ECR 075 97gb Installation, Operation & Maintenance Manual Download

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9-4 Combustion Analyzer Port

Combustion Analyzer Port

9-5 Burner Flame

Flame

Burner

9 - START UP PROCEDURE

NOTICE

Combustion analyzer port is provided. After use

replace cover.

Look for BLUE flame

with slight YELLOW tips

evenly spaced around

burner

9�6 Perform CSD-1 Compliance Test (see

paragraph 2�5 page 6)

Verify operation of boiler safety control operation with

regard to no flow conditions as follows:

Turn off boiler using boiler service switch.

Disable primary boiler pump. Disconnect multi pin

connector J7 from control module. See figure 9-6.

Disable secondary system pumps attached to

system.

Establish call for heat. Jump CHW T-T terminals

on low voltage terminal block. Turn on boiler using

boiler service switch.

Boiler will fire. Based on natural convection within

boiler, boiler will either:

A. Lockout A-06 "Safety Relay Error". Requires

manual reset of control module. Press reset

button on User interface. See

9.3 Program Boiler

Control

B. Shut off burner E40 "Return Water Temp". This

is a soft lockout. When water temperature drops

below limit boiler will automatically refire then

Lockout A-06 requiring manual reset of control

module. Press Reset button on User Interface.

C. Shut off burner E39 "Flue Temperature Sensor".

This is a soft lockout. When flue sensor drops

below limit, boiler will automatically refire then

Lockout A-06 requiring manual reset of control

module. Press Reset button on User Interface.

After safety operation is verified, turn off boiler via

service switch. Remove jumper in T-T. Replace J7

connector into control module, enable secondary

pump operation, turn service switch on and restart

system to verify operation.

Summary of Contents for 075 97gb

Page 1: ...001 2008 Certified Company ECR International Inc 2201 Dwyer Ave Utica NY 13501 P N 240008282 REV J 03 2014 CONDENSING GAS BOILER Models 075 100 WALL MOUNTED GAS BOILER INSTALLATION OPERATION MAINTENANCE MANUAL ...

Page 2: ...s Outdoor Sensor 18 Used for measuring outside temperature Stopper Rubber 5 16 2 ea 17 Used for packaging holes on back of boiler Plastic Plug 2 ea 18 Used for packaging holes on back of boiler Outdoor Sensor 19 Used for measuring outside temperature Document Package 20 Includes essential documents 4 7 6 5 9 2 3 10 11 13 14 15 12 16 Boiler provided with 30 psig 206 kpa safety relief valve Field so...

Page 3: ...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 4: ...Configurations 21 6 8 SideVentingTerminalRequirements 26 6 9 Condensate Piping 28 7 Gas Supply Piping 29 8 Electrical Connections 31 8 2 Line Voltage Connections 31 8 3 External Connections 31 9 Start Up Procedure 33 9 6 Perform Csd 1 Compliance Test 37 9 7 Complete Start Up Procedure 38 10 Operating Instructions 39 11 General Maintenance And Cleaning 40 12 Ratings And Capacities 43 13 Trouble Sho...

Page 5: ...llation Closet or alcove installation Direct vent boiler For use with natural gas or liquefied petroleum gases LP propane 1 2 The unit MUST NOT Directly heat potable water Indirect heating is acceptable Heat water with non hydronic heating system chemicals present example swimming pool water Exceed 150 psig 1 03 MPa system pressure Exceed 195 F 90 5 C system design temperature 1 3 Operational Feat...

Page 6: ... 248 CMR which includes but is not limited to Installation by licensed plumber or gas fitter CAUTION Indicates a hazardous 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 ...

Page 7: ...uantity of combustion air receives fuel from gas valve mixes air and fuel sending mixture to burner for combustion 20 Gas Control Valve Delivers proper quantity of fuel to Combustion Air Blower See section 7 21 Supply Water Temperature Sensor and High Limit Switch 22 Low Water Cutoff Senses inadequate quantity of water Turns off boiler before damage can occur 23 Safety Relief Valve Factory supplie...

Page 8: ...SAFETY RELIEF VALVE 30 AIR VENT 3 RETURN WATER FROM HEATING SYSTEM IN 24 HIGH VOLTAGE JUNCTION BOX 14 SUPPLY WATER TO HEATING SYSTEM OUT 26 GAS CONNECTION 29 SERVICE SWITCH 28 AUXILIARY POWER OUTLET 31 CENTRAL HEATING PUMP CIRCUIT BREAKER 27 BRACKET FOR OPTIONAL WALL MOUNT NOTE See Section 5 3 For Safety Relief Valve Piping Instructions ...

Page 9: ...IR BLOWER 9 HEAT EXCHANGER 20 GAS CONTROL VALVE 1 USER INTERFACE 3 RETURN WATER FROM HEATING SYSTEM IN 1 1 4 NPT 14 SUPPLY WATER TO HEATING SYSTEM OUT 1 1 4 NPT 13 HEAT EXCHANGER PUMP 10 CONDENSATE COLLECTOR 12 DRAIN VALVE 6 FLAME SENSOR SHOWN IN OPEN POSITION 15 VENT TEMPERATURE SENSOR 23 SAFETY RELIEF VALVE 25 VENT CONNECTOR 2 PVC 21 HIGH TEMPERATURE SUPPLY SWITCH 11 RETURN TEMPERATURE SENSOR 38...

Page 10: ...ENT LISTING 33 INTERNAL ACCESS PANEL CLOSED 33 INTERNAL ACCESS PANEL OPEN 32 CONTROL MODULE 34 CENTRAL HEATING PUMP RELAY 35 TRANSFORMER Control Module Fuse and holder Note To open Lift panel up then pull forward ...

Page 11: ...oiler on carpeting Protection of 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 ...

Page 12: ...ttach 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 WARNING Fire explosion hazard Mount boiler vertically or slightly tilted backward to insure proper function of low water cutoff Failure to follow these instructions could result in death or serious injury Wh...

Page 13: ...s located in air handling unit exposed to refrigerated air 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 150 psig 1 03 MPa maximum allowable working pressure Boiler provided with 30 psig 206 kPa safety relief valve Field source safety relief valve for s...

Page 14: ...utomatic fill valves require back flow prevention device Single boiler system See figures 5 4 5 5 5 6 5 7 for general guidance Additional considerations Boiler control is designed for single central heating pump Installer responsible for integration of multiple central heating pumps Boiler control allows domestic hot water prioritization Function could be lost if central heating pump not directly ...

Page 15: ...able 3 System Piping Configurations Single Boiler Two Pipe Zoned System With Zone Valves figure 5 5 With Zone Pumps figure 5 6 Primary Secondary Pumping Closed External Primary Loop or figure 5 7 Open External Primary Loop figure 5 7 Multiple Boilers Typical Mulitple Boiler Piping With Zone Valves figure 5 8 With Zone Pumps Not Shown Primary Secondary Pumping Closed External Primary Loop Not Shown...

Page 16: ...em With Zone Valves FIGURE 5 6 Single Boiler Two Pipe Zoned System With Zone 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 9 5 mm Open End Wrench 3 8 9 5 mm Open End Wrench He ...

Page 17: ...le Boiler Using Primary Secondary Pumping With Open External Primary Loop 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 eat exchanger ball valve open Heat exchanger ball valves closed 3 8 9 5 mm Open End Wrench 3 8 9 5 mm Open End Wrench ...

Page 18: ...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 9 5mm Open End Wrench DHW Pump See Multiple Boiler Guide ...

Page 19: ...ns Adjust thermostat so appliances will operate continuously Test for spillage at draft hood relief opening after 5 minutes of main burner operation Use flame of match or candle smoke from cigarette cigar or pipe Determine each appliance remaining connected to common venting system properly vents when tested as outlined above Then return doors windows exhaust fans and any other gas burning applian...

Page 20: ...Certified vent system components must NOT be interchanged with other vent systems or unlisted pipe fittings Canadian installations only All venting material primer and glue must be listed to ULC S636 Canadian installations only First 3 ft 0 9 m of plastic vent pipe from vent connector must be readily accessible for visual inspection 6 5 Termination Terminate combustion air and vent pipes with fitt...

Page 21: ... Two Pipe figure 6 1 Concentric figure 6 7 Side Wall Single Pipe figure 6 8 Inside Air Single Pipe figure 6 9 Side Wall Roof Single Pipe figure 6 10 Side Wall Two Pipe figures 6 2 6 3 Concentric figures 6 4 6 5 6 6 Inside Air Single Pipe figure 6 11 Table 7 Venting Configurations NOTICE Use of vent covers may cause freezing If using vent covers overall vent length must be considered Failure to hee...

Page 22: ...ke and vent of same appliance 8 21 cm Minimum vertical separation between combustion air intake and vent of different appliances 15 38 cm Maximum horizontal length of vent Minimum vent intake between different appliances 12 30cm Maximum allowable total vertical vent length with outside exposure equals 10 ft 3 05m Abandoned unused masonry chimney may be used as chaseway for combustion air and vent ...

Page 23: ...ction Note Securing strap must be field installed to prevent movement of termination kit in side wall Vent Combustion Air 1 25 4mm Maximum See Note 2 or 3 51 or 77 mm Diameter PVC intake combustion air Combustion Air 2 51mm Diameter 41 Length 1 1m 3 77mm Diameter 47 Length 1 2m Note Overall length may be modified by cutting or extending both combustion air and vent pipes 12 305mm is minimum allowa...

Page 24: ...ighest anticipated snow level 24 610mm above roof FIGURE 6 8 Flue on Roof Air Intake on Side Wall FIGURE 6 9 Flue on Roof Combustion Air Grade Snow Ice Terminate vent system bottom 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 Doors ...

Page 25: ...ow Line 6 COMBUSTION AIR AND VENT PIPING NOTICE Configurations of single pipe vent with flue on the sidewall requires a tee as the vent terminal See figures 6 10 and 6 11 Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof Ground Level 12 305mm Anticipated Snow Line Vent Combustion Air Ground Level ...

Page 26: ... 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 Termination must be 12 305mm from or below doors windows or gravity inlet 12 305mm Minimum Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less than 10 3m Minimum 3 0 9m Minimum FIGUR...

Page 27: ...ot be effected by wind eddy air born leaves snow 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 Canad...

Page 28: ... 2 Attach PVC tee provided with boiler and field sourced piping to condensate drain vertical tee on left side of boiler See figure 6 17 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 29: ...onversion 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 supplier call the fire department 7 GAS SUPPLY PIPING TABLE 8 GAS SUPPLY PRESSURE S...

Page 30: ...nd 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 Isolate 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 31: ... amps B Connect pump to line voltage terminal strip CH PUMP L N G Domestic Hot Water Pump if used A Isolate pump from control module if pump FLA exceeds 1 0 amp B Connect pump to line voltage terminal strip DHW PUMP L N G 8 3 External Connections Figure 8 2 User Interface Terminals A Factory wired to low voltage terminal plug USER INTERFACE terminals B Optional Remote mount user interface for impr...

Page 32: ...ry contact only use of isolation relay may be necessary B Maximum wire length is 330 ft 100 m 22 gauge wire C Connect wires interchangeable to low voltage terminal plug DHW T T terminals Wires are interchangeable Central Heating Thermostat A 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 ...

Page 33: ...luding CH calls and DHW calls if available Close manual gas shut off valve Let system run for 30 minutes When boiler goes into lockout reset boiler by pressing Reset button until boiler resets Do not open gas shutoff valve until all air is purged from system 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 ...

Page 34: ... C 104 195 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 ...

Page 35: ...k control module operation 9 Check field sourced limits low water cutoffs etc per manufacturer s instructions 9 START UP PROCEDURE 9 5 Check Combustion Natural Gas 1 Measure input English units Turn off gas to all other appliances Activate some heating zones to dissipate heat Set boiler on high fire Use 1 or 2 cu ft dial on gas meter Measure time required for one or more complete revolutions Measu...

Page 36: ...spicuous location adjacent to boiler Gas CO2 CO Min Max Natural Gas 9 0 9 5 200ppm Propane 10 0 11 0 200ppm NOTICE Contact Technical Support 800 325 5479 for additional information or assistance Natural Gas only 1 Measure input Compare to table above Continue to measure input and CO2 until both measured values are within range specified in tables Propane Gas Most propane systems do not have flow m...

Page 37: ...itch 5 Boiler will fire Based on natural convection within boiler boiler will either A Lockout A 06 Safety Relay Error Requires manual reset of control module Press reset button on User interface See 9 3 Program Boiler Control OR B Shut off burner E40 Return Water Temp This is a soft lockout When water temperature drops below limit boiler will automatically refire then Lockout A 06 requiring manua...

Page 38: ...artup and operation test 2 Follow instructions TO TURN OFF GAS TO APPLIANCE page 39 if boiler is not being placed into immediate operation 3 Enter installer information on Warranty Registration Card 4 Gather all instructions manuals wiring diagrams warranty registration card and other supporting information Review with user and or affix in conspicuous location adjacent to boiler ...

Page 39: ...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 40: ...er 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 securely seated on pipes Check boiler for any sign of leaks Check low water cutoff using user interface Check operation by pressing test button...

Page 41: ...from removed burner Clean burner using air hose directed into top of burner opening to dislodge any debris in burner ports Inspect burner for foreign matter in flame ports or inside burner Remove foreign matter by blowing with compressed air or vacuuming Replace burner if it cannot be cleaned or is showing deterioration Clean heat exchanger with low pressure water spray Use flexible handle nylon b...

Page 42: ...ve 20 hex flange nuts securing condensate collector to heat exchanger using 7 16 deep well socket See figure 11 3 Remove condensate collector assembly from heat exchanger and flue pipe Flush collector and condensate trap with water Follow Burner Inspection Kit instructions to reassemble boiler and resume operation Combustion Chamber Condensate Collector Condensate Drain ...

Page 43: ...ate 4 for each 1000 ft 300m beyond 4500 ft Canada Boiler derates input 10 for every 2000 feet 610 m above an elevation of 4500 feet 1 37 km SEA LEVEL RATINGS NATURAL AND PROPANE GASES Size Boiler Input Rate MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Maximum Minimum 075 75 15 69 60 97 100 100 20 91 79 97 1 1000 Btu hr British Thermal Units Per Hour 2 Heating Capacity and AF...

Page 44: ...44 13 TROUBLE SHOOTING ...

Page 45: ...e Control Module High Temperature opens during normal operation Go to Page 51 Control Module detects flame after gas valve is closed more than 10 seconds Replace Gas Valve Flame is detected before gas valve opens Replace Gas Valve Control module internal error Replace Control Module Lost flame signal 3 times during one heat call Go to Page 52 Control Module internal error Replace Control Module Co...

Page 46: ...o 61 Hz Go to Page 56 Boiler power supply ground wire is not grounded Go to Page 57 Control board internal error Power down then power up boiler If error repeatedly occurs replace control module Replace Control Module Supply temperature sensor is open No continuity Go to Page 56 Return water temperature sensor is open No continuity Go to Page 57 Flue temperature sensor is open No continuity Go to ...

Page 47: ... Valve and J13 connector on Control Module NO YES Disconnect J13 connector on Control Module Measure resistance across third blue wire and fourth brown wire terminals Is resistance between 1 0 and 1 2 kΩ NO YES Disconnect harness from Gas Valve Does each wire have continuity between Gas Valve and Control Module NO YES Is supply pipe copper pipe at top of boiler hot NO YES Boiler has been dry fired...

Page 48: ...48 13 TROUBLE SHOOTING ...

Page 49: ...m piping Flush system if water is dirty Is boiler supply pipe above heat exchanger hot Wait for boiler to cool down YES NO Replace Broken Switch Unplug molex connector on supply temperature sensor Check continuity between two pins on sensor two pins connected to two pink wires Is continuity available YES NO Check for loose connections on two pink wires on J13 connector supply sensor and safety tem...

Page 50: ...50 13 TROUBLE SHOOTING ...

Page 51: ... Continuity from J13 5 to Switch 1 Continuity from J13 6 to Switch 3 continuity of the two purple wires Disconnect harness from High Temperature Supply Switch and Control Module J13 Check continuity of both purple wires Continuity available for both purple wires 13 TROUBLE SHOOTING ...

Page 52: ... TURN OFF GAS TO APPLIANCE Replace Gas Valve Turn off manual gas shutoff valve Follow instructions TO TURN OFF GAS TO APPLIANCE Replace Gas Valve Follow Operating Instructions to initiate boiler operation Enter Installer Menu Boiler Status Flame Signal Is flame signal greater than 3 7µA Boiler may be running at any firing rate YES NO Replace Control Module Replace Flame Sensor and Burner 13 TROUBL...

Page 53: ...TROUBLE SHOOTING Connect harness to Transformer Disconnect harness from Low Water Cutoff Is 24 vac at terminals 1 2 Between blue and yellow wires YES NO Repair System Piping remove any remaining air in system ...

Page 54: ...oblem if any purging all air out of the system Replace Flue Gas Sensor Replace Control Module Use thermal couple to measure flue gas temperature through sampling port Is the measured temperature and flue temperature reading on User Interface significantly different YES NO 3 B l o c k i n g E r r o r F l u e G a s E r r o r 13 TROUBLE SHOOTING E 39 ...

Page 55: ...er or antifreeze solution NO Is Heat Exchanger Pump properly oriented Pump arrow pointing down YES NO Disconnect harness from Return Water Sensor Measure resistance using digital ohm meter Is resistance between 950 to 33 000 ohms Install Heat Exchanger Pump in proper orientation YES NO Replace Control Module Verify order of pins on J2 Pin order should be empty black or red white green Mea sure vol...

Page 56: ...r supply rated at 60 Hz 2 Replace Control Module YES YES NO NO Replace circuit breaker 13 TROUBLE SHOOTING Fix the connection These error messages are displayed when the control board detects fault in blower motor system Check wire connector to blower Check connector J9 on control board Is any connection loose YES NO Replace blower motor Does this correct the problem YES NO Boiler is operating pro...

Page 57: ...0 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 field grounding conductor connected to High Voltage Terminal Strip 120 VAC G NO YES _ P _ _ _ Blocking Error E 4 6 Faulty ground Connect ground conductor YES NO Correc...

Page 58: ...ure 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 Temperature Sensor Resistance Chart YES NO Insert Harness YES NO YES NO Measur...

Page 59: ...E SHOOTING Supply Water Temperature Sensor Resistance Chart Disconnect wire harness from High Temperature Supply Switch Measure resistance across terminals 2 and 4 Does temperature fall within ranges shown in chart ...

Page 60: ...r 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 32 to 54 66 to 94 Ven...

Page 61: ...61 14 WIRING DIAGRAM 14 1 Connection Diagram ...

Page 62: ...62 14 WIRING DIAGRAM 14 2 Schematic Diagram of Ladder Form ...

Page 63: ...companied 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 CONDENSATE...

Page 64: ...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 65: ...Scroll up to next menu item Increase value Scroll down to next menu item Decrease value 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 Air Blower Speed Ind...

Page 66: ... based on type of heating demand CH call is illustrated Control Module compares supply temperature to set point Boiler proceeds to ignition if supply temperature is less than set point Combustion Air Blower speed modulates to prepurge setting for 15 seconds Sparking initiated sequence S t a n d b y N o D e m a n d Heat Demand DHW CH Pump on Supply Temperature Setpoint 15 Second Prepurge Ignition S...

Page 67: ...ng 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 determines maximum time allowed for DHW heating mode Please refer to section Appendix A secti...

Page 68: ... as part of multiple boiler installation submenu used to view runtime parameters See Multiple Boiler Manual This line is not shown if boiler is not in cascade system 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 runnin...

Page 69: ... to OD Reset Setpoint and cannot be changed Controller calculates set point based on outdoor temperature Note For explanation of available CH heating modes refer to CH Mode section located in CH Settings submenu in Installer Menu 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 User interface ...

Page 70: ...n DHW Settings Domestic hot Water control settings such as DHW priority time Cascade Settings Refer to Multiple Boiler Manual System Test Tool aids setup of boiler installation or diagnosis of common problems Boiler Status Combustion air Blower provides through Combustion and Vent systems Fan speed status screen indicates actual and operational fan speeds in RPM high low and ignition power speed s...

Page 71: ...nition 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 3 after which lockout occurs Intermittent Operation Boiler can be firing continuously for 24 hours Burner switched off and restart sequence follows Flame out too late If flame detected after post purge loc...

Page 72: ...iler Configuration 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 Boiler incorporates integrated Low Water Cutoff device LWCO that disables boiler when low water condition exists LWCO device located at high point of internal Heat Exchan...

Page 73: ...is pump to CH System Pump electrical terminal block See page 35 for diagram DHW pump terminal does not function This is typical of hydronic system design which utilizes zone valves for all CH zones and 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 he...

Page 74: ... and Warm Weather Shutdown temperature Boiler will permanently attempt to satisfy CH demand when CH demand is available 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 CH demand is prermanently on Boiler will permanently attempt to satisfy CH demand CH thermostat input is ignored C...

Page 75: ...lculated 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 Calculated supply temperature follows thick black line in graph below based on outdoor temperature Note Modes only function when outdoor temperature sensor connected If Open outdoor sensor detected CH set point equal to Boiler Reset Curve D...

Page 76: ... 100 Default Setting 100 DHW Settings 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 meet DHW demand similar to CH Mode except DHW set point is used DHW set point set in Settings submenu found in U...

Page 77: ... 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 After ign...

Page 78: ...78 NOTES ...

Page 79: ...79 Company Address Phone Company Name Tech Initials Service Performed Date ...

Page 80: ...ECR International Inc 2201 Dwyer Ave Utica NY 13501 www ecrinternational com CONDENSING GAS BOILER Models 075 100 ...

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