ECR International 075 97gb Installation, Operation & Maintenance Manual Download

Page: 37 / 76

Examine fl ue passages by removing blower/burner

•

assembly from heat exchanger.

Confi rm manual gas valve is closed.

•

Disconnect fl ame sensor and igniter wires.

•

Remove 2 screws and carefully remove igniter.

•

Remove 2 screws and carefully remove fl ame rod

•

sensor.
Loosen and remove four nuts connecting fuel mixer

•

assembly to heat exchanger.
Entire gas train can be moved aside. Take precaution

•

to not kink fl exible gas hose.
Remove gasket and burner. It may be necessary to

•

unlatch both of the Heat Exchanger locking straps.
Clean burner using air hose directed into top of

•

burner opening. This will dislodge any debris build up

in burner ports.
Remove four nuts holding condensate collector from

•

bottom of heat exchanger assembly. Also remove

gasket.
Clean heat exchanger with low pressure water spray.

•

If this does not clean fi ns adequately, use fl exible

handle nylon brush to loosen sediment and oxide on

all accessible heating surfaces of heat exchanger.

Take care not to get brush stuck in heat exchanger.
After brushing and rinsing, remove any remaining

•

loosened sediment using shop vacuum with snorkel

attachment. Inspect burner for foreign matter in

fl ame ports or inside burner. Foreign matter should

be removed by blowing with compressed air or

vacuuming. If burner cannot be cleaned, it must be

replaced.
Reinstall refractory, burner holder, burner and

•

replace gasket (in that order). Position fuel mixer

assembly over studs. Install four nuts and tighten.

Reinstall igniter and igniter gasket and fasten with

two screws. Replace gasket and condensate collector

to bottom of heat exchanger assembly. Replace and

tighten four nuts holding collector to heat exchanger

assembly.

Connect igniter wires, and gas valve wires.

•

Visually inspect condensate trap. Remove any foreign

•

material visible in condensate lines as described below:

•

nspect for sediment or blockage.

Flush out with water or vacuum.

•

Follow the instructions “Filling The Condensate Trap

•

With Water”

section 9.1.

Follow Boiler Start-up and Operational Test. See section

•

9.4.

11 - GENERAL MAINTENANCE AND CLEANING

11-2 Condensate Collector

Condensate Collector

Combustion Chamber

Condensate Collector

Condensate Drain

Summary of Contents for 075 97gb

Page 1: ...H INSTALLATION OPERATION MAINTENANCE MANUAL P N 240008282 REV D 10 2010 CONDENSING GAS BOILER Models 075 100 ...

Page 2: ...ternate Gas Connection F C B F Table 1 Physical Data Size Width A Height B Depth C Bracket D Water Connections Gas Connection G Condensate Drain Weight Shipping Unit Size E Height F H I 075 100 22 1 16 560mm 35 5 8 905mm 16 3 16 411mm 27 1 2 969mm 1 1 4 NPT 31 1 16 789mm 1 2 NPT 7 1 2 5 140 lb 63 5 kg 115 lb 51 2 kg Vent Connection Combustion Air Floor D H I Condensate Drain ...

Page 3: ... Installation 19 6 5 Termination 19 6 6 Condensate Piping 25 7 Gas Supply Piping 26 8 Electrical Connections 28 8 2 Line Voltage Connections 28 8 3 Low Voltage Connections 28 9 Start Up Procedure 30 10 Operating Instructions 34 11 General Maintenance And Cleaning 35 12 Ratings And Capacities 38 13 Trouble Shooting 39 14 Wiring Diagram 56 15 Glossary 58 Appendix A Control Module 60 1 1 Introduction...

Page 4: ...tly heat potable water Indirect heating is acceptable Heat water with non hydronic heating system chemicals present example swimming pool water Exceed 50 psig 344 kPa system pressure Exceed 195 F 90 5 C system design temperature 1 3 Operational Features Modulating 20 100 Integral Dual Limit Integral Low Water Cutoff with test button Outdoor Temperature Reset Integral Multiple Boiler Control 1 INTR...

Page 5: ...zardous situation which if not avoided could result in minor or moderate injury WARNING Indicates a hazardous situation which if not avoided could result in death or serious injury DANGER Indicates a hazardous situation which if not avoided WILL result in death or serious injury This is the safety alert symbol Symbol alerts you to This is the safety alert symbol Symbol alerts you to potential pers...

Page 6: ...ity of combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner gas valve mixes air and fuel sending mixture to burner for combustion for combustion Gas Control Valve Gas Control Valve 20 see page 8 Delivers Delivers proper quantity of fuel to Combustion Air Blower proper quantity of fuel to Combustion Air Blower See section 7 See section 7 High Temperature Supply S...

Page 7: ...EATING SYSTEM IN SYSTEM IN HIGH VOLTAGE HIGH VOLTAGE JUNCTION BOX JUNCTION BOX SUPPLY WATER TO SUPPLY WATER TO HEATING SYSTEM HEATING SYSTEM OUT OUT GAS CONNECTION GAS CONNECTION SERVICE SWITCH SERVICE SWITCH AUXILIARY POWER AUXILIARY POWER OUTLET OUTLET CENTRAL HEATING CENTRAL HEATING PUMP CIRCUIT BREAKER PUMP CIRCUIT BREAKER BRACKET FOR BRACKET FOR OPTIONAL WALL OPTIONAL WALL MOUNT MOUNT NOTE Se...

Page 8: ...MBER CHAMBER GAS CONTROL GAS CONTROL VALVE VALVE USER INTERFACE USER INTERFACE RETURN WATER RETURN WATER FROM HEATING FROM HEATING SYSTEM IN SYSTEM IN 1 1 4 NPT 1 1 4 NPT SUPPLY WATER TO SUPPLY WATER TO HEATING SYSTEM HEATING SYSTEM OUT 1 1 4 NPT OUT 1 1 4 NPT HEAT EXCHANGER HEAT EXCHANGER PUMP PUMP CONDENSATE COLLECTOR DRAIN VALVE FLAME SENSOR SHOWN IN OPEN POSITION VENT TEMPERATURE SENSOR SAFETY...

Page 9: ... COMPONENT LISTING INTERNAL ACCESS PANEL CLOSED INTERNAL ACCESS PANEL OPEN CONTROL MODULE CENTRAL HEATING PUMP RELAY TRANSFORMER Control Module Fuse and holder Note To open Lift panel up then pull forward ...

Page 10: ...gas ignition system components from water dripping spraying rain etc during operation and service circulator replacement condensate trap control replacement etc Floor or wall mounting Wall must be plumb and capable of supporting boiler weight plus 60 lbs 28 kg See Table 1 Floor must be level Leveling feet allow adjustment up to 1 4 6 mm Wall mounting See section 4 2 Access to outdoors to meet mini...

Page 11: ...bracket to wood studs Field source appropriate fasteners for other wall constructions masonry concrete Attach wall mount bracket level on wall Boiler must engage with wall mount bracket Avoid overhang on sides of wall mount bracket Verify boiler bracket is centered on wall bracket See figure 4 2 4 LOCATING BOILER FIGURE 4 2 Wall Mount Bracket Engaged with Bracket on Boiler 4 Slots for attaching Wa...

Page 12: ...r circulation Install flow control valves or other automatic means to prevent gravity circulation of boiler water during cooling cycle 5 3 Safety Relief Valve and Air Vent NOTICE Boiler rated at 50 psig 345 kPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve Field source safety relief valve for system pressures greater than 30 psig 206 kPa Temperature Pr...

Page 13: ...lant Temperature Pressure Gauge Install temperature pressure gauge using nipple bushing and tee provided with boiler See figure 5 3 5 5 System Piping Single boiler system See figures 5 4 5 5 5 6 5 7 for general guidance Additional considerations Control system designed for single central heating pump Installer responsible for integration of multiple central heating pumps Control system allows dome...

Page 14: ...PIPING NOTICE Illustrations are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction Check Local Codes For Maximum Distance To Floor System Return System Supply F L O O R ...

Page 15: ...ONED SYSTEM WITH VALVES 5 6 TWO PIPE ZONED SYSTEM WITH PUMPS Heat exchanger ball valve open as shipped Heat exchanger ball valve open as shipped DHW Pump CH System Pump DHW Pump Zone Pump 3 8 10mm Open End Wrench 3 8 10mm Open End Wrench ...

Page 16: ...ONDAY PUMPING 12 305mm Max apart 12 305mm Max apart Limit length to 5 1 6 m Existing closely spaced tees in primary system loop CH System Pump Heat exchanger ball valve open Heat exchanger ball valves closed 3 8 10mm Open End Wrench 3 8 10mm Open End Wrench ...

Page 17: ...tiple Boiler Guide CH System Pump 12 305mm Max apart System Temperature Sensor Size common piping according to maximum heat capacity of entire system Up to 16 boilers All heat exchanger ball valves closed 3 8 10mm Open End Wrench DHW Pump See Multiple Boiler Guide ...

Page 18: ...pace in which appliances remaining connected to common venting system are located and other spaces of building Turn on clothes dryer and any appliance not connected to common venting system Turn on exhaust fans such as range hoods and bath room exhaust so they will operate at maximum speed Do not operate summer exhaust fan Close fireplace dampers Turn on appliance being inspected Follow lighting i...

Page 19: ... transition has no equivalent length Slope vent pipes minimum 1 4 per foot 21 mm m back toward boiler Support horizontal sections to prevent sags capable of accumulating condensate Support piping in accordance with pipe manufacturer s instruction and authority having jurisdiction In absence of manufacturer s instruction use pipe hooks pipe straps brackets or hangers of adequate and strength locate...

Page 20: ...ke and vent of same appliance y 8 21 cm Minimum vertical separation between combustion air intake and vent of different appliances y 15 38 cm Maximum horizontal length of vent y Maximum vent intake between different appliances 12 30cm y Maximum allowable total vertical vent length with outside exposure equals 10 ft 3 05m y Abandoned unused masonry chimney may be used as chase way for combustion ai...

Page 21: ...PVC intake combustion air Elbow field supplied Combustion Air Note Securing strap must be field installed to prevent movement of termination kit in side wall 2 5 0cm Diameter 41 Length 1 0m 3 7 6cm Diameter 47 Length 1 2m Note Overall length may be modified by cutting or extending both combustion air and vent pipes 12 is minimum allowable length and 60 is maximum allowable length for this dimensio...

Page 22: ...ic Vent Roof Termina tions y Glue inner vent pipe to prevent recirculation y Maintain 12 30 cm US 18 46 cm Canada minimum clearance above highest anticipated snow level Maximum of 24 0 61m above roof y Support must be field installed to secure termination kit to structure y Elbow roof boot flashing field supplied y Allowed Wall Roof thickness 1 2 30 1 2 76cm y Vertical concentric vent system can b...

Page 23: ... minimum 12 300 mm above highest anticipated snow level Avoid locations where snow may drift and block vent and combustion air Ice or snow may cause boiler to shut down if vent or combustion air becomes obstructed Condensate Vent gas may condense forming moisture may be corrosive Protect building materials at vent from exhaust of vent gas 6 COMBUSTION AIR AND VENT PIPING Termination must be 12 30 ...

Page 24: ...ent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable 6 COMBUSTION AIR AND VENT PIPING Walkways Locate vent termination minimum 7 2 1 m above any public walkway with consideration to condensate 7 2 1 m Minimum 3 0 9 cm Minimum Termination Meters Regulators deck porch Vent termination US only...

Page 25: ...6 1 Attach PVC tee provided with boiler and field sourced piping to condensate drain vertical tee on left side of boiler See figure 6 1 Slope condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use condensate pump if boiler located below disposal point 120 VAC auxiliary power outlet can be used to power condensate pump Field source condensate neutralizing kit as required by authorit...

Page 26: ...de sediment trap up stream of gas valve 7 2 Conversion Kit Instructions See Gas Conversion Kit Instructions included with Boiler CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switches do not use any phones in your building Immediately call your gas supplier from a neighbor s phone Follow gas supplier s instructions If you cannot reach your gas su...

Page 27: ...d gas connection before placing boiler in operation Pressure test over 1 2 psig 3 5 kPa Disconnect boiler and its individual gas shutoff valve from gas supply system Pressure test at 1 2 psig 3 5 kPa or less Iso late boiler from gas supply system by closing manual gas shutoff valve See figure 7 6 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptab...

Page 28: ... line voltage terminal strip DHW B PUMP L N G 8 3 Low Voltage Connections Figure 8 2 User Interface Terminals Factory wired to low voltage terminal plug USER A INTERFACE terminals Optional Remote mount user interface for B improved access Maximum wire length is 100 ft 30m for 22 ga C wire or 150 ft 45m for 18 ga wire Argus Link Multiple boiler applications only Outdoor Sensor if used Provided with...

Page 29: ...length is 330 ft 100 m 22 gauge B wire Connect wires interchangeable to low voltage C terminal plug DHW T T terminals Wires are interchangeable Central Heating Thermostat Use thermostat or boiler system control with dry A contacts related 0 5 amps 120 VAC Boiler control does not provide 24 VAC power to central heating thermostat Locate and install thermostat per manufacturer s B instructions Maxim...

Page 30: ...s immediately 9 2 Fill Condensate Trap with Water Disconnect collet clip from elbow See figure 9 1 Disconnect tubing below elbow Pour about 1 cup 237ml of water into condensate drain Reconnect tubing to elbow with collet clip See Figure 9 1 9 START UP PROCEDURE 2 Reconnect collet clip to hose barb before starting boiler NOTICE IMPORTANT Condensate trap must be manually filled with water at initial...

Page 31: ...195 F 40 91 C Temperature Units F F C Language English English French Installer Menu Boiler Configuration Boiler Address 0 0 15 Low Water Cutoff Enabled Enable Disabled Pump Mode 0 0 4 Service Reminder Status On ON OFF Service Reminder Days 365 Days 1 999 Days CH Settings CH Mode 1 0 3 Warm Weather Shutdown 70 F 21 C 35 100 F 2 38 C Reset Curve Design Temperature Boiler 180 F 82 C 60 195 F 40 91 C...

Page 32: ...ut English units 1 Turn off gas to all other appliances Use 1 or 2 cu ft dial on gas meter Measure time required for one or more complete revolutions Measure time for 1 2 minutes Calculate input Input MBH 3600 x cu ft seconds Example Gas flow from Meter 2 cu ft Measured time 72 seconds Rate MBH 3600 x 2 cu ft 100 MBH 72 seconds Metric See Glossary 9 START UP PROCEDURE Compare to boiler rating 2 Si...

Page 33: ...cluding domestic hot water if used Verify proper operation Reset control parameters to operating settings if 3 adjusted to allow startup and operation test Follow instructions TO TURN OFF GAS TO APPLIANCE 4 if boiler is not being placed into immediate operation Enter installer information on Warranty Registration 5 Card Gather all instructions manuals wiring diagrams 6 warranty registration card a...

Page 34: ...with an ignition device which automatically lights the burner Do not try to light burner by hand Remove front jacket panel Turn gas shutoff valve clockwise to closed position Handle should be perpendicular to gas pipe Wait 5 minutes for any gas to clear Smell for gas including near floor If you smell gas STOP Follow instructions on this page What To Do If You Smell Gas If you do not smell gas go t...

Page 35: ...nd require no further lubrication Lubricate field sourced pumps and or motors should be lubricated according to pump and or motor manufacturer s instruction Check following components are operating properly and are free of blockages or obstructions air vent check venturi air inlet for blockage and clean as required check air hose is tight supply return and flue temperature sensor clips must be sec...

Page 36: ...y qualified service agent Boiler owner shall not attempt these steps WARNING Use gloves when handling refractory to avoid absorption of crystiline silica a potentially dangerous compound 11 3 Annual Examination and Cleaning of Boiler Components Obtain Burner Inspection Kit See Parts Kits and Optional Accessories manual Before servicing turn off electrical power to boiler at service switch Follow i...

Page 37: ... heat exchanger After brushing and rinsing remove any remaining loosened sediment using shop vacuum with snorkel attachment Inspect burner for foreign matter in flame ports or inside burner Foreign matter should be removed by blowing with compressed air or vacuuming If burner cannot be cleaned it must be replaced Reinstall refractory burner holder burner and replace gasket in that order Position f...

Page 38: ...aving jurisdiction for installations above 4500 feet 1350 m above sea level TABLE 12 1 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net I B R Rating Water MBH 1 3 AFUE 2 Maximum Minimum 075 75 15 69 60 97 0 100 100 20 91 79 97 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficiency are based ...

Page 39: ...p lit User Interface Display or LWCO lamps lit NO YES Replace Switch YES NO YES NO Repair wiring or call utility company Is voltage at Service Receptacle more than 104Vac Remove User Interface from base Using Digital Voltmeter check for 25 to 30 Vdc Is voltage present Make sure all wire harness plugs are properly pushed in Release plug lock with finger remove and reconnect all 7 plugs Check wiring...

Page 40: ...ut Too Late Flue Sens Shorted _ _ _ _ _ _ _ P _ _ _ _ Lockout Alarm Blocking Error E 5 9 Flame Error 1 Supply Sens Shorted _ _ _ _ _ _ _ P _ _ _ _ Lockout Alarm Blocking Error E 6 0 Various Text Messages Return Sens Shorted _ _ _ _ _ _ _ P _ _ _ _ Lockout Alarm Blocking Error E 6 5 3 Flame Failures Flue Sens Shorted _ _ _ _ _ _ _ P _ _ _ _ Lockout Alarm Blocking Error E 6 6 Various Text Messages R...

Page 41: ...Gas Valve Is harness connected to Control Module J13 NO YES _ P _ _ _ Lockout Alarm A 0 5 GV relay error Replace Control Module Connect harness Disconnect harness from Control Module J13 Measure resistance across J13 3 and J13 4 Is resistance between 1 0 and 1 2 kohms Replace Gas Valve YES NO Disconnect harness from Gas Valve Does each wire have continuity between Gas Valve and Control Module YES ...

Page 42: ...re any apparent debris or obstruction of the flue way YES NO Reset the boiler by pressing the Reset button When the boiler tries to ignite is there a strong consistent spark evident throught the sight glass YES NO Does the boiler ignite and stay running YES NO Enter the Installer Menu and place the boiler into test mode in high fire Once the boiler starts go to the boiler status screen and monitor...

Page 43: ...from Control Module J9 Measure voltage between J9 2 and J9 3 Is voltage 120 Vac 10 Disconnect 3 wire harness from Combustion Air Blower Measure continuity in each wire Continuity in each wire Replace harness Connect harness Replace Combustion Air Blower Disconnect harness from Control Module J9 Continuity in each wire of 4 wire harness yellow red white black Replace Control Module Replace harness ...

Page 44: ... and C terminals interchangeable YES NO Correct wiring Disconnect orange wires from Air Pressure Switch Continuity across NO and C terminals Replace Air Pressure Switch Replace harness Replace Control Module Is 4 wire harness connected to Combustion Air Blower Connect harness Disconnect 4 wire harness from Combustion Air Blower and Control Module J9 Continuity in each wire Replace wire s Replace C...

Page 45: ... SHOOTING 13 1 Differential Air Pressure Switch DANGER Replace all test port caps Failure to comply will result in death or serious injury 13 2 Test Port Locations Connect manometer to Air Pressure Switch tubing see figure 13 2 Follow operating instructions to initiate boiler operation Refer to Trouble Shooting Tree page 46 Combustion Analyzer Test Port Test Port In line Pressure Switch Vapor Coll...

Page 46: ... and J9 3 Is voltage approximately 120 VAC Connect wires Replace Combustion Air Blower Replace Control Module Disconnect wires from Air Pressure Switch Disconnect harness from J16 Continuity is each wire Replace wires Is combustion air and vent piping free of obstructions Connect manometer to Air Pressure Switch tubing see figure Follow OPERATING INSTRUCTIONS to initiate boiler operation Is pressu...

Page 47: ... 6 to Switch 3 YES NO YES NO Replace wire s YES NO Is High Temperature Supply Switch open no continuity between terminals 1 and 3 YES NO 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 High Temperature Supply Switch Resistance Chart Replace Control Module Replace High Temperature Supply Switch Is H...

Page 48: ...ection clean and secure NO Replace Flame Sensor or harness Remove Flame Sensor Is rod free of contamination Clean or replace Flame Sensor Replace Control Module Replace Flame Sensor and Burner YES YES YES NO NO Inspect burner through sight glass Is flame present NO YES _ P _ _ _ Blocking Error E 3 5 False flame detect Replace Control Module Turn Gas Shutoff Valve clockwise to closed position Follo...

Page 49: ...ity if harness Harness OK YES NO Replace Harness Is Harness plugged into Low Water Cutoff Is Blue Yellow Harness plugged into 24 Vac Transformer Is Black White Harness plugged into 24 volt harness YES NO Insert Harness Disconnect Blue Yellow harness from Transformer Using digital meter check for 24 Vac Is 24 to 30 Vac present YES NO Connect harness to Transformer Disconnect harness from Low Water ...

Page 50: ...e between 950 to 33 000 ohms Is Heat Exchanger Pump oriented properly Pump Arrow pointing down YES NO YES NO Correct wiring Install Heat Exchanger Pump in proper orientation Replace Control Module Replace Return Water Sensor Measure incoming power with volt meter Is terminal 120 VAC L approximately 120 VAC Is 120 VAC N approximately 0 VAC NO YES _ P _ _ _ Blocking Error E 4 4 Phase error Replace C...

Page 51: ...upply between 59 and 61 Hz NO YES _ P _ _ _ Blocking Error E 4 5 Net frequency error Correct wiring Is power supply circuit breaker loose or faulty Provide frequency stabilized power supply rated at 60 Hz 2 Replace Control Module YES YES NO NO Replace circuit breaker ...

Page 52: ...with digital meter Estimate Sensor temperature Does it fall in the range of the Resistance Chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Supply Water Sensor Resistance Chart Disconnect field wiring Is continuity between field wiring neutral and ground less than 10 ohms Is fiel...

Page 53: ...urn Temperature Sensor and Control Module J5 4 and J5 12 Continuity Measure Return Temperature Sensor resistance with digital meter Estimate Sensor temperature Do temperature and resistance fall within ranges shown in chart Replace Wires 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 32 to 54 66 to 94 Return Temper...

Page 54: ...e Replace Vent Temperature Sensor Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Do temperature and resistance fall within ranges shown in chart NO YES _ P _ _ _ Blocking Error E 5 9 Supply Sensor Shorted Disconnect J5 from Control Module Continuity between J5 11 and Switch 2 Continuity between J5 3 and Switch 4 YES NO 50 to 90 10 to 32 9K t...

Page 55: ... Replace Return Water Sensor Replace Control Module Disconnect wire harness from Vent Temperature Sensor Measure Sensor resistance Does resistance match estimated flue temperature NO YES _ P _ _ _ Blocking Error E 6 5 Flue Sens Shorted Replace Vent Temperature Sensor 50 to 90 10 to 32 9K to 24K ohms 150 to 200 90 to 130 F C Resistance 130 to 150 2K to 1K ohms 2K to 3K ohms 3K to 9K ohms 54 to 66 3...

Page 56: ...56 14 WIRING DIAGRAM 14 1 Connection Diagram ...

Page 57: ...57 14 WIRING DIAGRAM 14 2 Schematic Diagram of Ladder Form ...

Page 58: ...s accompanied by production of heat or heat and light Complete combustion of fuel is possible only in presence of adequate supply of Oxygen COMBUSTIBLE MATERIAL Materials made of or surfaced with wood compressed paper plant fibers or other materials capable of being ignited and burned Such material shall be considered combustible even though flame proofed fire retardant treated or plastered CONDEN...

Page 59: ...Y RELIEF VALVE Valve designed to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve VENT Passageway used to convey flue gas...

Page 60: ... parameter value Scroll up to next menu item Increase value Scroll down to next menu item Decrease value Key Boiler Status Indicator F Flame Detected P Central Heating System pump On B Combustion Air Blower On S Safety Relay Check G Gas Valve Open D DHW Pump On Service Reminder Indicator Boiler in Standby Mode Boiler Supply Water Temperature Indicator Boiler Running in Central Heat mode Combustion...

Page 61: ...ir Blower Closed Air Pressure Switch during this stage will result in Lockout Error Combustion Air Blower is energized to prove flow though Combustion and Vent Systems Air Pressure Switch is checked for closed circuit Open Air Pressure Switch during this stage will result in Lockout Error after 3 trials Combustion Air Blower speed modulates to prepurge setting for 15 seconds Sparking initiated seq...

Page 62: ...g rate according to heating demand When Boiler detects demand met will enter post purge mode then standby mode If simultaneous demand for Central Heat and DHW boiler will enter DHW Priority Mode Priority mode limits amount of time boiler can run in DHW mode to meet CH demand Max DHW Priority Time setting deter mines maximum time allowed for DHW heating mode Please refer to section Appendix A secti...

Page 63: ...n submenu used to view runtime parameters See Multiple Boiler Manual Boiler Status Supply Temperature set point displayed If boiler running in CH mode CH set point displayed Note While running in Outdoor Reset mode this value may change in proportion with the outdoor temperature If the boiler is running in DHW mode the DHW supply set point is displayed B O I L E R S T A T U S S u p p l y 1 4 0 F R...

Page 64: ...perature Note For explanation of available CH heating modes refer to CH Mode section located in CH Settings submenu S E T T I N G S D H W S e t p o i n t F Setting Range 104 F to 195 F 40 C to 91 C Default Value 180 F 82 C DHW set point determines supply water temperature set point while operating in DHW mode S E T T I N G S C h a n g e T e m p e r a t u r e U n i t s F a h r e n h e i t F User in...

Page 65: ... or diagnosis of common problems Boiler Status S T A T U S F a n S p e e d A c t u a l 4 0 0 0 R P M L o w P o w e r 1 5 6 0 R P M Combustion air Blower provides airflow through Combustion and Vent systems Fan speed status screen indicates actual and operational fan speeds in RPM high low and ignition power speed settings Settings are for information only to aid in troubleshooting S T A T U S F a ...

Page 66: ...ted at end of pre spark period Ignit_0 than lockout will occur Re ignition If at end of safety period no flame detected control will go to post purge removing unburned gas Re ignition attempt started following same cycle Number of re ignition attempts limited to 4 after which lockout occurs Intermittent Operation Boiler can be firing continuously for 24 hours Burner switched off and restart sequen...

Page 67: ...c k I g n i t i o n E r r o r Boiler Confi guration B O I L E R C O N F I G A d d r e s s S e l e c t i o n B o i l e r A d d r e s s 0 Address Selection screen used to set boiler position in multiple boiler cascade installation Refer to Multiple Boiler Installation Manual Default setting of 0 indicates boiler is operating in single boiler mode B O I L E R C O N F I G L O W W A T E R C U T O F F D...

Page 68: ... the CH System Pump electrical terminal block See page 56 for diagram The DHW pump terminal does not function This is typical of a hydronic system design which utilizes zone valves for all CH zones and an DHW indirect tank Note Pump Mode selection depends on electrical and hydronic system design Please refer to sections 5 and 8 for recommended hydronic piping and electrical configurations Internal...

Page 69: ...set curve See Figure A 2 CH Mode 2 CH with Full Outdoor Reset Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point calculated as function of outdoor temperature using outdoor reset curve See Figure A 2 CH Mode 3 CH with Permanent Demand Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored CH set point is adjusted in Setting...

Page 70: ...atures See points A B of Reset Curve below Calculated CH set point always limited between Reset Curve Boiler Minimum Maximum temperatures See points C D of Reset Curve below Figure A 2 Outdoor Reset Curve Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point equal to Boiler Reset Curve Design temperature Outdoor temperature used for CH set ...

Page 71: ... in CH Mode Allowable Range 1 100 Default Setting 100 DHW Settings D H W S E T T I N G S D H W m o d e M O D E 1 D H W s t o r e w i t h s e n s o r Two DHW modes are available DHW Mode 0 No DHW DHW Mode is disabled The DHW thermostat input is ignored and the DHW pump is not used DHW Mode 2 DHW Store with Thermostat Boiler reacts to DHW demand when DHW thermostat input closes Boiler modulates to m...

Page 72: ...r DHW demand being present System Test has priority over any system demand while test mode activated System test mode automatically ends after 30 minutes boiler resumes normal operation The following modes are available Disabled Low power Burner starts After ignition period has finished the burner stays at low power Ignition power Burner starts Stays at ignition power High power Burner starts Afte...

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Page 76: ...ECR International Inc 2201 Dwyer Ave Utica NY 13501 www ecrinternational com CONDENSING GAS BOILER Models 075 100 ...

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