ECR International Dunkirk DMG-240 Installation, Operation & Maintenance Manual Download

Page: 16 / 86

5 - HYDRONIC PIPING

FIGURE 5-5 - Primary/Secondary, Zoned, WITH ZONE PUMPS, (Optional) Indirect Tank

12” (305mm) Maximum

Separation

Note

* Manufacturer requires all domestic

hot water (DHW) installations use

an anti-scald valve. Local codes

may require additional equipment

(expansion tank, relief valves,

etc.) Select and size equipment

to suit installation and meet code

requirements.

T & P Relief

Valve to

Drain

Cold

Water

Supply

Optional

Indirect

DHW Tank

BOILER

Make-up

Water

Supply

Tank

Sensor

CH /System

Pump

ASME

Relief

Valve

DHW Pump

* Hot

Water

Supply

Tempered

Note

Use external pump relay or Argo Zone

Control to interface system pump to boiler.

Note

Refer to pump manufacturer

literature for proper pump sizing.

PN 240011656 REV. K [11/01/2020]

Summary of Contents for Dunkirk DMG-240

Page 1: ...AS FIRED BOILER INSTALLATION OPERATION MAINTENANCE MANUAL Model DMG 240 Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 325 5479 www ecrinternational com PN 240011656 REV K 11 01 2020 ...

Page 2: ...toff Valve TP Gauge and Safety Relief Valve Connections Document Package Used for measuring outside temperature Used for connecting condensate piping to boiler Outdoor Sensor Condensate Drain Connections VERIFY CONTENTS RECEIVED PN 240011656 REV K 11 01 2020 For Parts lists see manual 240011657 included with your boiler literature package ...

Page 3: ...re Sensor 41 8 10 Central Heating Thermostat 41 8 11 DHW Indirect Water Heater 44 8 12 Frost Protection 44 8 13 Pump Anti Seize Protection 44 9 Start Up Procedure 47 9 1 Fill Condensate Trap With Water 47 9 2 Commission Setup Water 47 9 3 Commission Setup Gas 48 9 4 Commission Setup Electric 48 9 5 Control Panel 49 9 6 Deaeration Function 50 9 7 Commissioning 51 9 8 Before Gas Conversion 51 9 9 Ga...

Page 4: ... 4 NPT Condensate Drain Connection Location J 2 57 2mm Size 3 4 NPT Weight Shipping 145 LBS 65 8 Unit 120 LBS 54 5kg Vent Connector 80 125 mm Electrical Cord Length 5 ft 1 5m Dimensions Vent Connector Combustion Air A D B Front View Top View Bottom View Dimensions I H G C J Condensate Drain Connection Return Water Gas Connection Bottom View Connection Identification Supply Water 50 psi safety reli...

Page 5: ...y and infirm or physically handicapped persons are more likely to be permanently injured by hot water Never leave them unattended in bathtub or shower Never allow small children to use a hot water tap or draw their own bath If anyone using hot water in the building fits the above description or if state laws or local codes require certain water temperatures at hot water taps you must take special ...

Page 6: ... F 80 C system design temperature 2 7 Operational Features Modulating 6 7 1 ratio Integral Dual Limit Integral Low Water Pressure Cutoff Outdoor Temperature Reset Heat exchanger over heat protection Recommended system pressure cold 21 7 psig 1 5 bar 2 Introduction 2 1 Installation shall conform to requirements of authority having jurisdiction or in absence of such requirements United States Nation...

Page 7: ...rt 12 Thermal fuse 6 on wire diagram 13 Exchanger flange high limit 4 on wire diagram 14 Ignition Flame detection electrode 15 Spark generator 16 Automatic air vent 17 Auxiliary control board box 18 Air gas venturi 19 Pump 20 Boiler drain 21 Low water pressure switch A Condensate trap drain B Gas inlet connection C Heating supply connection D Heating return connection PN 240011656 REV K 11 01 2020...

Page 8: ...of the boiler Boiler may be installed in any room or internal space special attention shall be given to the requirements of the current electrical provisions with respect to the installation of the boiler in a room or internal space containing a bath or shower Where a room sealed boiler is installed in a room containing a bath or shower it must not be possible for a person using the bath or shower...

Page 9: ...de Boiler Front View FIGURE 4 2c Service Clearances Closet Installation 17 3 4 450mm Minimum Service clearance to front of boiler Boiler Left Side View 17 3 4 450mm CLOSET INSTALLATION TOP VIEW 1 3 4 400mm 1 3 4 400mm 1 3 4 400mm BACK CLEARANCES REQUIRED FOR CLOSET INSTALLATION 0 in 0 mm between the Back of the Unit and the wall 0 0mm A 0 0mm 1 3 4 45mm 1 3 4 45mm See Table 2 page 8 See Table 2 pa...

Page 10: ...r This will give the position of the center of the hole for the flue Cut 5 5 16 135 00 mm diameter hole in the wall for concentric flue Lift boiler and hang it on wall Adjust the position of the boiler verify it is level For Direct Vent installations air vents are not required in the room boiler is installed in or when installed in closet or compartment Note Lift boiler using chassis Using front j...

Page 11: ...Use inhibited propylene glycol solutions certified by fluid manufacturer for use with closed water heating system Do not use automotive or ethylene glycol Boiler installed above radiation level or as required by authority having jurisdiction Integral low water pressure switch is provided in boiler Boiler used in connection with refrigeration system Install piping in parallel with boiler with appro...

Page 12: ...e as short and straight as possible to location protecting user from scalding and properly drain piping Install union if used close to safety relief valve outlet Install elbow s if used close to safety relief valve outlet and downstream of union if used Terminate pipe with plain end not threaded Check Local Codes For Check Local Codes For Maximum Distance To Maximum Distance To Floor Floor 5 4 Low...

Page 13: ...ise internal seals may be damaged B Verify appropriately sized isolating valve with filter is fitted to heating return connection C Fit pressure relief valve connection vertically before heating isolating valve Connect system valve pipe work to the boiler Route pressure relief valve discharge piping to the floor Follow local code with respect to necessary distance to the floor See Figure 5 1 Verif...

Page 14: ...ns are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction WARNING Burn Scald Hazard Water temperature over 125 F 51 C can cause severe burns and scalding See User s Manual before setting water temperature Failure to follow these instructions could result in death or serious injury Piping Legend Boiler PN 24001165...

Page 15: ... Relief Valve 1 DHW Pump 1 12 305mm Maximum Separation Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Hot Water Supply Tempered S Note Refer to pump manufacturer literature for proper pump sizing PN...

Page 16: ...pansion tank relief valves etc Select and size equipment to suit installation and meet code requirements T P Relief Valve to Drain Cold Water Supply Optional Indirect DHW Tank BOILER Make up Water Supply Tank Sensor CH System Pump ASME Relief Valve 1 DHW Pump 1 Hot Water Supply Tempered S Note Use external pump relay or Argo Zone Control to interface system pump to boiler Note Refer to pump manufa...

Page 17: ...oiler Support horizontal sections of vent pipe to prevent sags capable of accumulating condensation Unless otherwise specified support venting every 3 feet using steel strapping or equivalent Unless specifically stated in other sections of this manual use vent pipe manufacturer s specified material for lubrication during assembly of vent pipe Check for proper joint construction when joining pipe t...

Page 18: ...tion of common venting system should be corrected so installation conforms with National Fuel Code ANSI Z223 1 NFPA 54 and or Natural Gas and Propane Installation Code CAN CSA B149 1 When re sizing any portion of common venting system common venting system should be re sized to approach minimum size as determined using appropriate tables in Chapter 13 of the National Fuel Gas Code ANSI Z223 1 NFPA...

Page 19: ...ue pipe at sidewall air inlet terminal shall be at least 36 or more away from vent terminal Locate combustion air termination as far as possible from swimming pool swimming pool pump house and other sources of airborne chlorine Locate combustion air intake and vent terminals as required by authority having jurisdiction Use black ultra violet stabilized polypropylene when exposed to sunlight wind o...

Page 20: ...ted Snow Line Ground Anticipated Snow Line Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof or ground Anticipated Snow Line 18 Vertical Clearance to ventilated soffit Maximum Length L A B 21 6 4 m E F 21 6 4 m L1 L2 L L1 L2 Illustration shows examples of maximum equivalent lengths Coaxial Elbows Equivalent length Elbow Total Length Reduction 4...

Page 21: ...hen installing mechanical fastener Take dual flue mechanical fastener with larger hole in it and place it onto male end of pipe Slide clamp all the way down the pipe with smaller opening of clamp towards female end of the pipe Bend clamp over the female end of pipe A and slide male end of pipe B through clamp and into female end of pipe A WARNING Asphyxiation hazard Improper installation could res...

Page 22: ...ipe CPVC PVC a kit is available B Twin Pipe Polypropylene System Single wall polypropylene is used for both exhaust and air intake piping To transition from Coaxial at the top of the boiler to Twin Pipe polypropylene venting an adapter kit is available C Twin Pipe Separated Flue Exhaust and combustion air intake are not located in same general location D Twin Pipe Common Atmospheric Zone Terminati...

Page 23: ... 6 10 Inside Air Single Pipe Figure 6 14 Table 6A Combustion Air Venting Locations Type Location Terminal Type Corresponding Figures Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 8 6 9 T Terminal Figure 6 12 Roof Straight Terminal Figure 6 11 6 12 Combustion Air Fresh Air Side Wall Raised 90 down elbow Figure 6 8 90 down elbow Figure 6 10 6 12 Roof Raised 90 down elbow Figure 6 8 6 ...

Page 24: ...Abandoned unused masonry chimney may be used as chaseway for combustion air and vent Both combustion air and vent pipe must exit above top of chimney with clearances as shown in figure 6 7 FIGURE 6 7 Two Pipe Roof Vent FIGURE 6 8 Two Pipe Side Wall Vent FIGURE 6 9 Two Pipe Side Wall Vent Multiple Appliances Vent 12 305mm Min Separation Manuf Recommends Greater Separation Combustion Air 6 COMBUSTIO...

Page 25: ...0 does not have a max separation requirement between flue gas and fresh air Fig 6 11 Flue on Roof Air Intake on Side Wall Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof or ground Combustion Air Vent Snow Line Ground Level Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof or ground Fig 6 1...

Page 26: ...ipe vent with flue on sidewall requires tee as vent terminal See figures 6 12 and 6 14 Vent Combustion Air Outer Ring Ground Level Snow line Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow line Combustion Air Vent 24 610mm Minimum Length Maintain 12 305mm US 18 457mm Canada minimum clearance above highest anticipated snow level maximum 24 610mm above roof 18 Vertical ...

Page 27: ...t be min 12 305mm from or below doors windows or gravity inlet If boiler uses inside air min 4 1219 mm 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less Than 10 3m Minimum 3 914mm Minimum FIGURE 6 15 FIGURE 6 16 FIGURE 6 17 6 9 Side Venting Terminal Requirements of USA National Fuel Gas Code ANSI Z223 1 NFPA 54 Venting terminal from doors...

Page 28: ... or recirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkways Locate vent termination minimum 7 2 1m above any public walkway with consideration to condensate Meters Regulators deck porch Vent termination US only 4 1 2m Canada 6 1 9m horizontally from no case above or belo...

Page 29: ...rance to non mechanical air supply inlet to building or the combustion air inlet to any other appliance 12 305mm 3 ft 0 9m K Clearance to mechanical air supply inlet 3 ft 0 9m 6 ft 1 8m L Clearance above paved sidewalk or paved driveway located on public property 7 ft 2 1m 7 ft 2 1m 1 M Clearance under veranda porch deck or balcony 12 305mm 2 12 305mm 2 For clearances not specified in ANSI Z223 1 ...

Page 30: ...250 0 mm from boiler Secure flue pipe to wall with supports 3 ft 0 92 meters from each other Secure supports along the joint of each pipe 6 11 Multiple Boiler Venting Mounting Procedure See Figures 6 21 thru 6 23 1 Vent pipes correctly mounted See Figure 6 23 2 Line horizontal common vent pipes with male end towards condensate collector end cap 3 Follow vent manufacturer s instructions when assemb...

Page 31: ... cascade vent system to flue connection on top of boilers 11 Secure flue adapters using approved clamps to wall Ensure clamps are connected minimum of 10 in from top of boiler See Figure 6 24 12 Secure approved clamp around flue adapter Ensure clamp is locked in to proper position See Figure 6 24 A Position 1 Clamping around bell end of adapter B Position 2 Clamping around flue pipe adapter 13 Max...

Page 32: ...gth 45 5 ft 7 in 1 7m 12 ft 3 8 m 90 13 ft 1 in 4 0m 19 ft 5 8 m 6 in Cascade Vent System Example Elbow Equivalent Length 45 90 Number of Elbows 3 Equivalent Length 13 ft 1 in 4 0m Total Equivalent Length 39 ft 4 21 64 in 12 0m Total Equivalent Length 39 ft 4 21 64 in 12 0m Horizontal Length 5 ft 1 5m Total Equivalent Horizontal Length 44 ft 13 4m Maximum Vertical Length 98 ft 29 9m Total Vertical...

Page 33: ...in line each connected to common exhaust manifold 3 2 in per 3 ft 4 in 50 0 mm per 1 0 m B Back to Back System This system consists of boilers installed back to back connected to a common exhaust manifold 2 in per 3 ft 4 in 50 0 mm per 1 0 m 3 FIGURE 6 27 FIGURE 6 28 PN 240011656 REV K 11 01 2020 ...

Page 34: ...r 3 ft 4 in 50 0 mm per 1 0 m 3 6 12 Multiple Boiler Venting Parameter Settings To set parameter P19 see section 9 PARAMETER P19 Revs min rpm at minimum Power Natural Gas LPG 30 30 Flue header size shall be calculated by qualified service agency during system design as required by local authority having jurisdiction FIGURE 6 29 PN 240011656 REV K 11 01 2020 ...

Page 35: ...e condensate drain pipe minimum 1 4 per foot 21mm m away from boiler Use field source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal FIGURE 6 30 Condensate Drain 6 COMBUSTION AIR AND VENT PIPING Condensate Tee field installed on condensate drain pipe Do ...

Page 36: ...reach your gas supplier call the fire department FIGURE 7 1 Gas Connection Gas Connection 7 GAS SUPPLY PIPING Note 7 2 Drip Leg Gas Supply Pressure Natural Gas LP Min Max Min Max 3 0 w c 0 87 kPa 10 5 w c 2 61 kPa 8 0 w c 1 99kPa 13 0 w c 3 23kPa Use two 2 wrenches when tightening and fitting to pipe boiler s threaded fittings Boiler s internal piping can be damaged if subjected to excessive torqu...

Page 37: ...stem by closing manual gas shutoff valve See figure 7 3 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source Correct leaks immediately and retest Manual Main Gas Shutoff Valve DANGER Fire Hazard Do not use matches candles open...

Page 38: ...rvice panel before making electrical connections Failure to do so could result in death or serious injury FIGURE 8 1 Electric Knockouts Bottom Of Boiler 8 Wire Knockouts Front of Boiler Back of Boiler 8 ELECTRICAL CONNECTIONS Note Wiring diagrams can be found in Section 14 of this Manual 8 3 Electrical Connections Boiler requires 120V 60Hz power supply Verify electrical supply is polarized Boiler ...

Page 39: ...cabinet by unfastening clip on front of control box Push lip back for latch 5 Run wire s through grommet s in control panel cabinet 6 Unscrew wire clamp to access connection block and bring wires through 7 Connect wires to appropriate terminals on connection block 8 Firmly tighten wire clamps and close control panel cabinet Various thermostats and controllers can be connected to standard control P...

Page 40: ...01 IF 01 control PCB is built into auxiliary control box Refer to instructions supplied with product Do not connect freeze thermostat or room thermostat to boiler if using 0 10 V control PCB 1 Connection Status Nc If boiler locks out a relay is de energized and an alarm can be transmitted via a dry set of contacts maximum 120 VAC 1A on terminals Nc and C of the control board connection 2 Connectio...

Page 41: ...aximum values are limited Minimum output is linked to boiler s modulation depth Output varies between minimum and maximum value on basis of value determined by controller Jumper 1 Input Signal V Temperature F C Description 0 32 59 0 15 Boiler off 0 5 59 72 15 20 Hysteresis 2 0 10 01 72 176 20 80 Temperature required 1 Dependent on minimum modulation depth set speeds standard 20 FIGURE 8 7 Analog T...

Page 42: ...e set using parameter P34 Three way valve is connected as follows N neutral C heating system D indirect tank If neutral position of three way valve is adjusted with parameter P34 connect the pump as follows N N pump C L pump Ground 3 External Gas Valve Control EgV If there is a call for heat alternating voltage of 120 VAC 1 A maximum becomes available on EgV terminals of control board to control a...

Page 43: ... occupied room C Connect 2 wire dry contact room thermostat to ON OFF OT terminals of boiler s control board connection Note ON OFF OT terminals are NOT able to supply 24V to the thermostat D Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Boiler control does NOT provide 24 VAC power to central heating thermostat E Locate and install thermostat per manufacturer s...

Page 44: ... be open where there is a risk of freezing Connect 1 K Ω outdoor temperature sensor to T out terminals of control board Frost protection activates when 1 K Ω outdoor temperature sensor reads a temperature lower than 10 F 10 C This can be adjusted using parameter P30 Circulation pump will switch on and operate continuously until the outdoor temperature increases past value set on parameter P30 FIGU...

Page 45: ... 11 Connect CH Central Heating pump on terminal N L Pump of control PCB SCU 02 see section 8 8 Connect DHW Domestic Hot Water pump on terminal N D 3wV of control PCB SCU 02 see section 8 8 FIGURE 8 15 Example Of System Shutdown Input Connection Example below shows connection of shutdown input for system connecting to auxiliary board See section 8 6 PN 240011656 REV K 11 01 2020 ...

Page 46: ...46 8 ELECTRICAL CONNECTIONS FIGURE 8 16 Wiring Diagram 13 PN 240011656 REV K 11 01 2020 ...

Page 47: ...an Check distribution system to ensure it is sized and installed correctly Before filling open all valves on the heating circuit in the installation Flush heating system including all heating zones Fill boiler with potable water Fill boiler and system piping with water or antifreeze water solution if used See antifreeze information page 11 Purge air from boiler using air vent Purge air from system...

Page 48: ... 60 mbar B Purge gas supply pipe within boiler by unscrewing pressure outlet on gas valve C Tighten the port when pipe has been sufficiently purged 12 Check all gas connections in the boiler are tight 13 Check piping and connections for leaks immediately after gas is turned on Shut off gas supply and make necessary repairs if leaks are found 9 4 Commission Setup Electric 1 Check electrical connect...

Page 49: ...el can be changed Energy saving mode Economic mode activated Fault Boiler fault indicated Can be seen from é code and red display Frost protection Boiler running in frost protection mode Hour counter menu Readout of operating hours number of successful starts and hours on main supply ON OFF switch After 5 lock outs boiler must be switched OFF ON again Boiler pump Pump operates Heating system funct...

Page 50: ...i See Figure 9 4 Boiler pump will run on and off for up to 10 minutes This will purge air from the system The burner will switch on for a few seconds to verify increasing temperature on flow return sensors Boiler is ready to start in standard operation Repeat Deaeration function at least 3 times switching boiler on off using button Manually operated purge valve can also be performed by using purgi...

Page 51: ...unction to set boiler to operate on full load and on part load in Heating mode 2 Adjust Fan Speed as indicated in table found in section Parameter Settings if required 3 Modify fan speeds using parameters P17 P18 and P19 4 Set air gas ratio O2 CO2 Full load and Part load as describe below 5 Use combustion analyzer to properly set gas valve 6 Allow time between adjustments for your combustion analy...

Page 52: ...hen taking measurements Set boiler to low fire by pressing two buttons simultaneously If the boiler is already in combustion setup mode for high fire press the button several time until L3 is displayed on the screen Measure percentage of O2 or CO2 in flue gases Compare the measured values with values in table below Remove front panel when comparing values Adjust gas air ratio using low fire adjust...

Page 53: ...installer To prevent unwanted settings some parameter settings can only be changed after special access code 0012 is entered Modification of factory settings may be detrimental to operation of the boiler Press the two Menu buttons simultaneously and then button until the symbol flashes on the menu bar Select the INSTALLER menu using the button CODE appears on the display Use or button to input the...

Page 54: ...1 P7 Pump post run time CH 1 to 98 minutes 99 minutes continuous 3 P8 Display brightness when backlight is active 0 Low 1 High 1 P17 Max fan speed during CH mode Natural gas 1 x100 rpm 64 Propane x100 rpm 63 P18 Max fan speed during DHW mode Natural gas 1 x100 rpm 64 Propane x100 rpm 63 P19 Minimum fan speed during CH DHW mode Natural gas 1 x100 rpm 16 Propane x100 rpm 15 P20 Offset on partload fa...

Page 55: ... 0 CH enable 1 Blocking without frost protection 2 Blocking with frost protection 3 Lock out with frost protection 1 P37 Function of release input 0 DHW enable 1 Burner release 1 P38 Wait time for valid release signal 0 to 255 seconds 0 No check 0 P39 Wait time for flue gas valve 0 to 255 seconds 0 P40 Position from alarm operation signal relays 0 Operation signal 1 failure signal 1 P41 Minimum ga...

Page 56: ...1 CPVC 90 C 194 F 2 PP SS 110 C 230 F 1 P52 Air pressure sensor 0 Off 1 On 0 P53 DHW time out mode 0 None 1 Absolute 1 P54 DHW time out 10 to 180 minutes 150 P55 CH prior time 10 to 180 minutes 120 P56 RPM min antiwind 10 to 30 100rpm 25 Parameter Description Adjustment Range Factory Setting DMG 240 1 Do not modify these factory settings unless absolutely necessary E g to adapt the boiler to Propa...

Page 57: ...s the button is displayed alternating with the current sub status for example 4 Press the button is displayed alternating with the current flow temperature 1 5 7 F for example 5 Press the button successively to scroll down to the various parameters 6 Press the button is displayed alternating with the internal set point 4 5 F for example 7 Press the button is displayed alternating with the current ...

Page 58: ... protection gradient level 3 Blockage 36 Modulate up for flame control 37 Temperature stabilization time 38 Cold start 4 Burner on DHW mode 30 Temperature control 31 Limited temperature control ΔT safety 32 Output controlled 33 Temperature protection gradient level 1 Modulate down 34 Temperature protection gradient level 2 low fire 35 Temperature protection gradient level 3 Blockage 36 Modulate up...

Page 59: ...ing Press button df x is displayed with x flashing This is the current value of X for dF Check this against the value of X on the type plate Enter the value of X shown on the type plate using the or button Confirm the value with the button df y is displayed with y flashing This is the current value of Y for dU Verify the value of y on the rating plate is the same Enter the value of y shown on the ...

Page 60: ...ceeds central heating loop setpoint unit will shutdown and go through 3 minute time delay burner pause time before another call for heat During this time the pump will run for additional three minutes to dissipate any residual heat FOR YOUR SAFETY READ BEFORE OPERATING 10 OPERATING INSTRUCTIONS 10 2 OPERATING INSTRUCTIONS Stop Read Safety information above Set thermostat to lowest setting Turn OFF...

Page 61: ... valve manufacturer s instructions packaged with relief valve Examine flue passages in heat exchanger burner condensate lines and cleaning if necessary by following instructions in Annual Examination and Cleaning of Boiler Components in this section CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation FIGURE 11 1 Sight Glas...

Page 62: ...d from factory and require no further lubrication Lubricate field sourced pumps and or motors 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 verify pressure test port cap and combustion test port are in place return temperature s...

Page 63: ...stles this might damage the injector 4 Remove any fallen deposits from bottom of inner case 5 Clean burner with soft brush and check flame ports are clear Blockages may be removed with stiffer brush 6 Check condition of electrodes 7 Check spark gap positioning and height of electrodes 8 Check fan impeller is clean and free to rotate WARNING Following service procedures must be performed by qualifi...

Page 64: ...lose central heating flow and return valves Connect suitable pipe to drain point Route it to suitable container Open drain tap 11 GENERAL MAINTENANCE AND CLEANING DANGER Before servicing turn off electrical power to boiler at service switch Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury 11 1 Electrodes 1 1 8 1 16 4 mm 0 5 mm A B C 1...

Page 65: ...Net AHRI Rating Water MBH 1 3 AFUE 2 Maximum Minimum 241 36 216 188 95 0 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficiency are based on DOE Department of Energy test procedures 3 Net AHRI Ratings based on piping and pickup allowance of 1 15 Contact Technical Support before selecting boiler for installations having unusual piping and pickup ...

Page 66: ...ng correctly Check sensor has been correctly fitted Replace sensor if necessary CHART 1 E04 E05 Temperature of heat exchanger too low Heat exchanger temperature too high Bad connection Sensor fault Sensor not poorly connected No circulation Check the wiring Replace sensor if necessary Purge air in heating system Check for water circulation direction pump valves Check water pressure Check sensors a...

Page 67: ...heck that the air inlet and exhaust flue are not blocked Check the wiring on the gas valve Defective control SU PCB CHART 5 Presence of the flame but insufficient ionization 3 μA Check that the gas valve is fully opened Check the supply pressure Check the ionization ignition electrode Check the grounding Check the wiring on the ionization ignition electrode CHART 5 E16 False flame signal Ionizatio...

Page 68: ...ange during boiler operation burner on Bad connection Supply Return sensor damaged No water circulation Check the sensor connection Replace the sensor Check the pump connection CHART 11 E44 Difference between supply return temperature too high Bad connection Supply Return sensor damaged No water circulation Check sensor connection Replace sensor Check pump connection 13 2 Shutdowns and Lock outs B...

Page 69: ...1 Power supply incorrectly wired Floating or 2 phase network Line and neutral mixed up Set parameter p43 to 0 Su 10 Shutdown input is open External cause Parameter error Bad connection Correct the external cause Check the parameters Check the wiring Su 11 Shutdown input active or frost protection active External cause Parameter error Bad connection Correct the external cause Check the parameters C...

Page 70: ...u 30 2 No tFG sensor connected shorted Boiler stop Flue high limit disconnected Sensor error Replace flue high limit Su 33 After 5 times tF tF Max controlled stop Non existent or insufficient circulation sensor error Replace supply sensor Check circulation direction pump valves Check water pressure Check sensors are operating correctly Check sensor has been correctly fitted Check cleanliness of he...

Page 71: ... using button Er xx is displayed with xx flashing Last error which occurred for example 2 Use or buttons to scroll through faults Press button to display details of faults or shutdowns Press or buttons to view the following information n 1 Number of times that the error occurred hr The number of operating hours St State Su Sub status t1 Supply temperature ºF ºC t2 Return temperature ºF ºC t3 DHW t...

Page 72: ...3 279 84 2 858 28 4 3 131 86 0 827 30 2 2 990 87 8 796 32 0 2 857 89 6 767 33 8 2 730 91 4 740 35 6 2 610 93 2 713 37 4 2 496 95 0 687 39 2 2 387 96 8 663 41 0 2 284 98 6 640 42 8 2 186 100 4 617 44 6 2 093 102 2 595 46 4 2 004 100 4 617 48 2 1 920 102 2 595 50 0 1 840 104 0 575 51 8 1 763 106 0 556 CHART 2 INDIRECT TANK SENSOR DATA T R T R F Ohm F Ohm 32 0 32 505 86 0 8 060 33 8 30 898 87 8 7 726...

Page 73: ...tions tight and wires undamaged NO YES Check continuity across sensor OK NO YES Repair wire and or fix connection Check sensor element is properly installed in pipe NO YES Replace Sensor Replace Control Board Re Install Sensor Properly Check sensor resistance and compare to temperature resistance curve Figure 13 1 page 88 Remove sensor if needed OK NO YES Replace Sensor Note DOMESTIC HOT WATER SEN...

Page 74: ...lass Is flame present NO YES Replace Flame Sense Adjust Gas Mixture See Section 9 Re check E 16 still present NO YES Replace Gas Valve Condition Corrected E16 False Flame Signal Initiate heat call Check CO2 at high fire is 9 1 9 5 Out of Range In Range Replace Flame Sense PN 240011656 REV K 11 01 2020 ...

Page 75: ...ce Heat Exchanger E12 High Temperature Is external High Limit Switch off NO or N A YES 13 TROUBLE SHOOTING Troubleshooting Chart 3 Reset Switch Check Boiler Pump OK NO YES Water Circulation Adequate NO YES Purge air in system Repair Piping Repair plug or replace switch Does heat exchanger switch 6 in wire diagram have continuity NO YES PN 240011656 REV K 11 01 2020 ...

Page 76: ...rol board Check both sensors are properly inserted into pipe lines NO YES Repair sensor insertion into pipe lines E10 E11 Temperature Difference Between Supply and Return Too Great E35 Supply and Return Sensors Reversed Onboard pump operation properly NO YES Replace pump Possible air in system De aerate Are any water valves partially closed NO YES Open all valves Check wire harness against wiring ...

Page 77: ...gas line Check gas inlet pressure at least equals rating plate requirements NO YES Press RESET for two 2 seconds and retry Is there a strong consistent spark NO YES Remove igniter and inspect Is there contamination NO YES Clean Or Replace Igniter Does the boiler ignite NO YES Restart the boiler and place into high fire chimney sweep Go to display and check flame current Is there at least 3 mA NO Y...

Page 78: ...NO YES Provide proper ground Purge all air from gas line Check gas inlet pressure at least equals rating plate requirements NO YES Check gas line for obstructions Check venting Is exhaust gas recirculating to the air intake NO YES Clean or Replace Igniter Clear Vent Obstruction Remove igniter and inspect Is there damage or contamination NO YES Restart boiler Go to display and check flame current I...

Page 79: ...BL connection on control board terminal strip Is this function being utilized NO YES Secure wire connections Install jumper securely in place Repair Replace External Accessory Item As Required E39 Shutdown Input In Locked Out Mode Are the wire connections secure NO YES Is factory installed jumper securely in place NO YES Check external accessories are correct NO YES Check external accessories are ...

Page 80: ...r Is wiring connection to HRU terminal secure NO YES Is wiring connection from SCU board to main board secure NO YES Is Parameter P42 set to 1 NO YES Is P42 parameter set to 0 NO YES Done Set P42 to 0 NOT OK OK Replace SCU board NOT OK OK Replace Main Control Board Done Set P42 to 1 Not OK OK Done Is HRU accessory operating properly NO YES Correct HRU Accessory PN 240011656 REV K 11 01 2020 ...

Page 81: ... Check wire harness connections are secure NOT OK OK The error code is accurate Correct water pressure and or correct system leaks Replace Sensor NOT OK OK Note This error code refers to the onboard low water pressure switch not any field installed external low water cutoff device Is low water pressure sensor item 12 in wiring diagram securely installed to block NO Yes Correct Installation Done PN...

Page 82: ...rence During Operation Check wire plugs are securely connected to temperature sensors NO YES Onboard pump operating properly NO YES Check both sensors are properly inserted into pipe lines NO YES Possible air in the system De aerate NOT OK OK Done Not OK OK Repair Sensor Insertion Into Pipe Lines Refer to Temperature Sensor Chart both sensors Replace Sensor Replace Control Board PN 240011656 REV K...

Page 83: ...ensors T C T F R Ohm 40 40 309396 30 22 171840 20 4 98932 10 14 58879 0 32 36129 10 50 22804 20 68 14773 25 77 12000 30 86 9804 40 104 6652 50 122 4607 60 140 3252 70 158 2337 80 176 1707 90 194 1266 100 212 952 110 230 726 120 248 560 130 266 438 140 284 345 150 302 275 PN 240011656 REV K 11 01 2020 ...

Page 84: ...hough flame proofed fire retardant treated or plastered COMBUSTION AIR Air that is drawn into an appliance to mix with fuel and support combustion CONDENSATE Liquid separated from flue gas due to reduction in temperature DIRECT VENT BOILER Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors 14 GLOSSARY GAS SUPPLIER ...

Page 85: ... 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 SERVICE Supply installation or maintenance of goods carried out by a...

Page 86: ...S OVERRIDE MUST NOT BE USED UNLESS AT LEAST ONE OF THE FOLLOWING CONDITIONS IS TRUE An external energy management system is installed that reduces the boiler water temperature as the heating load decreases This boiler is not used for any space heating This boiler is part of a modular or multiple boiler system having a total input of 300 000 BTU hr or greater This boiler is equipped with a tankless...

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