High Efficiency Gas-Fired Hot Water Direct Vent Condensing Boilers InstallatIon anD oPERatInG InstRuCtIons these instructions must be affixed on or adjacent to the boiler and retained for future reference. Models: PHNTM080 • 9700609 PHNTM100 • PHNTM120 WaRnInG: Improper installation, adjustment, alteration, •...
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IMPoRtant InFoRMatIon - REaD CaREFullY The following terms are used throughout this manual to bring attention to the presence of hazards of various risk levels, or to important information concerning product life. DanGER CautIon Indicates an imminently hazardous situation Indicates a potentially hazardous situation which, if not avoided, will result in death, serious which, if not avoided, may result in moderate or injury or substantial property damage.
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DanGER Explosion Hazard. Do not store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. If you smell gas vapors, Do not try to operate any appliance - Do not touch any electrical switch or use any phone in the building.
Table of Contents Product Description II. Specifications 4 III. Before Installing Locating The Boiler Mounting The Boiler Air For Ventilation VII. Venting A. Vent System Design B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems C. Design Requirements Unique to Vertical Venting Systems D.
I Product Description This boiler is a stainless steel gas fired condensing boiler designed for use in forced hot water heating systems requiring supply water temperatures of 180°F or less. It is designed for installation on a wall. This boiler may be vented vertically or horizontally with combustion air supplied from outdoors. It is not designed for use in gravity hot water systems or systems containing significant amounts of dissolved oxygen.
4) All boilers are shipped from the factory configured for use with natural gas. They may be converted for use with LP gas (“propane”) using a combustion analyzer in accordance with the instructions in Appendix A. DanGER • Do not attempt to operate this boiler on lP gas without converting it in accordance with the instructions shown in appendix a. • Do not attempt to convert this boiler to lP gas without the use of a combustion analyzer.
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Figure 4.1: Minimum Clearances To Combustible Construction...
V Mounting The Boiler A. Wall Mounting CautIon this boiler weighs as much as 119 pounds: • two people are required to safely lift this boiler onto the wall mounting hook. • Make sure that wall mounting hook is anchored to a structure capable of supporting the weight of the boiler and attached piping when fi lled with water.
VI Air for Ventilation WaRnInG outdoor combustion air must be piped to the air intake. never pipe combustion air from areas containing contaminates such as swimming pools and laundry room exhaust vents. Contaminated combustion air will damage the boiler and may cause property damage, personal injury or loss of life.
VII 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. • Do not interchange vent systems or materials unless otherwise specified. •...
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All of these systems are considered “direct vent” because the air for combustion is drawn directly from the outdoors into the boiler. One of the vent option columns in the tables referenced above must match the planned vent and air intake system exactly. Design details applying to all vent systems are shown in this section.
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notICE Do not exceed maximum vent/combustion air system length. Refer to tables 7.1, 7.13 and 7.21 in this section for maximum vent/combustion air system length. use only vent and combustion air terminals and terminal locations shown in tables 7.1, 7.13 and 7.21 and related Figures.
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7. Supporting Pipe - Vertical and horizontal sections of pipe must be properly supported. Maximum support spacing is as follows: • Support CPVC/PVC horizontally and vertically every 4 feet. • Support DuraVent Polypro horizontally near the female end of each straight section of pipe and vertically every 10 feet. • Support Centrotherm Innoflue horizontally every 39 inches with additional supports at elbows and vertically every 78”. • Support 2” Selkirk Polyflue horizontally every 30”. Support 3” Polyflue horizontally every 39”. Support vertical runs of both 2” and 3” Polyflue every 16 ft. Les instructions d´installation du système d´évacuation doivent préciser que les sections horizontales doivent être supportées pour prévenir le fléchissement. Les méthodes et les intervalles de support doivent être spécifiés. Les instructions divent aussi indiquer les renseignements suivants: •...
B. Design Requirements Unique to Horizontal Twin Pipe Venting Systems Table 7.5 summarizes all horizontal twin pipe vent options. Illustrations of horizontal twin pipe vent systems are shown in Figures 7.6 – 7.10. In addition to the requirements in Part VII-A, observe the following design requirements: Permitted Terminals for Horizontal Venting: Terminal Option A: Fittings (Acceptable for Vent Options 1-8) –...
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2. Horizontal Vent and Air Intake Terminal Location - Observe the following limitations on the vent terminal location (also see Figure 7.11). When locating a concentric terminal, observe the limitations outlined below for “vent terminals”. • Vent terminal must be at least 1 foot from any door, window, or gravity inlet into the building. •...
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FIGURE 7.7: HORIZONTAL CPVC/PVC VENTING WITH LOW PROFILE TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS B & C) FIGURE 7.8: HORIZONTAL CPVC/PVC WITH CONCENTRIC VENT TERMINAL, (VENT OPTIONS #1 & 2, TERMINAL OPTIONS D & E)
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FIGURE 7.11a: LOCATION OF VENT TERMINAL RELATIVE TO WINDOWS, DOORS, GRADE FIGURE 7.11b: LOCATION OF VENT TERMINAL RELATIVE TO METERS AND FORCED AIR INLETS Max. “X” Min. “Y” (in.) (in.) Ventilated Soffit Unventilated Soffit or Other Overhang. “X” May never exceed 36” Example: For an unventilated 18”...
FIGURE 7.12: SNORKEL TERMINAL CONFIGURATION (CPVC/PVC VENT SYSTEMS ONLY) C. Design Requirements Unique to Vertical Venting Systems Table 7.13a summarizes all vertical twin pipe vent options. Table 7.13.b summarizes vent options in which an abandoned B-vent chimney is used both as a chase for the vent pipe and as a conduit for combustion air. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
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Table 7.13b: Summary of Vertical “B-Vent Air Chase” Vent Options (B-Vent Chase MUST Be Sealed) Option Illustrated in Figure 7.19 7.19 7.20 7.20 Vent Roof Roof Roof Roof Pipe Penetration Through Structure Intake Roof Roof Roof Roof DuraVent DuraVent Centrotherm Centrotherm Vent PolyPro...
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Terminal Option J: Diversitech Concentric Terminal (Acceptable for Vent Options 10 & 11) - This terminal is shown in Figure 7.16 and may be used with CPVC/PVC vent systems. See Part VII-E of this manual and the Diversitech instructions provided with the terminal, for installation details. Terminal Option K: DuraVent PolyPro Concentric Terminal (Acceptable for Vent Options 12, 13) - This terminal is shown in Figure 7.18 and may be used with DuraVent 2” or 3” PolyPro vent systems. Use a compatible DuraVent roof flashing and storm collar in accordance with the DuraVent instructions for this terminal See Part VII-F of this manual and the DuraVent...
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Table 7.14: Equivalent Length of Flex Pipe Equivalent Length (ft) Flex Vent (1 ft): 2” DuraVent PolyPro Flex 2.0 ft 2” Centrotherm Innoflue Flex 2.0 ft 2” Selkirk Polyflue 2.0 ft 3” DuraVent PolyPro Flex 2.0 ft 3” Centrotherm Innoflue Flex 2.3 ft 3” Selkirk Polyflue 2.3 ft B-Vent Air Chase (1ft): 2”...
D. Design Requirements Unique to Split Vent Systems Table 7.21 summarizes all split vent options. Illustrations of split vent systems are shown in Figures 7.22, 7.23, and 7.24. In addition to the requirements in Part VII-A, observe the following design requirements: 1.
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Example: A 100MBH model is to be installed as using Vent Option 34 in a masonry chimney as shown in Figure 7.23. The following components are used: Vent: 3” DuraVent Poly-Pro (Rigid) – 4ft 3” DuraVent Poly-Pro Flex – 30ft Poly-Pro elbows –...
E. Assembly of CPVC/PVC Vent Systems 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 the boiler) for near-boiler vent piping before transitioning to schedule 40 PVC pipe (astM 2665) components for remainder of vent system.
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FIGURE 7.27: VENT CONNECTIONS AND FLUE GAS SAMPLE CAP LOCATION Assemble the rest of the vent system, being sure to pitch horizontal sections back towards the boiler 1/4”/ft. Support the vent at intervals not exceeding 4ft. Maintain the clearances from the vent pipe outlined in Part VII-A of this manual. If exiting the exterior wall using PVC pipe, use half of an appropriately sized wall thimble (or a sheet metal plate) on the exterior of the building, to provide a weather tight seal while maintaining the proper clearance in the wall penetration.
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FIGURE 7.28: INSTALLATION OF STANDARD HORIZONTAL TERMINALS FIGURE 7.29: INSTALLATION OF STANDARD VERTICAL TERMINALS...
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Installation of Vertical Fitting Terminals (Terminal Option H): See Figure 7.29 for the proper orientation of twin pipe vertical terminals. The coupling is used to secure the rodent screen to the end of the vent pipe. A 180° bend (or two 90° elbows) are installed on the top of the air intake pipe. If two 90° elbows are used, the rodent screen provided can be installed between them (Figure 7.29).
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FIGURE 7.30: INSTALLATION OF IPEX LOW PROFILE TERMINAL THROUGH SIDEWALL FIGURE 7.31: INSTALLATION OF DIVERSITECH LOW PROFILE TERMINAL THROUGH SIDEWALL...
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FIGURE 7.32: CUTTING IPEX AND DIVERSITECH CONCENTRIC VENT TERMINALS FIGURE 7.33: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH SIDEWALL...
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FIGURE 7.34: INSTALLATION OF IPEX AND DIVERSITECH CONCENTRIC TERMINAL THROUGH ROOF Cement the outer pipe to the Wye, being careful, to keep the inner and outer pipes concentric. Slip the partially assembled terminal through the wall or ceiling from the inside and for horizontal installations orient so that the side outlet on the Wye is on or above the horizontal plane.
F. Assembly of DuraVent PolyPro Vent Systems 1. This boiler has been approved for use with the DuraVent PolyPro single wall polypropylene vent system to be provided by the installer. WaRnInG • asphyxiation Hazard. Follow these instructions and the installation instructions included by the original polypropylene venting component manufacturer, M&G/DuraVent.
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3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air intake pipe into the air intake connection and drill a 1/8” tap hole into the PVC which lines up with the 7/32” clearance hole and secure them together with a #10 x 1”...
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FIGURE 7.36: INSTALLATION OF DURAVENT POLYPRO UV RESISTANT SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.37: INSTALLATION OF DURAVENT POLYPRO UV RESISTANT SINGLE WALL VERTICAL TERMINAL...
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6. Installation of DuraVent PolyPro Horizontal Concentric Vent Terminal (Terminal Option D) - Install PolyPro Horizontal Concentric Termination Kit #2PPS-HK or #3PPS-HK (Figure 7.39) as follows: At the planned location cut a 4-1/8” round hole for the 2” terminal or a 5-1/8” round hole for the 3” terminal in the exterior wall.
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FIGURE 7.39: INSTALLATION OF DURAVENT POLYPRO CONCENTRIC VENT TERMINAL THROUGH SIDEWALL FIGURE 7.40: INSTALLATION OF DURAVENT POLYPRO CONCENTRIC TERMINAL THROUGH ROOF...
8. Installations using PolyPro-flex (Vent Options 18,19,33,34): WaRnInG asphyxiation Hazard. When using Polypro flex, observe the following precautions: • Polypro flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42F without allowing it to warm to a higher temperature first.
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e. Support each pipe section as described in Polyflue manual at intervals not exceeding the following: Pipe size Horizontal Vertical 2” 30in 16ft 3” 39in 16ft notICE once a vent pipe is inserted into this adaptor, it is IMPossIBlE to remove it. Make sure the correct type of pipe is selected, and that it is of the correct length, before inserting it into the vent adaptor. 3.
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6. Installations using flexible Polyflue (Vent Options 35,36): WaRnInG asphyxiation Hazard. When using Polyflue flex, observe the following precautions: • Polyflue flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42F without allowing it to warm to a higher temperature first.
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FIGURE 7.42: INSTALLATION OF SELKIRK POLYFLUE UV RESISTANT SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.43: INSTALLATION OF SELKIRK POLYFLUE UV RESISTANT SINGLE WALL VERTICAL TERMINAL...
H. Assembly of Centrotherm Innoflue Vent Systems This boiler has been approved for use with the Centrotherm Innoflue single wall polypropylene vent system to be provided by the installer. WaRnInG • asphyxiation Hazard. Follow these instructions and the installation instructions included by the original polypropylene venting component manufacturer, Centrotherm. Failure to do so could cause products of combustion to enter the building, resulting in severe property damage, personal injury or death.
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3. Installation of Air Intake System - Start assembly of the PVC air intake system at the boiler. Assembly of the air intake system is done in the same manner as the vent system except as follows: Drill a 7/32” clearance hole into the front side of the air intake adapter. Insert the first piece of PVC air intake pipe into the air intake connection and drill a 1/8” tap hole into the PVC which lines up with the 7/32” clearance hole and secure them together with a #10 x 1”...
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FIGURE 7.45: INSTALLATION OF CENTROTHERM INNOFLUE UV STABILIZED SINGLE WALL HORIZONTAL TERMINAL FIGURE 7.46: INSTALLATION OF CENTROTHERM INNOFLUE UV STABILIZED SINGLE WALL VERTICAL TERMINAL...
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6. Installations using InnoFlue Flex (Vent Options 20,21,37,38): WaRnInG asphyxiation Hazard. When using InnoFlue Flex, observe the following precautions: • InnoFlue Flex may be damaged by handling at low temperatures. Do not bend, uncoil, or attempt to install if it has been stored at a temperature below 42F without allowing it to warm to a higher temperature first.
I. Condensate Trap and Drain Line All condensate which forms in the boiler or vent system passes through the heat exchanger and out of a bottom drain port which is connected to the condensate trap with a hose. This trap allows condensate to drain from the heat exchanger while retaining flue gases in the boiler. This trap is an integral part of the boiler but must be connected to a drain pipe as shown in Figure 7.47.
J. Removing an Existing Boiler From a Common Chimney This section only applies if this boiler is replacing an existing boiler that is being removed from a common chimney. In some cases, when an existing boiler is removed from a common chimney, the common venting system may be too large for the remaining appliances.
VIII Gas Piping WaRnInG Explosion Hazard. Failure to properly pipe gas supply to boiler may result in improper operation or leaks of flammable gas. • Gas supply to boiler and system must be absolutely shut off prior to installing or servicing boiler gas piping.
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CautIon • support the weight of the gas line piping independently from the boiler gas connection fitting located on the bottom of the boiler. • If an additional regulator is used to reduce boiler inlet pressure below 1/2 psig (3.4 kPa) it must be at least 6 to 10 feet upstream of the boiler.
IX System Piping A. General System Piping Precautions WaRnInG • Failure to properly pipe boiler may result in improper operation and damage to boiler or structure. • Install boiler so that the gas ignition system components are protected from water (dripping, spraying, rain, etc.) during boiler operation and service (circulator replacement, etc.).
B. Near Boiler Piping Design Proper operation of this boiler requires that the water flow rate through it remain within the limits shown in Table 9.1 any time the boiler is firing. At flow rates below the minimum shown, the boiler’s flow switch and/or temperature rise limit function may prevent the boiler from firing. Flow rates through the boiler in excess of the maximum shown in Table 9.1 can result in excessive noise or erosion damage to piping There are two basic methods that can be used to pipe this boiler into the system. Method #1 (primary-secondary piping) is always preferred. Additional information on hydronic system design can be found in the I=B=R Guide RHH published by the Air-Conditioning, Heating and Refrigeration Institute (AHRI).
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Example – A 120MBH model is to be connected to a heating system as shown in Figure 9.6. A total of 20 ft of straight pipe will be installed between the boiler and the system loop. Count all fittings in the boiler loop (shaded in Figure 9.6): 3 90 Elbows 2 Turn in Tee (under boiler- primary-secondary tees not counted) 2 Isolation Valves 1 Y Strainer having a Cv of 30.
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Method 2: Direct Connection to Heating System (Generally NOT Recommended) In some relatively rare cases it may be possible to connect this boiler directly to the heating system as is done with conventional boilers (Figure 9.7). If this is done, the flow rate through the boiler will equal the flow rate through the system. The flow rate through the system must therefore always remain within the limits shown in Table 9.1. For this reason, the pressure drop through the entire system must be known. This method is generally not recommended because it is often very difficult to accurately calculate the pressure drop through the system.
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40 Models with Taco 0013 35 30 25 20 15 150/180 10 5 0 Flow (GPM) FIGURE 9.8a: TACO NET CIRCULATOR PERFORMANCE CURVE Fig9.8b: Models with Grundfos 26‐99 (Speed #3 ‐ Do not Use Speeds 1 or 2) 150/180 Flow (GPM) FIGURE 9.8b: GRUNDFOS NET CIRCULATOR PERFORMANCE CURVE...
C: Standard Piping Installation Requirements Observe the following requirements when installing the boiler piping: 1) Relief Valve (Required) – The relief valve is shipped loose and must be installed in the location shown in Figure 9.9, using the side outlet Tee and other fittings provided. ASME Section IV currently requires that this relief valve be installed above the heat exchanger as shown. Pipe the outlet of the relief valve to a location where water or stream will not create a hazard or cause property damage if the valve opens.
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10) Drain Valve (required) – Install the drain valve supplied as shown in Figure 9.9. 11) Low Water Cut-off (may be required by local jurisdiction) – Protection of this boiler against low water and/or inadequate flow is provided by the UL353 certified flow switch built into the boiler. This is a water tube boiler and this flow switch is therefore the only effective way to provide such protection. Section HG614(c ) of the 2013 ASME boiler and Pressure Vessel Code recognizes the use of a listed flow switch in lieu of a low water cut-off on water tube boilers. In the event that a local jurisdiction insists upon the installation of a low water cut-off with this boiler, a low water cut-off kit is available that plugs into the low voltage circuit board (see Part X).
D. Piping for Special Situations 1) Systems containing oxygen - Many hydronic systems contain enough dissolved oxygen to cause severe corrosion damage to a this boiler. Some examples include: • R adiant systems that employ tubing without an oxygen barrier. • S ystems with routine additions of fresh water. • S ystems which are open to the atmosphere. If the boiler is to be used in such a system, it must be separated from the oxygenated water being heated with a heat exchanger as shown in Figure 9.10.
X Wiring DanGER Positively assure all electrical connections are unpowered before attempting installation or service of electrical components or connections of the boiler or building. lock out all electrical boxes with padlock once power is turned off. WaRnInG all wiring and grounding must be done in accordance with the authority having jurisdiction ...
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The use of the pump outputs are as follows: a) System Pump - Pumps water through the radiation. This pump is hydraulically separated from the boiler pump, either by closely spaced tees, or by a hydraulic separator. The system pump is always on when the system is responding to a call for CH. Depending on the DHW configuration, it may also be on during a call for DHW.
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FIGURE 10.2: HIGH VOLTAGE PCB TERMINAL CONNECTIONS FIGURE 10.3: LOW VOLTAGE PCB TERMINAL CONNECTIONS...
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• Outdoor Sensor - Tasseron TSA00AA Outdoor Temperature Sensor (1) • Outdoor Sensor - Tasseron TSA00AA Outdoor Temperature Sensor (2) • Header Sensor - Optional Honeywell 32003971-003 Sensor (1) • Header Sensor - Optional Honeywell 32003971-003 Sensor (2) • MODBUS - (A) • MODBUS - (B) • MODBUS - (-V) With the exception of the alarm contacts, external power must not be applied to any of the low voltage terminals - doing so may damage the boiler control. Also note the following: a) External Limit - The external limit terminals are intended for use with a field supplied safety device, such as a manual reset high limit.
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FIGURE 10.4: PROPER INSTALLATION OF HEADER SENSOR...
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120V Line L Boiler Control (R7910B) F1 (6.3A Slow Blow) DHW(L) DHW(N) P3‐10 J4‐2 J4‐3 P3‐4 DHW Pump P3‐11 J4‐4 J4‐5 L1‐1 L1‐2 P3‐1 Grounded to Boiler Frame via PCB Standoff/Mounting Screw Boiler Pump SYS(L) SYS(N) P3‐7 J4‐6 J4‐7 P3‐6 System Pump Combustion Fan Ground Screw (120V Conn.) Bottom Panel P3‐9 P3‐2 Internal, non replaceable 2 amp P3‐12 L2‐1 L2‐3 P3‐3 F2 (1.6A ...
XI Start-up and Checkout WaRnInG Completely read, understand and follow all instructions in this manual before attempting start-up. notICE safe lighting and other performance criteria were met with the gas train assembly provided on the boiler when the boiler underwent the test specified in Z21.13. Use the following procedure for initial start-up of the boiler: 1) Verify that the venting, water piping, gas piping and electrical system are installed properly.
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DanGER asphyxiation Hazard. Failure to properly convert this boiler for use on lp gas can cause unreliable operation at elevated carbon monoxide (Co) levels, resulting in personal injury or death. notICE To minimize the risk of premature heat exchanger failure, observe the following water chemistry requirements: 1) Minimize the introduction of make-up water, dissolved oxygen, and contaminants into the boiler by following the installation guidelines shown in the Water Quality and Boiler Water Additives Note on Page 64.
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MANUAL AIR VENT ATTACH 1/4" ID CLEAR TUBING TO HOSE BARB AND ROUTE TO SAFE PLACE AWAY FROM CONTROLS BEFORE OPENING VENT. FIGURE 11.1: LOCATION OF MANUAL AIR VENT 10) If the boiler is to be converted to propane (LP gas) or used at altitude above 2000ft, start-up and adjust throttle as described in Appendix A.
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PHNTM080 FIGURE 11.2a: HOME SCREEN AT POWER-UP (No Call for Heat) PHNTM080 FIGURE 11.2b: HOME SCREEN ON HEAT DEMAND PHNTM080 FIGURE 11.2c: HOME SCREEN WITH ACTIVE FAULT FIGURE 11.3: BURNER FLAME...
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WaRnInG asphyxiation Hazard. Each boiler is tested at the factory and adjustments to the air-fuel mixture are normally not necessary when operating on natural gas at sea level. Consult the factory before attempting to make any such adjustments. Improper gas valve or mixture adjustments could result in property damage, personal injury or loss of life due to carbon monoxide (Co) poisoning.
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16) Perform a combustion test. Boilers are equipped with a screw cap in the vent adapter. Be sure to replace this cap when combustion testing is complete. Check CO (or O ) and CO at both high and low fire. The boiler may be temporarily locked into high or low fire as follows: a) From the Home Screen, press “MENU” to enter the main menu. b) Press “SETTINGS”.
XII Operation A. General Information This boiler uses the microprocessor based Honeywell R7910B “boiler control” to manage all boiler functions including flame supervision and modulation. Two set point or “target” boiler supply temperatures are stored in the control’s memory; one for space heating (CH) and one for domestic hot water (DHW) production. If an outdoor temperature sensor is connected to the boiler, and enabled, the space heating supply set point will automatically shift downward as the outdoor temperature increases. For more information on this feature see the discussion on boiler water reset below.
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IMPORTANT This boiler is equipped with a feature that saves energy by reducing the boiler water temperature as the heating load decreases. This feature is equipped with an override which is provided primarily to permit the use of an external energy management system that serves the same function. THIS OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE: •...
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2) Press the CH Button to access central heating options. These include: a) Setpoint Location - Identifies the sensor that will be used to obtain the target water temperature when the boiler is responding to a call for heat. Choices include: • Supply (Generally Recommended) - Boiler attempts to obtain the target temperature during a call for heat at the supply sensor built into the boiler.
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DHW, No DHW priority Outdoor Reset pumping. Options: Enabled* Disabled (see Note on Page 73) Advanced Configuration: See Appendix A. WWSD Options: Off* Boiler Model Options: PHNTM080 (S.L. – 2000ft) ODR Boost Options: PHNTM100 (S.L. – 2000ft) Disabled* PHNTM120 (S.L. – 2000ft) Enabled PHNTM150 (S.L. – 2000ft) PHNTM180 (S.L. – 2000ft) * Default HOW TO CHANGE OPTIONS For Buttons with Three or More For Buttons with Two Options Options Like This: Like These: ...
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WaRnInG Burn Hazard. Water temperatures over 125°F can cause personal injury or death due to scalding. Children Disabled, and Elderly are at most risk of being scalded. this boiler is not designed to directly control domestic water temperature. • use only the thermostat recommended by the indirect water heater manufacture to control the DHW temperature.
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CH (Heating) Zone Indirect Water Heater System Pump* Pump Boiler * System Pump Operation: Exp. Option 1 – Off during DHW Tank priority Option 2 – On any time there is call for CH Boiler Pump FIGURE 12.2: PIPING FOR DHW OPTIONS #1 & 2 (ALSO SEE FIGURES 9.3A & 9.3B) CH (Heating) Zone Indirect Water Heater CH (Heating) Pump Pump – Control supplied by installer SystemPump‐ Boiler Runs on Call for CH or DHW Exp. ...
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DHW Priority - Like all boilers, the Phantom is capable of regulating only one target boiler water temperature at any given time. This means that priority must be given to either the CH or DHW target temperature. For this reason, the Phantom gives priority to the DHW demand for the first 60 minutes during which both calls for CH and DHW continuously exist. If there are still simultaneous calls for DHW and CH at the end of this time, the boiler will attempt to maintain the target CH temperature and operate the pump/s needed to satisfy the call for heat.
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Table 12.4: Summary of Target Temp and Pump Behavior Demands Description Status of: CH+DHW CH+DHW Option # None CH Only DHW Only (<60 min) (>60 min) Boiler Pump System Pump used for DHW Pump CH only (Fig. 12.2). System Pump DHW priority pumping.
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FIGURE 12.5: SETTINGS MENU (SEE PART C FOR ADDITIONAL INFORMATION)
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FIGURE 12.6: OUTDOOR RESET CURVE (DEFAULT SETTINGS SHOWN) 3) DHW Settings - From the Settings Menu, press the DHW button to change the setpoint temperature when the boiler is responding to a call for DHW. The “DHW Setpoint” is the setpoint of the boiler supply temperature during a call for DHW. Control of the potable water temperature is accomplished using the thermostat on the storage type indirect water heater.
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D. Enter Service Contact Information If desired, the technician can enter contact information so that the owner knows who to contact for future service. To do this: 1) From the Main Menu, press the DIAGNOSTICS button. 2) From the Diagnostic Menu, press either the INSTALLER or MORE button (only one will be visible depending on whether you are “logged in”).
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From Main Menu (Figure 12.0) Password Required 0 s Copy Service Contact Instructions (with Wiley) from existing IOM FIGURE 12.7: DIAGNOSTIC MENU (SEE PART D AND SECTION XIV FOR ADDITIONAL INFORMATION)
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2) Current Priority Screen: a) Current Demand - The demand to which the boiler is currently responding. If more than one demand is present, it is the one having the highest priority. See above descriptions under “Home Screen” for specific types of Current Demands. b) Setpoint - The temperature that the boiler is currently trying to achieve. c) Supply (or Header) Temperature - The actual water temperature at the current setpoint location (either the boiler supply or header, depending on the demand and what setpoint location was selected in the Configuration Menu).
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FIGURE 12.8: STATUS MENU (SEE PART E FOR ADDITIONAL INFORMATION)
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5) Modulation Status Screen: a) Fan Speed - Current actual fan speed in RPM b) Setpoint - Current target fan speed in RPM c) Speed Control - Indicates the function currently controlling fan speed (and therefore firing rate). Typical possibilities include: • Off - Blower is off. • Burner system - The blower speed is being determined by that needed for pre-purge, ignition, or post purge. •...
XIII. Service and Maintenance WaRnInG • asphyxiation Hazard. Fire Hazard. Explosion 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 loss of life.
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notICE Warranty does not cover boiler damage or malfunction if the following steps are not performed at the intervals specified. 1) Continuously: Keep the area around the boiler free from combustible materials, gasoline and other flammable vapors and liquids. Keep the area around the combustion air inlet terminal free from contaminates. Keep the boiler room ventilation openings open and unobstructed.
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FLEXIBLE GAS LINE WHEN DISCONNECTING FLEXIBLE GAS LINE CONNECTION PLACE A BACKUP WRENCH ON THIS NUT TO PREVENT DAMAGE TO THE GAS VALVE. FIGURE 13.0: DISCONNECTING FLEXIBLE GAS LINE BURNER DOOR MOUNTING NUT (FOUR PLACES) FLAME ROD IGNITION ELECTRODE FIGURE 13.1: FLAME IONIZATION ELECTRODE AND IGNITION ELECTRODE LOCATION...
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Unplug the ignition, ground, and flame rod wires from the ignition electrode and the flame rod (Figure 13.1). Use a 10mm wrench to remove the four nuts securing the fire door to the heat exchanger (Figure 13.1). Carefully remove the door/blower/gas valve assembly from the heat exchanger, being careful not to damage the refractory insulation on the inside of the door (see Refractory Warning on next page) or the electrodes. k.
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Important Product Safety Information Refractory Ceramic Fiber Product Warning: The Repair Parts list designates parts that contain refractory ceramic fibers (RCF). RCF has been classified as a possible human carcinogen. When exposed to temperatures above 1805°F, such as during direct flame contact, RCF changes into crystalline silica, a known carcinogen.
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FIGURE 13.2: IGNITION ELECTRODE GAP FIGURE 13.3: CONDENSATE TRAP EXPLODED PARTS VIEW...
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Refer to Part VII (Venting) to re-assemble any vent system components that are disassembled during this inspection. Also refer to Part VII for details on supporting, pitching, and terminating the vent system. Replace any wiring which has been disconnected. Inspect the hydronic system. Look for leaks and repair any found. If system contains antifreeze, or other additives, test and/or maintain them as directed by the additive manufacturer.
XIV. Troubleshooting 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.
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a) Soft Lockout - A soft lockout prevents the boiler from firing until the problem has been corrected and, in some cases, a specified amount of time (up to 1 hour, depending on the nature of the fault) has passed. An example of the Fault Menu structure during a soft lockout is shown in Figure 14.0 b) Hard Lockout - A hard lockout prevents the boiler from firing until the problem has been corrected AND the boiler has been manually reset. This can either be done at the boiler control itself or on the hard lockout screen. An example of the Fault Menu structure during a hard lockout is shown in Figure 14.2.
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PHNTM080 FIGURE 14.0: EXAMPLE OF DIAGNOSTIC MENU DURING SOFT LOCKOUT APS Definitely Closed External Limits Definitely Closed Sump Switch/TF Definitely Open Flow Switch Could be Open or Closed FIGURE 14.1: READING LIMIT STATUS SCREEN...
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PHNTM080 214F Reset Boiler Here or at Sola Control FIGURE 14.2: EXAMPLE OF DIAGNOSTIC MENU DURING HARD LOCKOUT Thermal Fuse – The thermal fuse is designed to prevent boiler operation in the event that the heat exchanger is damaged by excessive flue gas temperatures. It is set to open at 358F and is a one shot non-replaceable device. If this fuse opens, the heat...
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START Is display Is “ER**” present in completely upper left corner of dark? screen? Is boiler control’s green power light Is boiler fan running at high Consult factory speed? Loose or defective Loose or defective display harness wiring connection between the Mismatched display and boiler control software Is 120VAC present display and terminal J3 on across 120V Line Unauthorized Modbus application – interrupt boiler control. connections L & N on power to the boiler. If normal display re‐ Defective Display High Voltage PCB? appears, restore factory settings. Temporary error caused by noise – interrupt power to the boiler and see if error clears. Defective display. Is 24VAC present between J8‐1 and J8‐2 (Blue and Yellow) ...
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FLUE TEMPERATURE SENSOR THERMAL FUSE SUMP PRESSURE SWITCH PROVING SWITCH RETURN SENSOR GAS VALVE SUPPLY SENSOR FLOW SWITCH PUMP FUSE 24V FUSE COMBUSTION FAN FIGURE 14.4: CONTROLS LOCATION Air Proving Switch (APS) – This pressure switch is normally open and is connected to the outlet tapping on the gas valve as shown in Figure 14.5.
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FIGURE 14.5: PRESSURE SWITCH TUBING CONNECTIONS • Seized or disconnected boiler pump • Blown Pump Fuse Supply Sensor – The boiler control infers the supply temperature based on the resistance measured at the supply sensor. Table 14.6a shows this resistance as a function of water temperature. Because the control/supply sensor is used as the boiler’s water temperature limit control, there are actually two “thermistors” in the supply sensor wired in parallel (Figure 10.5). The control compares the resistances across these two thermistors and prevents boiler operation if there is a significant difference between the readings.
Table 14.6b: Outdoor Air Temperature Sensor Table 14.6a: Supply, Return and Flue Temperature versus Resistance Temperature Sensor Temperature versus Resistance Outdoor Temperature Ohms of Resistance °F °C Temperature Ohms of Resistance -28.9 106926 °F °C -23.3 80485 32624 19897 -17.8 61246 -12.2 47092...
XV Parts The following parts may be obtained from any Crown distributor. To find the closest Crown distributor, consult the area Crown representative or the factory at: Crown Boiler Co. Customer Service P.O. Box 14818 Philadelphia, PA 19134 www.crownboiler.com NOTE • When replacing boiler pump, use only one recommended by Crown for use with this boiler. • Grundfos 26-99 must always be set at speed 3.
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QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN FIXING CLAMP BRACKET 2 EA 430003 430004 430005 430006 430006 HOLDING CLAMP 430002 2 EA 2 EA 2 EA 2 EA 2 EA M4 x 6mm FIXING CLAMP SCREW 900240 4 EA 4 EA...
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QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN M5 x 20mm SET SCREW 9000021 4 EA 4 EA 4 EA 4 EA 4 EA BLOWER OUTLET GASKET 430030 1 EA 1 EA 1 EA 1 EA 1 EA M5 LOCKNUT 900003 4 EA...
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Blower/Gas Valve Assembly for 80, 100, 120...
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Blower/Gas Valve Assembly for 150, 180...
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QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN GASKET, CONDENSATE TRAP 430105 1 EA 1 EA 1 EA 1 EA 1 EA CONDENSATE TRAP BRACKET 430106 1 EA 1 EA 1 EA 1 EA 1 EA CONDENSATE TRAP (INCLUDES 53A) 430100 1 EA 1 EA...
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QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN BASE-REAR PANEL 1 EA 430303 430303 430303 430304 430304 BOTTOM SECURING BRACKET 430420 1 EA 1 EA 1 EA 1 EA 1 EA HANGING BRACKET, BOILER 430435 1 EA 1 EA 1 EA 1 EA...
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QUANTITY PER BOILER OR CROWN QTY. OR PART NUMBER DESCRIPTION CROWN 3” STAINLESS STEEL RODENT SCREEN 230833 2 EA 2 EA 2 EA 2 EA 2 EA 3” X 30” SCHEDULE 40 CPVC PIPE 230823 1 EA 1 EA 1 EA 1 EA 1 EA 3”...
WaRnInG • PHntM080, PHntM180 - Do not attempt to convert PHntM080 for use with lP gas at altitudes above 2000ft. also, do not attempt to convert PHntM180 for use with lP gas at altitudes above 7800ft. attempts to do so may result in unreliable operation, property damage, personal injury, or loss of life due to carbon monoxide (Co) poisoning.
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All Phantom boilers are factory configured for use on Natural gas at altitudes below 2000 feet. Perform the steps listed in these instructions if either, or both, of the following are true: • Boiler is to be used with LP gas • Boiler is to be installed at an altitude above 2000ft. Follow steps 1-13 below in the order they are presented. Steps applying to only one type of conversion (LP or altitude) may be skipped if that type of conversion is not being performed. 1) If not already done, install the boiler in accordance with this manual, following all instructions in Part XI (Start-up and Check-out) up to Step 10.
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WaRnInG • the throttle adjustments shown in table a.2 are approximate. the final throttle setting must be found using a combustion analyzer. leaving the boiler in operation with a Co level in excess of 200PPM air-free could result in injury or death from carbon monoxide poisoning. leaving the boiler in operation with a Co2 level outside of the range shown in table a.4 could also result in injury or death from carbon monoxide poisoning, even if the boiler is operating at an air-free Co level below 200PPM during this adjustment procedure.
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FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1a: GAS VALVE DETAIL (80MBH THRU 120MBH) FIGURE A.1b: GAS VALVE DETAIL (150MBH, 180MBH) TABLE A.2: STARTING NUMBER OF THROTTLE TURNS FOR CONVERSION TO LP GAS MODEL # COUNTERCLOCKWISE TURNS (FROM FULLY CLOSED) 3-3/4 5-3/4 6-1/2...
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Home Screen (Password Access Revoked When Operator Returns Here) Password Required Home Screen After Setting Altitude: Pressing large button cycles through altitude ranges. Press SET to save change To restore original option before SET is pressed, press CANCEL or EXIT. Altitude ranges above 2000ft appear here in thousands of feet (2000 ‐ 4500ft shown) FIGURE A.3: ALTITUDE CONVERSION NAVIGATION...
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TABLE A.4: ACCEPTABLE COMBUSTION READINGS Max Co allowable Co2 Readings (%) (PPM air-Free) Model Fuel sea level - 2000 ft 2001 - 4500 ft 4501 - 7800 ft 7801 - 10200 ft all altitudes nat. Gas 8.7 - 9.3 8.7 - 9.2 8.7 - 9.1 8.7 - 9.1 10.1 - 10.3...
Appendix B: Special Requirements For Side-Wall Vented Appliances In The Commonwealth of Massachusetts IMPORTANT The Commonwealth of Massachusetts requires compliance with regulation 248 CMR 4.00 and 5.00 for installation of side-wall vented gas appliances as follows: (a) For all side wall horizontally vented gas fueled equipment installed in every dwelling, building or structure used in whole or in part for residential purposes, including those owned or operated by the Commonwealth and where the side wall exhaust vent termination is less than seven (7) feet above finished grade in the area of the venting, includ- ing but not limited to decks and porches, the following requirements shall be satisfied:...
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1. Detailed instructions for the installation of the venting system design or the venting system components; and 2. A complete parts list for the venting system design or venting system. (d) MANUFACTURER REQUIREMENTS - GAS EQUIPMENT VENTING SYSTEM NOT PROVIDED. When the manufacturer of a Product Approved side wall horizontally vented gas fueled equipment does not provide the parts for venting the flue gases, but identifies “special venting systems”, the following requirements shall be satisfied by the manufacturer:...
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Manufacturer of Hydronic Heating Products P.O. Box 14818 3633 I. Street Philadelphia, PA 19134 www.crownboiler.com PN 980125 Rev D, 12/14...
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