Green Mountain GMCB150 Page 21 Installation, Operation & Maintenance Manual Download

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5 - HYDRONIC PIPING

FIGURE 5-6 MULTI ZONE SYSTEM WITH ZONE VALVES

BOILER DOES NOT INCLUDE EXTERNAL PUMP RELAY

Note

1 12” (305MM) MAXIMUM SEPARATION

Note

ASME Relief

Valve

Cold Water

Supply

CH System

Pump

Zone Valves

PN 240012363 REV. B [03/29/2019]

Summary of Contents for GMCB150

Page 1: ...onal Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012363 REV B 03 29 2019 Condensing Wall Mounted Gas Fired INSTALLATION OPERATION MAINTENANCE MANUAL Models GMH...

Page 2: ...ressure Gauge 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 Reli...

Page 3: ...n 43 8 5 Install Room Thermostat 44 8 6 Optional Electrical Connections 45 8 7 Indirect Storage Tank 47 Wiring Diagrams 49 56 9 Start Up Procedure 57 9 1 Central Heating System Connections Heat Only 5...

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 i...

Page 5: ...ensions 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 op...

Page 6: ...ll 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...

Page 7: ...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...

Page 8: ...rect 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 Ign...

Page 9: ...ating 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 Sens...

Page 10: ...a 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...

Page 11: ...t 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...

Page 12: ...n 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 ele...

Page 13: ...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...

Page 14: ...re 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 di...

Page 15: ...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 sea...

Page 16: ...r 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 manua...

Page 17: ...harge 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 pos...

Page 18: ...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 2 Verify all valves are closed 5 HYDRON...

Page 19: ...e to Floor 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 Separ...

Page 20: ...PIPING Low Water Cutoff LWCO Electrical Conduit J Box 120 V 60 HZ Conduit or Power Supply cord Polarized L1 N G GND L1 N GND BLK WHT 120 V 60 HZ Socket Polarized 120 V 60 HZ Cord Set From Boiler N O F...

Page 21: ...RE 5 6 MULTI ZONE SYSTEM WITH ZONE VALVES BOILER DOES NOT INCLUDE EXTERNAL PUMP RELAY Note 1 12 305MM MAXIMUM SEPARATION Note 2 ASME Relief Valve Cold Water Supply CH System Pump 1 2 Zone Valves PN 24...

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 B 03 29 2019...

Page 23: ...23 5 HYDRONIC PIPING 160 with Zone Circulator Pumps MAGNETIC DIRT SEPARATOR FROM SYSTEM TO SYSTEM PN 240012363 REV B 03 29 2019...

Page 24: ...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 ig...

Page 25: ...pering 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 Wate...

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 conne...

Page 27: ...ith this boiler ABS venting shall not to be used this product Use of DWV plumbing pipes to vent this boiler shall be prohibited Use of cellular core PVC ASTM F891 cellular core CPVC or Radel polypheno...

Page 28: ...ion 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 ASS...

Page 29: ...t 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...

Page 30: ...cturers 6 7 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...

Page 31: ...m Centrotherm 24 60 ft 7 5 m Coaxial Elbows Equivalent length 4 2 100 mm 60 mm 45 1 64 ft 0 5 m 90 3 28 ft 1 0 m 5 3 128 mm 80 mm 45 1 64 ft 0 5 m 90 3 28 ft 1 0 m Coaxial Termination Equivalent leng...

Page 32: ...e roof or ground Ground Anticipated Snow Line Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated snow level 24 610 mm above roof or ground Anticipated Snow Line 18 Vertical Cle...

Page 33: ...n D Twin Pipe Common Atmospheric Zone Termination Exhaust and combustion air intake are located in same general location and are of equal length FIGURE 6 8 TWIN PIPE ON ROOF COMBUSTION AIR ON SIDEWALL...

Page 34: ...plications Follow venting manufacturer s instructions for applying the securing mechanism on twin pipe polypropylene venting Example for Fixed Natalini venting system For other venting system supplier...

Page 35: ...12 305mm US 18 458mm Canada Min Above Anticipated Snow Line Roof Line 12 305mm Min FIGURE 6 12 HORIZONTAL TWIN PIPE EXHAUST AND INTAKE 12 305mm Minimum Separation Manufacturer Recommends Greater Separ...

Page 36: ...paration Between Bottom Of Combustion Air Intake And Bottom Of Vent Combustion Air Opening Separation 24 Min Grade Snow Ice Maintain 12 305 mm US 18 457 mm Canada clearance above highest anticipated s...

Page 37: ...chimney Follow venting manufacturer s instructions on assembly and clearances to maintain Avoid sharp bends in flexible venting FIGURE 6 17 FLEXIBLE VENTING SYSTEM Combustion Air Vent Terminal Flexib...

Page 38: ...thin 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...

Page 39: ...rce 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...

Page 40: ...G If overheating occurs or gas supply fails to shut off do not turn off or disconnect the electrical supply to the pump Shut off gas supply at a location external to the appliance Do not use this boil...

Page 41: ...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...

Page 42: ...es 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 electr...

Page 43: ...trollers can be connected 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 su...

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 P...

Page 45: ...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 acco...

Page 46: ...T 2 10 k 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...

Page 47: ...nk Aquastat Heating Only Boilers DO NOT USE 1K Outdoor Reset Sensor Zone Control T Stat Use of Indirect Storage Tank DHW Use either 10k DHW sensor or Indirect Tank Thermostat to interface with boiler...

Page 48: ...ELS GMCB 150 200 SUPPLY RETURN DHW COLD INLET DHW HOT OUTLET COLD WATER SUPPLY PIPING LEGEND RETURN SUPPLY COLD WATER SUPPLY COLD WATER SUPPLY HOT WATER SUPPLY TEMPERED HEAT ONLY BOILER WITH ZONE CIRC...

Page 49: ...49 8 ELECTRICAL CONNECTIONS FIGURE 8 12A WIRE DIAGRAM GMHB125 CENTRAL HEAT BOILER PN 240012363 REV B 03 29 2019...

Page 50: ...50 FIGURE 8 12B 8 ELECTRICAL CONNECTIONS LADDER DIAGRAM GMHB125 CENTRAL HEAT BOILER PN 240012363 REV B 03 29 2019...

Page 51: ...51 8 ELECTRICAL CONNECTIONS FIGURE 8 13A WIRE DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV B 03 29 2019...

Page 52: ...52 FIGURE 8 13B 8 ELECTRICAL CONNECTIONS LADDER DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV B 03 29 2019...

Page 53: ...53 8 ELECTRICAL CONNECTIONS FIGURE 8A 14A WIRE DIAGRAM GMHB160 CENTRAL HEAT BOILER PN 240012363 REV B 03 29 2019...

Page 54: ...R 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 SAFE...

Page 55: ...55 8 ELECTRICAL CONNECTIONS FIGURE 8 15A WIRE DIAGRAM GMCB200 COMBI BOILER PN 240012363 REV B 03 29 2019...

Page 56: ...56 8 ELECTRICAL CONNECTIONS FIGURE 8 15B LADDER DIAGRAM GMCB150 COMBI BOILER PN 240012363 REV B 03 29 2019...

Page 57: ...2 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 16...

Page 58: ...ozzle Nozzle mm mm GMHB125 6 0 4 6 GMCB150 6 0 4 6 GMHB160 6 6 5 0 GMCB200 7 4 5 4 2 Disconnect gas tube by loosening nut See Figure 9 3 3 Carefully separate from gas valve 4 Remove existing orifice a...

Page 59: ...he 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 approximately 6 secon...

Page 60: ...ndicating de aeration function is active Open aeration valve to allow complete de aeration This function lasts 10 minutes 3 To manually exit this function press button and hold for 6 seconds 4 Close a...

Page 61: ...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...

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...

Page 63: ...ess 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 in...

Page 64: ...ate again after setting the combustion following steps in section 9 11 Table 9 2 Input Rate High Fire MBH 9 14 Adjusting Maximum Heating Power Maximum boiler heating power can be reduced to suit requi...

Page 65: ...ely 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...

Page 66: ...enu 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 Ope...

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 C...

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 A2...

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...

Page 70: ...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 heati...

Page 71: ...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 ov...

Page 72: ...on 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 opti...

Page 73: ...er 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 Manufa...

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...

Page 75: ...on 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 informati...

Page 76: ...ther 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...

Page 77: ...ed by pressing the board exits from the Command functions menu and the related function starts 10 3 7 Command Functions Service Use To enter the Command functions menu press and with a long push This...

Page 78: ...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...

Page 79: ...ure 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...

Page 80: ...on 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...

Page 81: ...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 GENER...

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...

Page 83: ...r heating 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 thermosta...

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 R...

Page 85: ...Speed rpm 60 1350 60 1350 CO Limit ppm 400 To modify the fan speed see section 10 3 MIN 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 2...

Page 86: ...en 1 3 seconds 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...

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 loa...

Page 88: ...HW 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...

Page 89: ...ve 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...

Page 90: ...h 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...

Page 91: ...r 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 design...

Page 92: ...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 decre...

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