Lochinvar Noble NKC 199 User manual

100275092_2000533999_Rev G
If the information in this manual is not followed exactly, a fire or
explosion may result causing property damage, personal injury or
loss of life.
This appliance MUST NOT be installed in any location where
gasoline or flammable vapors are likely to be present.
WHAT TO DO IF YOU SMELL GAS
• Do not try to light any appliance.
• Do not touch any electric switch; do not use any phone in your
building.
• Immediately call your gas supplier from a near by phone.
Follow the gas supplier’s instructions.
• If you cannot reach your gas supplier, call the fire department.
• Installation and service must be performed by a qualified
installer, service agency, or the gas supplier.
WARNING
Save this manual for future reference.
FIRE TUBE COMBI
™
Noble Fire Tube Boiler and Combi
User Manual
NKC 110 - 199
NKB 80 - 150

2
Hazard definitions
The following defined terms are used throughout this manual to bring attention to the presence of hazards of various risk levels or
to important information concerning the life of the product.
DANGER
WARNING
CAUTION
CAUTION
NOTICE
DANGER indicates an imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
injury.
CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
avoided, may result in property damage.
NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
related to personal injury or property damage.
Contents
HAZARD DEFINITIONS .................................................... 2
PLEASE READ BEFORE PROCEEDING ........................ 3
1. PREVENT COMBUSTION AIR CONTAMINATION..... 4
2. MAINTENANCE SCHEDULE....................................... 5
Maintenance Procedures................................................... 6
Boiler Must Be Serviced and Maintained .................... 6
Check Boiler Area......................................................... 6
Check Pressure Temperature Gauge........................... 6
Check Vent Piping........................................................ 6
Check Air Piping........................................................... 6
Check Relief Valve....................................................... 6
Inspect Condensate System...................................... 6-7
Test Low Water Cutoff (if installed).............................. 8
Reset Button (low water cutoff).................................... 8
Check Boiler Piping (gas and water)............................ 8
Operate Relief Valve .................................................... 8
Shut Boiler Down.......................................................... 8
3. OPERATING INSTRUCTIONS..................................... 9
4. SMART SYSTEM CONTROL MODULE
SMART SYSTEM Control Module................................... 10
Access Modes ............................................................ 10
Saving Parameters..................................................... 10
Set Space Heating Operation..................................... 11
Set Domestic Hot Water (DHW) Operation.................11
Status Display Screens ......................................... 12-13
Revision Notes.................................................. Back Cover

Please read before proceeding
The Noble Combi Boiler Installation
and Service Manual is for use only by
a qualified heating installer/service
technician. Refer only to this User’s
Information Manual for your reference.
Improper installation, adjustment,
alteration, service or maintenance can
cause property damage, personal injury
(exposure to hazardous materials) or loss
of life. Installation and service must be
performed by a qualified installer, service
agency or the gas supplier (who must
read and follow the supplied instruction
before installing, servicing, or removing
this boiler. This boiler contains materials
that have been identified as carcinogenic,
or possibly carcinogenic, to humans).
Failure to adhere to the guidelines on this
page can result in severe personal injury,
death, or substantial property damage.
Boiler service and maintenance –
• To avoid electric shock, disconnect electrical supply
before performing maintenance.
• To avoid severe burns, allow boiler to cool before
performing maintenance.
Boiler operation –
• Do not block flow of combustion or ventilation air to
the boiler. This boiler is equipped with a control which
will automatically shut down the boiler should air or
vent be blocked. If vent or air blockage is easily
accessible and removable, remove it. The boiler should
attempt to restart. If blockage is not obvious or cannot
be removed, have the boiler and system checked by a
qualified service technician.
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to the
circulator. Instead, shut off the gas supply at a location
external to the appliance.
• Do not use this boiler if any part has been under water.
The possible damage to a flooded appliance can be
extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Boiler water –
• Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
heat exchanger can be damaged by build-up or
corrosion due to sediment.
• Do not use petroleum-based cleaning or sealing
compounds in the boiler system. Gaskets and seals in
the system may be damaged. This can result in
substantial property damage.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
and/or property may result.
• Continual fresh make-up water will reduce boiler life.
Mineral buildup in the heat exchanger reduces heat
transfer, overheats the stainless steel heat exchanger,
and causes failure. Addition of oxygen carried in by
makeup water can cause internal corrosion. Leaks in
boiler or piping must be repaired at once to prevent
makeup water.
Freeze protection fluids –
• NEVER use automotive antifreeze. Use only inhibited
propylene glycol solutions, which are specifically
formulated for hydronic systems. Ethylene glycol is
toxic and can attack gaskets and seals used in hydronic
systems.
When calling or writing about the boiler
– Please have the boiler model and serial
number from the boiler rating plate.
Consider piping and installation when
determining boiler location.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
the consignee.
Factory warranty (shipped with unit) does
not apply to units improperly installed or
improperly operated.
3
NOTICE
WARNING
NOTICE
WARNING DO NOT install units in rooms or
environments that contain corrosive
contaminants (see Table 1 on page 4).
Failure to comply could result in severe
personal injury, death, or substantial
property damage.
User’s Information Manual
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1 Prevent combustion air contamination
4
If the boiler combustion air inlet is located
in a laundry room or pool facility, for
example, these areas will always contain
hazardous contaminants.
To prevent the potential of severe
personal injury or death, check for areas
and products listed in Table 1 before
installing the boiler or air inlet piping.
If contaminants are found, you MUST:
• Remove contaminants permanently.
—OR—
• Relocate air inlet and vent
terminations to other areas.
WARNING
WARNING
Products to avoid:
Spray cans containing chloro/fluorocarbons
Permanent wave solutions
Chlorinated waxes/cleaners
Chlorine-based swimming pool chemicals
Calcium chloride used for thawing
Sodium chloride used for water softening
Refrigerant leaks
Paint or varnish removers
Hydrochloric acid/muriatic acid
Cements and glues
Antistatic fabric softeners used in clothes dryers
Chlorine-type bleaches, detergents, and cleaning solvents
found in household laundry rooms
Adhesives used to fasten building products and other similar
products
Areas likely to have contaminants
Dry cleaning/laundry areas and establishments
Swimming pools
Metal fabrication plants
Beauty shops
Refrigeration repair shops
Photo processing plants
Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops
Table 1 Corrosive Contaminants and Sources
WARNING If the boiler combustion air inlet is located
in any area likely to cause contamination,
or if products which would contaminate
the air cannot be removed, you must have
the combustion air and vent re-piped
and terminated to another location.
Contaminated combustion air will damage
the boiler, resulting in possible severe
personal injury, death, or substantial
property damage.
Pool and laundry products and common household
and hobby products often contain fluorine or chlorine
compounds. When these chemicals pass through the boiler,
they can form strong acids. The acid can eat through the
boiler wall, causing serious damage and presenting a possible
threat of flue gas spillage or boiler water leakage into the
building.
Please read the information listed in Table 1. If contaminating
chemicals will be present near the location of the boiler
combustion air inlet, have your installer pipe the boiler
combustion air and vent to another location, per the Noble
Combi Boiler Installation and Service Manual.
User’s Information Manual
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2 Maintenance schedule
5
Service technician
General:
• Address reported problems
•Inspect interior; clean and vacuum if
necessary;
• Clean condensate trap
•Check for leaks (water, gas, flue,
condensate)
• Verify flue and air lines in good condition
and sealed tight
•Check system water pressure/system
piping/expansion tank
• Check fill water meter
• Test boiler water. When test indicates,
clean system water with approved
system restorer following manufacturer’s
information.
• Check control settings
• Check ignition electrodes (sand off any
deposits; clean and reposition)
• Check wiring and connections
•Perform start-up checkout and
performance verification per Section 10
of this manual.
• Flame inspection (stable, uniform)
• Flame signal (at least 10 microamps at
high fire)
• Clean the heat exchanger if flue
temperature is more than 54°F above
return water temperature.
• Inspect and clean the DHW flow switch filter
and sanitary bypass filter in the Combi water
set.
If combustion or performance indicate
need:
• Clean heat exchanger
•Remove and clean burner using
compressed air only
• Clean the blower wheel
Owner maintenance
(see pages 6 - 8 for detailed instructions)
Daily
• Check boiler area
•Check pressure/temperature
gauge
Monthly
• Check vent piping
• Check air piping
• Check air and vent termination
screens
• Check relief valve
• Inspect condensate drain system
Periodically • Test low water cutoff (if used)
• Reset button (low water cutoff)
Every
6 months
•Check boiler piping (gas and
water) for leaks
• Operate relief valve
End
of season
months
•Shut boiler down (unless boiler
used for domestic hot water)
WARNING Follow the maintenance procedures given throughout this manual. Failure to perform the service and
maintenance or follow the directions in this manual could result in damage to the boiler or system,
resulting in severe personal injury, death, or substantial property damage.
ANNUAL START-UP
User’s Information Manual
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2 Maintenance schedule
6
Maintenance procedures
Boiler must be serviced and maintained
WARNING The boiler must be inspected and started
annually at the beginning of the heating
season by a qualified service technician.
In addition, the maintenance and care
of the boiler designated on page 5 of this
manual and explained on pages 6 through
8 must be performed to assure maximum
boiler efficiency and reliability. Failure to
service and maintain the boiler and system
could result in equipment failure, causing
possible severe personal injury, death, or
substantial property damage.
NOTICE The following information provides
detailed instructions for completing
the maintenance items listed in the
maintenance schedule on page 5. In
addition to this maintenance, the boiler
must be serviced and started up at the
beginning of each heating season by a
qualified service technician.
Check boiler area
WARNING To prevent potential of severe personal
injury, death, or substantial property
damage, eliminate all materials discussed
below from the boiler vicinity and the
vicinity of the boiler combustion air inlet.
If contaminants are found:
Remove products immediately from the
area. If they have been there for an
extended period, call a qualified service
technician to inspect the boiler for possible
damage from acid corrosion.
If products cannot be removed,
immediately call a qualified service
technician to re-pipe vent and air piping
and locate vent termination/air intake
away from contaminated areas.
1. Combustible/flammable materials -- Do not store
combustible materials, gasoline or any other flammable
vapors or liquids near the boiler. Remove immediately if
found.
2. Air contaminants -- Products containing chlorine or
fluorine, if allowed to contaminate the boiler intake air,
will cause acidic condensate in the boiler. This will cause
significant damage to the boiler if allowed to continue.
Read the list of potential materials listed in Table 1 on
page 4 of this manual. If any of these products are in the
room from which the boiler takes its combustion air, they
must be removed immediately or the boiler combustion
air (and vent termination) must be relocated to another
area.
Check pressure/temperature gauge
1. Make sure the pressure reading on the boiler pressure/
temperature gauge does not exceed 24 psi. Higher
pressure may indicate a problem with the expansion
tank.
2. Contact a qualified service technician if problem persists.
Check vent piping
1. Visually inspect the flue gas vent piping for any signs of
blockage, leakage, or deterioration of the piping. Notify
your qualified service technician at once if you find any
problems.
WARNING Failure to inspect the vent system as noted
above and have it repaired by a qualified
service technician can result in vent system
failure, causing severe personal injury or
death.
Check air piping
1. Visually inspect the air inlet termination to be sure it is
unobstructed. Inspect the entire length of air piping to
ensure piping is intact and all joints are properly sealed.
2. Call your qualified service technician if you notice any
problems.
Check relief valve
1. Inspect the boiler relief valve and the relief valve
discharge pipe for signs of weeping or leakage.
2. If the relief valve often weeps, the expansion tank may
not be working properly. Immediately contact your
qualified service technician to inspect the boiler and
system.
Inspect condensate system
Inspect/check condensate lines and fittings
Inspect the condensate drain line, condensate PVC fittings
and condensate trap (FIG. 2-1).
User’s Information Manual
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2 Maintenance schedule (continued)
7
Figure 2-2 Condensate Disposal
User’s Information Manual
Condensate drain
1. This boiler is a high efficiency appliance that produces
condensate.
2. The bottom of the boiler has a 3/4 inch pipe for
connection of a 3/4 inch PVC pipe (FIG. 2-2).
3. Slope condensate tubing down and away from the
boiler into a drain or condensate neutralizing filter.
Condensate from the Noble Combi Boiler will be
slightly acidic (typically with a pH from 3 to 5). Install
a neutralizing filter if required by local codes.
A Neutralizer Kit is available from the factory.
4. Do not expose condensate line to freezing temperatures.
5. Use only plastic tubing or piping as a condensate drain
line (FIG. 2-2).
Clean/Inspect Trap Assembly
Remove the clean out cap on the bottom of the trap. Let
the condensate and any debris drain out.
DIR #2000529332 00
HOSE BARB
MOUNTING NUT
FLOAT BALL
CONDENSATE
DRAIN
REMOVABLE CAP
TO CLEAN OUT TRAP
Figure 2-1 Condensate Trap
Use materials approved by the authority
having jurisdiction. In the absence of other
authority, PVC and CPVC pipe must comply
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493. For Canada use CSA or ULC certified
PVC or CPVC pipe, fittings, and cement.
6. A condensate removal pump is required if the boiler is
below the drain. When installing a condensate pump, select
one approved for use with condensing boilers and furnaces.
The pump should have an overflow switch to prevent
property damage from condensate spillage.
NOTICE
NOTICE To allow for proper drainage on large
horizontal runs, a second line vent may be
required and tubing size may need to increase
to 1 inch.
The condensate line must remain
unobstructed, allowing free flow of
condensate. If condensate is allowed to
freeze in the line or if the line is obstructed in
any other manner, condensate can exit from
the boiler tee, resulting in potential water
damage to property.
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2 Maintenance schedule
8
WARNING Have leaks fixed at once by a qualified
service technician. Failure to comply
could result in severe personal injury,
death, or substantial property damage.
Operate relief valve
1. Before proceeding, verify that the relief valve outlet has
been piped to a safe place of discharge, avoiding any
possibility of scalding from hot water.
WARNING To avoid water damage or scalding due
to valve operation, a metal discharge
line must be connected to the relief
valve outlet and run to a safe place of
disposal. This discharge line must be
installed by a qualified heating installer
or service technician in accordance with
the instructions in the Noble Combi
Boiler Installation and Service Manual.
The discharge line must be terminated
so as to eliminate possibility of severe
burns or property damage should the valve
discharge.
2. Read the boiler pressure/temperature gauge to make
sure the system is pressurized. Lift the relief valve
top lever slightly, allowing water to relieve through
the valve and discharge piping.
3. If water flows freely, release the lever and allow the valve
to seat. Watch the end of the relief valve discharge pipe
to ensure that the valve does not weep after the line has
had time to drain. If the valve weeps, lift the seat again to
attempt to clean the valve seat. If the valve continues to
weep afterwards, contact your qualified service
technician to inspect the valve and system.
4. If water does not flow from the valve when you lift the
lever completely, the valve or discharge line may be
blocked. Immediately shut down the boiler, following
the operating instructions on page 9 of this manual. Call
your qualified service technician to inspect the boiler and
system.
Shut boiler down (unless boiler is used
for Domestic Water)
1. Follow “To Turn Off Gas to Appliance” on page 9 of this
manual.
2. Do not drain the system unless exposure to freezing
temperatures will occur.
3. Do not drain the system if it is filled with an antifreeze
solution.
4. DO NOT shut down boilers used for domestic water
heating, they must operate year-round.
3. Replace the front access door.
Test low water cutoff (if installed)
1. If the system is equipped with a low water cutoff, test the
low water cutoff periodically during the heating season,
following the low water cutoff manufacturer’s
instructions.
Reset button (low water cutoff)
1. Testing the low water cutoff shuts the unit off. Press the
RESET button on the low water cutoff to turn the unit
back on.
Check boiler piping (gas and water)
1. Remove the boiler front access door and perform a gas
leak inspection per steps 1 through 7 of the Operating
Instructions on page 9. If gas odor or leak is detected,
immediately shut down the boiler following the
procedures on page 9. Call a qualified service
technician.
2. Visually inspect for leaks around water piping.
Also inspect the circulators, relief valve, and fittings.
Immediately call a qualified service technician to repair
any leaks.
User’s Information Manual
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9
3 Operating instructions
User’s Information Manual
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4 SMART SYSTEM control module
10
User’s Information Manual
Noble Combi Boiler control module
Figure 4-1 Control Panel
Use the control panel (FIG. 4-1) to set temperatures, operating conditions, and monitor boiler operation.
DISPLAY WINDOW
RESET BUTTON
LEFT BUTTON RIGHT BUTTON
DOWN BUTTON
UP BUTTON
The information below shows the functions of the buttons
on the display:
MENU / ENTER = ►
SETPOINTS = ▲and ▼
SAVE = ◄
RESET = ●
Saving parameters
To save parameters and exit programming:
Press the ►button to go to the end of the Parameter List,
then press ►again. Otherwise, the parameters will be saved
automatically after Timeout.
To enter a parameter and continue programming:
Press the ▲or ▼button to change parameters. Press ►to
move to the next parameter and to the end of the Parameter
List. Press ◄to save and return to the Base Screen. Otherwise,
the parameters will be saved automatically after Timeout.
Access modes
User
Press the ◄button.
Installer
Most parameters are available only to the installer, accessible
by entering the installer menu: Press the ►button.
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11
4 SMART SYSTEM control module (continued)
User’s Information Manual
Adjust DHW set point temperature
1. Press the
◄button to access the SETPTS Menu.
2. Press the ►button to page to the DHW SETPT
parameter.
3. Press the
▲and ▼buttons to adjust the set point.
4. Press the
◄button to save the new DHW set point and
return to the default screen.
Set space heating operation
Determine controlling sensor
For space heating systems, the temperature control can be
based on the outlet or the system supply sensor (optional).
The control will automatically switch to the system supply
sensor once it is connected.
Verify space heat circulator operation
The Space Heating Mode controls the boiler pump and the
diverter valve. When the boiler control receives a space
heating call for heat and the boiler is not heating a DHW
(Domestic Hot Water) call, and the set point is not met, it
turns on the boiler pump and places the diverter valve in the
space heating position. After the space heating call for heat
ends, the boiler pump continues to run for a short period of
time. This pump delay is factory set to 30 seconds. After this
pump delay, the pump is turned off and the diverter valve is
placed into the DHW position.
Adjust set point temperature
1. Press the ◄button to access the SETPTS Menu.
2. Press the ▲and ▼buttons to adjust the SH SETPT (Cold
Day) parameter.
3. Pressthe◄button to save the new SHset point and return
to the default screen.
Set domestic hot water (DHW) operation
Verify DHW operation
The DHW Heating Mode controls the boiler pump and the
diverter valve. When the boiler control receives a DHW call
for heat from the DHW flow switch, it turns on the boiler
pump and puts the diverter valve in the DHW position to
route boiler water through the brazed plate heat exchanger.
During the call, the boiler control will modulate to maintain
the DHW outlet temperature to the DHW set point.
After the DHW call for heat ends, the boiler pump continues
to run for a short period of time. This pump delay is factory
set to 30 seconds.
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12
Figure 4-2 Status Display Screen
4 SMART SYSTEM control module
User’s Information Manual
OPERATION DISPLAY
1. Once the gas pressure switch(es) are closed, the control turns
on the appropriate pumps (system and boiler pumps for space
heating, DHW pump for DHW). The LWCO must close.
Upon a call for heat, the control turns on the appropriate pumps.
The LWCO must close. Once the LWCO has closed, the
auxiliary limit switch must close.
2. The control turns on power to the louver relay. The louver
proving switch, and blocked drain switch must close.
3. The control starts the prepurge cycle by initiating the blower.
4. The control starts the trial for ignition by firing the spark
electrode and opening the gas valve.
5. If flame is not detected after the sparking ends, the control will
perform a postpurge, then start another prepurge cycle and try
to light the burner again. The control will perform a total of 4
attempts before locking out.
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4 SMART SYSTEM control module (continued)
13
User’s Information Manual
OPERATION DISPLAY
6. If flame is detected, it holds the firing rate steady for a few
seconds to let the flame stabilize, then it begins to modulate the
firing rate based on a set point or some other command.
7. If the space heating call for heat is active and the DHW flow
switch starts a DHW call for heat, the diverter valve will move to
the DHW position and the boiler will switch to the DHW Mode.
This will divert the boiler's outlet water from the heating system to
the brazed plate heat exchanger. The control will then modulate
to maintain the DHW outlet temperature at the DHW set point.
8. Once all calls for heat are satisfied, the control will turn off
the burner. The blower will continue to run during the postpurge
period.
9. Any pumps that are running will continue to run for their
respective pump delay times before turning off. A 60 second
anti-cycle period will start, which will delay any new space
heating call for heat until it times out.
10. In Standby, ready to start a new cycle.
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14
Notes
User’s Information Manual
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15
Notes
User’s Information Manual
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Revision A (PCP #3000004508 / CN #500004666) initial
release.
Revision B (PCP #3000005203 / CN #500005353) reflects the
addition of the Noble logo.
Revision C (PCP #3000008325 / CN #500008312) reflects
the addition of the need to clean the flow switch filter and the
sanitary bypass filter to the Service Technician column of the
Maintenance and Annual Startup Chart on page 5.
Revision D (PCP #3000009959 / CN #500009745) reflects
the addition of the fill water meter and check boiler water
information on page 5.
Revision E (PCP #3000010423 / CN #500010150) reflects an
update to the neutralizer information on page 7.
Revision F (PCP #3000024821 / CN #500014945) reflects the
addition of the Noble Boiler.
Revision G (PCP #3000027055 / CN #500016866) reflects the
removal of information related to an external flow switch.
MM #100275092_DIR #2000533999_Rev G
08/18