Velocity PHNTM210 Installation, Operating And Service Instructions

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Installation, Operating and Service Instructions for

Phantom-X Series

Models:

This manual is for use with

• PHNTM210

boilers having a part number

• PHNTM285

ending in "B" (example:

PHNTM285HNT1SUB).

Manual Contents

Product Description, Specifications and

Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . .4

Unpacking Boiler . . . . . . . . . . . . . . . . . . . . . . . .7

Pre-Installation and Boiler Mounting . . . . . . . .8

Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Condensate Disposal . . . . . . . . . . . . . . . . . . . .51

Water Piping and Trim . . . . . . . . . . . . . . . . . . .53

Gas Piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

9. System Start-up . . . . . . . . . . . . . . . . . . . . . . . . .83

10. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

11. Service and Maintenance . . . . . . . . . . . . . . . .120

12. Before Leaving Jobsite . . . . . . . . . . . . . . . . .127

13. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . .128

14. Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . .133

This boiler must only be installed, serviced, or repaired by a qualified heating installer or service technician.

Improper installation, adjustment, alteration, service or maintenance can cause severe personal injury, death,

or substantial property damage. For assistance or additional information, consult a qualified installer, service

agency, or the gas supplier. Read these instructions carefully before installing.

These instructions must be affixed

on or adjacent to the boiler and

retained for future reference.

105357-06 -12/24

• High Efficiency/Hot Water

• Condensing

• Direct Vent

• Gas Fired

Page

WARNING

9700609

Manufacturer of Hydronic Heating Products

P.O. Box 14818 3633 I. Street

Philadelphia, PA 19134

www.velocityboilerworks.com

VELOCITY LOGO CMYK COLOR

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Summary of Contents for Velocity PHNTM210

Page 1 Read these instructions carefully before installing. These instructions must be affixed on or adjacent to the boiler and Manufacturer of Hydronic Heating Products retained for future reference. P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.velocityboilerworks.com 105357-06 -12/24 VELOCITY LOGO CMYK COLOR...
Page 2 Installation, Operating & Service Instructions PHANTOM-X IMPORTANT INFORMATION - READ CAREFULLY NOTE: The equipment shall be installed in accordance with those installation regulations enforced in the area where the installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be consulted before installations are made.
Page 3 Installation, Operating & Service Instructions PHANTOM-X Special Installation Requirements for Massachusetts A. For all sidewall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes and where the sidewall exhaust vent termination is less than seven (7) feet above grade, the following requirements shall be satisfied: 1.
Page 4 “B” (example: Code, which provide a maximum heat transfer and PHNTM285HNT1SUB). Table 1-1: Specifications Boiler Model Specification PHNTM210 PHNTM285 Altitude (ft. above sea level) - USA 0-10000* 0-10000* Altitude (ft. above sea level) - Canada...
Page 5 Installation, Operating & Service Instructions PHANTOM-X Product Description, Specifications and Dimensional Data (continued) 105357-06 - 12/24...
Page 6 Installation, Operating & Service Instructions PHANTOM-X Product Description, Specifications and Dimensional Data (continued) 105357-06 - 12/24...
Page 7 Model Number (MBH) (MBH) Min. Max. PHNTM210 95.0 PHNTM285 95.0 Ratings shown are for installations at sea level and elevations up to 2,000 ft. For elevations above 2,000 ft., the boiler will naturally derate by 2.5% for each 1,000 ft. above sea level. Boilers not suitable for use with LP gas above 7,000 ft.
Page 8 CSA B149.1, or applicable provisions of local heating system load will result in excessive boiler building Codes. cycling and accelerated component failure. Velocity Boiler Works, LLC DOES NOT warrant WARNING failures caused by mis-sized boiler applications. Asphyxiation Hazard. DO NOT oversize the boiler to the system. Multiple...
Page 9 Boiler Service Clearances – Applicable to all Boiler boiler. Models: 4. PHNTM210 boilers can be installed as floor Top = 24 in. (610 mm), Front = 24 in. (610 mm), standing or as wall hung. Left Side = 24 in. (610 mm), Right Side = 24 in.
Page 10 Installation, Operating & Service Instructions PHANTOM-X Pre-Installation and Boiler Mounting (continued) Minimum Vent Pipe Listed Direct Vent Pipe Clearance to Vent Pipe Material Enclosure Nominal Vent System Direction Combustible Diameter Material Factory Standard 3 in. (80 mm) CPVC/PVC 1 in. (25 mm) Two-Pipe CPVC/PVC Vent and 4 in.
Page 11 Installation, Operating & Service Instructions PHANTOM-X Pre-Installation and Boiler Mounting (continued) Figure 3-2: Clearances To Combustible and Non-combustible Material, Wall Mounted 6. Boiler Wall Hung Installation: CAUTION a. If the boiler is installed on a framed wall, Phantom-X boiler approximate dry weight: minimum acceptable framing is 2 x 4 studs PHNTM210B –...
Page 12 “B” is to use template P/N 102986-01 enclosed into Vent Part Carton [P/N 102981- m. See Section 4 Venting; Paragraph B, item 02 (PHNTM210)], which can be found #4 “Field Installation of CPVC Vent Pipe - inside boiler carton.
Page 13 Installation, Operating & Service Instructions PHANTOM-X Pre-Installation and Boiler Mounting (continued) 1.0" MIN. CLEARANCE TO COMBUSTIBLE TOP EDGE OF BOILER 2.0" MIN. CLEARANCE TO COMBUSTIBLE 'HOLE B' WALL MOUNTING BRACKET CENTER LINE " DIA. PILOT HOLES 'HOLE A' " LAG SCREWS (4 PLACES) 10.0"...
Page 14 Installation, Operating & Service Instructions PHANTOM-X Pre-Installation and Boiler Mounting (continued) 16" C/C WALL BRACKET BOILER HANGING BRACKET BOILER BOILER HANGING #8 X " SMS (2X) BRACKET BOILER BOTTOM SECURING BRACKET 2 X 4 WALL STUD " X 2" LAG SCREW (4X) BOTTOM SECURING...
Page 15 PHNTM210 PHNTM210 positioning dimples in the top boiler and PHNTM285 PHNTM210 or PHNTM285 bottom boiler left side panels, then secure 2. To field assemble individual Phantom boilers bracket with the screws. into a stackable configuration, use the steps g.
Page 16 Installation, Operating & Service Instructions PHANTOM-X Pre-Installation and Boiler Mounting (continued) c. Water Piping and Trim - Follow instructions Follow instructions in Section 4 “Venting” in Section 6 “Water Piping and Trim” of of the manual for specifics of individual the manual for system piping and boiler boiler vent termination.
Page 17 Installation, Operating & Service Instructions PHANTOM-X Venting WARNING Asphyxiation Hazard. Failure to vent this boiler in accordance with these instructions could cause products of combustion to enter the building resulting in severe property damage, personal injury or death. • The installer must verify that at least one carbon monoxide alarm has been installed within a residential living space or home following the alarm manufacturer’s instructions and applicable local codes before putting the appliance into operation •...
Page 18 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) A. General Guidelines 1. Listed Vent/Combustion Air Systems a. Install vent system in accordance with “Venting of Equipment” of the National Fuel Gas Code, ANSI Z223.1/ NFPA 54 or “Venting Systems and Air Supply for Appliances” of the Natural Gas and Propane Installation Code, CAN/CSA B149.1, or applicable provisions of local building codes.
Page 19 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) 3. Vent/Combustion Air Terminals Install venting system components on exterior of building only as specifically required by these instructions (refer to Figure 4-1). a. Use only listed vent/combustion air terminals. Horizontal Sidewall Venting: For models PHNTM210B and PHNTM285B, use coupling for vent terminal and 90°...
Page 20 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) o. Do not locate combustion air terminal in areas that might contain combustion air contaminants, such as near swimming pools. p. For multiple boiler installations with horizontal wall terminals, maintain minimum 12 in. (300 mm) horizontal distance between adjacent boiler vent terminals.
Page 21 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-3: Vent and Combustion Air Pipe Sizes and Equivalent Lengths (Applies to All Listed Vent/Combustion Air System Options) Combustion Air Length Vent Length Boiler Model Option Pipe Dia., in. Min., ft. Max., ft.
Page 22 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) B. CPVC/PVC Venting WARNING Asphyxiation Hazard. Failure to follow these instructions could cause products of combustion to enter the building, resulting in severe property damage, personal injury, or death. • Use all CPVC vent components (supplied with boiler) for near-boiler vent piping before transitioning to Schedule 40 PVC pipe (ASTM 2665) components for remainder of vent system.
Page 23 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-7: Direct Vent - Snorkel Vent and Air Intake Figure 4-6: Direct Vent - Vent and Air Intake Horizontal Sidewall Terminations Horizontal Sidewall Terminations Figure 4-9: Split Rigid Vent Option Figure 4-8: Direct Vent - Staggered Vent and Air Intake Horizontal Sidewall Terminations 105357-06 - 12/24...
Page 24 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) PVC VENT PIPE CPVC VENT PIPE PITCH VENT PIPE 1/4" PER (FIRST 30" + ELBOW) FOOT TOWARDS BOILER PVC AIR INTAKE PIPE ALTERNATE ORIENTATION Figure 4-10: Direct Vent - Horizontal Two-pipe Venting/Air Intake with IPEX Low Profile or DiversiTech HVENT Terminal PITCH INTAKE AWAY FROM BUILDING EXTERIOR...
Page 25 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-14: Cutting IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 4-15: Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Sidewall Figure 4-16: Direct Vent - Vent and Air Intake Vertical Terminations with Flat Roof 105357-06 - 12/24...
Page 26 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-17: Direct Vent - Vertical Two-Pipe Venting/Air Intake with IPEX FGV or DiversiTech CVENT Concentric Terminal Figure 4-18: Installation of IPEX FGV or DiversiTech CVENT Concentric Terminal thru Roof 105357-06 - 12/24...
Page 27 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Extend vent/combustion air piping to maintain minimum vertical (‘X’) and minimum horizontal (‘Y’) distance of 12 in. (300 mm) [18 in. (460 mm) Canada] from roof surface. Allow additional vertical (‘X’) distance for expected snow accumulation.
Page 28 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-23: Expansion Loop Lengths Nominal Length of Loop Length Pipe Dia. Straight Run “L” (In.) (In.) (Ft.) Figure 4-22: Field Installation of CPVC Vent Pipe - Wall Mounted Boiler Builds Figure 4-24: CPVC/PVC Expansion Loop and Offset 105357-06 - 12/24...
Page 29 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) WARNING Asphyxiation Hazard. Apply supplied dielectric grease to gasket inside vent section of two-pipe vent connector. Failure to apply the grease could result in flue gas leaks from gasket rupture during vent pipe installation or gasket deterioration due to condensate exposure.
Page 30 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-27: CPVC/PVC Vent & Air Intake Components (Installer Provided) for Optional Vertical (Roof) Termination (Applicable to Twin-Pipe Venting with Separate Vent & Air Intake Roof Terminations) Quantity Vent Components PHNTM210B Vertical (Roof) PHNTM285B Vertical (Roof) Termination Termination...
Page 31 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) 1. Components a. See Table 4-25 for CPVC/PVC vent and combustion air components included with boiler. b. See Table 4-26 for CPVC/PVC installer provided vent and combustion air components required for optional horizontal snorkel terminals shown in Figure 4-7.
Page 32 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) c. Insert provided 3 in. Schedule 40 x 30 in. long CPVC pipe through air box top combination vent/ combustion air collar vent opening and slide down with a slight twisting motion, until the pipe lower end is firmly inserted into female end of factory installed 90°...
Page 33 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-33: Rodent Screen Installation, Horizontal Figure 4-32: Wall Penetration Clearances Vertical, Straight Vent Terminations for PVC Vent Pipe • Following the installation of factory supplied near boiler CPVC venting components (30 in. long pipe and 90°...
Page 34 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) • Install maximum vertical run of 7 ft. (2.1 m) of Schedule 40 PVC vent pipe. See Figure 4-8. • Install another PVC 90° elbow at top of vent pipe length so that elbow leg is opposite the building’s exterior surface.
Page 35 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Extend combustion air pipe to maintain minimum vertical and horizontal distance of 12 in. (300 mm) from roof surface. Allow additional vertical distance for expected snow accumulation. Provide brace as required. Install storm collar on combustion air pipe immediately above flashing. Apply Dow Corning Silastic 732 RTV Sealant or equivalent between combustion air pipe and storm collar to provide weather-tight seal.
Page 36 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Venting of Other Appliances (or Fireplace) into Chase or Adjacent Flues Prohibited! Figure 4-36: Flexible PP Vent in UNUSED Masonry Chimney with Separate Combustion Air Intake 105357-06 - 12/24...
Page 37 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-37: Flexible PP Vent in UNUSED B-vent with Separate Combustion Air Intake Figure 4-38: Flexible M&G/DuraVent PP Vent in UNUSED B-vent with Integrated Combustion Air Intake 105357-06 - 12/24...
Page 38 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-39: Flexible Centrotherm PP Vent in UNUSED B-vent with Integrated Combustion Air Intake Table 4-40: Listed Polypropylene Vent System Manufacturers Make Model PolyPro Single Wall Rigid Vent M&G/DuraVent PolyPro Flex Flexible Vent InnoFlue SW Rigid Vent Centrotherm Eco Systems Flex Flexible Vent...
Page 39 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-41: Approved Polypropylene Pipe, Fittings and Terminations - M&G/DuraVent M&G / DuraVent Part Numbers/Sizes CPVC Side Wall/ Coupling Pipe Side Wall Roof Chimney Vertical Boiler Nominal Male Boiler Adapter, Flex Termination Termination Flex Kit B-Vent...
Page 40 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-43: Approved Polypropylene Pipe, Fittings and Terminations – Z-Flex Z-Dens™ Z-Flex Z-Dens Part Numbers/Sizes CPVC Extended Coupling Male Boiler Male Boiler Side Wall/ Chimney Adapter, Adapter, Adapter, Pipe Side Wall Roof Vertical Boiler Nominal...
Page 41 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) a. Install supplied 30 in. long CPVC pipe into 3. Phantom-X Boiler Two-Pipe Vent System Field a factory installed vent connector 90° elbow Installation Procedure to Accept Polypropylene and secure with the elbow band clamp. Vent Piping - Wall Mounted Boiler Builds b.
Page 42 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) g. Install the adapter connector PPS-PACL WARNING (applicable to M& G/DuraVent vent system Asphyxiation Hazard. only) to secure PVC to PP coupling adapter Flexible polypropylene vent must be installed to a coupling and a polypropylene rigid only in an UNUSED chimney.
Page 43 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) e. When flexible polypropylene pipe (liner) D. Stainless Steel Venting is used for combustion product venting, it must not be installed at an angle greater WARNING than 45 degrees from vertical plane. This Asphyxiation Hazard.
Page 44 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Figure 4-45: Field Installation of Two-Pipe Vent System Adapter for Stainless Steel Figure 4-46: Flexible Stainless Steel Vent in UNUSED Masonry Chimney with Separate Combustion Air Intake 105357-06 - 12/24...
Page 45 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Table 4-47: Velocity Boiler Works Vent System Components (Stainless Steel) Part Numbers Vent System Component PHNTM210B PHNTM285B Equivalent Feet of Pipe 3 in. Vent 4 in. Vent SS Vent Kit (includes Horizontal Vent Terminal and...
Page 46 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) 1. Components e. Do not install PVC to stainless steel adapter at the lower combustion air supply port of a. For use on models PHNTM210B and the two-pipe vent system connector when PHNTM285B, U.S.
Page 47 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) 4. System Assembly WARNING Asphyxiation Hazard. Vent systems made by Heat Fab, M&G / DuraVent and Z-Flex rely on gaskets for proper sealing. When these vent systems are used, take the following precautions: •...
Page 48 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) d. Follow flexible stainless steel pipe Combustion Air Termination (liner) manufacturer specific installation • After penetrating wall, install a 90° instructions regarding application/ elbow so that the elbow leg is in the up listing, permits, minimum clearances to direction.
Page 49 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) WARNING Asphyxiation Hazard. Flexible stainless steel vent must be installed only in an UNUSED chimney flue. A chimney flue is considered UNUSED when it is not being used for any appliance venting. Where one of the multiple flues is being used for an appliance venting, the flexible stainless vent installation is permitted through an adjacent unused flue providing a local authority having jurisdiction approves such installation.
Page 50 Installation, Operating & Service Instructions PHANTOM-X Venting (continued) Multiple Boiler Installation Venting WARNING Asphyxiation Hazard. No common manifold venting (vent piping and vent terminals) is permitted. NOTICE: Installing multiple individual boiler vent terminations too close together may result in combustion product water vapor condensation on building surfaces, where vent terminations are placed, and subsequent frost damage.
Page 51 Installation, Operating & Service Instructions PHANTOM-X Condensate Disposal A. Condensate Trap and Drain Line c. If the point of condensate disposal is above 1. All condensate which forms in the boiler or the trap, a condensate pump is required to vent system collects in the sump under heat move the condensate to the drain.
Page 52 *Maximum Condensate Flow, accordance with the above instructions could Model cause flue gas to enter the building, resulting in personal injury or death. PHNTM210 PHNTM285 NOTICE: Boiler condensate is *Assumes 100% of water in fuel condenses. corrosive. Route condensate drain line in a manner such that any condensate leakage will not cause property damage.
Page 53 • Oxygen contamination of boiler water will cause corrosion of iron and steel boiler components, and can lead to boiler failure. Velocity Boiler Works, LLC Standard Warranty does not cover problems caused by oxygen contamination of boiler water or scale (lime) build-up caused by frequent addition of water.
Page 54 The flow rate through the heating system 3. Temperature /Pressure Gauge Piping, loop(s) is controlled by installer sized/ PHNTM210 Boiler Models provided system loop circulator(s). a. Locate and remove 1 in. NPT x 4 in. long d. This piping arrangement can be used either black nipple, 1 in.
Page 55 Taco Circulators shown are not equipped with internal flow check valve (IFC). When selecting Circulators other than recommended, contact Circulator Manufacturer for sizing information. Near-Boiler Piping Size shown is based on 2 to 5.5 ft/sec. velocity range to avoid potential noise and pipe erosion. 105357-06 - 12/24...
Page 56 30 PSI maximum working pressure a Phantom Series boiler. See Paragraph B for for PHNTM210 and PHNTM285. Optional 50 information on sizing the circulators. PSI, 80 PSI and 100 PSI maximum working pressure rated relief valves are available.
Page 57 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) 105357-06 - 12/24...
Page 58 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) 105357-06 - 12/24...
Page 59 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) • Install as shown in Figure 6-5, 6-6, 6-9 3. Expansion Tank (Required) – If this boiler or 6-12. is replacing an existing boiler with no other changes in the system, the old expansion tank •...
Page 60 Local Table 6-7: Multiple Boiler Water Manifold Sizing Codes. Number of Boilers Boiler Model Recommended Minimum Common Water Manifold Size (NPT) PHNTM210 2 in. 2½ in. 2½ in. 3 in. 3½ in. 3½ in. 3½ in.
Page 61 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) NOTICE: Installing a low water cutoff in the system piping of multiple boilers is strongly recommended and may be required by Local Codes. Figure 6-9: Multiple Boiler Water Piping w/Domestic Hot Water Heater (Page 2 of 2) 105357-06 - 12/24...
Page 62 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) NOTICE: • The Phantom boiler heat exchanger is made from stainless steel tubular coil having relatively narrow waterways. Once filled with water, it will be subject to the effects of corrosion. Failure to take the following precautions to minimize corrosion and heat exchanger waterways overheating could result in severe boiler damage.
Page 63 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) 105357-06 - 12/24...
Page 64 Installation, Operating & Service Instructions PHANTOM-X Water Piping and Trim (continued) Full Port Y-Strainer* Isolation (Recommended) Valve * Swing Check From Previous From Previous Valve * Page Page Consult table for common pipe sizing Boiler Circulator * Full Port Isolation Valve * Purge Valve *...
Page 65 Installation, Operating & Service Instructions PHANTOM-X Gas Piping 2. Maximum gas demand. Refer to the boiler’s WARNING input as printed on its rating label. Also Explosion Hazard. Failure to properly pipe consider existing and expected future gas gas supply to boiler may result in improper utilization equipment (i.e.
Page 66 Installation, Operating & Service Instructions PHANTOM-X Gas Piping (continued) Table 7-2: Maximum Capacity of Schedule 40 Black Pipe in CFH* (Propane) For Gas Pressures of 0.5 psig or Less Inlet Pressure 11.0 Inch W.C.; 0.3 Inch W.C. Pressure Drop Nominal Inside Length of Pipe, Ft.
Page 67 Locate and remove either ½ in. NPT x 6 in. long black nipple and ½ in. NPT external gas shutoff valve (PHNTM210), or ¾ in. NPT x 6 in. long black nipple and ¾ in. NPT external gas shutoff valve (PHNTM285 only).
Page 68 Installation, Operating & Service Instructions PHANTOM-X Gas Piping (continued) D. Gas Piping for Multiple Boiler Installation CAUTION 1. Individual module (boiler) gas pipe sizing specific If gas pressure in the building is above ½ psig details - see Paragraph A. (3.4 kPa), an additional gas pressure regulator 2.
Page 69 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) NOTICE: This boiler is equipped with a high water temperature limit located inside the internal wiring of the boiler. This limit provides boiler shutdown in the event the boiler water temperature exceeds the set point of the limit control.
Page 70 Table 8-1: Boiler Current Draw control system. The Tekmar Model 264 and Model Nominal Current 265 based control wiring diagrams (Figures 8-9 and Model Number (amps) 8-10) are provided as examples of typical multiple PHNTM210 <3 boiler control systems. PHNTM285 <5 105357-06 - 12/24...
Page 71 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 72 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 73 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) Figure 8-3: Ladder Diagram 105357-06 - 12/24...
Page 74 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) Figure 8-4: Modified Wiring For DHW Priority When Using Low Flow Circulator Piped Off System Header - Heating (with Central Heating Circulators) Plus Alternately Piped Indirect Water Heater 105357-06 - 12/24...
Page 75 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 76 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) Velocity PN 3501505 Figure 8-6: DHW Priority/Circulators (with Velocity PN 3501505 Zone Panel) Piped Off System Header Wiring Schematic for Heating Zone Circulators 105357-06 - 12/24...
Page 77 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 78 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 79 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 80 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) 105357-06 - 12/24...
Page 81 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) G. Multiple Boiler Operating Information 1. Required Equipment and Setup a. Header Sensor A header sensor must be installed and wired to the Master Sequencer “enabled” Sage2.X Controller. The header sensor is installed on the common system piping and provides blended temperature information to the Sequence Master.
Page 82 Installation, Operating & Service Instructions PHANTOM-X Electrical (continued) Figure 8-13: RJ45 Splitter Installation Detail Step Description Comments Wire the header sensor to low voltage terminal strip terminals “Header sensor”. Install and wire the NOTE Header Sensor This step can not be skipped. The Sequence Master can not be “enabled”unless a Header Sensor is installed.
Page 83 Installation, Operating & Service Instructions PHANTOM-X System Start-up Follow the manufactures instructions for proper dosage, use. For long-term protection ensure concentration levels are maintained WARNING and checked annually as part of the boiler or Explosion Hazard. Asphyxiation system service. Hazard. Electrical Shock Hazard. 4.
Page 84 Installation, Operating & Service Instructions PHANTOM-X System Start-up (continued) Phantom Series Lighting and Operating Instructions Figure 9-1: Operating Instructions 105357-06 - 12/24...
Page 85 Model % CO Range CO, PPM should go through sequence of operation shown 9.9 - 8.2 3.5 - 6.5 in Table 10-3. PHNTM210 (High Fire) (High Fire) Less than 100 PPM 9.9 - 7.9 3.5 - 7.0 PHNTM285 (Low Fire)
Page 86 CO, PPM set using precision instruments and must never be adjusted in the field unnecessarily. 11.4 - 9.5 3.5 - 6.5 PHNTM210 (High Fire) (High Fire) Attempting to adjust the offset screw Less than unnecessarily could result in damage to the...
Page 87 Installation, Operating & Service Instructions PHANTOM-X System Start-up (continued) 7. Verify measured input rate is within 88% to 100% of the max. input listed on the boiler WARNING rating label. Asphyxiation Hazard. 8. If measured input is too high, reduce maximum Install flue temperature sensor and sensor modulation fan speed (either central heat or cap into two-pipe vent connector port upon...
Page 88 S. Field Conversion From Natural Gas to Propane WARNING (LP) Asphyxiation Hazard. Phantom models PHNTM210 and PHNTM285 are The throttle adjustments shown in Table 9-5 are factory shipped as natural gas builds. Models approximate. The final throttle setting must be configured for use at altitudes below 7,000 ft.
Page 89 Table 9-5: Number of Clockwise Throttle Screw Turns for Propane (LP) Conversion Throttle Screw Turns at Altitude Range Boiler Model Gas Valve 0 - 7,000 ft. 2¾ Dungs PHNTM210 GB-055 3¼ Figure 9-6: Dungs Gas Valve Detail (½ in. NPT) WARNING Dungs PHNTM285 GB-057 4½...
Page 90 Installation, Operating & Service Instructions PHANTOM-X System Start-up (continued) U. Controls Startup Check List The Control is factory programmed with default parameters. Before operating the boiler, these parameters must be checked and adjusted as necessary to conform to the site requirements. Follow the steps below, making selections and adjustments as necessary to ensure optimal boiler operation.
Page 91 Installation, Operating & Service Instructions PHANTOM-X Operation A. Overview water temperature control. The result is longer run times, dramatic reduction in boiler excessive 1. Sage2.X Controller cycling and higher operating efficiency. Avoiding The Sage2.X Controller (Control) contains features extra cycling saves customer fuel dollars (pre and and capabilities which help improve heating post purge sends heat up stack) and saves wear system operation and efficiency.
Page 92 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 2. Setpoint Purpose period after not being used for longer than 7 The Control starts and stops the boiler and days. Circulator exercise helps prevent pump modulates the boiler input from minimum (MBH) rotor seizing.
Page 93 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 2. High Differential Temperature Limit 7. Domestic Hot Water (DHW) Setpoint The Control monitors the temperature difference Upon a DHW call for heat the setpoint is either the between the return and supply sensors. If this user entered DHW setpoint or the Thermostat’s difference exceeds 43°F (23.9°C), the Control “Sleep”...
Page 94 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 4. Improved Availability 7. Ignition Failure The following features help improve the heat The Control monitors ignition using a burner availability: mounted flame sensor. In the event of an a. Backup Header Sensor: In the event of a ignition failure, the control retries 5 times and header sensor failure the lead boiler’s supply then goes into soft lockout for one hour.
Page 95 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 8. DHW Two boiler Start When the Indirect Water Heater (IWH) parameter is set to “Primary Piped” and the DHW Two Boiler Start parameter is set to “Enabled” two boilers are started without delay in response to a DHW call for heat.
Page 96 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) E. Boiler Sequence of Operation 1. Normal Operation Table 10-3: Boiler Sequence of Operation Status Screen Display Description Priority: (burner Off, circulator(s) Off) Standby Boiler is not firing and there is no call for heat, priority equals standby. Boiler is Status: ready to respond to a call for heat.
Page 97 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 2. Using The Display The Control includes a touch screen LCD display. The user monitors and adjusts boiler operation by selecting screen navigation “buttons” and symbols. The “Home Screen” and menu selections are shown below.
Page 98 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 3. Status Screens Boiler Status screens are the primary boiler monitoring screens. The user may simply “scroll” though boiler operation by repeatedly selecting the right or left “arrow” symbol. These screens are accessed by selected the “Status”...
Page 99 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 3. Status Screens (continued) Bargraph Screen Bargraph Screen The bargraph screen presents measured values for easy comparison. Included on this screen is firing rate and when the Zone Panel is connected the measure Heat Loss. Measured heat loss is the heat rate kbtu/hr sum of all active (call for heat) zones.
Page 100 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Circulator Status Screen Pumping is a major part of any hydronic system. This screen provides the status of the boiler’s demand to connected pumps as well as the status of Frost Protection and pump Exercise functions. Head Demand Screen This screen provides the status of the boilers five (5) possible heat demands.
Page 101 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 5. Multiple Boiler Sequencer Screens available When the Sequence Master is enabled the following screens are The Sequencer Status screen is selected by “pressing” “Status” button from the “Home Screen” when Sequence Master is enabled.
Page 102 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) F. Changing Adjustable Parameters 1. Entering Adjust Mode The Control is factory programmed to include basic modulating boiler functionality. These settings are password protected to discourage unauthorized or accidental changes to settings. User login is required to view or adjust these settings: - Press the “Adjust”...
Page 103 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) 2. Adjusting Parameters (continued) The following pages describe the Control’s adjustable parameters. Parameters are presented in the order they appear on the Control’s Display, from top to bottom and, left to right. From the “Home Screen” select the Adjust button to access the adjustment mode screens show below (if required, refer to the previous page to review how to enter Adjustment mode): System...
Page 104 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) WARNING Asphyxiation Hazard. Boiler type is factory set and must match the boiler model. Only change the boiler type setting if you are installing a new or replacement Control. The boiler type setting determines minimum and maximum blower speeds.
Page 105 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Expected Heat Rate Adjustment Screens (HeatMatch Software) The Control is shipped with defaults that will provide improved operation. Adjustment is only required to optimize setup. The expected heat rate adjustment is used to better match boiler output to the home heating needs. After receiving a call for heat the Control first uses the expected heat rate value to set a maximum heat rate.
Page 106 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Modulation “Press” button to access the following parameters: Setup Factory Range / Choices Parameter and Description Setting Central Heat Maximum Expected Heat Rate Minimum to This parameter defines the highest modulation rate the Control will go to during a central heat 100% Maximum call for heat.
Page 107 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” Pump Setup button to access the following parameters: Factory Setting Range / Choices Parameter and Description System Pump run pump for: Activates the system pump output according to selected function. Never, Never: Pump is disabled and not shown on status screen.
Page 108 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Example Pump Parameter selections (continued): Single boiler Indirect Water Heater (IWH)Piped to Primary, Optional Domestic Hot Water Priority. Parameter Selections: System Pump= “Central Heat , Optional Priority” Boiler Pump = “any demand” DHW Pump = “Primary Loop Piped IWH”...
Page 109 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Example Pump Parameter selections (continued): Multiple boilers IWH Piped to Primary, Optional Domestic Hot Water Priority Sequencer Master Boiler 2 (Boiler 1) Wiring locations: Thermostat DHW call for heat System pump DHW pump Boiler Pump Sequencer Master Parameter Selections: Sequencer Master...
Page 110 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Contractor Setup “Press” button to access the following parameters: Contractor Name For Service Contact: Bill Smith Press box to input contractor information. > < Bill Smith 12 Victory Lane Plainview, New York Save 516 123-4567 Press SAVE button to store revisions.
Page 111 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Central Heat “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting 180°F 60°F to 190°F Central Heat Setpoint (82.2°C) (16°C to 87.8°C) Target temperature for the central heat priority. Value also used by the outdoor air reset function. Central Heat Thermostat “Sleep”...
Page 112 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Setpoint 180°F 60°F to 190°F Target temperature for the Auxiliary Heat priority. Value also used by the outdoor air reset (82.2°C) (16°C to 87.8°C) function.
Page 113 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Domestic “Press” button to access the following parameters: Hot Water Factory Range / Choices Parameter and Description Setting Domestic Hot Water Setpoint 60°F (16°C) to The Domestic Hot Water (DHW) Setpoint parameter is used to create a minimum boiler water 170°F 190°F temperature setpoint that is used when DHW heat demand is “on”.
Page 114 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Central Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 10-12.
Page 115 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Auxiliary Heat Outdoor Reset Enable If an outdoor sensor is installed and Outdoor Reset is Enabled, the boiler will automatically adjust the heating zone set point temperature based on the outdoor reset curve in Figure 10-12.
Page 116 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Figure 10-12: Outdoor Reset Curve - Typical for Central Heat and Auxiliary Heat Central Heat Central Heat Heating Element Type Heating Element Type Setpoint Setpoint 180°F to 190°F 100°F to 140°F In Slab Radiant High Fan Coil (82.2°C to 87.8°C) (37.8°C to 60°C)
Page 117 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” button to access the following parameters: Factory Range / Choices Parameter and Description Setting Master Enable/Disable Enable, Disable The Sequencer Master Enable/Disable is used to “turn on” the Multiple Boiler Controller. Warning! Disable enable ONLY one Sequence Master.
Page 118 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) Sequence “Press” button to access the following parameters: Slave Factory Range / Choices Parameter and Description Setting Boiler Address Each boiler must be given a unique address. When ”Normal” slave selection order is used, the None boiler address is used by the Master Sequencer as the boiler start order.
Page 119 Installation, Operating & Service Instructions PHANTOM-X Operation (continued) “Press” button to access the following parameters: Factory Range / Parameter and Description Setting Choices Central Heat Modulation Source This parameter enables the 4-20mA input to control firing rate and the thermostat input to control boiler on/off demand directly without using the internal setpoint.
Page 120 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance Important Product Safety Information: Refractory Ceramic Fiber Product WARNING Some boiler components use materials that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to elevated temperatures, RCF may change into crystalline silica, a known carcinogen.
Page 121 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance (continued) WARNING Asphyxiation Hazard. This boiler requires regular maintenance and service to operate safely. Follow the instructions contained in this manual. • Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury or death.
Page 122 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance (continued) DANGER • Explosion Hazard. Electrical Shock Hazard. Burn Hazard. This boiler uses flammable gas, high voltage electricity, moving parts, and very hot water under high pressure. Assure that all gas and electric power supplies are off and that the water temperature is cool before attempting any disassembly or service.
Page 123 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance (continued) 3. Remove the igniter assembly and flame sensor 9. Inspect the flue temperature sensor cap to verify and inspect them for oxide deposits. Clean the that it is free from leakage and deterioration. oxide deposits from the igniter electrodes and Replace if needed.
Page 124 Service and Maintenance (continued) Fernox™ Protector Alphi 11 (combined 6002 and/or selected HVAC distributors. antifreeze and inhibitor). Contact Velocity Boiler Works, LLC for Follow manufacturer application procedure specific details. to ensure proper antifreeze concentration iii. Sentinel® X400 System Restorer (For and inhibitor level.
Page 125 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance (continued) E. Condensate Overflow Switch and Condensate Trap g. Restore power supply to boiler. Fill the trap (see Section 5 “Condensate Disposal”) and Removal and Replacement: verify the switch operation. For removal or replacement of the condensate 2.
Page 126 Installation, Operating & Service Instructions PHANTOM-X Service and Maintenance (continued) Header Temperature Sensor Supply, Return and Stack Temperature Sensor Temperature versus Resistance Temperature versus Resistance (12kOhm NTC Sensor), Beta of 3750 (10kOhm NTC Sensor), Beta of 3950 Temperature Ohms of Resistance Temperature Ohms of...
Page 127 Installation, Operating & Service Instructions PHANTOM-X Before Leaving Jobsite Before leaving jobsite Verify installation and operation of CO alarm(s)  Installed bottom securing bracket (wall hung boilers only)  Flushed heating system  Boiler and system filled with water  Air purged from boiler system ...
Page 128 Installation, Operating & Service Instructions PHANTOM-X Troubleshooting WARNING Electrical Shock Hazard. Turn off power to boiler before working on wiring. A. Troubleshooting problems where no error code is displayed. Condition Possible Cause • Boiler is not seeing call for heat. Boiler not responding to call for heat, “Status”...
Page 129 Installation, Operating & Service Instructions PHANTOM-X Troubleshooting (continued) C. Help Screen Faults Indication Condition Possible Cause Zone Panel 1 communication lost, typical for Panel 1 through 4: The zone panel’s communication was established and then lost. Check the following to correct the issue: Zone Panel 1 •...
Page 130 Installation, Operating & Service Instructions PHANTOM-X Troubleshooting (continued) E. Active Fault Screen Faults Indication Condition Possible Cause The Limit String Status screen shows the faulty safety limit. A contact icon, either Limit String Status “open” or “closed”, graphically represents each safety limit. The “closed” contact icon is steady;...
Page 131 Gas pressure under minimum value shown on rating plate. • Gas line not completely purged of air. • Defective Electrode. Models PHNTM210 through PHNTM285B - flame • Loose burner ground connection. Ignition failure failure after 5 tries to restart. •...
Page 132 Installation, Operating & Service Instructions PHANTOM-X Troubleshooting (continued) G. Troubleshooting problems where a Hard Lockout Code is displayed. When a hard lockout occurs, the boiler will shut down, the display will turn red and the “Help” button will “blink”. Select the “blinking” “Help” button to determine the cause of the Hard Lockout.
Page 133 PHANTOM-X Service Parts The following parts may be obtained from any Velocity Boiler Works, LLC distributor. To find the closest Velocity distributor, consult the area Velocity representative or factory, at: Velocity Boiler Works, LLC Customer Service, P.O. Box 14818, Philadelphia, PA, 19134 www.velocityboilerworks.com...
Page 134 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description PHNTM210 PHNTM285 Bare Heat Exchanger and Related Components (1B through 1E) 1A, 1B, Heat Exchanger assembly (includes bare heat exchanger, 1C, 1D, supply and return water temperature sensors, air vent valve,...
Page 135 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) 2B-1 Part Number Key No. Description PHNTM210 PHNTM285 2A, 2E Blower Kit (includes blower, hardware, and gasket) 105758-01 104999-01 +hardware Blower Inlet Shroud Assembly (includes gas orifice, gas orifice o-ring, (3) M4x20 mm or (3) M4x25 mm self-threading...
Page 136 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description PHNTM210 PHNTM285 Repair Condensate Trap and Related Components 3A, 3B, Condensate Trap Kit (Includes condensate 3C, 3D trap, flow switch, (2) clamps, grommet, 104704-01 +coupling coupling, and sealant) Condensate Float Switch Kit (Includes float 3B &...
Page 137 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description Control Kit (0 - 7,000 ft. Altitude) 106193-01 Control Kit (7,000 - 10,000 ft. Altitude) 106193-02 106193-03 5B + clips Display Kit (programmed; includes mounting hardware) 106217-04 5C + screws Transformer Kit (includes mounting hardware) 106034-01...
Page 138 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description PHNTM210 PHNTM285 6B, 6C, Jacket Panel Kit (includes right side panel, left side 6J, 6K, 6F, panel, access panel, high voltage terminal bracket, 109069-01 109070-01 +gaskets,...
Page 139 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description 080B 105B 150B 210B 285B Vent System Service Parts Vent Kit, 2 in. (includes 2 in. schedule 40 PVC coupling 7A, 7B, 7C, (vent terminal), 2 in. stainless steel (2) rodent screens, +CPVC 2 in.
Page 140 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Description PHNTM210 PHNTM285 Miscellaneous Parts Carton Service Parts Temperature/Pressure Gauge 105894-01 External Gas Shut Off Valve 1/2 in. NPT: Obtain Locally 3/4 in. NPT: Obtain Locally Safety Relief Valve , 30 PSI...
Page 141 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description 080B 105B 150B 210B 285B Air Box Service Parts 9A, +flue Vent Elbow w/Flue Sensor Port (includes elbow, flue exit exit 109075-01 gasket, and MOLYKOT® 111 grease) gasket Wall Bracket Kit (includes wall side top hanging bracket 9C &...
Page 142 Installation, Operating & Service Instructions PHANTOM-X Service Parts (continued) Part Number Key No. Description PHNTM210 PHNTM285 Main (Low Voltage) Harness 109079-01 High Voltage Harness 109080-01 Blower Power Harness 109081-01 Communication Harness 109077-01 Igniter Harness 109078-01 Wiring Harness, Thermal Link & Burner Door Thermostat...
Page 143 Installation, Operating & Service Instructions PHANTOM-X SERVICE RECORD DATE SERVICE PERFORMED 105357-06 - 12/24...
Page 144 Installation, Operating & Service Instructions PHANTOM-X Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia. PA 19134 www.velocityboilerworks.com 105357-06 - 12/24 VELOCITY LOGO CMYK COLORS...

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Phantom-x series Phntm285