Page 1: ...INSTALLATION OPERATION HAINTENANCE HANUAL i lh i llh Illl i iiiiiiii _ _i r_ _ _ IIIIIIIIIIIIIII _ _ _ _ _ i d _ X _ _ _ _i_ f O r _j_ _ _ _ i_ _ o _ _ 7 _ _ L _2 _ _ d 4_ L J __ US M_nuf_d _re_ by EC...
Page 2: ...azard Improper installation could result in death or serious injury Read this manual and understand all requirements before beginning installation Keep boiler area clear and free from combustible mate...
Page 3: ...n Society of Mechanical Engineers Boiler and Pressure Vessel Code Section IV Standards for heating boilers Boilers are certified in accordance with ANSI American National Standards Institute Z21 13 st...
Page 4: ...183 600 183 000 162 600 159 800 137 600 136 800 117 200 114 000 5 000 179 500 178 750 159 500 156 000 134 500 133 500 115 250 111 250 6 000 175 400 174 500 156 400 152 200 131 400 130 200 113 300 108...
Page 5: ...on must comply with local codes 9 Boiler and related hot water heating systems are not do it yourself items Installation and service by qualified professionals are required Installers Follow local reg...
Page 6: ...ontrol replacement etc 8 Boiler must be located where ambient temperatures minimum possible room temperatures where boiler is installed assuming boiler is not in operation and therefore contributes no...
Page 7: ...of common venting system common venting system should be resized to approach minimum size as determined using appropriate tables in chapter 13 of the National Fuel Code ANSI Z223 1 NFPA 54 Placing Th...
Page 8: ...iping COK_iqA IOI _JICK ILL EXI _ _9 S TA i 1ST P O5t FOR FEED WATER 2_b P_ O_ _OR FEEID WA FEI_ Expansion Tank And Hake Up Water Determine required system fill pressure design temperature and water c...
Page 9: ...8 Install safety relief valve with spindle in vertical position Do not install shutoff valve between boiler and safety relief valve Install discharge piping from safety relief valve A Use 3 4 or larg...
Page 10: ...able or is inaccessible Filling Condensate Trap With Water Manually fill condensate trap at initial start up with water Following steps are required to fill condensate trap for start up Steps are only...
Page 11: ...9 Sidewall Vent Intake Terminations 12 305mm Separation Between Bottom Of Combustion Air Intake And Bottom Of Vent Figure 8 Roof Vent Intake Terminations 3 76mm Maximum Combustion Air 8 203mm Minimum...
Page 12: ...om swimming pool and swimming pool pump house All combustion air and vent pipes must be airtight and watertig ht Combustion air and vent piping must also terminate exactly as shown in Figures 8 and 9...
Page 13: ...30 pieces of 2 CPVC pipe and one 2 CPVC coupling are furnished with boiler See Figure 13 Length of pipe is counted from boiler jacket air intake pipe or from vent tee vent pipe First five feet of Tota...
Page 14: ...next termination See Figure 8 9 and 10 o All field installed vent pipe must be 3 Terminate vent system at least 4 feet 1 22 m horizontally from and in no case above or below unless a 4 feet 1 22 m ho...
Page 15: ...000 l _c_des Fittings _Ou_ide Diame_r Length of pipe or tubing should be measured from gas meter or propane second stage regulator Refer to Figure 14 for general layout at boiler Gas line enters boile...
Page 16: ...ated on exterior boiler jacket See Figure 15 for location of service switch junction box and power supply connection points Connect black hot lead from power supply to either of unused brass screws on...
Page 17: ...nnect 24 volt thermostat leads to the two 2 yellow wires located in service switch junction box located on outer jacket of boiler See Figure 15 Page 16 for service switch junction box and thermostat f...
Page 18: ...ype 150 C Thermoplastic wire or its equivalent _N TEGRATED BO_LER CONTROL CASTING TEMPERATURESAFETY S W TCH M _UAL RESET PURGE IGNITOR VALVE W_RING cAB_GE F_ME LINE VOETAGE BY FACTORY LIGNE DE VOLTAGE...
Page 19: ...BLOWER P6 1 P12 1 1 BK P4 3 l m I CIRCULATOR FIELD WIRED P10 2 P10 3 HOT SURFACE IGNITER P12 2 P6 2 5K2 a n n n a 1_ P1 1 P2 1 P3 7 CASTING TEMPERATURE SAFETY SWITCH MANUAL RESET II II _ 4K1 3K1 DIFFE...
Page 20: ...d Flame diagnostic indicator lamps blink indicating failure mode as lack of flame signal C Manually reset BC from lockout by removing and re establishing thermostat s call for heat or turn service swi...
Page 21: ...Install discharge piping per these instructions A S H E Rated Pressure Relief Valve Each boiler must have properly sized and installed A S M E rated pressure relief valve Water expands as it is heate...
Page 22: ...agrams Near Boiler Piping on page 8 and 9 1 Close all zone service valves on supply and return piping Open feed valve and fill boiler with water Verify air vent is open Hold relief valve open until wa...
Page 23: ...es for any gas to clear Then smell for gas including near the floor If you smell gas STOP Follow instructions at left under What To Do If You Smell Gas If you do not smell gas go to the next step 8 Tu...
Page 24: ...boiler Refer to Check Gas Supply on page 15 3 Check for orifice in negative pressure hose at gas valve and 2 air intake pipe upstream of gas valve 4 Relight boiler 5 If boiler still does not light A D...
Page 25: ...0 second post purge I i If airflow does not re establish control lockout problem with combustion airflow Purge light blinks Control automatically reset after 15 minutes CASTING TEMPERATURE SAFETY SWIT...
Page 26: ...ds call for heat Gas valve and circulator pump are de energized valve and flame lights go out Blower runs for 30 seconds post purge purge light is on Blower is de energized after 30 seconds purge ligh...
Page 27: ...iiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iiiiiiiiiiii iiii iii...
Page 28: ...ter through observation port on boiler 6 After igniter warm up period integrated boiler control energizes gas valve initiating 6 second trial for ignition mode indicated by illumination of Lamp D Lamp...
Page 29: ...highest setting Verify boiler goes through normal start up cycle Lower thermostat to lowest setting and verify boiler shuts off Test And Adjust High Limit Control At initial start up with Economy Feat...
Page 30: ...gas stream A Take flue gas reading and observe CO2 value B Adjust throttle screw until CO2 value is between 8 5 And 10 02 between 5 5 and 2 C Turning throttle screw counter clockwise increases rate an...
Page 31: ...ation during this condition Important System must be checked by qualified service agency prior to resuming operation __ ACTIVE Indicates that thermal targeting function is active and control reduces b...
Page 32: ...r condition is satisfied _ Verify system filled with water I_ Verifysensor is inserted correctly into well Note Use of heat conductive grease may interferewith contact between spring clip and copper w...
Page 33: ...s unlikely two consecutive controls are defective If this seems to be the case chances are the controls are not the cause but rather malfunction is due to some other problem such as electrical short b...
Page 34: ...red on or air flow is not proven Off during igniter and run cycle normal operation purge cycle complete IBC is locked out Problem could indicate false positive proof of air flow Blocked vent intake ai...
Page 35: ...t CLOSED GREEN POWERINDICATOR LIGHTIS ILLUMINATED ON THEIBC YES CHECK SYSTEM STATUS IF LOCKED OUT NOTE FAILURE MODE WHICH INDICATOR LIGHT IS BLINKING RESET SYSTEM BY TURNING SERVICE SWITCH OFF THEN ON...
Page 36: ...ESS PLUG CN2 _V YES REPLACE IBC CHART 1 CHECK FOR 120 VAC BETWEEN TERMINALS 1 AND 3 AT CONNECTOR CN5 ON IBC YES CHECK FOR 120 VAC AT CIRCULATOR YES REPAIR REPLACE CIRCULATOR 1 I i l i I I I 1 I I I I...
Page 37: ...E SWITCH PER INSTRUCTIONS ON FOLLOWING PAGES ARE SAMPLING LINES CLEAR AND CONNECTED PROPERLY YES CLEAN OUT BLOCKAGE AT ORIFICE CLEAN OUT VENT PIPE AND OR AIR INTAKE PIPE CHECK FOR SAGS OR LOW SPOTS WH...
Page 38: ...VALVE FLAME INDICATOR LIGHT IS ON YES _r CHECK IF IGNITER SENSOR POSITION IS OK TIP SHOULD BE SLANTED TOWARDS BURNER _1_YES CHECK GAS SUPPLY PRESSURE AT INLET PRESSURE TAPPING ON GAS CONTROL IS GAS P...
Page 39: ...SEE REPAIR PARTS DIAGRAM IS ORIFICE CORRECT SIZE NO I NO 2 NO 3 7 IF THE ANSWER IS NO CHOOSE THE APPROPRIATE PATH 1 2 OR 3 BASED ON SYMPTOMS SHOWN CHART 6 CHART 6 I i __ CLEAN REPLACE GAS LINES BE SU...
Page 40: ...I LIMIT SET POINT MINUS 30 F CONTROL DIFFERENTIAL REPLACE GAS CONTROL AlpYES CHECK GAS ORFICICE SIZE IS GAS ORIFICE SIZE CORRECT CHECK REPAIR PARTS LIST FOR CORRECT SIZE IS GAS ORIFICE CLEAR OF BLOCKA...
Page 41: ...50 for Model 175 Closed Closed 2 00 for Model 200 Running With Greater Than or Equal 3 5 Open Blockage To Setpoints 0 5 Closed iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiiiii iiiii iiiii iiii...
Page 42: ...ts if necessary H Remove jacket front and top panels and check for piping leaks around relief valve and other fittings Repair if found DO NOT use stop leak compounds 2 Check boiler area is free from c...
Page 43: ...ith your fingers or hands as oils or debris will cause premature failure G Remove five nuts and blower adapter assembly Remove burner and gaskets 2_ 3_ H Aluminum oxide deposits are water soluble and...
Page 44: ...this information in place of any related information in Installation Operation Maintenance Manual Accompanying this boiler DIELECTRIC ISOLATION Two 2 1 1 4 X 1 1 4 Female to female dielectric isolati...
Page 45: ...ational and properly sized Undersized expansion tanks cause relief valve weeping and substantial make up water addition Operation of this boiler in system containing significant amounts of dissolved o...
Page 46: ...ntifreeze manufacturer s instructions to adjust pH If system has leaked water and antifreeze chemistry will need to be adjusted To avoid damage to boiler check pH and chemistry of boiler solution and...
Page 47: ...rs as listed in this supplement Hydronic Agencies Ltd Alphi ll Intercool NFP 30 40 50 AA Intercool RPH 15 Hercules cryo tekT 100 AI Fernox North Distributor 15363 117 Avenue Edmonton AB T5M 3X4 Canada...
Page 48: ...DUNKIRK BOILERS 2201 Dwyer Avenue Utica NY 13501 web site www ecrinternational com...
