can causing

an explosion, extensive property

damage, severe personal injury

or death!

CAUTION!!!

Electrical caution! Risk of electric

shock: failure to observe this warning

may compromise the smooth running

of the appliance or cause serious

damage to individuals, animals or

property.

CAUTION!!!

General caution. Failure to observe

this warning may compromise the

smooth running of the appliance or

cause serious damage to individuals,

animals or property.

NOTE:

Operation symbol

Important indication symbol

2.2 - Description of

models:

160

B= heating only version, for inside

installation

C= combi version (space heating and

instantaneous D.H.W. production),

for inside installation.

OB = heating only version, for outdoor

installation

OC =

combi version (space heating

and

instantaneous D.H.W. production),

for outdoor installation.

Modulating gas-ﬁred, condensing hot

water boiler, with sealed combustion

chamber and pre-mix burner, with

maximum power input of 160,000 Btu/hr

(47 kW) and minimum of 30,000 Btu/hr

(9 kW)

1 - P/N 61206001 -Automatic air vent

2 - P/N 61405160 -Air intake and ﬂue gas discharge ﬁtting

(venting system)

3 - P/N 62111015 - U7 ﬂue gas temp. sensor and ﬂue safety switch

4 - P/N 62201005 - Expansion tank

(not present on 160B and 160OB models)

5 - P/N 62651016 - Inlet air plenum

6 -Air/gas mixer device (For P/N see Section 15)

7 - P/N 62111017 - U2 d.h.w. temp. sensor

(not present on 160B and 160OB models)

8 - P/N 62113035 - Heating pressure switch (low water cut-off)

9 - Heating supply connection

10 - DHW connection (not present on 160B and 160OB models)

11 - Gas inlet connection

12 - Cold water connection (not present on 160B and 160OB models)

13 - Heating return connection

14 - P/N 62110076 - Power Control Board

15 - P/N 62118015 - Openterm interface board (optional)

16 - P/N 60507056 - Connection board

17 - P/N 62649004 - Primary heat exchanger

18 - P/N 60504206 - Spark cable

19 - External jacket (For P/N see Section 15)

20 - Combustion chamber door

21 - Instrument panel door

Figure 1 - Main components

3 - MAIN COMPONENTS

22 - Combustion analysis tap

(For P/N see Section 15)

23 - P/N 62111016 - U1 supply temperature

sensor

24 - Burner window (For P/N see Section 15)

25 -Air/gas manifold (For P/N see Section 15)

26 - P/N 62111017 - U6 high temperature limit

sensor

27 - Flue gases back ﬂow preventer

(For P/N see Section 15)

28 - P/N 61901029 - Fan

29 - P/N 61201040 - Gas valve

30 - P/N 62102009 - Heating pressure gauge

31 - Display

32 - Domestic hot water temperature control

33 - Heating temperature control

34 - P/N 60506019 - On/off power switch

35 - Three way valve (not present on 160B and

160OB models) (For P/N see Section 15)

36 - P/N 62110052 - U3 domestic cold water

temp. sensor (not present on 160B and

160OB models)

37 - P/N 61101001 - Cable clamp

38 - P/N 61205010 -ASME Safety relief valve

39 - P/N 62111016 - U8 return temperature

sensor

40 - P/N 60305073 - By-pass pipe (not present

on 160B and 160OB models)

41 - P/N 60322010 - Condensation discharge

pipe

42 - Secondary heat exchanger for domestic

hot water production (not present on 160B

and 160OB models) (For P/N see Section

15)

43 - P/N 62625064 - Expansion tank

connection pipe (not present on 160B and

160OB models)

44 - Circulator pump screw (not present on

160B and 160OB models)

45 - P/N 62301031 - Circulator pump (not

present on 160B and 160OB models)

46 - P/N 62630136 - Condensation discharge

trap

47 - P/N 60505024 - Flame-proving electrode

48 - Burner (For P/N see Section 15)

49 - P/N 60505023 - Right ignition electrode

50 - P/N 60505022 - Left ignition electrode

51 - P/N 60510022 - Spark generator

52 - P/N 62113041 - Flue pressure switch

Figure 1 - Main components

3 - MAIN COMPONENTS

Key to ﬁgure 2:

1 = boiler model 160C or 160OC

2 = automatic air vent

3 = air intake

4 = ﬂue gases discharge

5 = sealed combustion chamber

6 = expansion tank

7 = burner

8 = fan

9 = gas valve

10 = condensate discharge trap

11 = circulator pump

12 = 3-way valve

13 = secondary heat exchanger for d.h.w.

14 = pressure gauge

15 = by-pass valve

17 = safety relief valve

21 = condensate discharge pipe

22 = heating supply pipe

23 = domestic hot water outlet

24 = gas inlet

25 = cold water inlet

26 = heating return pipe

45 = U7 = ﬂue gas temperature sensor

46 = U1 = boiler temperature sensor

47 = U6 = high limit temperature sensor

48 = U3 = domestic cold water sensor/storage tank

sensor

49 = U2 = domestic hot water temperature sensor

50 = U8 = return temperature sensor

51 = ﬂue pressure switch

Figure 2 - 160C and 160OC Hydronic functional schematic

4 - FUNCTION OVERVIEW

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