Green Mountain GMHB227 Installation, Operation & Maintenance Manual Download Page 45

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LEGEND

GMHB227

GMHB380

Pressure Relief Valve

30.00 psig

50 psig

Heating return connection

1" NPT

1/4"

NPT

Heating supply connection

1" NPT

1/4"

NPT

Gas connection

3/4" NPT

1" NPT

Drain connection for condensate

3/4 NPT

3/4 Hose

9.1 Central Heating System Connections

GMHB227 HEATING ONLY

WITH

OPTIONAL INDIRECT DHW

CONNECTION

GMHB380 HEATING ONLY

* Not Shown

PN 240012369, REV A [08/31/2018]

9 - START UP PROCEDURE

Summary of Contents for GMHB227

Page 1: ...ed Gas Fired INSTALLATION OPERATION MAINTENANCE MANUAL Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com PN 240012369 REV A 08 31 2018 Mo...

Page 2: ...perature Gauge Includes essential documents Used for measuring outside temperature Used for connecting condensate piping to boiler Gas Shutoff Valve Document Package Outdoor Sensor Optional Condensate...

Page 3: ...6 9 4 Commission Setup Electric 47 9 5 Control Panel 47 9 6 Commissioning Setup Overview 48 9 7 De aerationFunction 48 9 8 Commissioning 48 9 9 Before Gas Conversion 50 9 10 Gas Conversion Propane 50...

Page 4: ...r 50 00 psig 3 44 bar Recommended System Pressure cold 21 7 psig 1 5 bar 21 7 psig 1 5 bar SYSTEM Pressure relief valve connection 3 4 NPT Onboard pressure switch display limit PN 240012369 REV A 08 3...

Page 5: ...Front View All Models Top View All Models GMHB227 0NLY Bottom View Dimensions 101 2 4 GMHB380 0NLY Bottom View Dimensions 33 4 73 4 83 4 PN 240012369 REV A 08 31 2018 PHYSICAL DATA D E G F B A D E G C...

Page 6: ...BEFORE OPERATING Hot Water Can Scald Water heated to temperature for clothes washing dish washing and other sanitizing needs can scald and cause permanent injury Children elderly and infirm or physic...

Page 7: ...eatures Modulating GMHB227 20 100 Input Rate GMHB380 16 100 Input Rate Integral Dual Limit Integral Low Water Pressure Cutoff Outdoor Temperature Reset Optional Heat exchanger over heat protection Rec...

Page 8: ...10 Ignition Electrode 11 Flue Sensor 12 Coaxial Connector 13 Heat Exchanger Temperature Sensor 14 Heat Exchanger 15 Burner not shown 16 Flame Detection Electrode 17 Air Gas Blend Manifold 18 Air Purg...

Page 9: ...13 Flue Sensor 14 De Aerator 15 Heat Exchanger 16 Heat Exchanger Temperature Sensor 17 Water Safety Thermostat 18 NTC Heating sensor Supply Return QTY 2 1 Shown for clarity 19 Spark Generator 20 Ventu...

Page 10: ...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 contain...

Page 11: ...rvice Clearances Boiler Front FIGURE 4 1b Clearance to Combustible Materials FIGURE 4 2b Service Clearances Boiler Left side Boiler Front View FIGURE 4 2c Service Clearances Closet Installation CLOSET...

Page 12: ...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 position of the boiler verify it is level...

Page 13: ...piping in parallel with boiler with appropriate valves to prevent chilled medium from entering boiler System piping connected to heating coils located in air handling unit exposed to refrigerated air...

Page 14: ...threaded 5 4 Low Water Cutoff These guidelines are supplied when necessary to install an additional Low Water Cut Off LWCO for sensing a low water level condition in a boiler as required by the Autho...

Page 15: ...apped in the water pump impeller and reduce water flow rate Non flushed systems have low energy efficiency and potential boiling noise due to ineffective heat transfer and reduced water flow rate Flus...

Page 16: ...tions are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction Piping Legend Boiler PN 240012369 REV A 08 31 2018 5...

Page 17: ...N 240012369 REV A 08 31 2018 5 HYDRONIC PIPING 1 12 305mm Maximum Separation Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may require ad...

Page 18: ...l equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Use external pump relay or Zone Control to interface system pump to boiler N...

Page 19: ...of 1 4 per foot or vent manufacturer s recommendation whichever is greater back toward the boiler Any in line elbows in flue system must be taken into consideration First elbow on the top of the boile...

Page 20: ...ystem 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 pip...

Page 21: ...uirements of authority having jurisdiction or in absence of such requirements USA National Fuel Gas Code ANSI Z223 1 NFPA 54 WARNING Manufacturer recommends this condensing boiler be vented with appro...

Page 22: ...d 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 soff...

Page 23: ...ents between connected indoor spaces vi All Outdoor Air Provide permanent opening s communicating directly or by ducts with outdoors 01 Two Permanent Opening Method Provide opening commencing within 1...

Page 24: ...ake To transition from Coaxial at the top of the boiler to Twin Pipe CPVC PVC a kit is available B Twin Pipe Polypropylene System Single wall polypropylene is used for both exhaust and air intake pipi...

Page 25: ...ructions for applying the securing mechanism on twin pipe polypropylene venting Example for Natalini venting system For other venting system suppliers see their instructions 1 Place clamp so etched UP...

Page 26: ...e Air Single Pipe 380 Figure 6 16 Table 5A Combustion Air Venting Locations Type Location Terminal Type Corresponding Figures Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 10 6 11 T Ter...

Page 27: ...doned 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 9 FIGURE 6 9 Two...

Page 28: ...2 does not have a max separation requirement between flue gas and fresh air Fig 6 13 Flue on Roof Air Intake on Side Wall Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow...

Page 29: ...air and Vent Piping Length Page 23 PN 240012369 REV A 08 31 2018 Vent Combustion Air Outer Ring Ground Level Snow line Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow lin...

Page 30: ...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 Termin...

Page 31: ...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...

Page 32: ...ance 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 abo...

Page 33: ...re supports along the joint of each pipe Do not mix boiler sizes on the same piping manifold 6 13 Multiple Boiler Venting Mounting Procedure See Figures 6 23 thru 6 25 1 Vent pipes correctly mounted S...

Page 34: ...e adapters using approved clamps to wall Ensure clamps are connected minimum of 10 in from top of boiler See Figure 6 26 12 Secure approved clamp around flue adapter Ensure clamp is locked in to prope...

Page 35: ...bow Type 6 in 8 in Equivalent Length Equivalent Length 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 Eq...

Page 36: ...n 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 manif...

Page 37: ...3 ft 4 in 50 0 mm per 1 0 m 3 6 15 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 sha...

Page 38: ...boiler Support condensate pipe to eliminate any sagging Use field source condensate pump if boiler located below disposal point Condensate pump should have overflow switch Condensate from Boiler is s...

Page 39: ...d pipe dope suitable for liquefied petroleum gas Install external field sourced manual main gas shutoff valve ground joint union and sediment trap upstream of gas valve See figures 7 2 and 7 3 Leak te...

Page 40: ...tem 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...

Page 41: ...on all sizes Note Wiring diagrams can be found in Appendix A of this Manual 8 2 Electrical Connections Boiler requires 120V 60Hz power supply Verify electrical supply is polarized Boiler shall be grou...

Page 42: ...al 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 Neutr...

Page 43: ...s per thermostat manufacturer instructions NOTE maximum load allowed is 10 mA FIGURE 8 4 Thermostat Connections 8 5 Install Room Thermostat Install room thermostat on inside wall Do not install where...

Page 44: ...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 NOTE Temperatur...

Page 45: ...ting supply connection 1 NPT 1 1 4 NPT C Gas connection 3 4 NPT 1 NPT D Drain connection for condensate 3 4 NPT 3 4 Hose 9 1 Central Heating System Connections GMHB227 HEATING ONLY WITH OPTIONAL INDIR...

Page 46: ...il water flows out Close drain as soon as water appears Systems using radiators to remove air Vent each radiator in turn starting with lowest in the system It is important the pump is properly vented...

Page 47: ...djustment 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 Operating mode D...

Page 48: ...ll valves at unused outlets are closed and plugged capped Ensure gas connections are tight 4 Purge air from piping Confirm there is a steady gas supply to the boiler 5 Pressure test the gas line A Tes...

Page 49: ...ion 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 Che...

Page 50: ...upted if the central heating supply temperature reaches its MAX SETPOINT To measure combustion efficiency and emissions of products of combustion boiler has two dedicated built in test ports One conne...

Page 51: ...port with boiler operating at maximum heat capacity matches that indicted in Combustion Table below If it does not turn adjustment screw V Throttle on gas valve Turn the screw clockwise to decrease l...

Page 52: ...valve must be adjusted before turning boiler on Failure to follow these instructions could result in death or serious injury 9 13 Check Firing Rate 1 Measure input if a gas meter is installed in the s...

Page 53: ...display to inform the user that moving the Data Knob has no consequences NOP No OPeration 7 short push parameter visualized in display is selected and the board goes in the Value setting menu 8 short...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...hows the outdoor temperature value no influence on supply temperature 02 no function is associated 03 heating request input e g telephonic trigger 04 Low temperature safety thermostat 05 DHW pump acti...

Page 60: ...ptions 7 7 7 7 P30 Manufacturer information Set to 10 Ignore other options 10 10 10 10 P31 Manufacturer information Set to 20 Ignore other options 20 20 20 20 C00 Fault History C00 C01 Fault History C...

Page 61: ...acturer information Set to 0 Ignore other options 0 0 0 0 P69 Manufacturer information Set to 0 Ignore other options 0 0 0 0 P70 Ignition fan speed Fan speed F70 100rpm Consult factory before adjustin...

Page 62: ...s that set by adjustable temperature selector burner output is reduced 4 When set temperature is reached burner is turned off and fan stops Pump continues to run for three minutes to remove residual h...

Page 63: ...quire no further lubrication Lubricate field sourced pumps and or motors according to pump and or motor manufacturer s instruction CAUTION Label all wires prior to disconnection when servicing control...

Page 64: ...Check condition of electrodes 7 Check spark gap positioning and height of electrodes 8 Check fan impeller is clean and free to rotate 9 Replace used gaskets with new gaskets see parts literature for c...

Page 65: ...e the system 11 7 Final Assembly Place front jacket in position over boiler Ensure bottom is located behind the control panel Secure in position at top using screws previously removed If boiler is to...

Page 66: ...om thermostat if fitted are set to User s requirements E Tell User about sealed system pressure F Tell User if display is active and boiler has not operated for 24 hours for heating or hot water the p...

Page 67: ...ns above 4500 ft 1350m above sea level TABLE 14 SEA LEVEL RATINGS NATURAL AND PROPANE GASES Model Number Input MBH 1 Heating Capacity MBH 1 2 Net AHRI Rating Water MBH 1 3 AFUE 2 Thermal Efficiency Ma...

Page 68: ...n the flue duct E 83 87 shows possible error of communication with Room units Go to section P E 110 shows overheat of the primary E 117 is displayed when the primary water pressure is more than 2 7 ba...

Page 69: ...s elapsed from the error event System Status Phase Status CH flow temperature value during the error event See the following table for error codes The system status is the operating mode before the er...

Page 70: ...SYSTEM STATUS PHASE STATUS CH FLOW TEMPERATURE VALUE DURING ERROR EVENT NO RESET ERROR P32 C00 P33 C01 P34 C02 P35 C03 P36 C04 P37 C05 P38 C06 RESET ERROR P39 C07 P40 C08 P41 C09 Table 13 3 Error Tab...

Page 71: ...the Calibration Function Enable the Calibration function E71 Fan parameter Out of range in auto calibration Check the fan speed E72 Combustion test Out of range in auto calibration Check the correct p...

Page 72: ...f the water and the pump Check the status of the primary exchanger E131 Flue thermostat sensor tripped lockout Check the sensor correct circulation of the water and the pump Check the status of the pr...

Page 73: ...l Check flue recirculation and the combustion levels E66 Obstruction of the flue duct at minimum power Check obstruction on the flue duct E67 Antiwind activation at maximum power Check the position of...

Page 74: ...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 10 K Ohm INDIRECT TANK SENSOR DATA T R T R F Ohm F Oh...

Page 75: ...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 7...

Page 76: ...STION 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 an...

Page 77: ...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 designe...

Page 78: ...78 PN 240012369 REV A 08 31 2018 A 1 MODEL GMHB227 APPENDIX A WIRING DIAGRAMS...

Page 79: ...2 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 RE...

Page 80: ...80 PN 240012369 REV A 08 31 2018 A 2 MODEL GMHB380 APPENDIX A WIRING DIAGRAMS...

Page 81: ...10 3 FAN X11 1 X23 1 X11 2 X23 2 X23 3 X23 4 X13 1 X13 2 PUMP X1 FLAME SENSOR X5 1 X5 3 GAS VALVE X3 1 X3 2 X37 3 X37 4 JUMPER X22 1 X22 2 FLOW SENSOR X22 3 X22 4 RETURN SENSOR WATER PRESSURE SENSOR X...

Page 82: ...82 PN 240012369 REV A 08 31 2018 NOTES...

Page 83: ...83 PN 240012369 REV A 08 31 2018 NOTES...

Page 84: ...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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