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3

SAFETY INSTRUCTIONS

Table of Contents

Default Chapter1
- Installation and Operation1
Safety Instructions2
Table of Contents8
1 Code Requirements12
- Regulations and Guidelines12
  - Commonwealth of Massachusetts13
  - Installation Requirements13
2 General Information14
- Key to Symbols Used14
- Manufactured by14
- Description of Models14
3 Main Components15
4 Function Overview25
- Intended Use and Functions29
  - Intended Use and Functions of the IB Boiler29
  - Intended Use and Functions of the IW Water Heater29
- Efﬁ Ciency up to 98% (IB Boiler Only)29
5 INSTALLATION - Location30
- Choosing the Installation Location30
  - Location of an IB Boiler30
  - Location of a IW Water Heater30
- Residential Garage Installation30
- Closet and Alcove Installations31
- Clearances for Installation and Servicing31
- Clearances from Combustible Material31
- Vent and Combustion Air Piping31
- Prevent Combustion Air Contamination31
6 INSTALLATION - Mounting the Heater34
- Transporting the Heater34
- Mounting the Heater34
- Dimensions35
7 INSTALLATION - IB Boiler Water Connection38
- IB Boiler Water Connections38
- Supply and Return Piping38
8 INSTALLATION - IW Water Connections44
- IW Water Heaters' Water Connections44
- Hot and Cold Water Piping44
- Scalding46
- Water Chemistry47
9 INSTALLATION - Condensate Disposal50
- Condensate Disposal50
10 INSTALLATION - Electrical Connections52
- Electrical Connections: Overview52
- Connecting the IB Boiler to an Indirect Water Heater55
  - Indirect Water Heater Priority Selection55
- Connecting the IW Water Heater to a Storage Tank55
- Connecting the Heater in Cascade59
11 INSTALLATION - Vent and Combustion Air60
- Removing of a Heater from a Common Venting System60
- Prevent Combustion Air Contamination61
- Venting and Air Piping Systems61
- Minimum / Maximum Allowable Combustion Air and Vent Piping Lengths63
- Install Vent and Combustion Air Piping63
- Air Inlet Pipe Materials65
  - Sealing of PVC, CPVC or ABS Air Inlet Pipe65
- PVC/CPVC Vent Piping Materials66
- Stainless Steel Vent Piping Materials68
  - Stainless Steel Air Intake Connection69
  - Stainless Steel Vent Connection69
- Polypropylene Vent Piping Materials70
  - Polypropylene Air Intake Connection71
  - Polypropylene Vent Connection71
- Single Pipe Vent (Not Sealed Combustion)72
  - Combustion Air and Ventilation Openings72
  - Determine Location73
- Sidewall Termination - Two Pipes74
- Sidewall Termination - Concentric Vent77
- Vertical Termination - Two Pipes79
- Vertical Termination - Concentric Vent81
12 INSTALLATION - Gas Supply83
- Gas Supply Piping83
- Pipe Sizing for Natural Gas84
- Propane Gas84
- Check Inlet Gas Supply Pressure85
- Operating at High Altitudes85
- Convert a Heater Model 199 from Natural Gas to Propane Gas or Viceversa86
- Convert a Heater Model 399, 500, 750 or 1000 from Natural Gas to Propane Gas or Viceversa88
13 Start-Up90
- Operating90
- General Warnings Concerning Gas Supply90
- Natural Gas91
- Conﬁ Rming the Heater's Gas Type91
- Gas Type Conversion91
- Start-Up91
  - Start-Up of the IB Boiler91
  - Start-Up of the IW Water Heater91
- Ignition Control Testing91
- Gas Supply Pressure Checking92
- Checking and Adjusting CO2 Levels93
  - Checking CO2 Level on Units Model 19993
  - Checking CO2 Level on Units Model 399 up to 100093
- Check the Capacity Input94
- Minimum Water Fl Ow94
14 Use95
- Check Water Pressure96
  - Check Water Pressure on IB Boiler96
  - Check Water Pressure on IW Water Heater96
- Overview96
- Displays96
- Start-Up Procedure96
- IW Supply Water Temperature Adjustment96
- IB Boiler - Indirect Water Heater Temperature Adjustment97
- IB Boiler - Heating Temperature Adjustment97
- IB Boiler - Outdoor Reset Adjustment97
  - Outdoor Reset Applications97
  - Outdoor Reset: Setting Parameters97
- Delays, Alarms and Protective Actions99
- Circulator Pump Protection99
- Heater's Freeze Protection99
- Display in Energy Saver Mode99
- Users' Menu100
- Installer's Menu101
- Diagnostic102
- Diagnostic: Lockouts "Loc103
- Diagnostic: Blocking Errors "Err105
- Flue Blocked Pressure Switch106
- Shuts Heater down106
- How to Clean the Appliance Jacket106
15 Maintenance107
- Care and Maintenance107
- Removing the Casing110
- Cleaning the Burner and Primary Heat Exchanger, Fl Ue Gas Side111
- Correct Positioning of the Ignition and Fl Ame Detection Electrodes113
- Clean the Air Fi Lter113
- Condensate Trap and Neutralizing Box Maintenance and Cleaning114
- Connection of the Display to Other Burners115
- How to Move a Control Board116
- Draining the Water from the Heater117
- Water and Fl Ue Temperature Sensor117
- Outdoor Temperature Sensor117
- 199 Model Wiring Diagram118
- 399 To 1000 Models Wiring Diagram120
16 Technical Data124
17 Spare Parts126
18 Read out Flow Chart148
19 Factory Menu149
20 SEQUENCE of OPERATION for BOILER152
21 SEQUENCE of OPERATION for WATER HEATER153

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