ECR International Green Mountain GMCB150 Installation, Operation & Maintenance Manual Download

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• APPLIANCE -

Device to convert gas into energy; term

includes any component, control, wiring, piping or tubing

required to be part of the device.

• ANSI

- American National Standards Institute, Inc. over

see's creation and maintenance of voluntary consensus

standards, including ANSI Z21.13/CSA 4.9: Gas-Fired Low

Pressure Steam and Hot Water Boilers.

• ASME -

Association of Mechanical Engineers

Establishes rules of safety governing the design, fabrication,

and inspection of boilers and pressure vessels, determining

the MAWP of such vessels.

• ASTM

- American Society for Testing and Materials.

ASTM International is one of largest voluntary standards

development organizations in world trusted source for

technical standards for materials, products, systems, and

services. Known for their high technical quality and market

relevancy, ASTM International standards have important

role in information infrastructure that guides design,

manufacturing and trade in the global economy.

• AUTHORITY HAVING JURISDICTION

Individual or

organization adopting and enforcing codes, rules, and by-

laws governing various concerns of community. Commonly

referred to as "final authority" for any matters relating

to LIFE SAFETY and BUILDING CONSTRUCTION within a

community.

• BOILER

- Appliance intended to supply hot liquid for space-

heating, processing or power purposes.

• BTU

- Abbreviation for British Thermal Unit. Quantity of heat

required to raise temperature of 1 pound of water 1°F.

• BURNER

- Device for final conveyance of gas or mixture of

gas and air, to combustion zone.

• CALIBRATE

- Make fine adjustments or divide into marked

intervals for optimal measuring.

• COAXIAL VENTIN

G Sharing the same center line.

• COMBUSTION

- Rapid oxidation of fuel gases 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.

• 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.

14 - GLOSSARY

• DIRECT VENT BOILER

- Boiler constructed and installed so

all combustion air is derived directly from outdoors and all

vent gases are discharged to outdoors.

• DOMESTIC -

Relating to household usage as opposed to

commercial usage.

• DOMESTIC WATER -

Potable drinking water - tap water.

• DRAFT

- Pressure difference causes gases or air to flow

through a chimney, vent, flue or appliance.

• FLA

- Full load amps.

• FLUE

- Enclosed passageway for conveying combustion

gases.

• FLUE GASES

- Products of combustion plus excess air in

appliance flues or heat exchanger.

• GAS SUPPLIER -

Party that sells commodity of Natural Gas

(Gas A) or LPG (Gas E).

• HIGH-VOLTAGE

- Circuit involving potential of not more

than 600 volts and having circuit characteristics in excess of

those of low-voltage circuit.

• HYSTERESIS (DIFFERENTIAL) -

difference between the

temperature at which the thermostat switches off - and the

temperature at which it switches on again.

• IGNITER

- Device utilizing electrical energy to ignite gas at

main burner.

• LEAK CHECK

- Operation performed on gas piping system

to verify system does not leak.

• LICENSED QUALIFIED INSTALLER / SERVICE

TECHNICIAN -

any individual, firm, corporation or

company that either directly or through a representative is

engaged in the installation, replacement, repair or servicing

of gas piping, venting systems, appliances, components,

accessories, or equipment, and whose representative is

experienced and trained, in such work and has complied

with the requirements of the authority having jurisdiction.

• LOW WATER CUTOFF

- Device constructed to automatically

cut off fuel supply when surface of water in boiler falls to

lowest safe water level.

• LOW-VOLTAGE

- Circuit involving potential of not more

than 30 volts.

PN 240012363 REV. A [08/31/2018]

Summary of Contents for Green Mountain GMCB150

Page 1: ...ional Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012363 REV A 08 31 2018 Condensing Wall Mounted Gas Fired INSTALLATION OPERATION MAINTENANCE MANUAL Models GMHB125 GMHB160 GMCB150 GMCB200 ...

Page 2: ...4 ea 17x24x2 Gaskets Includes Essential Documents and Warranty 11x17 Wire Diagrams 5 GPM Flow Restrictor GMCB200 Combi Only Used for Valve Connections Document Package 30 PSI Safety Relief Valve Gas Ball Valve 1K Ohm Outdoor Reset Sensor Drain Valve VERIFY CONTENTS RECEIVED PN 240012363 REV A 08 31 2018 Not Shown Literature Package ...

Page 3: ...n 43 8 5 Install Room Thermostat 44 8 6 Optional Electrical Connections 45 8 7 Indirect Storage Tank 47 Wiring Diagrams 48 56 9 Start Up Procedure 57 9 1 Central Heating System Connections Heat Only 57 9 2 Central Heating System Connections Combi 57 9 3 Gas Conversion 58 9 4 System Start Up 58 9 5 Commission Setup Electric 59 9 6 Control Panel 59 9 7 Commission Setup Gas 60 9 8 De Aeration Functio...

Page 4: ... psig 0 2 bar 2 9 psig 0 2 bar Min DHW Flow Rate 0 55 gpm 2 50 L min 0 55 gpm 2 50 L min Max DHW Temperature 140 F 60 C 140 F 60 C DHW Water Content 0 05 gal 0 23 L 0 10 gal 0 37 L SYSTEM When boiler is operating at maximum operating temperature providing heating with all heat emitters operating pressure gauge should not indicate more than 26 11 psi 1 80 bar If reading exceeds this figure larger e...

Page 5: ...mensions 41 2 7 51 2 3 51 2 101 2 125 HEAT ONLY Bottom View Dimensions 101 2 4 D E I G C B D E I G C B F H 31 2 9 1 2 125 150 Top View Vent Connector Combustion Air Wall Wall Wall Wall Wall Wall For optional 2 pipe venting otherwise use outside ring of vent connector PN 240012363 REV A 08 31 2018 D C E I H G F B A D E I G C 5 B 81 2 F J 5 7 31 2 6 6 5 7 31 2 31 2 6 6 9 91 2 9 B ...

Page 6: ...all requirements before beginning installation 1 Safety Information WARNING Do not tamper with or use this boiler for any purpose other than its intended use Failure to follow these instructions could result in death or serious injury Use only manufacturer recommended parts and accessories CAUTION Laceration burn hazard Metal edges and parts may have sharp edges and or may be hot Use appropriate p...

Page 7: ... h 39 kW capable of providing 3 4 U S gpm 13 2 liters min with a temperature rise of 70 F 39 C GMCB200 176 000 btu h 52 kW capable of providing 4 9 U S gpm 18 9 liters min with temperature rise of 70 F 39 C Integral Low Water Pressure Cutoff Outdoor Temperature Reset included Heat exchanger over heat protection Boiler operating at maximum operating temperature providing heat pressure gauge should ...

Page 8: ...irect Tank Supply 7 Low Water Pressure Cutoff 8 System Supply 9 Condensate Trap 10 3 Way Valve with Motor 11 Water Safety Thermostat 12 NTC Heating sensor Supply Return QTY 2 1 Shown for clarity 13 Ignition electrode 14 Spark Generator 15 Flue Sensor 16 Aerator 17 Coaxial Flue Connector 18 Heat Exchanger Temperature Sensor 19 Heat Exchanger 20 Burner not shown 21 Flame Detection Electrode 22 Air G...

Page 9: ...eating sensor Supply Return QTY 2 1 Shown for clarity 8 Water Safety Thermostat 9 Spark Generator 10 Ignition Electrode 11 Flue Sensor 12 Aerator 13 Coaxial Connector 14 Heat Exchanger Temperature Sensor 15 Heat Exchanger 16 Burner not shown 17 Flame Detection Electrode 18 Air Gas Blend Manifold 19 Acoustic Silencer 20 Air Purge 21 Venturi 22 Fan 2 1 13 11 7 6 14 9 17 5 22 18 20 10 19 15 21 3 4 8 ...

Page 10: ...6a DHW Hot Water Outlet 6b NTC DHW Sensor 7 Low Water Pressure Cutoff 8 System Supply 9 Condensate Trap 10 3 Way Valve with Motor 11 Water Safety Thermostat 12 NTC Heating sensor Supply Return QTY 2 1 Shown for clarity 13 Ignition electrode 14 Spark Generator 15 Flue Sensor 16 Aerator 17 Coaxial Flue Connector 18 Heat Exchanger Temperature Sensor 19 Heat Exchanger 20 Burner not shown 21 Flame Dete...

Page 11: ...utlet 6b NTC DHW Sensor 7 Low Water Pressure Cutoff 8 System Supply 9 Condensate Trap 10 3 Way Valve with Motor 11 Water Safety Thermostat 12 NTC Heating sensor Supply Return QTY 2 1 Shown for clarity 13 Ignition electrode 14 Spark Generator 15 Aerator 16 Flue Sensor 17 Coaxial Flue Connector 18 Heat Exchanger Temperature Sensor 19 Heat Exchanger 20 Burner not shown 21 Flame Detection Electrode 22...

Page 12: ...on flat vertical wall which is capable of supporting the weight of the boiler Boiler installed in a room containing bath or shower shall be installed so person using bath or shower cannot touch any electrical switch or boiler control utilizing line voltage electricity Multiple Boilers can be wall mounted placed side by side or back to back common venting is not permitted Consider service clearance...

Page 13: ...1 2 in 571 5 mm CLEARANCES REQUIRED FOR CLOSET INSTALLATION CLEARANCES FOR COMBUSTIBLES Top View Back Closet Installation 0 in 0 mm between Back of Unit and wall Left Side View of Boiler Front View of Boiler Front View of Boiler C F B C B C D D D SERVICE CLEARANCES CLEARANCES FOR COMBUSTIBLE MATERIALS F A PN 240012363 REV A 08 31 2018 ...

Page 14: ...ure lines are parallel and sloped properly towards the boiler refer to section 6 This will give position of center of hole for flue 6 Required hole size for coaxial flue GMHB125 GMCB150 4 3 8 110 mm diameter GMBH160 GMCB200 5 5 16 135 mm diameter Note Lift boiler using chassis Do not use front jacket vent piping water or gas fittings to lift boiler as it may cause damage to the boiler Use two 2 wr...

Page 15: ...n hazard Ethylene glycol is toxic Do not use ethylene glycol Never use automotive or standard glycol antifreeze even ethylene glycol made for hydronic systems Ethylene glycol can attack gaskets and seals used in hydronic systems Do not use petroleum based cleaning or sealing compounds boiler system Do not fill boiler or boiler system with softened water Use only inhibited propylene glycol solution...

Page 16: ...er and condensate piping to freezing temperatures 5 HYDRONIC PIPING When purging installations that include standing iron radiators and systems with manual vents at high points start with nearest manual air vent Open the vent until water flows out then close vent Repeat this procedure working toward furthest air vent Install a basket strainer if large amounts of sediment is present Keep basket cle...

Page 17: ...charge piping Size and arrange discharge piping to avoid reducing safety relief valve relieving capacity below minimum relief valve capacity stated on rating plate Run pipe 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 dow...

Page 18: ...rced control system logic may require equivalent water temperatures entering each boiler to properly sequence and adjust system supply temperature WARNING Burn and scald hazard Verify all plastic caps are removed from boiler connections Failure to follow these instructions could result in death or serious injury Thoroughly flush all hydronic piping Flush system wash clean after installing all pipi...

Page 19: ...or Arrange piping to prevent water dripping onto boiler Return Low Water Cutoff LWCO Installation if required by the Authority Having Jurisdiction See Figure 5 5 for detail Magnetic Dirt Separator Purge Valve PN 240012363 REV A 08 31 2018 Note Illustrations are meant to show system piping concept only Installer is responsible for all equipment and detailing required by authority having jurisdictio...

Page 20: ...ensing device in the supply piping or in a stand pipe off the boiler supply above the minimum height of boiler See Figure 5 3 Piping Diagram Position control in HORIZONTAL piping to assure proper boiler protection upright or 90 rotation For proper operation sensing element of the LWCO control shall be positioned in the tee to sense the main water stream Maintain minimum 1 4 spacing from pipe walls...

Page 21: ...URE 5 6 MULTI ZONE SYSTEM WITH ZONE VALVES ASME Relief Valve Cold Water Supply CH System Pump 1 BOILER DOES NOT INCLUDE EXTERNAL PUMP RELAY Note 1 12 305MM MAXIMUM SEPARATION Note 2 2 Zone Valves PN 240012363 REV A 08 31 2018 ...

Page 22: ...22 5 HYDRONIC PIPING 125 with Zone Circulator Pumps USE ONLY IF TANK IS WITHIN 5FT OF BOILER MAGNETIC DIRT SEPARATOR 5 FT MAX FROM SYSTEM TO SYSTEM PN 240012363 REV A 08 31 2018 ...

Page 23: ...ing Load TO SYSTEM FRO HOT WATER SUPPLY TEMPERED COLD WATER SUPPLY Z3 Z2 COLD WATER SUPPLY Z1 DHW PUMP 165 with Zone Circulator Pumps 160 with Zone Circulator Pumps MAGNETIC DIRT SEPARATOR FROM SYSTEM TO SYSTEM PN 240012363 REV A 08 31 2018 ...

Page 24: ...to change position This will allow the pump to circulate the primary water through the DHW plate heat exchanger GMCB150 GMCB200 Combi Boilers only Combustion fan will then come on and begin to run at ignition speed Once the fan reaches ignition speed the control board will allow power to flow to the spark generator and gas valve creating ignition in the combustion chamber The flame sensor will ack...

Page 25: ...mpering device such as an automatic mixing valve at hot water tap or water heater Automatic mixing valve must be selected and installed according to manufacturer s recommendations and instructions Water passing out of drain valves may be extremely hot To avoid injury Make sure all connections are tight Direct water flow away from any person DANGER Water Temperature Setting 1st Degree Burn Exposure...

Page 26: ... water supply will clog DHW water flow sensor resulting in error codes and causing boiler to lockout Locate the filter as close to the boiler as possible and place on DHW domestic hot water inlet connection located at bottom of the boiler Thermostatic Mixing Valve Filter DANGER Scald Burn Hazard Manufacturer recommends thermostatic mixing valve required on potable water supply to avoid potential s...

Page 27: ...pes to vent this boiler shall be prohibited Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polyphenolsulfone in venting systems shall be prohibited Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited Failure to follow these instructions could result in death or serious injury Note Follow venting manufacturer s equivalent lengths for specialty fi...

Page 28: ...densate trap pour water into exhaust vent until water begins to flow through the siphon Visually inspect the siphon to ensure it is full with clean water During operation check condensate trap to ensure it is draining properly Note Condensate trap must be manually filled with water at initial start up 6 COMBUSTION AIR AND VENT PIPING FIGURE 6 1 CONDENSATE DRAIN ASSEMBLY MODEL GMCB200 SHOWN LOCATIO...

Page 29: ...ini venting system For other venting system suppliers see their instructions 1 Place clamp so etched UP is facing up 2 Open clamp slightly by separating circular areas from each other 3 Slide male end of first pipe through open clamp so the shoulder of the female end of the pipe stops the clamp from sliding off the pipe 4 Insert the male end of the second pipe into the clamp on the up etched side ...

Page 30: ...ot use cellular core pipe Only specified sized pipes are to be used When using venting material other than boiler manufacturer s venting note the correct installation procedure Failure to follow these instructions could result in death or serious injury WARNING Covering non metallic vent pipe and fittings with thermal insulation shall be prohibited Use of cellular core PVC for venting flue gas cou...

Page 31: ...rers 6 8 Approved Polypropylene Manufacturers Note Maximum equivalent length may vary between manufacturers 6 COMBUSTION AIR AND VENT PIPING Combustion Air And Vent Pipe Fittings Must Conform With The Following Item Material Standards Vent Pipe and Fittings CPVC schedule 40 ANSI ASTM D1784 F441 PP Polypropylene Pipe and Components UL 1738 ULC S636 08 Pipe Cement Primer PVC ANSI ASTM D2564 CPVC ANS...

Page 32: ...sion to inner grey flue pipe Remove waste from both vents flue and air Verify cut ends are square and free from burrs Insert flue back into intake air vent and pass them through hole in wall Check all measurements before cutting Clearance to combustible materials is zero when using coaxial vent system After installing venting use calibrated analyzer to verify there is no recirculation of combustio...

Page 33: ...ance above highest anticipated snow level 24 610mm above roof or ground 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 FIGURE 6 6 COAXIAL VERTICAL EXHAUST 12 305mm Minimum Separation Manufacturer Recommends Greater Separation 6 COMBUSTION ...

Page 34: ...d for boiler exhaust CPVC or PVC are both approved for air intake To transition from Coaxial at the top of the boiler to Twin Pipe CPVC PVC a kit is available see parts list 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 provided with t...

Page 35: ...0 3 80 mm 3 80 mm 100 ft 100 ft Note Twin Pipe Common Atmospheric Zone termination can be run horizontal or vertical FIGURE 6 13 TWIN PIPE ROOF VENT 15 381mm Max Vent Combustion Air 12 305mm US 18 458mm Canada Min Above Anticipated Snow Line Roof Line 12 305mm Min FIGURE 6 14 HORIZONTAL TWIN PIPE EXHAUST AND INTAKE 12 305mm Minimum Separation Manufacturer Recommends Greater Separation PN 240012363...

Page 36: ...Min 24 610mm Max Separation Between Bottom Of Combustion Air Intake And Bottom Of Vent Combustion Air Opening Separation 24 Min Grade Snow Ice Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof 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 obstru...

Page 37: ...overall equivalent length calculations Flexible venting installations use single wall polypropylene to pass flue gasses to base of chimney then flexible venting to get them to termination at the top Combustion air is not supplied through masonry chimney Combustion air must be from outside using 3 80 mm single wall polypropylene Position boiler to use minimum length possible of rigid single wall po...

Page 38: ...ithin a height of 15 ft 4 5m above the meter regulator assembly 3 ft 0 9m I Clearance to service regulator vent outlet 3 ft 0 9m 3 ft 0 9m J Clearance 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 ...

Page 39: ...urce condensate pump designated for use with condensing boiler if boiler located below disposal point Condensate pump should have overflow switch Condensate from Boiler is slightly acidic and may cause property damage if overflow Manufacturer recommends the installation of a condensate neutralizer for all installations Follow local code when to determine if a condensate neutralizer is required FIG...

Page 40: ...Fire explosion asphyxiation and burn hazard Boiler piping and gas connections shall be leak tested before placing boiler in operation Failure to follow these instructions and or improper installation could result in death or serious injury Model Gas Rate FT3 H M3 H Nat LP GMHB125 119 6 3 38 48 0 1 35 GMCB150 144 0 4 08 57 8 1 64 GMBH160 156 9 4 44 63 0 1 78 GMCB200 196 0 5 55 78 7 2 22 Support pip...

Page 41: ...corrosive 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 NOTICE Sediment trap shall be located upstream of gas controls 7 GAS SUPPLY PIPING FIGURE 7 1 GAS LINE CONNECTION WITH MANUAL MAIN SHUTOFF VALVE WITH UNION AND SEDIMENT TRAP...

Page 42: ...izes 8 ELECTRICAL CONNECTIONS Note Wiring diagrams can be found in Appendix A of this Manual Minimum breaker sizing 15 Amp 8 2 Electrical Connections Boiler requires 120V 60Hz power supply Verify electrical supply is polarized Boiler shall be grounded and on dedicated circuit All wiring must be installed in accordance with requirements of the National Electrical Code and any additional national st...

Page 43: ...cted to standard control PCB 8 4 Main Supply Connection Main supply is connected to terminal block M1 which is high voltage 120V 60Hz Fuses 3 15 A are incorporated in the power supply terminal block To check or replace fuse pull out black fuse carrier TERMINAL BLOCK M1 L Live brown N Neutral light blue Ground yellow green TERMINAL BLOCK M2 Terminals 1 2 Not used Terminals 4 5 outdoor temperature s...

Page 44: ... 1 X NEC Class 2 Low Voltage ZONE 3 ZONE 2 ZONE 1 W R NEC Class 2 Low Voltage T T C THERMOSTATS ZONE VALVES ZONE 3 ZONE 2 4 3 2 1 4 3 2 1 4 3 2 1 NEC Class 2 Low Voltage 24Vac W R T T C W R T T C PRI PUMP ZC ZR Fuse 12A 250V 9 10 6 7 N G L PUMP DOMESTIC HOT WATER TANK W T STAT ZONE THERMOSTAT 115 Vac FIELD SUPPLIED POWER PER NEC AND LOCAL CODES 6 7 CH 9 10 DHW TANK BOILER DHW Z2 115 Vac FIELD SUPP...

Page 45: ...to M2 OUTDOOR SENSOR terminals 4 5 Wires are interchangeable See Accessories B Setting Kt Climate Curve When external sensor is connected to boiler the electronic board adjusts the flow temperature calculated according to set Kt coefficient Select required curve by rotating right knob as indicated in chart below for selecting the appropriate curve 00 to 90 Flow temp Outside temp 8 ELECTRICAL CONNE...

Page 46: ...RT 2 10k Ω 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 35 6 29 381 89 6 7 407 37 4 27 946 91 4 7 103 39 2 26 590 93 2 6 813 41 0 25 308 95 0 6 537 42 8 24 094 96 8 6 273 44 6 22 946 98 6 6 021 46 4 21 859 100 4 5 781 48 2 20 829 102 2 5 551 50 0 19 854 104 0 5 332 51 8 18 930 105 8 5 123 53 6 18 054 107 6 4 923 55 4 17 223 109 4 4 732 57 2 16 436 111...

Page 47: ...ECTRICAL CONNECTIONS Note Sensors supplied with this boiler are proprietary to the manufacturer Use of alternate sensors WILL diminish boiler performance SUPPLY Cord 120V 60HZ BOILER CONTROL 10k Ω DHW Indirect Tank Sensor or DHW Indirect Tank Aquastat Heating Only Boilers DO NOT USE 1K Ω Outdoor Reset Sensor Zone Control T Stat Use of Indirect Storage Tank DHW Use either 10k Ω DHW sensor or Indire...

Page 48: ... 8 10 HEAT ONLY BOILER WITH ZONE CIRCULATOR PUMPS INDIRECT TANK 160 ONLY FIGURE 8 11 COMBI BOILER WITH ZONE CIRCULATOR PUMP SUPPLY RETURN DHW COLD INLET DHW HOT OUTLET COLD WATER SUPPLY SUPPLY RETURN COLD WATER SUPPLY COLD WATER SUPPLY HOT WATER SUPPLY TEMPERED PIPING LEGEND PN 240012363 REV A 08 31 2018 ...

Page 49: ...49 8 ELECTRICAL CONNECTIONS FIGURE 8 12A WIRE DIAGRAM GMHB125 CENTRAL HEAT BOILER PN 240012363 REV A 08 31 2018 ...

Page 50: ...50 FIGURE 8 12B 8 ELECTRICAL CONNECTIONS LADDER DIAGRAM GMHB125 CENTRAL HEAT BOILER PN 240012363 REV A 08 31 2018 ...

Page 51: ...51 8 ELECTRICAL CONNECTIONS FIGURE 8 13A WIRE DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV A 08 31 2018 ...

Page 52: ...52 FIGURE 8 13B 8 ELECTRICAL CONNECTIONS LADDER DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV A 08 31 2018 ...

Page 53: ...53 8 ELECTRICAL CONNECTIONS FIGURE 8A 14A WIRE DIAGRAM GMHB160 CENTRAL HEAT BOILER PN 240012363 REV A 08 31 2018 ...

Page 54: ...ER X22 1 X22 2 FLOW SENSOR X22 3 X22 4 RETURN SENSOR WATER PRESSURE SENSOR X22 7 X22 6 X22 8 P X22 9 X22 10 EXCHANGER SENSOR OUTDOOR SENSOR X20 1 X20 2 DHW TEMP SENSOR X20 3 X20 4 X20 7 X20 8 FLUE SAFETY THERMOSTAT X31 2 X31 1 REMOTE CONTROL 2 3 1 5 4 6 24 VOLT CONTROL THERMOSTAT LADDER DIAGRAM 160 227 230 CENTRAL HEAT BOILER X23 5 X23 6 X11 3 X11 4 PUMP SAFETY THERMOSTAT SAFETY THERMOSTAT LADDER ...

Page 55: ...55 8 ELECTRICAL CONNECTIONS FIGURE 8 15A WIRE DIAGRAM GMCB200 COMBI BOILER PN 240012363 REV A 08 31 2018 ...

Page 56: ...56 8 ELECTRICAL CONNECTIONS FIGURE 8 15B LADDER DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV A 08 31 2018 ...

Page 57: ...22 2mm D DHW outlet indirect storage tank connection 3 4 NPT 3 4 NPT E Drain connection for condensate 3 4 NPT 3 4 NPT F Heating supply connection 1 NPT G 5 gpm DHW flow restrictor Factory installed 160C only na 3 4 NPT E F D C B A A B C D E F GMCB150 COMBI 9 2 Central Heating System Connections COMBI LEGEND 125B 160B A Heating return connection 1 NPT B Gas shutoff connection 3 4 NPT C Indirect ta...

Page 58: ...ne Nozzle Nozzle mm mm GMHB125 6 0 4 6 GMCB150 6 0 4 6 GMHB160 7 4 5 0 GMCB200 7 4 5 4 2 Disconnect gas tube by loosening nut See Figure 9 3 3 Carefully separate gas valve 4 Remove existing orifice and replace with LP orifice as shown in Figure 9 3 See Table above for orifice size Rounded edge faces the gas valve 5 Reinstall tube verify gasket is seated correctly and tighten nut 6 Place Natural to...

Page 59: ...mation DHW temperature adjustment CW to increase the temperature and CCW to decrease it Heating water temperature adjustment CW to increase the temperature and CCW to decrease it Boiler operating information Deaeration Long Push Comfort function Short Push Off Reset Exit menu functions Operating mode DHW DHW Heating Heating Only LEFT KNOB BUTTONS Key Off heating and DHW disabled only boiler frost ...

Page 60: ...2 indicating de aeration function is active This function lasts 10 minutes 3 Open aeration valve to allow complete de aeration 4 To manually exit this function press button and hold for 6 seconds 5 Close aeration valve WARNING Fire explosion and asphyxiation hazard Boiler is set for natural gas from the factory If propane is to be used the gas valve must be adjusted before turning boiler on Failur...

Page 61: ...n x 3 sec Pump On Display shows 312 Deaeration About 10 min Open Heat Exchanger Aeration purge Valve Boiler Decides If Deaeration OK Boiler ready for CH DHW request Boiler Displays Temperature Display shows Short push Unstable Power supply Check Restore E118 or 000 Low water Pressure too low 8 psig Check Restore YES NO NO NO 9 START UP PROCEDURE YES YES Display Goes Back to 000 See Note NO DONE PN...

Page 62: ...r port is connected to combustion air intake B used to check for recycling products for combustion The following can be measured at the exhaust flue test port temperature of combustion products oxygen O2 or carbon dioxide CO2 concentration carbon monoxide CO concentration The temperature of combustion air must be measured on the air intake test port B by inserting the measurement sensor approximat...

Page 63: ...and simultaneously with a long push To enter CSF the Right Knob has to be moved When CSF is active the display shows ON 2 seconds and code 304 with boiler power in Turn Right Knob clockwise and increase power of the boiler at 100 1 Calibrating MAXIMUM heat output Check CO2 measured at the flue test port with boiler operating at maximum heat capacity matches that indicted in Combustion Table below ...

Page 64: ...rate again after setting the combustion following steps in section 9 11 Table 9 2 Input Rate High Fire MBH 9 13 Adjusting Maximum Heating Power Maximum boiler heating power can be reduced to suit requirements of heating system it serves Table showing parameter P13 values according to desired maximum power model is shown for each single boiler To access and edit P13 values proceed as described in P...

Page 65: ...tely call a qualified service technician to inspect appliance and to replace any part of control system and any gas control which has been under water FOR YOUR SAFETY READ BEFORE OPERATING CAUTION WHAT TO DO IF YOU SMELL GAS Do not try to light any appliance Do not touch any electrical switch do not use any phone in your building Immediately call your gas supplier from a neighbor s phone Follow th...

Page 66: ...menu Fault in progress Set unit of measurement SYMBOL Key 10 OPERATING INSTRUCTIONS 10 3 Boiler Controls For correct boiler ignition proceed as follows Check system pressure is correct Power boiler Open manual gas shut off valve positioned under boiler Select required heating mode Push to select operating mode See page 60 Operating Modes RIGHT KNOB LEFT KNOB Note If is displayed without boiler wil...

Page 67: ... CSF moving Right Knob CH 10 3 1 Boiler Operating Mode To change the boiler MODE press with a very short push The mode changes are as follows Boiler Start Mode Boiler Mode After Pressing OFF DHW only COMBI only DHW only CH and DHW COMBI only CH and DHW CH only COMBI only CH only OFF All Models 10 3 2 Reset To change the boiler MODE press with a very short push The mode changes are as follows To re...

Page 68: ... is divided in pages each with 10 parameters i e Ax0 Ax9 While in the INFO menu short push to go to the next page e g from A10 A19 page to A20 A29 page short push to go to the previous page e g from A20 A29 page to A10 A19 Address Page Knob turning Left Knob permits scrolling between the parameters within the current selected page A00 Error subcode A01 CH temperature A02 External temperature if pr...

Page 69: ... 20 29 page 9 short push to go to previous page e g from values 20 29 page to 10 19 page 10 Data Knob turning Right Knob permits scrolling the values in the current selected page 11 short push to save the value visualized on the display and return to parameter setting menu 12 Address Page Knob returns to Parameter setting menu without saving the current value escape function This function always e...

Page 70: ...r application 15 only heating boiler with DHW pump for external tank 16 boiler with DHW storage tank and DHW pump with plate to plate DHW heat exchanger 17 System boiler 2 04 without pump 18 only heating boiler with DHW pump for external tank 19 System boiler 3 0 19 8 8 0 0 8 8 0 0 P04 Manufacturer information Shall be set to 02 Ignore all other options 0 15 2 2 2 2 2 2 2 2 P05 Manufacturer inform...

Page 71: ...0 P16 Maximum Central Heating setpoint C 00 176 F 80 C 01 113 F 45 C Hi temperature 0 low temperature 1 0 0 0 0 0 0 0 0 P17 Pump overrun time in heating mode min 1 240min 3 3 3 3 3 3 3 3 P18 Maximum overrun time before a new relight of burner in heating mode min 0 10min 3 3 3 3 3 3 3 3 P19 Manufacturer information Shall be set to 7 Ignore all other options 1 15min 7 7 7 7 7 7 7 7 P20 Pump overrun ...

Page 72: ...ion Set to 0 Ignore other options read only 0 0 0 0 0 0 0 0 P29 Manufacturer information Set to 7 Ignore other options read only 7 7 7 7 7 7 7 7 P30 Manufacturer information Set to 10 Ignore other options 0 15 C 10 10 10 10 10 10 10 10 P31 Manufacturer information Set to 20 Ignore other options 30 85 C 20 20 20 20 20 20 20 20 C00 P32 Fault History C00 read only C01 P33 Fault History C1 read only C...

Page 73: ...her options 0 2 1 1 1 1 1 1 1 1 P46 Manufacturer information Set to 63 Ignore other options 63 63 63 63 63 63 63 63 P47 Manufacturer information Set to 0 Ignore other options 0 0 0 0 0 0 0 0 P48 Manufacturer Information Shall be set to 1 Ignore other options 0 2 1 1 1 1 1 1 1 1 P49 Manufacturer information Set to 0 Ignore other options 0 100 default 50 0 0 0 0 0 0 0 0 P50 Manufacturer information ...

Page 74: ... 0 0 0 0 0 P59 Manufacturer information Set to 3 Ignore other options 0 15sec 3 3 3 3 3 3 3 3 P60 Manufacturer information Set to 1 Ignore other options 0 4 1 1 1 1 1 1 1 1 P61 Manufacturer information Set to 36 Ignore other options 6 60 36 36 36 36 36 36 36 36 P62 Manufacturer information Set to 9 Ignore other options 3 15 9 9 9 9 9 9 9 9 P63 Manufacturer information Set to 8 Ignore other options...

Page 75: ...n Shall be set to indicated value Ignore other options 1 10 1 1 2 2 3 3 4 4 P74 Manufacturer information Set to 0 Ignore other options 0 255sec 0 0 0 0 0 0 0 0 P75 Not Used P76 Manufacturer information Set to 0 Ignore other options 0 0 0 0 0 0 0 0 P77 Manufacturer information Set to 0 Ignore other options 0 1 0 0 0 0 0 0 0 0 P78 Manufacturer information Set to 0 Ignore other options 0 2 0 0 0 0 0 ...

Page 76: ...other options default 0 0 0 0 0 0 0 0 0 P85 Manufacturer information Set to 0 Ignore other options default 0 0 0 0 0 0 0 0 0 P86 Manufacturer information Set to 1 Ignore other options default 25 1 1 1 1 1 1 1 1 HEAT ONLY COMBI HEAT ONLY COMBI Parameter Parameter Description Range GMHB 125 NG GMHB 125 LPG GMCB 150 NG GMCB 150 LPG GMHB 160 NG GMHB 160 LPG GMCB 200 NG GMCB 200 LPG 10 OPERATING INSTRU...

Page 77: ...ected by pressing the board exits from the Command functions menu and the related function starts 10 3 7 Command Functions Service To enter the Command functions menu press and with a long push This function ends after 3 minutes or by pressing and simultaneously with a long push After accessing the Special functions menu F00 is displayed Address Page Knob is used to scroll between FXX parameters P...

Page 78: ... immediately revert to provide CH if there is demand 10 6 Combi Domestic Hot Water Mode Flow switch senses demand for hot water opening a hot water tap etc The pump starts and burner lights at its ignition output increasing to the output determined by the faucet tap Water in the boiler is diverted from central heating system to domestic hot water heat exchanger heating the incoming supply water Bu...

Page 79: ...lure to comply will result in death or serious injury Note Verify proper operation after servicing Note Perform regular service and maintenance by qualified service agency at least once every 12 months to assure safe trouble free operation and maximum efficiency 11 GENERAL MAINTENANCE AND CLEANING Circulator pump and combustion air blower motor furnished with boiler are permanently lubricated from...

Page 80: ...ion Maintenance Manual provided with boiler WARNING Following service procedures must be performed by qualified service agent Boiler owner shall not attempt these steps Failure to do so could result in death or serious injury CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation Failure to follow these instructions could res...

Page 81: ...t of electrodes See Figure 11 1 8 Check the fan impeller is clean and free to rotate 9 Replace used gaskets with new gaskets See Parts list for correct gasket kit number Figure 11 1 Electrodes 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 deat...

Page 82: ...tem to achieve temperature difference across heating supply and return pipes at the boiler Check system for proper pressure See page 4 for acceptable pressure Turn off boiler Check water and flush if necessary Clean filters in heating return and supply water isolating valves Repressurize the system 11 8 Final Assembly If boiler is to be left in service with the User set controls and room thermosta...

Page 83: ...g or hot water the pump will automatically operate for 1 minute g Explain to User an internal frost thermostat is fitted in boiler and electrical supply to boiler must be left on for thermostat to operate Frost protection protects the boiler not the system h Show User position of pressure relief valve discharge pipe i Leave this Installation Operation and Maintenance Manual with User for use on fu...

Page 84: ... 32 Max 147 200 Output Ratings MBH Min 21 28 Max 133 175 Domestic Water Pressure 2 9 psi 0 2 bar 116 psi 8 0 bar Minimum Flow Rate 0 50 GPM Maximum Flow Rate 3 5 gpm 5 0 GPM Flow Rate 77 F 43 C Temp Rise 3 2 GPM 4 5 GPM DHW Supply Connection Size 3 4 NPT 3 4 NPT Cold Water Input Connection Size 3 4 3 4 12 2 Domestic Hot Water Specifications Max DHW temp 140 F 60 C 12 1 Ratings and Capacities Const...

Page 85: ...rameter P72 Fan Speed rpm 60 1350 60 1350 CO Limit ppm 400 To modify the fan speed see section 10 3 GMHB125 Heat Only Boiler Natural gas A 17 4 mbar 7 0 in w c LP gas E 27 4 mbar 11 0 in w c 0 2000 Ft 0 610 m 0 2000 Ft 0 610 m Parameter P71 Fan Speed rpm 85 5625 85 5625 Parameter P72 Fan Speed rpm 55 1 300 60 1350 CO Limit ppm 400 GMCB150 Combi Boiler Natural gas A 17 4 mbar 7 0 in w c LP gas E 29...

Page 86: ...s when E 110 E 125 E 133 E 134 E 135 E 09 E 15 E 128 and E 384 are displayed it is possible to relight the boiler 3 If this does not have any effect or error codes are displayed regularly further investigation is required 13 1 Initial Fault Finding Checks 13 2 Error Diagnostics The PCB allows the display to list errors accrued in the boiler PCB has a counter which increases itself only if the anom...

Page 87: ... E133 02 000 03 F05 75 C In event of no error historical error values are 00 The phase status is a special sub operating mode before the error 00 Stand by 01 Pre purging function active 03 Ignition load purging between the first attempt and second one 04 Ignition load first attempt 05 Operation active 06 Lock out 08 Second ignition load attempt 11 Ignition load purging between the second attempt a...

Page 88: ...DHW NTC sensor fault tank boiler open Check the sensor E83 84 85 86 87 No communication Check cable between room unit and pcb or RF link E109 Pre circulation alarm Check the correct circulation of the water and the pump E110 R 437 Boiler max temperature exceeded for gradient probable pump jammed or air in the circuit Check the correct circulation of the water and the pump E110 R 438 Boiler max tem...

Page 89: ...lve open without gas Check the gas pressure sensing electrode spark electrode and cable replace the pcb if it necessary E135 Internal error Verify cables Replace pcb E154 Plausibility test flow return Check the correct circulation of the water and the pump check the correct position of the sensors E160 Fan fault Check the fan and the cable E169 Air pressure switch closed Check obstruction on the f...

Page 90: ...th 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 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 14 GLOSSARY DIRECT VENT BOILER Boi...

Page 91: ...or servicing of appliances and equipment Experienced in such work Familiar with all precautions required Complies with all requirements of authority having jurisdiction SAFETY 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 sourc...

Page 92: ...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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ECR International Green Mountain GMCB150, Installation, Operation & Maintenance Manual

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