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NTI Matrix Installation And Operation Instructions Manual

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Matrix
Model Numbers: M100 & M100V
Version Date: 2015-08-10
INSTALLATION AND OPERATION INSTRUCTIONS FOR Matrix
BOILER

TABLE OF CONTENTS

1.0
INTRODUCTION ................................................................................................................ 3
2.0
INTRODUCTION ................................................................................................................ 6
3.0
BOILER LOCATION .......................................................................................................... 7
4.0
GENERAL VENTING ......................................................................................................... 8
5.0
VENT AND AIR-INTAKE TERMINATION CLEARANCES ........................................ 17
6.0
CONDENSATE DRAIN .................................................................................................... 20
7.0
INSTALLING GAS PIPING .............................................................................................. 21
8.0
LIGHTING THE BOILER ................................................................................................. 23
9.0
GAS VALVE AND BURNER SET-UP ............................................................................ 25
10.0 BOILER AND HEATING SYSTEM PIPING ................................................................... 28
11.0 DOMESTIC HOT WATER PLUMBING AND OPERATION ........................................ 35
12.0 FIELD WIRING ................................................................................................................. 39
13.0 CONTROL SETUP ............................................................................................................ 43
14.0 MATRIX BLOWER OPERATION ................................................................................... 48
15.0 HEAT RECOVERY VENTILATION ............................................................................... 50
16.0 WIRING SCHEMATICS ................................................................................................... 55
17.0 INSTALLATION CHECKLIST ........................................................................................ 57
18.0 ANNUAL MAINTENANCE AND INSPECTION ........................................................... 58
19.0 PARTS LIST ....................................................................................................................... 60
20.0 TROUBLESHOOTING ....................................................................................................... 66
HAZARD SYMBOLS AND DEFINITIONS
Danger Sign: Indicates a hazardous situation which, if not avoided, will
result in serious injury or death.
Warning Sign: Indicates a hazardous situation which, if not avoided,
could result in serious injury or death.
Caution Sign plus Safety Alert Symbol: Indicates a hazardous situation
which, if not avoided, could result in minor or moderate injury.
Caution Sign without Safety Alert Symbol: Indicates a hazardous
situation which, if not avoided, could result in property damage.
Notice Sign: Indicates a hazardous situation which, if not avoided,
could result in property damage.
This Boiler must be installed by a licensed and trained Heating
Technician or the Warranty is Void. Failure to properly install this
unit may result in property damage, serious injury to occupants, or
possibly death.
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  • Page 1: Table Of Contents

    Matrix Model Numbers: M100 & M100V Version Date: 2015-08-10 INSTALLATION AND OPERATION INSTRUCTIONS FOR Matrix BOILER TABLE OF CONTENTS INTRODUCTION ........................ 3 INTRODUCTION ........................ 6 BOILER LOCATION ......................7 GENERAL VENTING ......................8 VENT AND AIR-INTAKE TERMINATION CLEARANCES ........17 CONDENSATE DRAIN ....................
  • Page 2 Matrix Installation and Operation Instructions Read Before Proceeding If you do not follow these instructions exactly, a fire or explosion may result causing property damage, serious injury or death. FOR YOUR SAFETY, READ BEFORE OPERATING_ A) This boiler does not have a pilot. It is equipped with an ignition device which automatically lights the burner.

  • Page 3: Introduction

    1.0 INTRODUCTION General Installation Requirements The installation of your NTI Matrix boiler must conform to the requirements of this manual, your local authority, and the National Fuel Gas Code ANSI Z223.1 and or CAN/CGA B149 Installation Codes. Where required by the Authority, the installation must conform to the standard for “Controls and Safety Devices for Automatically...
  • Page 4 LP Propane. The correct kit and LP orifice is listed below (Each kit comes with conversion instructions). Liquefied Petroleum (LP) propane gas is heavier than air; therefore, it is imperative that your Matrix boiler is not installed in a pit or similar location that will permit heavier than air gas to collect. Local Codes may require boilers fueled with LP gas be provided with an approved means of removing unburned gases from the room.
  • Page 5 IN THE STATE OF MASSACHUSETTS ONLY (a) For all horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned and operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, including but not limited to decks and porches, the following requirements shall be satisfied: INSTALLATION OF CARBON MONOXIDE DETECTORS At the time of installation of the side wall...

  • Page 6: Introduction

    High Altitude Operation The Matrix is designed to operate at its maximum listed capacity in installations less than or equal to 2000 ft [610 m] above Sea Level. Since the density of air decreases as elevation increases, maximum specified capacity should be de-rated for elevations above 2000 ft [610 m] in accordance with Table 2-2.

  • Page 7: Boiler Location

    3.0 BOILER LOCATION In all cases, the Matrix must be installed indoors in a dry location where the ambient temperature must be maintained above freezing and below 100F [38C]. Gas components must be protected from dripping, spraying water, or rain during operation and servicing. Consider the proximity of system piping, gas and electrical supply, condensate disposal drain, and proximity to vent termination when determining the best boiler location.

  • Page 8: General Venting

    Installation and Operation Instructions 4.0 GENERAL VENTING The Matrix is certified as a “Category IV” boiler requiring a “Special Venting System” designed for pressurized venting. The Exhaust Vent must be piped to the outdoors, using the vent materials and rules outlined in this section.
  • Page 9 Direct Vent Installation (Mandatory for all Matrix boilers) Direct Vent installation dictates that the combustion air-inlet must be piped directly to the outdoors using the methods described in this section and in accordance with the National Fuel Gas Code, ANSI Z223.1 (U.S.) or CSA B149.1 (Canada) and local requirements.
  • Page 10 Near Boiler Vent/Air-inlet Piping The Matrix air-inlet and exhaust fittings are 3” male PVC; use approved cement to secure to the venting system (see Table 4-2). Check the flue outlet gasket (inside the boiler cabinet) for proper insertion and sealing prior to and after attaching the venting.
  • Page 11 45º elbows at 5 equivalent feet each. Note: there are limitations when operating with Propane Gas (LP). Example: A Matrix can be installed with 105 equivalent feet of air-inlet piping and 105 equivalent feet of exhaust vent piping when operating with Natural Gas. When operating with Propane Gas (LP), the maximum length of each the exhaust vent and air-inlet pipe is limited to 50 equivalent feet (3”...
  • Page 12 Installation and Operation Instructions Termination Options The venting system of the Matrix may be terminated using field supplied piping to construct a “Two-Pipe” termination, see Figures 4-2(a) and 4-3(a); alternatively the venting may be terminated using a factory kit selected from Table 4-4.
  • Page 13 Sidewall Termination Details Figure 4-2(a) Figure 4-2(b) Two-Pipe Termination (Sidewall) IPEX Concentric Termination (Sidewall) Horizontal 4-12” or greater than 36” Refer to documentation included with termination kit for complete installation instructions. Exhaust Exhaust Exhaust Air-inlet Vertical Min. 18” Air-inlet Gas Vent Directly Below Keep Free of Obstructions Air-inlet around perimeter (1-2”...
  • Page 14 Matrix Installation and Operation Instructions Roof Termination Details Figure 4-3(a) Figure 4-3(b) Two-Pipe Termination (Roof) IPEX Concentric Termination (Roof) Exhaust Refer to documentation included with termination kit for Vent Screen complete installation instructions. Vent pipe piece to retain vent screen...
  • Page 15 Combustion air containing chemicals such as chloride, fluoride, bromine or iodine or dust and debris will cause corrosion damage of the heat exchanger voiding your NTI warranty. Refer to Table 4-1 for a list of corrosive products and contaminants sources to avoid.
  • Page 16 Under no circumstances may an existing chimney or chase-way be used to vent or provide combustion intake air to a Matrix. Failure to follow these instructions will result in fire, property damage, serious injury or death.

  • Page 17: Vent And Air-Intake Termination Clearances

    Figures 5-1 through 5-6, and the Venting Rules and Guidelines in Section 4.0. The instructions detailed in this section are a combination of Matrix specific and National Gas Code restrictions. Compliance alone doesn’t insure a satisfactory installation as good common sense must also be applied. Failure to follow these instructions may result in fire, property damage, serious injury or death.
  • Page 18 Matrix Installation and Operation Instructions Figure 5-1 Termination Clearances Quick Reference Diagram...
  • Page 19 Figure 5-2 Sidewall Termination Clearances (See Table 5-1) Clearances “F” and “G” Canada – Minimum 3 ft. [915 mm] The US – Minimum 1 ft. [305 mm] Two-Pipe Termination Clearance “Q” Adjacent to Public Walkway or Driveway Concentric Vent Minimum 7ft. [2.13 m] Termination G –...

  • Page 20: Condensate Drain

    Matrix Installation and Operation Instructions 6.0 CONDENSATE DRAIN This unit produces liquid condensate in the heat exchanger and venting system as a product of combustion. Steps must be taken to ensure that condensate does not collect in the venting system; therefore, all exhaust piping must slope back to the boiler a minimum 1/4”...

  • Page 21: Installing Gas Piping

    Ensure that:  The gas line connection to the boiler does not apply any weight to the gas valve. NTI recommends using approved flexible gas piping (if acceptable by local codes) to connect the boiler to the gas supply (See Figure 7-1 for details).
  • Page 22 Installation and Operation Instructions Matrix Strain on the gas valve and fittings may result in vibration, premature component failure and leakage and may result in a fire, explosion, property damage, serious injury or death. Flexible gas piping cannot be used within the boiler cabinet and cannot pass through the cabinet wall, use rigid piping as shown in Figure 7-1.

  • Page 23: Lighting The Boiler

    Matrix Installation and Operation Instructions 8.0 LIGHTING THE BOILER Before Start-up refer to Mandatory Pre-commissioning Procedure for Plastic Venting in Section 4.0. Failure to follow these instructions can result in explosions, injury or death. Prior to turning the gas supply on and lighting the boiler, ensure all aspects of the installation are complete and in conformance with the instructions provided in this manual, including the Vent/Air-inlet, Condensate Drain, and System Water Piping.
  • Page 24 Initial Start-Up 1. Turn on power to the Matrix and turn-up the Thermostat(s). The boiler should run through a purge, and combustion should occur. (The control system has a built in ignition retry, allowing the system to try at least three times, before locking-out.)

  • Page 25: Gas Valve And Burner Set-Up

    Matrix Installation and Operation Instructions GAS VALVE AND BURNER SET-UP The Matrix gas valve must be set-up by a licensed Gas Technician. Improper set-up may result in incorrect operation, damage to components or property, injury or death. Gas Line Pressure The boiler gas valve is equipped with a line pressure test port;...
  • Page 26 Installation and Operation Instructions Matrix Figure 9-1 Gas Valve and Venturi Assembly Gas Valve DO NOT Remove Cap Manifold Pressure Test Port Line Pressure Test Port Throttle / Input Adjustment Screw Venturi Gas Inlet Adjustment Input Screw Adjustments - The boiler is equipped with a Throttle/Input Adjustment Screw, located on the Gas Valve and Venturi Assembly.
  • Page 27 Failure to follow these instructions may result in serious injury or death. Analysis - The Matrix is not equipped with an integrated flue gas test port, flue gases must be sampled at the vent termination or at the condensate drain. When measuring from the termination, ensure the combustion gases are sampled from within the exhaust pipe by inserting the combustion analyzer probe several inches into the exhaust pipe.

  • Page 28: Boiler And Heating System Piping

    BOILER AND HEATING SYSTEM PIPING The heat exchanger of the Matrix boiler is designed to attain the highest level of heat transfer in a compact design. To accomplish this, the heating water flows through a series of fin shaped tubes, designed to maximize the heat transfer area.
  • Page 29 Matrix Installation and Operation Instructions Water Chemistry – The installer of the Matrix boiler must consider the condition of the water in the heating system. Ensure the condition of the boiler water falls within the following parameters:  PH – between 7.5 and 9.5.
  • Page 30 Installation and Operation Instructions Matrix Figure 10-1 Fitting Identification Pressure Relief Valve Connection Boiler Outlet DHW Inlet (Cold) Boiler Inlet DHW Outlet (Hot) Figure 10-2 Near Boiler Piping LWCO Must be at least as high as the top of the boiler...
  • Page 31 (brazed plate heat exchanger). An external circulator is only required if the Matrix is also being used to supply heat to a hydronic heating system, the external circulator must be sized for the requirements of the hydronic heating system.
  • Page 32 Installation and Operation Instructions Matrix Figure 10-3(a) Plumbing High Temperature Zones (w/ Zone Valves) Zone #3 Zone #2 Zone #1 High Temperature Zones Only Zone Valve System Circulator Separator Make Up Backflow Water Preventer Pressure Expansion Reducing Tank Valve Figure 10-3(b) Wiring Zones (w/ Zone Valve Controller)
  • Page 33 Matrix Installation and Operation Instructions Figure 10-4(a) Plumbing High Temperature Zones (w/ Zone Circulators) Zone #3 Zone #2 Zone #1 Check Valves Zone Circulators Air Separator Expansion Tank Make-up Water Feed Valve Backflow Preventer Figure 10-4(b) Plumbing Low Temperature Zones (w/ Mixing Valves)
  • Page 34 Installation and Operation Instructions Matrix Figure 10-5(a) Plumbing Single Temperature Zones (w/ Injection System) Zone Valves Zone #3 Zone #2 Zone #1 Temperature Sensor (S1) System Circulator Air Separator Injection Circulator Temperature Sensor (S3) Make-up Water Expansion Tank Backflow Preventer...

  • Page 35: Domestic Hot Water Plumbing And Operation

    DHW Inlet & Outlet Connections – The Matrix has two potable water connections, Inlet & Outlet, which exit the left side of the Matrix Cabinet; on the inside of the cabinet the two lines are connected to the Brazed Plate Heat Exchanger.
  • Page 36 Instantaneous DHW (w/o Storage Tank) The Matrix will provide domestic hot water continuously when flow is sensed by the flow sensor. This method is the most efficient means of heating water by allowing the boiler to operate at a lower return water temperature, thus increasing combustion efficiency, and by minimizing standby losses.
  • Page 37 DHW inlet fitting of the Matrix (see Figure 10-1 for identification of plumbing fittings). The DHW flow meter senses the water flow and triggers a DHW demand; heated water flows from the Matrix and enters the inlet fitting of the storage tank.
  • Page 38 Installation and Operation Instructions Matrix Figure 11-1 DHW Piping (Tankless – On demand) Figure 11-2 DHW Piping (w/ Storage Tank)

  • Page 39: Field Wiring

    Figure 12-1 and Table 12-1. Fuse (120 VAC) – The Matrix Sentry controller is equipped with one 15 Amp fuse to protect the 120VAC pump output. The fuse is located under the cover of the Sentry 2100 control (red control).
  • Page 40 Low voltage field connections are to be installed in accordance with Figure 12-2 and Table 12-2. Fuse (24 VAC) – The Matrix is equipped with a “blade style” 2 Amp fuse to protect the internal transformer located on the control panel.
  • Page 41 Matrix Installation and Operation Instructions Figure 12-2 Low Voltage Field Wiring...
  • Page 42 Maximum switching capacity of 2 Amps at 24VAC. 24VAC Common – Neutral for the 24VAC power supply from the Matrix. This contact can be used in conjunction with terminal R to provide a power source for a digital thermostat.

  • Page 43: Control Setup

    The Matrix uses two devices to control the functions required by the Matrix. The Matrix Boiler Control (red face) controls and ensures the safe operation of the boiler functions of the Matrix, much the same as the Sentry 2100 does in the Trinity products. The Matrix Fan Control (blue face) controls all of the operation functions related to air handling and hot water dispatching.
  • Page 44 Matrix Operation and Set-up The Matrix employs a pneumatic modulation system. This modulation system increases or decreases the velocity of the combustion blower, to meet the demand for heating. The gas valve senses this change in blower pressure and introduces the required amount of gas to ensure correct combustion. The (Red) Boiler Controller reads the boiler water temperature, compares it to the set point, and adjusts the burner firing rate accordingly by varying the speed of the combustion blower.
  • Page 45 Program Mode, the unit will turn off if left in program mode longer than 30 seconds without receiving an input. Press Function once to continue programming or to start boiler operation. See Table 13-4 for a description of the boiler control settings. Table 13-4 Matrix Boiler Control Programming Menu Settable...
  • Page 46 Setting Matrix Fan Control Just as the Matrix Boiler Controller controls all of the operation and safety functions of the boiler, the Matrix Fan Controller controls all of the operational functions related to air handling and hot water dispatching. The fan controller controls the forced air modulation, ventilation, as well as priority of domestic hot water and secondary heating systems.
  • Page 47 Outdoor Sensor (10K) To fully take advantage of the energy saving features of the Matrix, it is necessary to install the outdoor sensor provided. Install the sensor preferably on the north, or coldest side of the building, not within 10 feet of the discharge of the gas vent outlet, or other sources of heat.

  • Page 48: Matrix Blower Operation

    1200 105000 Example: At stage 4 (Profile 1) the Matrix provides 720 CFM across the fan coil, which is receiving 117°F water from the boiler. The coil then supplies plenum air at 108° F or ~27700 BTU/hr. On an initial thermostat call (24VAC @ W1), space heating begins by providing heat at Stage 3 (~24,000 BTU/hr) (if hydronic heat is also calling (24VAC @ H) heating will begin at stage 1) and so long as the thermostat is not satisfied, incrementally increases to a maximum of Stage 10 (maximum output).
  • Page 49 Call for Auxiliary Heat (24 VAC @ W2) – When calling, furnace will provide heat at a stage 10 output rate. With a call for auxiliary heating the Matrix will function as a single stage, full fire appliance. This means the burner will come on with a thermostat call and go off when the call is satisfied.

  • Page 50: Heat Recovery Ventilation

    Installation and Operation Instructions Matrix 15.0 HEAT RECOVERY VENTILATION Ventilation Requirements With the evolution toward more energy efficient, tighter homes, air quality problems have increased. With less natural ventilation, pollutants such as pet dander, humidity, tobacco smoke and wood ash now become trapped inside the home.
  • Page 51 Matrix Installation and Operation Instructions Types of Installation There are two basic methods of installing the ventilator in the Matrix: 1) Exhaust at the source.  Stale air is drawn from the kitchen and bathrooms. External Ducting to be 6”...
  • Page 52 This damper box eliminates the infiltration of cold outside air when the HRV is off or in defrost mode. It is to be installed with the actuator on the top side and screw to the Matrix using the four screws provided. Damper Box with Collar Installed...
  • Page 53 Flow is measured with the use of a Magnehelic (0-.25 inwg range) and an airflow grid, flow collar or “Flow Measuring Station”. NTI offers an airflow grid, PN: 83554, that is designed to be installed in a 1” hole located in a 6”...
  • Page 54 Installation and Operation Instructions Matrix Stale Fresh Figure 15-1 Sample Balancing Setup Exhaust Supply 6” Flow Measurement Station, Averaging Pitot Tube, or Pitot TransferTube Magnehelic (0-.25 inwg) or Digital Manometer Table 15-2 HRV Balancing Table Sample HRV Installed Installed Menu...

  • Page 55: Wiring Schematics

    Matrix Installation and Operation Instructions 16.0 WIRING SCHEMATICS Figure 14-1(a) Connection Diagram...
  • Page 56 Installation and Operation Instructions Matrix Figure 14-1(b) Ladder/Logic Diagram...

  • Page 57: Installation Checklist

    Matrix Installation and Operation Instructions 17.0 INSTALLATION CHECKLIST Installation  1. If operating on Propane Gas, convert boiler using appropriate Kit number. See Table 7-1.  2. Locate the boiler in accordance with Section 3.0 of this manual.  3. Install the Vent/Air-inlet piping in accordance with Sections 4.0 and 5.0 of this manual. Ensure all joints are secured and cemented properly.

  • Page 58: Annual Maintenance And Inspection

     8. Listen for water flow noises indicating a drop in boiler water flow rate. The hydronic system may need to be flushed to eliminate hard water scale (Use Fernox DS-40 Descaler, NTI PN: 83450; see Table 10-1). Combustion Chamber Cleaning Procedure Units operating with LP Gas or in an industrial environment will have to be cleaned a minimum of once per year.
  • Page 59 Matrix Installation and Operation Instructions Refractory Ceramic Fibers (RFC) Personal Protective Equipment Recommended - Read the following warnings and handling instructions carefully before commencing any service work in the combustion chamber. The insulating material on the inside of the burner door and at the back of the combustion chamber contains Refractory Ceramic Fibers and should not be handled without personal protective equipment.
  • Page 60 Once every three months. Replace furnace filter. May be required more frequently in beginning, especially if new construction. The Matrix HRV module is relatively maintenance free but does require routine cleaning. Table 14 describes the necessary maintenance. Table 18-1 HRV Maintenance Items...

  • Page 61: Parts List

    Matrix Installation and Operation Instructions 19.0 PARTS LIST For a list of parts that corresponds to the item numbers in the bubbles, refer to Table 19-1. Note that that some item numbers may appear more than once in the parts list depending on which model number is being referenced.
  • Page 62 Installation and Operation Instructions Matrix Table 19-1 Parts List: Item Part # Models Description 82657 Lx150, M100(V), Ti100-150 Premix Burner 135.8 82761 Lx150–500, M100(V), Ti100- Premix Burner Gasket, Lx/M/Ti/Ts (80-500) 400, Ts80 82771 Lx150-200, M100(V), Ti100- Extended Air Tube Lx/M/Ti/Ts (80-200)
  • Page 63 Matrix Installation and Operation Instructions Item Part # Models Description 83462 Lx150-200, M100(V), Ti100- Street Tee, Brass, 1/4" Lx150-200 (see bullets)  All M100(V) models sold in US 200, Ts80  All Lx150-200 models (see bullets)  All ASME stamped Ti100-150 models ...
  • Page 64 200, Tft60-250, Ti100-200, Ts80, Tx200, Tx200C 83083 M100(V) Fan Control Matrix 83425-1 (82622- Lx150-200, M100(V) Air Metering Elbow Lx150-200, Matrix 83291-2 M100(V) Flue Adapter Assembly 2" CPVC x 3.5" (Models manufactured before 12/9/2009) 83291-3 M100(V) Flue Adapter Assembly 2" CPVC x 4.75" (Models...
  • Page 65 Matrix Installation and Operation Instructions Item Part # Models Description 83206 Lx150-300, M100, M100V, Gas Valve to Venturi Screws & Seal T150-200, Tft60-250, Ti100- 200, Ts80, Tx200, Tx200C 82064 Lx150-300, M100(V), T150- Gas Valve Harness 200, Ti100-200, Tft60-250, Ts80 83991 Lx150-200, M100(V), Tft60- CPVC Pipe 3", System 636, 5"...

  • Page 66: Troubleshooting

    Symptom Detected Problem Solution If the boiler is extremely hot check for adequate water pressure and circulation, contact NTI for assistance. “Water Temperature Excessive” If not hot, check for sources of grounding or shorting at Sentry has sensed a water the Water Sensor electrical connections, check wiring temperature in excess of 250ºF at...
  • Page 67 “24V Limit Error” reoccurs: Control has sensed a lack of 24V Matrix boilers are equipped with a low water pressure on the outlet of the burner relay switch on the boiler return that requires a minimum of (B1). Lockout lasts for one hour 10PSI to complete the 24VAC ignition circuit.
  • Page 68 Reset the AL5 error by resetting the power or cycling the DHW call. Check for proper operation of the DHW call. Matrix units are provided with an integrated DHW flow “DHW Time-Out” meter, if the control is registering a flow rate when the The Control has locked out DHW water is turned off;...
  • Page 69 Boiler may be plugging with scale or magnetite, clean hisses insufficient flow with Fernox DS-40 Descaler and Cleanser (NTI PN: 83450). If glycol is being used the concentration may be to high, recommend using a concentration lower than 35%.
  • Page 70 Installation and Operation Instructions Matrix The following are the thermistor curves for diagnosing the water and outdoor air sensors:  Measure the resistance of the thermistor when disconnected.  Using the appropriate chart, find the resistance and move either vertical (water probe) or horizontal (air probe) until the line is intersected.
  • Page 71 Matrix Installation and Operation Instructions NOTES...
  • Page 72 Installation and Operation Instructions Matrix Visit us online NY Thermal Inc. 30 Stonegate Dr. Saint John, NB E2H 0A4 Canada Technical Assistance: 1-800-688-2575 Website: www.ntiboilers.com Fax: 1-506-432-1135...

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M100M100v

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