100298581_2000552611_Rev C

ProLine® XE
Combi Boiler
ProLine® XE Combi Boiler
User Manual
Models: 110 - 150 - 199
Series 100 - 101 & 110 - 111

⚠WARNING
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.
Save this manual for future reference.
 Contents
HAZARD DEFINITIONS .................................................. 2 3. OPERATING INSTRUCTIONS .................................. 9
PLEASE READ BEFORE PROCEEDING ..................... 3 4. CONTROL MODULE
1. PREVENT COMBUSTION AIR CONTAMINATION 4 Combi Boiler Control Module ........................................... 10
2. MAINTENANCE SCHEDULE .................................... 5 Access Modes ............................................................ 10
Maintenance Procedures ................................................... 6 Saving Parameters ..................................................... 10
Boiler Must Be Serviced and Maintained .................... 6 Set Space Heating Operation ..................................... 11
Check Boiler Area ......................................................... 6 Set Domestic Hot Water (DHW) Operation ................. 11
Check Pressure Temperature Gauge........................... 6 Status Display Screens ......................................... 12-13
Check Vent Piping ........................................................ 6 Revision Notes .................................................. Back Cover
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

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 indicates an imminently hazardous situation which, if not avoided, will result in death or serious
⚠ DANGER injury.

WARNING indicates a potentially hazardous situation which, if not avoided, could result in death or serious
⚠WARNING injury.

CAUTION indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate
⚠CAUTION injury.

CAUTION used without the safety alert symbol indicates a potentially hazardous situation which, if not
CAUTION avoided, may result in property damage.

NOTICE indicates special instructions on installation, operation, or maintenance that are important but not
NOTICE related to personal injury or property damage.

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Combi Boiler User’s Information Manual

Please read before proceeding

NOTICE
The Combi Boiler Installation and Service Boiler service and maintenance –
Manual is for use only by a qualified
• To avoid electric shock, disconnect electrical supply
heating installer/service technician. Refer
before performing maintenance.
only to this User’s Information Manual
for your reference. Improper installation, • To avoid severe burns, allow boiler to cool before
adjustment, alteration, service or performing maintenance.
maintenance can cause property damage,
personal injury (exposure to hazardous Boiler operation –
materials) or loss of life. Installation • Do not block flow of combustion or ventilation air to
and service must be performed by a the boiler. This boiler is equipped with a control which
qualified installer, service agency or the will automatically shut down the boiler should air or
gas supplier (who must read and follow vent be blocked. If vent or air blockage is easily
the supplied instruction before installing, accessible and removable, remove it. The boiler should
servicing, or removing this boiler. This attempt to restart. If blockage is not obvious or cannot
boiler contains materials that have been be removed, have the boiler and system checked by a
identified as carcinogenic, or possibly qualified service technician.
carcinogenic, to humans).
• Should overheating occur or gas supply fail to shut off,
do not turn off or disconnect electrical supply to the
When calling or writing about the boiler circulator. Instead, shut off the gas supply at a location
NOTICE
– Please have the boiler model and serial external to the appliance.
number from the boiler rating plate.
• Do not use this boiler if any part has been under water.
Consider piping and installation when The possible damage to a flooded appliance can be
determining boiler location. extensive and present numerous safety hazards. Any
appliance that has been under water must be replaced.
Any claims for damage or shortage in
shipment must be filed immediately
against the transportation company by
Boiler water –
the consignee. • Thoroughly flush the system (without boiler
connected) to remove sediment. The high-efficiency
Factory warranty (shipped with unit) does heat exchanger can be damaged by build-up or
not apply to units improperly installed or corrosion due to sediment.
improperly operated.
• Do not use petroleum-based cleaning or sealing
Failure to adhere to the guidelines on this compounds in the boiler system. Gaskets and seals in
⚠WARNING the system may be damaged. This can result in
page can result in severe personal injury,
death, or substantial property damage. substantial property damage.
• Do not use “homemade cures” or “boiler patent
medicines”. Serious damage to the boiler, personnel,
⚠WARNING DO NOT install units in rooms or
environments that contain corrosive and/or property may result.
contaminants (see Table 1 on page 4). • Continual fresh make-up water will reduce boiler life.
Failure to comply could result in severe Mineral buildup in the heat exchanger reduces heat
personal injury, death, or substantial transfer, overheats the stainless steel heat exchanger,
property damage. 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.

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Combi Boiler User’s Information Manual

1 Prevent combustion air contamination

If the boiler combustion air inlet is located
⚠WARNING Table 1 Corrosive Contaminants and Sources
in any area likely to cause contamination,
or if products which would contaminate
the air cannot be removed, you must have Products to avoid:
the combustion air and vent re-piped Spray cans containing chloro/fluorocarbons
and terminated to another location.
Contaminated combustion air will damage Permanent wave solutions
the boiler, resulting in possible severe
personal injury, death, or substantial Chlorinated waxes/cleaners
property damage. Chlorine-based swimming pool chemicals
If the boiler combustion air inlet is located Calcium chloride used for thawing
⚠WARNING
in a laundry room or pool facility, for
example, these areas will always contain Sodium chloride used for water softening
hazardous contaminants.
Refrigerant leaks
Pool and laundry products and common household Paint or varnish removers
and hobby products often contain fluorine or chlorine
compounds. When these chemicals pass through the boiler, Hydrochloric acid/muriatic acid
they can form strong acids. The acid can eat through the
Cements and glues
boiler wall, causing serious damage and presenting a possible
threat of flue gas spillage or boiler water leakage into the Antistatic fabric softeners used in clothes dryers
building.
Chlorine-type bleaches, detergents, and cleaning solvents
Please read the information listed in Table 1. If contaminating found in household laundry rooms
chemicals will be present near the location of the boiler Adhesives used to fasten building products and other similar
combustion air inlet, have your installer pipe the boiler products
combustion air and vent to another location, per the Combi
Areas likely to have contaminants
Boiler Installation and Service Manual.
Dry cleaning/laundry areas and establishments
To prevent the potential of severe
⚠WARNING Swimming pools
personal injury or death, check for areas
and products listed in Table 1 before Metal fabrication plants
installing the boiler or air inlet piping.
Beauty shops
If contaminants are found, you MUST:
Refrigeration repair shops
• Remove contaminants permanently.
—OR— Photo processing plants
• Relocate air inlet and vent
terminations to other areas. Auto body shops
Plastic manufacturing plants
Furniture refinishing areas and establishments
New building construction
Remodeling areas
Garages with workshops

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Combi Boiler User’s Information Manual

2 Maintenance schedule

Service technician Owner maintenance

(see pages 6 - 8 for detailed instructions)

General:
• Address reported problems
• Inspect interior; clean and vacuum if • Check boiler area
necessary; Daily • Check pressure/temperature
• Clean condensate trap gauge
• 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 vent piping
• Check fill water meter
ANNUAL START-UP

• Check air piping

• Test boiler water. When test indicates,
clean system water with approved
• Check air and vent termination
system restorer following manufacturer’s Monthly screens
information.
• Check control settings • Check relief valve
• Check ignition electrodes (sand off any
deposits; clean and reposition) • Inspect condensate drain system
• Check wiring and connections
• Perform start-up checkout and
performance verification per Section 10 • Test low water cutoff (if used)
of the Installation and Service Manual. Periodically
• Flame inspection (stable, uniform) • Reset button (low water cutoff)
• Flame signal (at least 10 microamps at
high fire)
• Check boiler piping (gas and
• Clean the heat exchanger if flue Every water) for leaks
temperature is more than 54°F above
return water temperature.
6 months
• Operate relief valve
• Inspect and clean the DHW flow switch filter
and sanitary bypass filter in the Combi water
set.

If combustion or performance indicate End

•Shut boiler down (unless boiler
need: of season used for domestic hot water)
• Clean heat exchanger months
• Remove and clean burner using
compressed air only
• Clean the blower wheel
Follow the maintenance procedures given throughout this manual. Failure to perform the service and
⚠WARNING
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.

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Combi Boiler User’s Information Manual

2 Maintenance schedule
Maintenance procedures Read the list of potential materials listed in Table 1 on
page 4 of this manual. If any of these products are in the
Boiler must be serviced and maintained 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
The boiler must be inspected and started
⚠WARNING area.
annually at the beginning of the heating
season by a qualified service technician.
In addition, the maintenance and care Check pressure/temperature gauge
of the boiler designated on page 5 of this
1. Make sure the pressure reading on the boiler pressure/
manual and explained on pages 6 through
temperature gauge does not exceed 24 psi. Higher
8 must be performed to assure maximum
pressure may indicate a problem with the expansion
boiler efficiency and reliability. Failure to
tank.
service and maintain the boiler and system
could result in equipment failure, causing 2. Contact a qualified service technician if problem persists.
possible severe personal injury, death, or
substantial property damage. Check vent piping
The following information provides
NOTICE 1. Visually inspect the flue gas vent piping for any signs of
detailed instructions for completing
blockage, leakage, or deterioration of the piping. Notify
the maintenance items listed in the
your qualified service technician at once if you find any
maintenance schedule on page 5. In
problems.
addition to this maintenance, the boiler
must be serviced and started up at the Failure to inspect the vent system as noted
⚠WARNING
beginning of each heating season by a above and have it repaired by a qualified
qualified service technician. service technician can result in vent system
failure, causing severe personal injury or
Check boiler area death.
To prevent potential of severe personal Check air piping
⚠WARNING
injury, death, or substantial property
damage, eliminate all materials discussed 1. Visually inspect the air inlet termination to be sure it is
below from the boiler vicinity and the unobstructed. Inspect the entire length of air piping to
vicinity of the boiler combustion air inlet. ensure piping is intact and all joints are properly sealed.
If contaminants are found:
2. Call your qualified service technician if you notice any
Remove products immediately from the problems.
area. If they have been there for an
Check relief valve
extended period, call a qualified service
technician to inspect the boiler for possible 1. Inspect the boiler relief valve and the relief valve
damage from acid corrosion. discharge pipe for signs of weeping or leakage.
If products cannot be removed, 2. If the relief valve often weeps, the expansion tank may
immediately call a qualified service not be working properly. Immediately contact your
technician to re-pipe vent and air piping qualified service technician to inspect the boiler and
and locate vent termination/air intake system.
away from contaminated areas.
Inspect condensate system
1. Combustible/flammable materials -- Do not store
combustible materials, gasoline or any other flammable Inspect/check condensate lines and fittings
vapors or liquids near the boiler. Remove immediately if Inspect the condensate drain line, condensate PVC fittings
found. and condensate trap (FIG. 2-1).
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.

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Combi Boiler User’s Information Manual

2 Maintenance schedule (continued)

Clean/Inspect Trap Assembly NOTICE Use materials approved by the authority

having jurisdiction. In the absence of other
Remove the clean out cap on the bottom of the trap. Let
authority, PVC and CPVC pipe must comply
the condensate and any debris drain out.
with ASTM D1785 or D2845. Cement and
primer must comply with ASME D2564 or
F493. For Canada use CSA or ULC certified
Figure 2-1 Condensate Trap
PVC or CPVC pipe, fittings, and cement.
HOSE BARB

To allow for proper drainage on large

MOUNTING NUT NOTICE
horizontal runs, a second line vent may be
required and tubing size may need to increase
to 1 inch.
The condensate line must remain
FLOAT BALL 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
CONDENSATE
DRAIN the boiler tee, resulting in potential water
damage to property.
REMOVABLE CAP
TO CLEAN OUT TRAP
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.
DIR #2000529332 00 The pump should have an overflow switch to prevent
property damage from condensate spillage.

Condensate drain
Figure 2-2 Condensate Disposal
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 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).

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Combi Boiler User’s Information Manual

2 Maintenance schedule
Test low water cutoff (if installed) Operate relief valve
1. Before proceeding, verify that the relief valve outlet has
1. If the system is equipped with a low water cutoff, test the
been piped to a safe place of discharge, avoiding any
low water cutoff periodically during the heating season,
possibility of scalding from hot water.
following the low water cutoff manufacturer’s
instructions. To avoid water damage or scalding due
⚠WARNING
to valve operation, a metal discharge
Reset button (low water cutoff) line must be connected to the relief
valve outlet and run to a safe place of
1. Testing the low water cutoff shuts the unit off. Press the disposal. This discharge line must be
RESET button on the low water cutoff to turn the unit installed by a qualified heating installer
back on. or service technician in accordance with
the instructions in the Combi Boiler
Check boiler piping (gas and water) Installation and Service Manual. The
discharge line must be terminated so as
1. Remove the boiler front access door and perform a gas to eliminate possibility of severe burns
leak inspection per steps 1 through 7 of the Operating or property damage should the valve
Instructions on page 9. If gas odor or leak is detected, discharge.
immediately shut down the boiler following the
procedures on page 9. Call a qualified service 2. Read the boiler pressure/temperature gauge to make
technician. sure the system is pressurized. Lift the relief valve
top lever slightly, allowing water to relieve through
2. Visually inspect for leaks around water piping. the valve and discharge piping.
Also inspect the circulators, relief valve, and fittings.
Immediately call a qualified service technician to repair 3. If water flows freely, release the lever and allow the valve
any leaks. to seat. Watch the end of the relief valve discharge pipe
to ensure that the valve does not weep after the line has
Have leaks fixed at once by a qualified had time to drain. If the valve weeps, lift the seat again to
⚠WARNING
service technician. Failure to comply attempt to clean the valve seat. If the valve continues to
could result in severe personal injury, weep afterwards, contact your qualified service
death, or substantial property damage. technician to inspect the valve and system.
3. Replace the front access door. 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.

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Combi Boiler User’s Information Manual

3 Operating instructions

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Combi Boiler User’s Information Manual

4 Control module
Combi Boiler control module

Use the control panel (FIG. 4-1) to set temperatures, operating conditions, and monitor boiler operation.

Figure 4-1 Control Panel

DISPLAY WINDOW
RESET BUTTON

UP BUTTON

DOWN BUTTON

LEFT BUTTON RIGHT BUTTON

The information below shows the functions of the buttons Saving parameters
on the display:
To save parameters and exit programming:
MENU / ENTER = ►
SETPOINTS = ▲ and ▼ Press the ► button to go to the end of the Parameter List,
SAVE = ◄ then press ► again. Otherwise, the parameters will be saved
automatically after Timeout.
RESET = ●
To enter a parameter and continue programming:

Access modes Press the ▲ or ▼ button to change parameters. Press ► to

move to the next parameter and to the end of the Parameter
User
List. Press ◄ to save and return to the Base Screen. Otherwise,
the parameters will be saved automatically after Timeout.
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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Combi Boiler User’s Information Manual

4 Control module (continued)

Set space heating operation

Determine controlling sensor Adjust DHW set point temperature

For space heating systems, the temperature control can be 1. Press the ◄ button to access the SETPTS Menu.
based on the outlet or the system supply sensor (optional).
The control will automatically switch to the system supply 2. Press the ► button to page to the DHW SETPT
sensor once it is connected. parameter.
3. Press the ▲ and ▼ buttons to adjust the set point.
Verify space heat circulator operation
4. Press the ◄ button to save the new DHW set point and
The Space Heating Mode controls the boiler pump and the return to the default screen.
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. Press the ◄ button to save the new SH set 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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Combi Boiler User’s Information Manual

4 Control module
Figure 4-2 Status Display Screen

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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Combi Boiler User’s Information Manual

4 Control module (continued)

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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Combi Boiler User’s Information Manual

Notes

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Combi Boiler User’s Information Manual

Notes

15
Revision A (PCP #3000022264 / CN #500012232) initial
release.
Revision B (PCP #3000027055 / CN #500016866) reflects the
removal of information related to an external flow switch.

Revision C (PCP #3000033791 / CN #500022618) reflects the

addition of series numbers.

MM #100298581_DIR #2000552611_Rev C
07/19