ECR Dunkirk DMG-380 Installation, Operation & Maintenance Manual Download

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INSTALLATION, OPERATION &

MAINTENANCE MANUAL

P/N 240011664, Rev. E [09/15/2017]

Model

DMG-380

CONDENSING GAS FIRED

FLOOR OR WALL MOUNTED

BOILER

Manufactured by:

ECR International Inc.

2201 Dwyer Avenue, Utica, NY 13501

Tel. 800 253 7900

www.ecrinternational.com

Summary of Contents for Dunkirk DMG-380

Page 1: ...AINTENANCE MANUAL P N 240011664 Rev E 09 15 2017 Model DMG 380 CONDENSING GAS FIRED FLOOR OR WALL MOUNTED BOILER Manufactured by ECR International Inc 2201 Dwyer Avenue Utica NY 13501 Tel 800 253 7900 www ecrinternational com ...

Page 2: ...ure Pressure Gauge Drain Valve Used for measuring outside temperature Includes essential documents Gas Shutoff Valve Outdoor Sensor Document Package Manifold See page 13 5 9 for install instructions VERIFY CONTENTS RECEIVED P N 240011664 Rev E 09 15 2017 ...

Page 3: ...t 46 8 11 DHW Indirect Water Heater 47 8 12 Frost Protection 47 9 Start Up Procedure 50 9 1 Fill Condensate Trap with Water 50 9 2 Commission Setup Water 50 9 3 Commission Setup Gas 51 9 4 Commission Setup Electric 51 9 5 Control Panel 52 9 6 Deaeration Function 53 9 7 Commissioning 54 9 8 Before Gas Conversion 54 9 9 Gas Conversion Propane 54 9 10 Combustion Setup High Fire 55 9 11 Combustion Set...

Page 4: ...on J 8 196 9mm Size 3 4 NPT Weight Shipping 255 LBS 115 7 Unit 225 LBS 102 1kg Vent Connector Concentric 110 160 mm Electrical Cord Length 5 ft 1 5m PHYSICAL DATA Dimensions Vent Connector Combustion Air A B Front View Top View Bottom View Dimensions H G C J Condensate Drain Connection Return Water Gas Connection Bottom View Connection Identification Supply Water 50 psi safety relief valve 3 44 ba...

Page 5: ...al and understand all requirements before beginning installation 1 Safety Information 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 gas supplier s instructions If you cannot reach your gas supplier call the fire department WARNING Do not...

Page 6: ... Integral Low Water Pressure Cutoff Outdoor Temperature Reset Heat exchanger over heat protection Recommended system pressure cold 21 7 psig 1 5 bar 2 8 CSD 1 Compliance Consult authority having jurisdiction pripr to installation Field source Manual reset low water cutoff see Section 5 4 Manual Reset External Hight Temperature Limit Connect to See wire diagram 2 Introduction 2 1 Installation shall...

Page 7: ...hanger flange high limit 4 on wire diagram 13 Ignition Flame detection electrode 14 Spark generator 15 Automatic air vent 16 Auxiliary control board box 17 Air gas venturi 18 Pump 19 Boiler drain 21 Low water pressure switch 22 Thermal fuse 6 on wire diagram A Condensate trap drain B Gas inlet connection C Heating supply connection D Heating return connection P N 240011664 Rev E 09 15 2017 DMG 380...

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

Page 9: ...RE 4 1a Clearance to Combustible Materials FIGURE 4 2a Service 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 INSTALLATION P N 240011664 Rev E 09 15 2017 ...

Page 10: ...opylene glycol solutions certified by fluid manufacturer for use with closed water heating system Do not use automotive or ethylene glycol Boiler installed above radiation level or as required by authority having jurisdiction Integral low water pressure switch is provided in boiler Boiler used in connection with refrigeration system Install piping in parallel with boiler with appropriate valves to...

Page 11: ...Install union if used close to safety relief valve outlet Install elbow s if used close to safety relief valve outlet and downstream of union if used Terminate pipe with plain end not threaded Check Local Codes For Maximum Distance To Floor 5 4 Low Water Cutoff Boiler is equipped with Low Water Pressure Switch Low Water Cutoff LWCO probe location See figure 5 2 for minimum probe height Do not inst...

Page 12: ...directly connected to control system Multiple boiler system See figures 5 6 5 7 for general guidance Additional considerations Control system requires 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 ...

Page 13: ...onnected to heating coils located in air handling units where they may be exposed to refrigerated air circulation must be equipped with flow control valves or other automatic means to prevent gravity circulation of the boiler water during the cooling cycle 5 HYDRONIC PIPING 5 8 Available Pump Head for Central Heating Design heating system to ensure minimum water flow rate of at least 7 8 gpm 3250 ...

Page 14: ...mping Zone Valves Figure 5 4 5 6 5 8 Zone Pumps Figure 5 5 5 7 5 HYDRONIC PIPING Note Illustrations are meant to show system piping concept only Installer responsible for all equipment and detailing required by authority having jurisdiction Piping Legend Boiler P N 240011664 Rev E 09 15 2017 ...

Page 15: ...lve 1 DHW Pump 1 12 305mm Maximum Separation Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Use external pump relay or Argo Zone Control to interface system pump to boiler Hot Water Supply Temp...

Page 16: ...ve 1 DHW Pump 1 1 12 305mm Maximum Separation Note Note Manufacturer requires all domestic hot water DHW installations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Hot Water Supply Tempered S Note Use external pump relay or Argo Zone Control to interface system pump to...

Page 17: ...nstallations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Use external pump relay or Argo Zone Control to interface system pump to boiler BOILER ASME Relief Valve ASME Relief Valve ASME Relief Valve System Temperature Sensor S Optional Indirect DHW Tank Tank Senso...

Page 18: ...nstallations use an anti scald valve Local codes may require additional equipment expansion tank relief valves etc Select and size equipment to suit installation and meet code requirements Note Use external pump relay or Argo Zone Control to interface system pump to boiler BOILER BOILER BOILER ASME Relief Valve ASME Relief Valve ASME Relief Valve System Temperature Sensor S Optional Indirect DHW T...

Page 19: ...e equipment to suit installation and meet code requirements Note Use external pump relay or Argo Zone Control to interface system pump to boiler Note SYSTEM PUMP 2 is required if System Pump 1 capacity is less than total boiler capacity Boilers on Pipe Branch Pipe Size 2 2 3 2 4 3 5 3 6 4 7 4 8 4 S Optional Indirect DHW Tank Tank Sensor CH System Pump 1 SEE NOTE Make up Water Supply ASME Relief Va...

Page 20: ...n and other deficiencies which could cause an unsafe condition When practical close all building doors windows and all doors between space in which appliances remaining connected to common venting system are located and other spaces of building Turn on clothes dryer and any appliance not connected to common venting system Turn on exhaust fans such as range hoods and bathroom exhaust so they will o...

Page 21: ...on or in absence of such requirements USA National Fuel Gas Code ANSI Z223 1 NFPA 54 A Vent Material Options 1 110 160 mm Polypropylene concentric 4 inch 6 inch or Note Follow venting manufacturer s equivalent lengths for specialty fittings 2 110 mm polypropylene twin pipe MUST be polypropylene on BOTH intake and exhaust 4 inch or 3 4 Twin pipe CPVC PVC optional on intake ONLY B Approved Polypropy...

Page 22: ...uction 45 1 8 0 5 m 90 3 4 1 0 m Total flue length shall not exceed 21 ft 6 4 m to include allowance for elbows Connect flue elbow to top of boiler and adjust direction of elbow to desired orientation rear right or left Measure distance from outside wall face to elbow This dimension will be known as X add distance Y 2 50 mm to X this is the total dimension of the vents Mark dimension from above on...

Page 23: ...3 ft 1 0m of flue length toward the boiler Ensure termination is positioned with slots at the bottom B Concentric Vent Support All venting must be supported every 4 ft 1 3 m using steel strapping or equivalent See Figure 6 4 C Flue Options Standard horizontal termination is suitable only for horizontal applications Maximum permissible equivalent flue lengths are Concentric venting 21 ft 6 4m Any i...

Page 24: ... the gaskets at equal distances approx 180º apart Note screws used must be no larger than No 8 1 2 sheet metal screws and must be zinc coated Length of this screw must be 0 75 in 19 00 mm When connecting vent pipes use only a small amount of silicone grease supplied with the exhaust pipes Do not use other types of grease FIGURE 6 5 Maximum Equivalent Length Maximum Length L A B 21 6 4 m C D 17 8 5...

Page 25: ...ere the flue terminal is located Splitting kit consists of adaptor and of intake air vent adaptor See Figure 6 8 Use screws and seals removed from the cap for the air duct adaptor 90 elbow allows boiler to connect to the venting termination regardless of direction since it can be rotated 360 It can also be used to connect the vent with 45 elbow Elbow Total Length Reduction 45 10 0 3 m 90 2 ft 0 6 ...

Page 26: ...female end of the pipe Bend clamp over the female end of pipe A and slide male end of pipe B through clamp and into female end of pipe A This clamp is necessary for the dual flue pipe Dual flue spring clamp is for indoor use only and should not be used in outdoor applications Note C Two Pipe Vent Support See Figure 6 12 All venting must be supported every 4 1m using steel strapping or equivalent S...

Page 27: ...6 19 Inside Air Single Pipe Figure 6 23 Table 5A Combustion Air Venting Locations Type Location Terminal Type Corresponding Figures Venting Flue Gas Side Wall S Terminal with 90 elbow Figure 6 17 6 18 T Terminal Figure 6 19 6 21 6 23 Roof Straight Terminal Figure 6 16 6 20 Combustion Air Fresh Air Side Wall Raised 90 down elbow Figure 6 17 90 down elbow Figure 6 18 6 20 Roof Raised 90 down elbow F...

Page 28: ...oned 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 14 FIGURE 6 14 Two Pipe Roof Vent FIGURE 6 15 Two Pipe Side Wall Vent FIGURE 6 16 Two Pipe Side Wall Vent Multiple Appliances Vent 12 305mm Min Separation Manuf Recommends Greater Separation Combustion Air 6 COMBUSTION...

Page 29: ...ig 6 17 does not have a max separation requirement between flue gas and fresh air Fig 6 18 Flue on Roof Air Intake on Side Wall Fig 6 19 Flue on Sidewall Combustion Air on Roof Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow level 24 610mm above roof or ground Combustion Air Vent Snow Line Maintain 12 305mm US 18 457mm Canada clearance above highest anticipated snow l...

Page 30: ...anticipated snow line 18 Vertical Clearance to ventilated soffit Combustion Air Vent 24 610mm Minimum Length Maintain 12 305mm US 18 457mm Canada minimum clearance above highest anticipated snow level maximum 24 610mm above roof Combustion Air Vent 24 610mm Minimum Length Maintain 12 305mm US 18 457mm Canada minimum clearance above highest anticipated snow level maximum 24 610mm above roof NOTICE ...

Page 31: ... be min 12 305mm from or below doors windows or gravity inlet If boiler uses inside air min 4 1219 mm 12 305mm Min Termination Forced Air Inlet 3 0 9m If located within 10 3m of forced air inlet Termination Less Than 10 3m Minimum 3 914mm Minimum FIGURE 6 22 FIGURE 6 23 FIGURE 6 24 6 7 Side Venting Terminal Requirements of USA National Fuel Gas Code ANSI Z223 1 NFPA 54 Venting terminal from doors ...

Page 32: ... or recirculated vent gases Give consideration to excessive wind and locate away from windward side of building Vapors Position termination where vent vapors are not objectionable Walkways Locate vent termination minimum 7 2 1m above any public walkway with consideration to condensate Meters Regulators deck porch Vent termination US only 4 1 2m Canada 6 1 9m horizontally from no case above or belo...

Page 33: ...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 above paved sidewalk or paved driveway located on public property 7 ft 2 1m 7 ft 2 1m 1 M Clearance under veranda porch deck or balcony 12 305mm 2 12 305mm 2 For clearances not specified in ANSI Z223 1 N...

Page 34: ...ld source condensate pump if boiler located below disposal point Field source condensate neutralizing kit as required by authority having jurisdiction or for environmentally friendly condensate disposal FIGURE 6 28 Condensate Drain 6 COMBUSTION AIR AND VENT PIPING Condensate Tee field installed on condensate drain pipe Do not glue cap on if used for dust protection End must be left open Do not pla...

Page 35: ...ts along the joint of each pipe 6 10 Multiple Boiler Venting Mounting Procedure See Figures 6 29 thru 6 33 1 Vent pipes correctly mounted See Figure 6 29 2 Line horizontal common vent pipes with male end towards condensate collector end cap 3 Fully insert male end of horizontal common vent pipe into bell end of another horizontal common vent pipe Mark horizontal common vent pipe male end once full...

Page 36: ...ing approved clamps to wall Ensure clamps are connected minimum of 10 in from top of boiler See Figure 6 32 13 Secure approved clamp around flue adapter Ensure clamp is locked in to proper position See Figure 6 32 A Position 1 Clamping around bell end of adapter B Position 2 Clamping around flue pipe adapter 14 Maximum distance between supports for horizontal pipes 3 ft 4 in Maximum distance betwe...

Page 37: ...00 mm Length between vertical vent pipe and last horizontal vent collector pipe 3 ft 4 in 1 00 m For calculating other lengths between last collector and shaft length of vertical height must be reduced by this additional length and by the numbers of bends according to the table Elbow 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 i...

Page 38: ...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 manifold 2 in per 3 ft 4 in 50 0 mm per 1 0 m 3 FIGURE 6 35 FIGURE 6 36 P N 240011664 Rev E 09 15 2017 ...

Page 39: ...3 ft 4 in 50 0 mm per 1 0 m 3 6 12 Multiple Boiler Venting Parameter Settings To set parameter P19 see section 9 PARAMETER P19 Revs min rpm at minimum Power Natural Gas A LPG E 30 30 Flue header size shall be calculated by qualified service agency during system design as required by local authority having jurisdiction FIGURE 6 37 P N 240011664 Rev E 09 15 2017 ...

Page 40: ...e 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 figure 7 2 Leak test boiler and gas line connections before placing boiler into operation 7 2 LP Conversion See conversion instructions included with LP Conversion Kit Purchased Separately CAUTION WHAT TO DO IF YOU SMELL GAS Do not ...

Page 41: ...a or less Isolate boiler from gas supply system by closing manual gas shutoff valve See figure 7 3 Locate leakage using gas detector noncorrosive detection fluid or other leak detection method acceptable to authority having jurisdiction Do not use matches candles open flames or other methods that can provide ignition source Correct leaks immediately and retest DANGER Fire Hazard Do not use matches...

Page 42: ... Turn OFF electrical power supply at service panel before making electrical connections Failure to do so could result in death or serious injury FIGURE 8 1 Electric Knockouts Bottom Of Boiler 8 Wire Knockouts Back of Boiler 8 ELECTRICAL CONNECTIONS 8 3 Electrical Connections Boiler requires 120V 60Hz power supply Verify electrical supply is polarized Boiler shall be grounded and on dedicated circu...

Page 43: ...ol panel cabinet by unfastening clip on front of control box Push lip back for latch 5 Run wire s through grommet s in control panel cabinet 6 Unscrew wire clamp to access connection block and bring wires through 7 Connect wires to appropriate terminals on connection block 8 Firmly tighten wire clamps and close control panel cabinet Various thermostats and controllers can be connected to standard ...

Page 44: ...1 IF 01 control PCB is built into auxiliary control box Refer to instructions supplied with product Do not connect freeze thermostat or room thermostat to boiler if using 0 10 V control PCB 1 Connection Status Nc If boiler locks out a relay is de energized and an alarm can be transmitted via a dry set of contacts maximum 120 VAC 1A on terminals Nc and C of the control board connection 2 Connection...

Page 45: ...2 Hysteresis 2 0 10 01 72 176 20 80 Temperature output required 1 Dependent on minimum modulation depth set speeds standard 20 5 Analog Heat Output Based Control 0 10V signal controls boiler output between 0 and 100 Minimum and maximum values are limited Minimum output is linked to boiler s modulation depth Output varies between minimum and maximum value on basis of value determined by controller ...

Page 46: ...n be set using parameter P34 Three way valve is connected as follows N neutral C heating system D indirect tank If neutral position of three way valve is adjusted with parameter P34 connect the pump as follows N N pump C L pump Ground 3 External Gas Valve Control If there is a call for heat alternating voltage of 120 VAC 1 A maximum becomes available on EgV terminals of control board to control an...

Page 47: ... used parameter P5 must be adjusted B Install thermostat in frequently occupied room C Connect 2 wire dry contact room thermostat to ON OFF OT terminals of boiler s control board connection Note ON OFF OT terminals are NOT able to supply 24V to the thermostat D Use thermostat or boiler system control with dry contacts related 0 5 amps 120 VAC Boiler control does NOT provide 24 VAC power to central...

Page 48: ... in combination with outdoor temperature sensor Radiator valve or zone must be open where there is a risk of freezing Connect outdoor temperature sensor to T out terminals of control board Frost protection activates when outdoor temperature sensor reads a temperature lower than 10 F 10 C This can be adjusted using parameter P30 Circulation pump will switch on and operate continuously until the out...

Page 49: ...Connect CH Central Heating pump on terminal N L Pump of control PCB SCU 02 see section 8 8 Connect DHW Domestic Hot Water pump on terminal N D 3wV of control PCB SCU 02 see section 8 8 FIGURE 8 15 Example Of System Shutdown Input Connection Example below shows connection of shutdown input for system connecting to auxiliary board See section 8 6 P N 240011664 Rev E 09 15 2017 ...

Page 50: ...50 8 ELECTRICAL CONNECTIONS FIGURE 8 16 Wiring Diagram B 13 P N 240011664 Rev E 09 15 2017 ...

Page 51: ... distribution system to ensure it is sized and installed correctly Before filling open all valves on the heating circuit in the installation Flush heating system including all heating zones Fill boiler with potable water Fill boiler and system piping with water or antifreeze water solution if used See antifreeze information page 10 Purge air from boiler using air vent Purge air from system piping ...

Page 52: ... 87 psig 60 mbar B Purge gas supply pipe within boiler by unscrewing pressure outlet on gas valve C Tighten the port when pipe has been sufficiently purged 12 Check all gas connections in the boiler are tight 13 Check piping and connections for leaks immediately after gas is turn on Shut off gas supply and make necessary repairs if leaks are found 9 4 Commission Setup Electric 1 Check electrical c...

Page 53: ...el can be changed Energy saving mode Economic mode activated Fault Boiler fault indicated Can be seen from é code and red display Frost protection Boiler running in frost protection mode Hour counter menu Readout of operating hours number of successful starts and hours on main supply ON OFF switch After 5 lock outs boiler must be switched OFF ON again Boiler pump Pump operates Heating system funct...

Page 54: ...e boiler Deaeration function starts Display shows 17 Deaeration and water pressure Psi See Figure 9 4 Boiler pump will run on and off for up to 10 minutes This will purge air from the system The burner will switch on for a few seconds to verify increasing temperature on flow return sensors Boiler is ready to start in standard operation Repeat Deaeration function at least 3 times switching boiler o...

Page 55: ...nction to set boiler to operate on full load and on part load in Heating mode 2 Adjust Fan Speed as indicated in table found in section Parameter Settings if required 3 Modifiy fan speeds using parameters P17 P18 and P19 4 Set air gas ratio O2 CO2 Full load and Part load as describe below 5 Use combustion analyzer to properly set gas valve 6 Allow time between adjustments for your combustion analy...

Page 56: ... exhaust flue test port Verify the opening around combustion analyzer probe is completely sealed when taking measurements Set boiler to low fire by pressing two buttons simultaneously If the boiler is already in combustion setup mode for high fire press the button several time until L3 is displayed on the screen Measure percentage of O2 or CO2 in flue gases Compare the measured values with values ...

Page 57: ...installer To prevent unwanted settings some parameter settings can only be changed after special access code 0012 is entered Modification of factory settings may be detrimental to operation of the boiler Press the two Menu buttons simultaneously and then button until the symbol flashes on the menu bar Select the INSTALLER menu using the button CODE appears on the display Use or button to input the...

Page 58: ...st run time CH 1 to 98 minutes 99 minutes continuous 3 P8 Display brightness when backlight is active 0 Low 1 High 1 P17 Max fan speed during CH mode Natural gas 1 x100 rpm 64 73 Propane x100 rpm 63 71 P18 Max fan speed during DHW mode Natural gas 1 x100 rpm 64 73 Propane x100 rpm 63 71 P19 Minimum fan speed during CH DHW mode Natural gas 1 x100 rpm 16 12 Propane x100 rpm 15 12 P20 Offset on partl...

Page 59: ... 0 CH enable 1 Blocking without frost protection 2 Blocking with frost protection 3 Lock out with frost protection 1 P37 Function of release input 0 DHW enable 1 Burner release 1 P38 Wait time for valid release signal 0 to 255 seconds 0 No check 0 P39 Wait time for flue gas valve 0 to 255 seconds 0 P40 Position from alarm operation signal relays 0 Operation signal 1 failure signal 1 P41 Minimum ga...

Page 60: ... P51 Flue gas temperature 0 PVC 65 C 149 F 1 CPVC 90 C 194 F 2 PP SS 110 C 230 F 1 P52 Air pressure sensor 0 Off 1 On 0 P53 DHW time out mode 0 None 1 Absolute 1 P54 DHW time out 10 to 180 minutes 150 P55 CH prior time 10 to 180 minutes 120 P56 RPM min antiwind 10 to 30 100rpm 25 Parameter Description Adjustment Range Factory Setting DMG 240 1 Do not modify these factory settings unless absolutely...

Page 61: ... for example 3 Press the button is displayed alternating with the current sub status for example 4 Press the button is displayed alternating with the current flow temperature for example 5 Press the button successively to scroll down to the various parameters 6 Press the button is displayed alternating with the internal set point for example 7 Press the button is displayed alternating with the cur...

Page 62: ... protection gradient level 3 Blockage 36 Modulate up for flame control 37 Temperature stabilization time 38 Cold start 4 Burner on DHW mode 30 Temperature control 31 Limited temperature control ΔT safety 32 Output controlled 33 Temperature protection gradient level 1 Modulate down 34 Temperature protection gradient level 2 low fire 35 Temperature protection gradient level 3 Blockage 36 Modulate up...

Page 63: ...ing Press button df x is displayed with x flashing This is the current value of X for dF Check this against the value of X on the type plate Enter the value of X shown on the type plate using the or button Confirm the value with the button df y is displayed with y flashing This is the current value of Y for dU Verify the value of y on the rating plate is the same Enter the value of y shown on the ...

Page 64: ...ng loop setpoint unit will shutdown and go through 3 minute time delay burner pause time before another call for heat During this time the pump will run for additional three minutes to dissipate any residual heat FOR YOUR SAFETY READ BEFORE OPERATING 10 2 OPERATING INSTRUCTIONS Stop Read Safety information above Set thermostat to lowest setting Turn OFF all electrical power to appliance This appli...

Page 65: ... valve manufacturer s instructions packaged with relief valve Examine flue passages in heat exchanger burner condensate lines and cleaning if necessary by following instructions in Annual Examination and Cleaning of Boiler Components in this section CAUTION Label all wires prior to disconnection when servicing controls Wiring errors can cause improper and dangerous operation FIGURE 11 1 Sight Glas...

Page 66: ...d from factory and require no further lubrication Lubricate field sourced pumps and or motors according to pump and or motor manufacturer s instruction Check following components are operating properly and are free of blockages or obstructions air vent check venturi air inlet for blockage and clean as required verify pressure test port cap and combustion test port are in place return temperature s...

Page 67: ...ny fallen deposits from bottom of inner case 5 Clean burner with soft brush and check flame ports are clear Blockages may be removed with stiffer brush 6 Check condition of electrodes 7 Check spark gap positioning and height of electrodes 8 Check fan impeller is clean and free to rotate WARNING Following service procedures must be performed by qualified service agent Boiler owner shall not attempt...

Page 68: ...ose central heating flow and return valves Connect suitable pipe to drain point Route it to suitable container Open drain tap 11 GENERAL MAINTENANCE AND CLEANING DANGER Before servicing turn off electrical power to boiler at service switch Close manual gas valve to turn gas supply OFF to boiler Failure to comply will result in death or serious injury 11 1 Electrodes 1 1 8 1 16 4 mm 0 5 mm A B C 1 ...

Page 69: ...sh Thermal Units Per Hour 2 Heating Capacity and AFUE Annual Fuel Utilization Efficiency are based on DOE Department of Energy test procedures 3 Net AHRI Ratings based on piping and pickup allowance of 1 15 Contact Technical Support before selecting boiler for installations having unusual piping and pickup requirements such as intermittent system operation extensive piping systems etc 12 RATINGS A...

Page 70: ...ng correctly Check sensor has been correctly fitted Replace sensor if necessary CHART 1 E04 E05 Temperature of heat exchanger too low Heat exchanger temperature too high Bad connection Sensor fault Sensor not poorly connected No circulation Check the wiring Replace sensor if necessary Purge air in heating system Check for water circulation direction pump valves Check water pressure Check sensors a...

Page 71: ...eck that the air inlet and exhaust flue are not blocked Check the wiring on the gas valve Defective control SU PCB CHART 5 Presence of the flame but insufficient ionization 3 μA Check that the gas valve is fully opened Check the supply pressure Check the ionization ignition electrode Check the grounding Check the wiring on the ionization ignition electrode CHART 5 E16 False flame signal Ionization...

Page 72: ...ange during boiler operation burner on Bad connection Supply Return sensor damaged No water circulation Check the sensor connection Replace the sensor Check the pump connection CHART 11 E44 Difference between supply return temperature too high Bad connection Supply Return sensor damaged No water circulation Check sensor connection Replace sensor Check pump connection 13 2 Shutdowns and Lock outs B...

Page 73: ...1 Power supply incorrectly wired Floating or 2 phase network Line and neutral mixed up Set parameter p43 to 0 Su 10 Shutdown input is open External cause Parameter error Bad connection Correct the external cause Check the parameters Check the wiring Su 11 Shutdown input active or frost protection active External cause Parameter error Bad connection Correct the external cause Check the parameters C...

Page 74: ...u 30 2 No tFG sensor connected shorted Boiler stop Flue high limit disconnected Sensor error Replace flue high limit Su 33 After 5 times tF tF Max controlled stop Non existent or insufficient circulation sensor error Replace supply sensor Check circulation direction pump valves Check water pressure Check sensors are operating correctly Check sensor has been correctly fitted Check cleanliness of he...

Page 75: ...using button Er xx is displayed with xx flashing Last error which occurred for example 2 Use or buttons to scroll through faults Press button to display details of faults or shutdowns Press or buttons to view the following information n 1 Number of times that the error occurred hr The number of operating hours St State Su Sub status t1 Supply temperature ºF ºC t2 Return temperature ºF ºC t3 DHW ta...

Page 76: ...4 2 858 28 4 3 131 86 0 827 30 2 2 990 87 8 796 32 0 2 857 89 6 767 33 8 2 730 91 4 740 35 6 2 610 93 2 713 37 4 2 496 95 0 687 39 2 2 387 96 8 663 41 0 2 284 98 6 640 42 8 2 186 100 4 617 44 6 2 093 102 2 595 46 4 2 004 100 4 617 48 2 1 920 102 2 595 50 0 1 840 104 0 575 51 8 1 763 106 0 556 CHART 2 INDIRECT TANK SENSOR DATA T R T R F Ohm F Ohm 32 0 32 505 86 0 8 060 33 8 30 898 87 8 7 726 35 6 2...

Page 77: ...e 1 page and Figure Wire Diagram Trace wire leads Are all connections tight and wires undamaged NO YES Check continuity across sensor OK NO YES Repair wire and or fix connection Check sensor element is properly installed in pipe NO YES Replace Sensor Replace Control Board Re Install Sensor Properly Check sensor resistance and compare to temperature resistance curve Figure 13 1 page 87 Remove senso...

Page 78: ...lass Is flame present NO YES Replace Flame Sense Adjust Gas Mixture See Section 9 Re check E 16 still present NO YES Replace Gas Valve Condition Corrected E16 False Flame Signal Initiate heat call Check CO2 at high fire is 9 1 9 5 Out of Range In Range Replace Flame Sense P N 240011664 Rev E 09 15 2017 ...

Page 79: ...ce Heat Exchanger E12 High Temperature Is external High Limit Switch off NO or N A YES 13 TROUBLE SHOOTING Troubleshooting Chart 3 Reset Switch Check Boiler Pump OK NO YES Water Circulation Adequate NO YES Purge air in system Repair Piping Repair plug or replace switch Does heat exchanger switch 6 in wire diagram have continuity NO YES P N 240011664 Rev E 09 15 2017 ...

Page 80: ...ol board Check both sensors are properly inserted into pipe lines NO YES Repair sensor insertion into pipe lines E10 E11 Temperature Difference Between Supply and Return Too Great E35 Supply and Return Sensors Reversed Onboard pump operation properly NO YES Replace pump Possible air in system De aerate Are any water valves partially closed NO YES Open all valves Check wire harness against wiring d...

Page 81: ...gas line Check gas inlet pressure at least equals rating plate requirements NO YES Press RESET for two 2 seconds and retry Is there a strong consistent spark NO YES Remove igniter and inspect Is there contamination NO YES Clean Or Replace Igniter Does the boiler ignite NO YES Restart the boiler and place into high fire chimney sweep Go to display and check flame current Is there at least 3 mA NO Y...

Page 82: ...O YES Provide proper ground Purge all air from gas line Check gas inlet pressure at least equals rating plate requirements NO YES Check gas line for obstructions Check venting Is exhaust gas recirculating to the air intake NO YES Clean or Replace Igniter Clear Vent Obstruction Remove igniter and inspect Is there damage or contamination NO YES Restart boiler Go to display and check flame current Is...

Page 83: ...BL connection on control board terminal strip Is this function being utilized NO YES Secure wire connections Install jumper securely in place Repair Replace External Accessory Item As Required E39 Shutdown Input In Locked Out Mode Are the wire connections secure NO YES Is factory installed jumper securly in place NO YES Check external accessories are correct NO YES Check external accessories are c...

Page 84: ...r Is wiring connection to HRU terminal secure NO YES Is wiring connection from SCU board to main board secure NO YES Is Parameter P42 set to 1 NO YES Is P42 parameter set to 0 NO YES Done Set P42 to 0 NOT OK OK Replace SCU board NOT OK OK Replace Main Control Board Done Set P42 to 1 Not OK OK Done Is HRU accessory operating properly NO YES Correct HRU Accessory P N 240011664 Rev E 09 15 2017 ...

Page 85: ... Check wire harness connections are secure NOT OK OK The error code is accurate Correct water pressure and or correct system leaks Replace Sensor NOT OK OK Note This error code refers to the onboard low water pressure switch not any field installed external low water cutoff device Is low water pressure sensor item 12 in wiring diagram securely installed to block NO Yes Correct Installation Done P ...

Page 86: ...rence During Operation Check wire plugs are securely connected to temperature sensors NO YES Onboard pump operating properly NO YES Check both sensors are properly inserted into pipe lines NO YES Possible air in the system De aerate NOT OK OK Done Not OK OK Repair Sensor Insertion Into Pipe Lines Refer to Temperature Sensor Chart both sensors Replace Sensor Replace Control Board P N 240011664 Rev ...

Page 87: ...nsors T C T F R Ohm 40 40 309396 30 22 171840 20 4 98932 10 14 58879 0 32 36129 10 50 22804 20 68 14773 25 77 12000 30 86 9804 40 104 6652 50 122 4607 60 140 3252 70 158 2337 80 176 1707 90 194 1266 100 212 952 110 230 726 120 248 560 130 266 438 140 284 345 150 302 275 P N 240011664 Rev E 09 15 2017 ...

Page 88: ...hough flame proofed fire retardant treated or plastered COMBUSTION AIR Air that is drawn into an appliance to mix with fuel and support combustion CONDENSATE Liquid separated from flue gas due to reduction in temperature DIRECT VENT BOILER Boiler constructed and installed so all combustion air is derived directly from outdoors and all vent gases are discharged to outdoors 14 GLOSSARY GAS SUPPLIER ...

Page 89: ... to relieve pressure in hot water supply system when pressure exceeds pressure capability of equipment SAFETY SHUTOFF DEVICE Device that will shut off gas supply to controlled burner in event source of ignition fails SEDIMENT TRAP Gas piping arrangement designed to collect any liquid or solid contaminant before reaching gas valve SERVICE Supply installation or maintenance of goods carried out by a...

Page 90: ...P N 240011664 Rev E 09 15 2017 ...

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